FILARC welder guide

book No.1

Welder Guide Book No. 1

PZ6125 basic flux-cored wire

and related types for high tensile and creep resistant steels

Index page 1

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FILARC PZ6125 basic flux-cored wire

and related types for high tensile
and creep resistant steels

A new generation of basic cored wires with excellent

welding characteristics for positional work
on high quality fabrication

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Due to its policy of continual improvements

in its welding consumables, FILARC reserves
the right to change data in this guide without notice.

FILARC Welder Guide Books provide practical information on

the use of specific FILARC flux and metal-cored wires. The
contents will assist welders to apply correct welding parameters and use the FILARC cored wire effectively, to achieve optimum productivity and avoid faults.
The information provided will be helpful to welders both qualified or still to qualify for cored wire welding. There is also helpful information for welding engineers establishing appropriate
welding procedures, also training instructors and welding foremen.
Overall the guide will enhance results from the FILARC flux or
metal-cored wire(s) described.

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Introduction
FILARC PZ 6125 represents a new generation of basic fluxcored wires, with much improved weldability. PZ 6125 yields
excellent mechanical properties, including satisfactory CTOD
values, both as-welded and stress relieved, with hydrogen
content dependably below 3ml /100g.
PZ 6125 and related types provide good all-position weldability, with useful tolerance in welding parameter setting; they are
far easier to use than conventional basic cored wires.
However, due to the new flux formulation, weldability has distinctive, but not difficult, characteristics.
This Guide Book provides all the information you need to ensure fully satisfactory use of these new basic cored wires.

Index
Correct use of equipment...........................................Page

Torch, liners and cable assembly ...........................................2

Wire drive unit.........................................................................2
Gas regulation ........................................................................2
Gas cup and contact tip combination ....................................4
Correct stickout length ...........................................................4
Gas cup sizes .........................................................................4

FILARC PZ6125 is decribed in this guide, together with related types, listed below, having identical welding performance. All types come in diameter size 1.0, 1.2 and 1.6mm
and are developed for use in Ar/CO2 mixed gas.
Low alloyed types AWS A5.29
E71T5-G
FILARC PZ 6125

EN 758

Power source facilities............................................................6

Welding parameter setting......................................................8
Choice of wire size ...............................................................10

T 42 6 1Ni B M 1 H5

Recommended average parameter setting ..........................12

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product page

High tensile types

FILARC PZ6145
FILARC PZ6146
FILARC PZ6147
FILARC PZ6148
FILARC PZ6149
Creep resistant
types
FILARC PZ6201
FILARC PZ6202
FILARC PZ6203
FILARC PZ6204
FILARC PZ6205

E81T5-G
E91T5-K2
E101T5-K3
E111T5-K4
E121T5-G

T 50 5 Mn1Ni B M 1 H5

AWS A5. .. /
DIN 8575
DIN: SGCrMo1
29:E71T5-A1
DIN: SGCrMo2
22:E502T-1
29:E81T5-B2

ASME and EN welding positions..........................................15

Welding advice .....................................................................16
Torch positions for positional welding ..................................18
Weaving technique ...............................................................22

Grinding ................................................................................24
Trouble shooting ...................................................................26
Causes of weld defects ........................................................27
1

FILARC welder guide

book No.1
Correct use of equipment
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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FILARC PZ 6125 and other cored wires will always perform

well when welding sets are used correctly and maintained according to the makers instructions.
Following are some simple guidelines for preventive inspection
and maintenance. When carried out regularly, the most common causes of malfunctioning are avoided.

Replace worn contact tip.

concentric hole

worn hole

Torch, liners and cable assembly

Ensure that the contact tip has the right size and is mounted
tight. Ideally, contact tips are checked for wear upon wire
spool change and replaced when necessary.
Check gas cups for spatter built-up and clean if necessary. Impeded gas flow from clogged cups may cause porosity.
Blowing-out the liner into the direction of wire delivery should
be a regularly recurring routine. Check liners for damage at
least weekly, and replace when necessary. Spiral steel liners
are recommended.
Check gas and water connections for leaks. When fitted, ensure water cooler is filled and pump operates satisfactorily.

Wire drive unit

Wire guide tubes must be as close to the rollers as possible to
prevent kinking of a cored wire. Proper alignment is essential
to avoid unnecessary friction. A substantial amount of fine
metallic swarf underneath the drive wheels indicates misalignment (or excessively worn drive wheels).
Use drive wheels with a V-groove and, by preference, flat pressure wheels. Check that the groove of the drive wheel is correctly selected for the wire diameter, and that the pressure
wheel is correctly tensioned. Too much pressure may flatten
the cored wire, giving increased wear of liner and contact tip.
Insufficient pressure may result in slip, causing erratic wire feed
and burn-back. Limit the use of knurled wheels to situations
where friction in the liner causes wheels with a V-groove to slip.
This is only likely to happen with long, extremely curved cable
assemblies, and/or with units with one set of rolls. Knurled
wheels cause increased wear of liner and contact tip. Test wire
delivery at the torch; this must be regular.

Inspect torch connections and clean liner

weekly.

Exit to torch

Correct location of wire guide tubes. Minimal space between

guide tubes and rollers. Proper alignment is essential.

Exit to torch

Excessive space between wire guide tubes and rollers can

cause kinking of wire. Misalignment, also in the plane perpendicular to the one shown here, causes friction.

Check gas pressure

and flow rate.

Gas regulation
Check that Ar/CO 2 (80/20) gas is used. Adjust the flow rate between 15 and 20 l /min to suit wire and joint configuration.
Outdoors, use 20l. Make a short test run to assure no porosity
arises from incorrect gas flow.
Always check gas flow with a flow meter which fits on the nozzle,
to be sure that required gas flow is available.
2

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Gas cup and contact tip combination

It is essential to mount the gas cup and contact tip at the right
distance relative to each other. The ideal 2mm distance is
shown right.
A larger distance increases stickout length, causing slag traps
and lack of fusion, mainly in narrow joints.

2mm

10mm

Correct positioning
of contact tip.

Correct stickout length

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The stand-off, here and in other FILARC sales literature referred

to as stickout, is the distance between the tip of the contact tip
and the workpiece. It must be held constant at 10 to 15mm for
PZ 6125 and related types in 1.0 and 1.2mm sizes and 15 to
20mm for 1.6mm size.
Correct, constant stickout length must be maintained, as far as
joint preparation will allow. Variations will cause arc voltage
and welding current to fluctuate and in turn adversely influence
droplet transfer.
Overlong stickout results in larger droplets, causing spatter, also
reducing gas protection, so bringing weld porosity.

Incorrect. Left: increased stickout causes slag traps and fusion faults, mainly in
narrow joints. Right: contact tip extends
beyond gas cup. Risk of insufficient
shielding gas protection.

Ideal stickout length for 1.0

and 1.2mm wire sizes.
10

-1

5m

Gas cup sizes

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Various cup diameters must be available, to allow satisfactory

access to the joint, and maintain the stickout length recommended above, according to wire size.
Small diameter gas cups are used for first layers only. Revert
to the standard gas cup diameter when access to the weld
joint allows this, so full gas protection can be assured.
Check gas flow after a change of gas cup size.

Trouble shooting
Porosity is normally the result of draught, the presence of condense water, rust or paint on the plate material or an overlong
stickout length. Also insufficient gas flow, due to clogged gas
nozzles is a common cause. Check the above, if porosity occurs.
Unstable arc or large droplets are a sign of excessive stickout,
possibly due to gas cup size not allowing suitable access to
the joint; replace gas cup with smaller size.
Also refer to the checklist of process faults and weld defects
as from page 26.

10-

15m

Correct. Smaller gas cup

diameter for 1st layers of
joints with limited access.

>10

-15

mm

Incorrect. Too large gas cup

diameter restricts access to
narrow joints, resulting in too
long stickout length.

Correct gas cup for

filling ensures good
gas protection and
correct stickout.

Incorrect. Too small gas cup

diameter for filling reduces
gas protection and brings
porosity.
4

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Power source facilities

Power source rating must be suitable for the basic cored wire
size at 60% duty cycle. These should have selectable choke
settings; automatic chokes are not recommended. Power
sources fall into the following categories for setting welding
parameters (arc voltage, wire feed speed/welding current,
choke setting).

Use negative polarity for

PZ6125 and related types
(straight polarity).

Manual selection, with or without Voltage and Ampre meters.

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Pre-programmed with variable selection of wire feed speed.

Available programs for flux-cored wires may not necessarily suit FILARC PZ 6125 and related wires. Test these carefully, and if not fully satisfactory check with equipment supplier for program revisions.

polarity

Programmable, select the parameters recommended for

FILARC PZ 6125 in preference to any already installed program(s) for flux-cored wires.
Polarity negative
It is essential to weld FILARC PZ 6125 and related types on
negative polarity, to avoid slag inclusions and lack of fusion,
also to obtain deeper penetration, especially when welding in
position.
Choke setting
A welder often has a preference for a particular setting, so will
adjust this until arriving at what is considered to be satisfactory.
Due to the variety of welding equipment available, it is impractical to define the exact setting. However, a minimum choke
value is best suited for FILARC PZ 6125, in all positions.
Advice
Start with a minimum value and adjust the arc voltage and wire
feed speed to recommended values, and trim these for
smoothest weldability in the welding position required. Only if
spatter is excessive, use the next higher choke setting.

Choke setting values may be indicated by various symbols.

Typical examples are shown here.

minimum

maximum

minimum

maximum

A
minimum

C
maximum

Recommended setting
for PZ6125 and related
types.
6

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Welding parameter setting

Arc voltage is related to welding current, which is established
by the wire feed speed adjustment on the wire drive unit.
Note, the arc voltage setting for FILARC PZ6125 is higher than
usually required for normal basic cored wires.

Correct arc length.

Arc is just over weldpool,
with smooth droplets or
spray arc.

Advice
After selecting the minimum choke value, set the recommended arc voltage (V) and wire feed settings/current values, see
following pages for examples.
Test weldability in the required welding position. Power sources fitted with voltage and current meters allow settings to be
monitored.
Correct parameter setting will bring the arc over the weld pool,
delivering either a smooth, fine droplet transfer at lower wire
feed speeds, or spray arc at higher speeds.
Too short or long arcs can arise from incorrect setting of parameters for the welding position. To obtain correct results:
adjust the wire feed speed slightly.
If the arc length remains unsatisfactory, or weldability unsmooth,

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adjust arc voltage in steps of 1 or 2V.

Results may be further improved by slight adjustment of wire
feed speed/welding current.
In case of continuing difficulty, especially at lower arc voltage/welding currents, use a higher choke value and repeat the
above adjustments.
Note, irregular wire feeding due to incorrect wire drive roller adjustment, a damaged torch cable liner, or a worn contact tip
can cause difficulties. Check these if weldability fluctuates; adjustment of welding parameters will not overcome these
equipment faults.

Arc length too short.

Stubbing. Wire dips into
weldpool, caused by
too high a wire speed
or too low an arc voltage.

Arc Voltage and Welding Current Meters

Usually fitted to power sources, these are helpful for training or
monitoring purposes. They are not a substitute for correct adjustment of welding parameters to suit the best combination of
wire size and welding position.

Arc length too long.

Wire speed too low, or arc
voltage too high.
8

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Choice of wire size

Wire

1.0mm

FILARC PZ 6125 and related types are all available in 1.0, 1.2
and 1.6mm diameters, so allowing optimal productivity for various combinations of plate thicknesses and welding positions.
The chart opposite shows recommended use.
The 1.2mm size is recommended for general all-positional use.
Diameter 1.6mm is a more productive choice when the majority of welding takes place in the downhand position.
Although it is not recommended by FILARC, the 1.2mm size is
also an option when fabricators wish to weld root passes without ceramic weld metal support.
The 1.0mm size is advantageous for pipe work and tubular
constructions with minimal 10-12mm wall thickness and minimal 4inch diameter, bringing excellent control of the weld pool
in the 3 to 9 o'clock positions.

Welding
position

Suitability for average application

Root
Fill

1G/PA
1G/PA

not recomm.
not recomm.

on backing
yes

on backing
yes

Root
Fill

2G/PC
2G/PC

not recomm.
not recomm.

on backing
yes

on backing
yes

Root
Fill

3G/PF
3G/PF

not recomm.
yes

on backing
yes

not recomm.
not recomm.

Root
Fill

4G/PE
4G/PE

not recomm.
yes

not recomm. not recomm.

not recomm.
yes1

Use with ceramic backing

High quality root runs can be deposited economically when
using ceramic weld metal support. Both the 1.2mm as well as
the 1.6mm size are very suited. Consult the special FILARC
brochure on ceramic backing materials.
The 1.6mm size is very productive for root passes in the 1G
and 2G positions. The thick root pass layer allows filling at
higher welding currents.

Root
Fill

5G/PF
5G/PF

not recomm.
yes

not recomm. not recomm.

not recomm.
possible1

Root

6G
HL045
6G
HL045

not recomm.

not recomm. not recomm.

yes

possible1

not recomm.

Chart recommendations are for average situations. There will

be exceptions for plate size, application area, etc. where the
versatility of PZ 6125 will still provide excellent results.
For additional advice contact your FILARC welding engineer or
nearest sales office.
A guide to ASME and EN welding positions is given on page 15.

Fill

1.6mm

1F/PA

possible2

yes

yes

2F/PB

possible2

yes

yes

3F/PF

not recomm.

yes

not recomm.

4F/PD

not recomm.

yes

not recomm.

1
2

10

1.2mm

For thicknesses below 20mm, 1.0mm size is recommended

1.2 or 1.6mm sizes will improve productivity.

11

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Recommended average
parameter settings

FILARC PZ 6125, 1.2mm , negative () polarity.

1G/PA

Root*: 180-230A /8.0-11.0m/min

22-28V (spray arc)
Fill : 240-320A/12.5-19.0m/min
28-34V

2G/PC

Root*: 170-230A/7.0-11.0m/min
21-28V (spray arc)
Fill : 190-280A /9.0-16.0m/min
23-33V

3G/PF

Root*: 150-180A /6.5-8.0m/min

19-22V (spray arc)
Fill : 180-200A /8.0-9.5m/min
22-25V

4G/PE

Root : not recommended

Fill : 130-150A /4.0-6.5m/min
18-19V

5G+6G/H-L000+H-L045

Root : not recommended

Fill : 130-180A /4.0-8.0m/min
18-22V

FILARC PZ 6125, 1.0mm , negative () polarity.

1G/PA

Not recommended. Diameters 1.2 and 1.6mm are

best suited.

Previous page
2G/PC

Next page

Not recommended. Diameters 1.2 and 1.6mm are

best suited.

3G/PF

Root : not recommended

Fill : 140-160A/8.5-9.8m/min
18-21V

3F/4F/PF/PD

Fill

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: not recommended

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4G/PE

Root : not recommended

Fill : 130-150A/7.8-9.2m/min
18-19V

5G/PF

Root : not recommended

Fill : 130-160A/7.8-9.8m/min
18-19V

6G/HL045

Root : not recommended

Fill : 140-150A/8.5-9.2m/min
18-20V

1F/2F/PA/PB

3F/4F/PF/PD
240-320A/
12.5-19.0m/min
28-34V

3F: 180-200A/
8.0-9.5m/min
22-25V
4F: 160-230A/
6.5-11.0m/min/18-28V

* One-sided root pass on ceramic backing (round groove)

12

13

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

ASME and EN Welding Positions

FILARC PZ 6125, 1.6mm , negative () polarity. Generally

used for plate thickness of 20mm and higher.
Also used with ceramic backing for plate thicknesses down to
16mm.
With ceramic backing

1G /PA

2G /PC

3G / PF & PG

4G /PE

Previous page
1G/PA

Root*: 220-260A /4.0-5.0m/min

26-28V (spray arc)
Fill : 220-380A /4.5-12.0m/min
27-36V

2G/PC

Root*: 200-240A /3.5-4.5m/min

24-26V (spray arc)
Fill : 240-270A /4.5-5.5m/min
26-30V

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Plate thickness 20mm
1F/PA

2F/PB

5G / PF & PG-H-L000
Fill

Fill

6G / H-L045

: 240-380A/4.5-12.0m/min
27-36V

1F/ PA

2F/ PB

3F / PF & PG

4F / PD

: 240-320A/4.5-8.0m/min
30-35V

* One-sided root pass on ceramic backing (round groove)

14

15

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Welding advice
Following pages provide advice on welding techniques for typical applications, followed by troubleshooting for typical faults.

direction of travel
70-90

Welding characteristics
FILARC PZ 6125 has distinctive, but not difficult welding characteristics. These differ from conventional basic cored wires,
by way of:

Higher arc voltage with smoother droplet transfer.

Semi-spray arc operation aids positional work.
Greater tolerance for arc voltage/welding current setting.
Warmer, more fluid weldpool for higher penetration.
Flatter weld beads.
Less risk of fusion faults and slag traps.
Less slag.
Grinding requirements considerably reduced.

Figure A
Correct backhand welding (trailing) with torch at 70-90.

These impressive advantages, including welder comfort, will

bring improved results when the welding guidelines are correctly followed. Some training is obviously needed to gain familiarity with the welding characteristics of the PZ 6125, also to
avoid using methods associated with rutile cored wires, or conventional basic types where colder weld pools and short arc
dip transfer lead to less favourable weldability.

direction of travel

Positive penetration
To ensure positive penetration, and so avoid the most common
cause of weld defects:
Always try to weld backhand

Figure B
Forehand welding (pushing). Risk of insufficient penetration,
lack of fusion and slag traps.

This ensures good penetration and prevents slag running

ahead of the weldpool. See figure A.
Forehand welding can deliver a reasonable appearance, but
penetration is often poor, due to the slag running ahead of the
weldpool. There is also the chance of overflowing the weldpool, causing slag traps and lack of fusion, see figure B.
Correct torch angle is 70-90 as shown figure A. At lower angles, see figure C, insufficient penetration and lack of fusion
can be expected.
direction of travel

Figure C
Backhand welding with too small a torch angle, causing insufficient penetration and lack of fusion.
16

17

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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C. Third layer builds up

weld thickness.

Torch positions for

positional welding
PZ 6125 and related types are well suited for all-position welding. Following are typical situations where correct torch positioning plays an important role in avoiding weld defects.
2G/PC
Torch position depends on plate thickness and bevel angle of
the joint. If the torch positions shown cannot be used, it is recommended that the bevel angle is enlarged.
Always maintain the torch angle of 70-90 relative to the weld
bead and direction of travel as advised on page 17.
Maintain a steady travel speed to achieve a regular bead thickness, without sagging.
See page 22 for guidance on weaving.
A. Root pass.
Without backing: grind opposite side.
With backing: use round ceramic. Avoid overthick bead.

10

D. Fourth layer creates

favourable angle for
following pass.

45

E. Fifth layer. Note how

layers are always
built up from bottom
side of joint as weld
thickness increases.

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30
10

Avoid sagging
Slag traps and fusion faults arise from sagging (rollover), typically caused by:
B. Second layer, using flatter bead.

45

18

Wrong travel speed.

Incorrect torch angle.
Too high welding current.
Wrong weld bead sequence.

Sagging requires grinding to

eliminate weld defects. This
can be avoided by keeping
weld beads as flat as possible
as shown by the diagrams, so
reducing repair rates and unproductive grinding.

wrong

Weaving advice is given on page 22.

right

19

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Torch positions, continued

3G/3F/PF
Note the torch positions shown below for root run and filling
layers.
Joint bevelling must allow good access to the root area. If necessary use a narrower gas cup.

4G/PE
Use basic electrode or TIG-welding for root pass. Use FILARC
PZ 6125 and related types for filling.
Figures A and B give ideal torch positioning.
B

ceramic backing

Previous page

90
80-90

Next page

2F/PB
Figures A and B show the ideal torch positioning, using the
backhand method recommended.

10

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A. Root pass

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45

70 - 90

Trouble shooting
Figures C and D show possible undercut and sagging faults,
and possible causes.
C

10

B. Filling layers

Weaving advice is given on page 22.

20

Undercut:
Welding current too high.
Arc voltage too high.
Travel speed too high.
Arc too close to vertical plane.
Torch angle () too small.

Sagging:
Welding current too high.
Arc voltage too high.
Torch angle () too big.
Layer too thick.

21

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Weaving technique
Use of correct weaving, in conjunction with the torch positions
described on previous pages, will avoid weld defects and reduce grinding requirements.
1G/PA Position
Restrict weaving width; try to weld stringer beads as far as
possible. For K joints, shown, restricted weaving and correct
torch position are important.
The arc must point into the corner between plate material and
weld as illustrated below.
A. Correct
Apply stringer beads as far
as possible.
Correct torch position.
Weave as little as possible.
Backhand welding.

B. Incorrect
Excessive weaving.
Wrong torch position.
Forehand welding.

3G/PF Position
Correct weaving technique is very important when welding
PZ 6125 in the 3G position. Incorrect weaving can lead to weld
defects.
Apply a little weaving; stop at the plate edges for approx. 2
seconds to allow weld metal to solidify. Always ensure satisfactory side plate wetting, as shown figure A.
A. Correct
Weave width 1.5-2.0cm.
Use an upward triangle
towards the joint centre.
Remain approximately
2 seconds at the plate
edges.
Assure good side plate
wetting.

B. Incorrect
Weave width correct
but wrong technique.
Downward triangle
causes convex weld
with risk of slag traps
and fusion faults.

2G/PC Position
A. Correct
Torch pointed onto plate.
Correct weaving width.
Good wetting onto plate
edges and weld.

C. Incorrect
Insufficient weaving,
giving a convex weld,
slag traps and fusion
faults.

B. Incorrect
Torch not pointed onto
plate.
Excessive weaving.
22

23

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Grinding
Grinding requirements for PZ 6125 welds are not excessive
when the recommended welding techniques are applied.
Avoid overgrinding, this can cause defects.
Also do not create sharp edges, leading to slag traps and lack
of fusion when filling.
Remove only the most obvious irregularities, like sagging,
starts, stops and undercut, always leaving smooth bead contours.

Sealing runs
Grind before welding, as shown figure D, to create a smooth,
slightly concave groove, giving easy access for the welding
torch.
D Correct.

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A Correct.

B Incorrect.

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E Incorrect.
Grinding wheel
pushed into root,
bringing deep
groove.
The narrow joint
is almost inaccessible to the
torch.

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C Always grind starts and stops.

24

25

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

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Trouble shooting/process faults

Trouble shooting/weld defects

Although good equipment maintenance and proper welder

training will help preventing process faults and weld defects,
they can never be avoided completely. In such cases, understanding of the most common causes will lead the welder to
quickly solving the problem encountered.
Listed below are the most common process faults and their
likely causes. For faults that result from incorrect setting or
wrong welding techniques, we refer to previous chapters
where correct handling of FILARC PZ 6125 and related types is
described in detail. Weld defects and their origins are discussed on next pages.

Lack of fusion defects. There are several types of lack of fusion defects, but all share the same feature that weld metal and
parent metal have not fused at one or more places.
Below, typical forms of lack of fusion are shown in a V-butt
weld. They can equally occur in other butt-weld types. Also
shown is a typical defect in fillet welds, where the weld metal
fails to fuse with, normally, the standing leg.

Process faults

Likely causes

1. wire stubbing

- parameter settings

2. wire burn-back

3. spatter

- parameter settings
- wrong shielding gas/gas flow rate
too high, too low or irregular
- irregular wire feed
- worn contact tip
- paint, rust or dirt in joint area

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wire reel brake too tight

parameter settings
damaged/worn contact tip
burn-back time too long

4. irregular wire feed/

- roll pressure too low
unstable arc/wire jam - damaged/worn contact tip
- wrong contact tip size
- overheated contact tip
- damaged/worn/bent liner
- dirty or rusty wire/wire kinks
- misalignment of rolls and
guide tubes/worn rolls
- wire reel brake too tight
- wire crossed on reel
(brake too loose)
- irregular gas flow

cold lap
lack of interrun fusion
lack of side wall fusion
lack of root fusion

lack of fusion

Possible causes
General
travel speed too high
wrong parameter setting
forehand welding
Lack of root fusion
root gap too small

Remedies
- reduce travel speed/allow
more dwell time at edges
- adjust parameters
- backhand welding, 70-90
torch angle
- enlarge gap

Fillet: lack of fusion at standing leg

torch too much pointed at - change torch orientation
horizontal leg

26

27

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Lack of weld penetration

Lack of penetration occurs when the weld metal fails to extend
into the complete root of a joint. Shown below are three typical cases.

Previous page
Examples of lack of root penetration

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Possible causes
General
welding current too low
arc voltage too high
travel speed too high
travel speed too low
forehand welding
torch angle too small

Butt welds
root gap too small/
face too big
joint included angle

Remedies
-

increase wire feed/arc voltage

reduce arc voltage
reduce travel speed
increase travel speed; avoid
slag running ahead of weld pool
- backhand welding
- use 70-90 torch angle; aim
the arc at the leading edge of
the pool
- increase gap/reduce face
- increase angle

Slag inclusions
Slag inclusions occur when molten slag is not allowed to escape to the surface of the weld pool, when the weld pool overrides slag running ahead of it, or when slag remainders at the
toe of beads are not sufficiently remolten.
Possible causes

Remedies

welding current too low

travel speed too low

- increase wire feed/arc voltage

- increase travel speed; avoid
slag running ahead of weld pool
- backhand welding
- use 70-90 torch angle; keep
slag behind arc
- increase arc voltage
- reduce travel speed; when
possible use split-weave
technique, otherwise reduce
weaving width.
Avoid thick layers.

forehand welding
torch angle too small
convex beads
too much weaving

28

Porosity.
Possible causes
draught /wind
paint, grease or dirt
in the weld area
gas cup clogged
gas cup distorted
gas cup too small
or too big
gas flow too high
or too low
gas leaks in system
aspirate air

Remedies
- close doors or windows/
place wind screens
- clean plates
- clean/replace
- replace
- replace with one suiting the
joint geometry
- adjust flow rate

- check by blocking gas cup;

continued gas flow indicates
leaks
water leaks in cooled guns - check connections
gas cup to workpiece
- check positioning of contact tip
distance too long
relative to gas cup;
readjust parameters
Undercutting

Undercutting is generally caused by an excessive welding current or arc voltage, or may be the result of a too high travel
speed. To avoid this, lower wire feed speed and/or travel
speed until satisfactory bead appearance is obtained. If undercutting appears at one leg of a fillet weld, the torch position
may be wrong; try increasing the angle between torch and opposite leg.

29

FILARC welder guide

book No.1
PZ6125 basic flux-cored wire
and related types for high tensile and creep resistant steels

Previous page
Next page
Back to index page 1

Back to catalogue

FILARC Welding Industries B.V.

P.O. Box 8086
NL-3503 RB Utrecht
The Netherlands
Tel : + 31 30 248 59 11
Fax : + 31 30 241 15 35

FILARC Welding Sales Organisations

Belgium & Luxembourg
S.A. Esab N.V.
Avenue Jules Bordetlaan 15
B-1140 Brussels
Tel : +32 2 726 84 00
Fax : +32 2 726 80 05

Norway
AS Esab
Frankendalsvn 97, P.O.Box 2050
N-3255 Larvik
Tel : + 47 331 210 00
Fax : + 47 331 152 03

Czech Republic
ESAB VAMBERK a.s.
Smetanovo nbrez 334
517 54 Vamberk
Tel : +42 445 50 11 11
Fax : +45 445 50 14 64

Poland
Esab Sp. z o.o.
ul. St. Augusta 75, lok. 47
03-846 Warszawa
Tel : + 48 22 612 59 61
Fax : + 48 22 612 59 57

Denmark
V. Lwener
Smedeland 2, P.O. Box 1330
DK-2600 Glostrup
Tel : +45 43 20 03 00
Fax : +45 43 43 03 59

Portugal
Esab LdA
Av. Infante D.Henrique
Lote 332 - 2 Esq.
P-1800 Lisbon
Tel : +35 118 371 527
Fax : +35 118 591 277

Finland
FILARC Hitsaustuotteet
Yliopistonkatu 37C
SF-20100 Turku
Tel : +358 2 251 3880
Fax : +358 2 251 3940
France
Esab France S.A.
Rue du Petit Albi
ZAC du Moulin Vent
Batiment D, Porte 402
F-95800 Cergy St. Christophe
Tel : 33 1 30 75 55 00
Fax : 33 1 30 75 55 25
Germany
Esab GmbH
Beethovenstrasse 135
Postfach 100763
D-42648 Solingen
Tel : +49 212 298 0
Fax : +49 212 298 415
Great Britain
Esab Group (UK) Ltd
Hertford Road, Waltham Cross
Hertfordshire EN8 7RP
Tel : +44 1992 76 85 15
Fax : +44 1992 71 58 03
Italy
Esab Saldatura SpA
Via E Mattei 24, I-20010 Mesero (MI)
Tel : +39 297 96 81
Fax : +39 297 289 300

Slovakia
Esab Slovakia s.r.o.
Rybnicn

40
835 54 Bratislava - Vajnory
Tel : + 42 728 87 41
Fax : + 42 728 87 41
Spain
Esab Ibrica SA
Calle Aragoneses, 17
E-28100 Alcobendas (Madrid)
Z.I. de Alcobendas
Tel : +34 1 661 55 80
Fax : +34 1 661 71 36
Sweden
Esab Sverige AB
Marknad Tillsatsmaterial
Herkulesgatan 72
P.O. Box 8004
S-402 77 Gteborg
Tel : +46 31 50 95 00
Fax : +46 31 50 92 22
Switzerland
Hulftegger & AG
Bahnhofstrasse 52
CH-8712 Stfa
Tel : +41 1 928 81 11
Fax : +41 1 926 67 55
For countries not listed here:
FILARC Lastechniek B.V.
International Division
Utrecht, The Netherlands

The Netherlands
FILARC Lastechniek B.V.
Kernkade 8, P.O. Box 8035
NL-3503 RA Utrecht
Tel : +31 30 248 59 11
Fax : +31 30 241 15 34

Member of The Esab Group

Printed in The Netherlands

CW-WG1-9604/ 01