PRAKSA
F. Winkler
NEKOLIKO PRIMERA EFIKASNE PRIMENE PRAHOM PUNJENE ŽICE SA
FORMIRANJEM TROSKE ZA SPAJANJE ZAVARIVANJEM
A FEW EXAMPLES OF THE EFFICIENCY OF SLAG FORMING FLUX-CORED
WIRES FOR JOINT WELDING
Stručni rad / Professional paper
UDK / UDC: 621.778:621.791.753.052
Rad primljen / Paper received:
Januar 2008.
Ključne reči: Zavarivanje, dodatni materijali, prahom
punjene žice.
Izvod
Prahom punjene žice postale su sastavni deo
tehnologije zavarivanja u mnogim oblastima industrije.
Zbog prednosti koje pružaju, upotreba ovih žica beleži
stabilan rast na evropskom tržištu potrošnih materijala.
Osnovne prednosti prahom punjene žice su: povećana
produktivnost, laka upotreba, smanjen rizik od grešaka
u zoni spoja i niži ukupni troškovi.
Trenutno, nedostatak prahom punjene žice u odnosu na
punu žicu je mnogo viša cena. U radu su prikazani
primeri primene ove žice sa ciljem da prikažu manji deo
mogućnosti inače široke primene prahom punjenih žica
koje formiraju trosku.
UVOD
Primena prahom punjene žice postala je sastavni deo
tehnologije zavarivanja u mnogim oblastima industrije.
Tokom protekle decenije, zbog prednosti koje pruža,
upotreba ovih žica beleži stabilan rast na evropskom
tržištu potrošnih materijala. Ovaj trend, vidljiv u
Japanu i SAD još od ranih 80-ih, doveo je do udela od
30% na tržištima ovih zemalja. Uopšte gledano,
prahom punjena žica nastavlja da bude potrošni
materijal koji beleži dvocifren porast, izraženo u
procentima.
Preduzeće Böhler Welding je uočilo ovaj trend još u
ranoj fazi. Rezultat toga je potpuna posvećenost
razvoju i proizvodnji ovih proizvoda u dugom nizu
godina. U 2004. godini, preduzeće je dostiglo nove
visine završetkom i puštanjem u rad potpuno nove
fabrike za proizvodnju prahom punjene žice, slika 1.
Proizvodni pogon u Kapfenbergu je proširen u 2006.
godini, tako da je ukupna godišnja proizvodnja
srednje i visokolegirane prahom punjene žice dostigla
1500 tona. Zahvaljujući ovoj fabrici, kompanija je
sposobna da proizvede prahom punjenu žicu najvišeg
kvaliteta za širok spektar primene. Nelegirane žice
proizvodi jedna evropska joint-venture kompanija.
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25
PRACTICE
Prevod: M. Pavlović
Adresa autora / Author's address:
Ing. Franz Winkler, Fa. Böhler Schweißtechnik Austria
GmbH - IWE/EWE - Head of Application Department,
Austria.
Keywords: Welding, filler materials, flux cored wires.
Abstract
Flux cored wires has become an integral part of
welding technology for a wide range of industries.
The advantage provided by this type of filler metal
has lead to a steady increase in European
consumption rates. The essential advantages of flux
cored wires are: increased productivity, user-friendly,
reduces the risk of weld seam errors and lower total
costs. Currently, the disadvantage posed by flux
cored wires is that they are still more expensive than
solid wires. The examples presented in the paper
have intend overview a small cross-section of a
large number of possible uses for slag forming flux
cored wires.
INTRODUCTION
The application of flux cored wires has become an
integral part of welding technology for a wide range of
industries.
Over the last decades, the advantage provided by this
type of filler metal has lead to a steady increase in
European consumption rates. This trend, visible in
Japan or the United States since the 1980’s, has lead
to a market share of approximately 30% in these
countries. Internationally, flux cored wires continue to
be the welding consumable still capable of booking
double-digit revenue increases.
Böhler Welding recognised this trend at an early
stage. As a result, we have already been dedicating
ourselves to the development and production of these
products for many years. In 2004 Böhler Welding
reached new heights with the completion and
inauguration of a completely new flux cored wire
factory, (Figure 1).
The production facility in Kapfenberg, Austria has
been upgraded to a yearly capacity of more than 1500
tons of medium - to high alloyed flux cored wires in
the year of 2006.
Thanks to this factory, the company is capable of
17
PRAKSA
Šta razlikuje prahom punjenu žicu od obložene
elektrode ili pune žice?
Osnovne prednosti prahom punjene žice su:
Povećana produktivnost - veće brzine deponovanja,
posebno kod pozicionog zavarivanja upotrebom
Böhler PW-žice
Laka upotreba - širok opseg tolerancija u odnosu na
parametre zavarivanja, lakše izvođenje zavarivanja,
prenos u mlazu.
Smanjen rizik od grešaka u zoni spoja - Troska i
zaštitni gas obezbeđuju dvostruku zaštitu tečnog
kupatila, manji rizik od poroznosti, čak i pri
nadglavnom zavarivanju, jače protapanje, smanjen
rizik od neprovara.
Niži ukupni troškovi - smanjeno vreme zavarivanja i
neproizvodno vreme.
Trenutno, nedostatak prahom punjene žice u odnosu
na punu žicu je mnogo viša cena. Uprkos tome,
smanjenje ukupnog vremena zavarivanja kompenzuje
ovaj nedostatak što na kraju dovodi do smanjenja
ukupnih troškova zavarivanja.
Primeri prikazani u ovom radu važeći su u velikom
broju industrijskih grana. Oni predstavljaju samo mali
deo spektra primene prahom punjene žice, koja je
uspešno zamenila druge postupke i dodatne
materijale. Navedeni primeri razmatraju isključivo
zavarivanje prahom punjenom žicom uz formiranje
troske.
Primena pri zavarivanju nelegiranih čelika
Tipičan primer je zavarivanje čeličnih konstrukcija
(slika 2) korišćenjem rutilne prahom punjene žice.
Ove žice su dokazale pogodnost primene u velikom
broju položaja pri zavarivanju ovakvih konstrukcija.
Slika 3 prikazuje proizvodnju dna rezervoara,
spojenog dodatnim materijalom ASTM SA 516 Gr.70,
Slika 1: Proizvodni pogon u Kapfenbergu, Austrija
Figure 1: The production facility in Kapfenberg, Austria
18
PRACTICE
producing the absolutely highest quality flux cored
wires for a wide variety of applications. The unalloyed
flux cored wires are manufactured by an European
based joint venture company.
What differentiates a flux cored wire from covered
electrodes or solid wires?
The essential advantages of flux cored wires are:
Increased productivity - A higher deposition rate,
especially for positional welding with Böhler PW-Wires
User-friendly - A large tolerance window for welding
parameters, i.e. a more userfriendly welding
technique. Drop transfer in the spray arc range
Reduces the risk of weld seam errors - Slags and
shielding gas provide double protection for the weld
pool, lower risk of porosity even during erection
welding, broader burn-in, lower risk of lack of fusion
Lower total costs - Less welding and non-productive
time
Currently, the disadvantage posed by flux cored wires
is that they are still more expensive than solid wires.
Nevertheless, through the reduction of welding and
nonproductive time there is still a reduction of the total
welding costs.
The examples presented in this report are valid for a
wide variety of industries. They only represent a small
spectrum of applications in which the flux cored arc
welding has successfully replaced other procedures
and other filler materials.
The present examples deal exclusively with welding
with so-called “slag-forming” flux cored wires.
Mild steel applications
A typical example is the welding of steel constructions
(Figure 2) using rutile flux cored wires. These wires
have proven themselves to be appropriate for a wide
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25
PRAKSA PRACTICE

debljine zida od 110 mm. Iz razloga ekonomičnosti,
zavarivanje ovakvih debelozidnih komponenti
klasifikovano je kao EPP zavarivanje.
Detaljno poređenje postupaka zavarivanja izvedeno
od strane kompanije Schoeler Bleckmann Nooter
Apparatetechnick GmbH, pokazalo je da se
zavarivanjem žicom BöhlerTi 52-FD dobijaju
zahtevane mehaničke osobine uz istovremenu
ekonomičnost.
Jedan od glavnih razloga primene prahom punjene
žice je njena pogodnost za poziciono zavarivanje,
odnosno mogućnost zavarivanja u svim položajima.
variety of welding positions for this type of
construction.
Figure 3 demonstrates the production of a tank bottom
made out of filler material ASTM SA 516 Gr. 70 with a
wall thickness of 110mm. For economic reasons, this
wall thickness is generally classified as SA welding.
A detailed comparison of welding processes carried
out by Schoeller Bleckmann Nooter Apparatetechnik
GmbH demonstrated that welding with BÖHLER Ti
52-FD attains both the required mechanical properties
and provides economic advantages.

Slika 2: Krovna konstrukcija, zavareno žicom BöhlerTi 52-FD

Figure 2: Roofing, welded with Böhler Ti 52-FD

Slika 3: Dno rezervoara, pogon fabrike Schoeler Bleckmann Nooter Apparatetechnick GmbH
Figure 3: A tank bottom made out of filler material ASTM SA 516 Gr.70 with a wall thickness of 110 mm.
Schoeller Bleckmann Nooter, Austria

ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25

19
PRAKSA
Primena visokolegiranih dodatnih
materijala pri zavarivanju u hemijskoj,
petrohemijskoj industriji i naftnim
platformama
Oblast primene prahom punjenih žica proteže se na
sve segmente industrije gde se koriste visokolegirani
materijali. Postoji značajan porast brzine zavarivanja,
posebno pri pozicionom zavarivanju korišćenjem
takozvanih PW žica.
Sledeći primeri prikazuju manji deo mogućnosti
primene visokolegiranih, koroziono postojanih prahom
punjenih žica u nekoliko proizvodnih pogona.
Slika 4 prikazuje proizvodnju filtera vlage u pogonu za
hemijsku preradu magnezijum-sulfata. Usled
korozionog delovanja, korišćen je duplex materijal
W.Nr.1.4462 (UNS 31803), koji je zavarivan
odgovarajućom duplex Böhler žicom.
Uglavnom zbog lake upotrebe na otvorenom prostoru,
parhom punjena žica je pogodna za zavarivanje
cisterni u skladištima, slika 5. Zbog dvostruke zaštite
rastopljenog metala, mala je osetljivost na strujanje
vazduha i vetar, pa je samim tim smanjena pojava
poroznosti.
U svetu se beleži porast upotrebe industrijske vode za
gašenje požara. Sve više cisterni za vodu na
vatrogasnim vozilima izrađeno je čak i od nerđajućeg
čelika. Cisterna na slici 6 proizvedena je od
nerđajućeg čelika W.Nr.14571 (AlSl 316Ti).
Postoji još jedna prednost upotrebe, prikazana u
sledećem primeru. Usled povećane brzine
zavarivanja, manji je unos energije, a samim tim
smanjeno je krivljenje spojnica debljine 3 mm.
Ovim se smanjuju troškovi dodatne obrade.
Slika 4: Filter vlage, koreni i prvi prolaz popune zavareni žicom FOX CN22/9 N (obložena elektroda) i
CN22/9 N-IG (TIG), respektivno. Prolazi popune i završni sloj zavareni žicom CN 22/9 N-FD
Figure 4: Wet filter, radix and 1st filler pass welded with FOX CN22/9 N (covered electrode) and CN
22/9 N-IG (TIG, GTAW), respectively. Filler and cover pass CN 22/9 N-FD
20
PRACTICE
One of the main reasons for the application of the flux
cored wire was its suitability for positional weldability.
High-alloyed applications in chemical,
petro-chemical and offshore industries
The application area for flux cored wires extends to all
industry segments in which these materials are
applied. There is a considerable increase in welding
speed, especially for positional welding using so-
called PW wires.
The following examples provide a small selection of
the possibilities for the application of high-alloyed,
corrosion-resistant flux cored wires in several
industries.
Figure 4 shows the production of a wet filter for a
chemical recovery plant (medium magnesium
sulphate). Due to corrosion strain, duplex material
W.Nr. 1.4462 (UNS 31803) was employed with a
Böhler duplex welding consumable of the same kind.
Primarily due to their unproblematic outdoor
workability, flux cored wires are especially suitable for
the welding of storage tanks (Figure 5). Through the
double protection of the weld pool, there is very little
wind sensitivity and as a result lower pore
susceptibility.
Through the increased use of industrial water for
extinguishing fires, more and more water tanks for fire
department vehicles are made up of stainless steels,
such as those produced using W.Nr. 1.4571 (AISI
316Ti), Figure 6.
There is an additional application advantage in this
example. Due to an increased welding speed and
resulting lower heat input, the distortion of the 3 mm
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25
PRAKSA PRACTICE

Slika 5: Cisterna za skladištenje hemikalija, izrađena od materijala 1.4301 (AlSi 304) i 1.4541
(AlSl 316Ti), širine 4 m i dužine 20 m, debljina zida 5 mm, zavareno žicom Böhler EAS 2 PW-FD
Figure 5: Chemical storage tank made out of materials 1.4301 (AISI 304) and 1.4541 (AISI 316Ti),
with an average width of 4 m and a length of 20 m, wall thickness 5mm – welded with Böhler EAS
2-FD and EAS 2 PW-FD, Apparatebau Schweißtechnik Austria

Slika 6: Rezervoar za vodu, W.Nr.14571 (AlSl 316Ti), debljina zida 3 mm, dodatni materijal
Böhler SAS 4-FD
Figure 6: Water tanks, W.Nr. 1.4571 (AISI 316Ti), wall thickness 3 mm,
welding consumable Böhler SAS 4-FD. Iveco, Italy

Još jedan primer je proizvodnja mlaznica za paru u
industriji papira, slika 7. Namena mlaznica je da
ovlaže papir i smanje rizik od cepanja.
Iz bezbednosnih razloga, instalacije na platformama
moraju biti opremljene pouzdanim protivpožarnim
sistemima. Slana morska voda koristi se kao sredstvo
za gašenje, pri čemu deluje koroziono na cevi
instalacija.
Za ovakve namene koriste se dupleks materijali, zbog
izuzetne otpornosti na piting-koroziju.
connexions can be reduced. Subsequently, there are
lower reworking costs.
An example from the paper industry is the production
of steam showers. Their task is to re-moisturise the
paper webs to counter the risk of tearing.
For reasons of safety, offshore platform installations
must be equipped with elaborate fire extinguishing
systems. In this case, sea water serves as an
extinguishing solution, which in turn leads to an
increased corrosion strain of the pipe materials.

Na slici 9 prikazan je sud za polimerizaciju sintetičkih Due to their exceptional resistance to pitting, duplex
materijala. Kao dodatni materijal za konektore materials are ideal for such applications.

ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25

21
PRAKSA PRACTICE

Slika 7: Fabrika papira Voith Paper Heidenheim, Nemačka. Osnovni materijal 1.4404, (AISI 316L),
debljina zida 5 mm, spojevi zavareni žicom Böhler EAS 4M-FD, prečnika 1.2 mm
Figure 7: Base metal 1.4404 (AISI 316L), wall thickness 5 mm, fillet welds and HV seams welded with
Böhler EAS 4M-FD, rd. 1.2 mm, Voith Paper Heidenheim, Germany

Slika 8: Zavarivanje spojnice na cev, materijal 1.4462 (UNS 31803). Dodatni materijal
žica CN 22/9 N-FD, prečnika 1.2 mm
Figure 8: Pipe/flange weld joint, material 1.4462 (UNS 31803) welded with CN 22/9 N-FD,
rd. 1.2 mm, Visser Smith Hanab, Netherlands

belo/belo izrađene od materijala W.Nr. 1.4541 (AISI Figure 9 shows a polimerizer for the production of
321) korišćena je žica EAS 2-FD, a za konektore synthetic materials. EAS 2-FD was used for the
crno/belo korišćena je žica CN23/12 Mo-FD. white/white connexions of material Nr. 1.4541 (AISI
Raznorodni spojevi i navarivanje 321), and CN23/12 Mo-FD for black/white connexions.

Kao što se može očekivati, prahom punjena žica
pogodna je za ostvarivanje spoja raznorodnih
materijala.Takođe, ovaj postupak je idealan i za
nanošenje površinskog sloja širokog spektra
materijala.
Dissimilar joints and claddings
As to be expected, flux cored wires are suitable for
diverse dissimilar joints. Likewise, this procedure is
also especially ideal for the cladding of a wide variety
of materials.

22 ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25

PRAKSA PRACTICE

Na slici 10 prikazan je spoj raznorodnih materijala,
finozrnog konstrukcionog čelika i visokolegiranog
CrNiMo metala, W.Nr. 1.4404 (AISI 316L), za namenu
u industriji papira.
Upotreba dodatnih materijala na bazi nikla je poželjna
za raznorodne spojeve koji se koriste na radnim
temperaturama iznad 350 °C.
Na slikama 11 i 12 prikazan je zaštitni pokrivač peći
za žarenje i osnova peći, izrađeni od niskolegiranog
čelika - rub, i materijala W.Nr. 1.4541 (AISI 321) - cev,
respektivno.
Korišćena je novorazvijena prahom punjena žica na
bazi nikla, Böhler NIBAS 70/20-FD, Ø 1.6 mm, zaštitni
gas Ar+18% CO2, horizontalna pozicija zavarivanja.
Figure 10 shows a dissimilar joint from fine grain
constructional steel with a highalloyed CrNiMo-metal,
W.Nr. 1.4404 (AISI 316L), for the paper industry.
Nickel based fillers are preferred for dissimilar joints
which are applied at operating temperatures above
350°C.
Figures 11 and 12 show the protective cover of an
annealing furnace and an annealing base, produced
from mild steel (flange) and W.Nr. 1.4541 (AISI 321)
(pipe), respectively.
A newly developed nickel based flux cored wire
Böhler NIBAS 70/20-FD, rd. 1.6mm, shielding gas
Argon+ 18% CO2 was used for flat-position welding.

Slika 9: Fabrika ACE-AG, Cristoph Group, Austria. Polimerizator za proizvodnju

sintetičkih materijala
Figure 9: Polimerizer for synthetic material production, ACE-AG (Christoph
Group), Austria

Slika 10: Fabrika ACE-AG, Cristoph Group, Austria. Spoj raznorodnih materijala
Figure 10: Dissimilar joint, a-dimension 30 mm – welding consumable CN 23/12 Mo-
FD, Andritz AG, Austria

ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25

23
PRAKSA
Prednosti dodatnih materijala na bazi nikla ogledaju
se u njihovoj lakoj upotrebi. Iznad svega, zbog
mogućnosti prenosa materijala u mlazu, čak i pri
najnižim parametrima procesa, a da ne dođe do
rasprskavanja. Povrh svega, mogu se koristiti
standardni zaštitni gasovi bez ikakvih daljih
komplikacija.
Prahom punjena žica je pogodna za navarivanje
koroziono otpornih slojeva odličnog kvaliteta, za širok
spektar osnovnih materijala.
Na slici 13 prikazani su rezultati nanošenja
jednostrukog, dvostrukog i trostrukog sloja CrNiMo
materijala 13CrMo45 (A335, Gr.911), za rad na
povišenim temperaturama.
Korišćena je prelegirana prahom punjena žica
BöhlerCN 23/12 Mo-FD za prvi sloj, a žica EAS 4M-
FD za ostale slojeve. U drugom sloju, sadržaj ferita je
preko 6-7%, mereno prema Förster 1.053 testu,
tabela 1.
ZAKLJUČAK
Navedeni primeri su izneti sa ciljem da prikažu manji
deo mogućnosti inače široke primene prahom
punjenih žica koje formiraju trosku.
Uz današnju tehnologiju, praktično ne postoje
prepreke za upotrebu ovih žica. Zbog njihove
Slika 11: Zaštitni pokrivač peći za žarenje, Ebner
Furnaces Inc, Leonding, Austria
Figure 11: Protective cover of an annealing furnace
Tabela 1: Sadržaj ferita prema Förster 1.053
Table 1: Ferrite content according to Förster 1.053
Merno mesto 1 Merno mesto 2
1. sloj 9 10
2. sloj 6 6
3. sloj 5 5
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PRACTICE
The advantages of nickel based flux cored wires lies
in their simple workability.
Above all, it is possible to use a spray arc even in the
lowest parameter range and still achieve a practically
spatter-free material transition.
Moreover, standard shielding gases can be used
without any further complications.
Flux cored wire welding is also suitable for the
excellent corrosion-resistant cladding of a wide range
of base materials.
Figure 13 shows the results of a one, double, and
triple CrNiMo cladding of hightemperature 13CrMo45
(A335, Gr. 911) material.
An over-alloyed flux cored wire Böhler CN 23/12 Mo-
FD is applied to the first pass and EAS 4M-FD for the
rest of the passes. In the 2nd pass, a ferrite content of
more than 6-7% is measured according to Förster
1.053, Table 1.
SUMMARY
These examples have been intended to present a
small cross-section of a large number of possible uses
for slag forming flux cored wires.
With today’s technology, there is almost no barrier to
the use of flux cored wires. As a result, because of the
Slika 12: Osnova peći, spoj raznorodnih materijala,
zavareni žicom Böhler NIBAS 70/20-FD
Figure 12: Annealing base – Dissimilar joint, welded with
Böhler NIBAS 70/20-FD
Merno mesto 3 Merno mesto 4
12 11
7 7
5 5
ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25
PRAKSA PRACTICE

1. prolaz prahom punjena žica CN 23/12 Mo-FD, Ø 1.2 mm

1. Pass Flux cored wire CN 23/12 Mo-FD, Ø 1.2mm
2. i 3. prolaz prahom punjena žica EAS 4M-FD, Ø 1.2 mm
2nd & 3rd passes Flux-cored wire EAS 4 M-FD, Ø 1.2 mm
Osnovni materijal: 13 CrMo 45 (A335, Gr.911)
Base material: 13 CrMo 45 (A335, Gr. 911)

Slika 13: Navareni antikorozioni sloj na osnovni materijal 13 CrMo 45 (A335, Gr.911):
CN 23/12 Mo-FD i EAS 4M-FD, respektivno
Figure 13: Weld cladding on base material 13CrMo45 (A335, Gr. 911) with CN 23/12
Mo-FD and EAS 4M-FD, respectively

efikasnosti, možemo očekivati stalan porast upotrebe
prahom punjenih žica u bliskoj budućnosti.
Tokom proteklih godina, Böhler Welding je vredno
radio na razvoju i proizvodnji ove vrste dodatnih
materijala, posebno visokolegiranih. Kompanija će u
budućnosti nastaviti sa navedenim aktivnostima.
Kompanija Böhler Welding želi posebno da zahvali
svim ostalim kompanijama koje su učinile dostupnim
za objavljivanje fotografije sa širokim spektrom
upotrebe prahom punjenih žica.
efficiency of flux cored wires, we can expect their use
to continuously expand in the near future.
Over the last several years, BÖHLER WELDING has
been working hard on developing and producing
these consumables, especially high alloyed fillers. We
will continue to do so in the future, too.
We would like to give a special thanks to all of the
companies who have made these pictures of a wide
variety of flux cored wires applications available for
reprinting.

LITERATURE

[1] Böhler welding catalogue, www.böhler-welding.com

ZAVARIVANJE I ZAVARENE KONSTRUKCIJE (1/2008), str. 17-25

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