Flux cored wire

Ideal combination of high quality and high efficiency

Dipl.-Ing. IWE Michael Reimann Product Manager OERLIKON Switzerland
Welding conference Lima, Peru 25.11.2005

Arrangement of flux cored wires

Seamless flux cored wire

Metal cored wire

Basic flux cored wire

Rutil flux cored wire

Flux cored wire classification Fluxofil 14 HD

DIN EN 758

T 46 2 P M 1 H5
T 46 2 P M 1 H5 : Flux cored wire : Yield and tensile Strenght : Toughness : Slag fast freezing slag : Mixed gas 82% Ar 18% CO2 : All welding position : Diffusible hydrogen H2

ASME Code Sec.II/C AWS SFA 5.20 E 71T-1 M H4

E 7 1 T-1M H4 : Electrode : Yield, tensile Strenght and toughness : welding position H,F,VU,OH : Slag characteristic, shielding gas : Diffusible hydrogen H2
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Welding project with Fluxofil 14 HD

Welding project with Fluxofil 14 HD WPS Fluxofil 14 HD with weldycar

WPS Fluxofil 14 HD with weldycar Root pass on ceramic backing

WPS Fluxofil 14 HD with weldycar Front view on round ceramic backing

WPS Fluxofil 14 HD with weldycar Fixation the weldycar

WPS Fluxofil 14 HD with weldycar Root pass on ceramic backing

WPS Fluxofil 14 HD with weldycar Cap welding Current I=225A Voltage U=24V Welding speed Vs=13cm/min Wire speed 8,0m/min Weld deposit 3,5 Kg/h
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WPS Fluxofil 14 HD with weldycar

Joint preparation Nahtvorbereitung Layers set up Lagenaufbau

Schweiparameter

Welding parameters

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WPS Fluxofil 14 HD with weldycar

Weldycar fixed in transver position

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WPS Fluxofil 14 HD with weldycar

Transver welding on ceramic in action

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WPS Fluxofil 14 HD with weldycar

Joint preparation Nahtvorbereitung Lagenaufbau Layers set up

Schweiparameter

Welding parameters in transver position

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Fluxofil 14 HD in project operation

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Fluxofil 14 HD in project operation

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Fluxofil 14 HD in project operation

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Fluxofil 14 HD in project operation

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Flux cored wire application tank building

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Flux cored wire application tank building

Joint preparation Vessel

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Fluxofil 14 HD Application pipe junction

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Flux cored wire application hall truss

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Flux cored wire application exhibition hall

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Fluxofil 14 HD in all welding position

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Calculation comparison between solid and flux cored wire

Schweiverfahren
Schweizusatz Ausfhrungen Nahtvorbereitung Lagenaufbau

MAG- Flldraht MAG- Massivdraht

Fluxofil 14 HD Halbmechanisiert Carbofil 1 Halbmechanisiert

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Lagenzahl/Raupenzahl Schweiposition (mm) Drahtdurchmesser I (mm) Schweistrom U (V) Schweispannung Schweigeschwindigkeit Vs (cm/min) SG (Kg/h) Abschmelzleistung ED (%) Schweizeitfaktor LS (Euro/h) Lohnsatz SZP (Euro/Kg) Schweizusatzpreis SP (Euro/l) Schutzgaspreis Schutzgasmenge SM (l/min) GKF (%) Gemeinkostenfaktor

3L/3R PF 1,2 210 23 26 3,0 45 13 3,3 0.01 15 300

3L/3R PF 1,2 140 18 13 1,5 45 13 0,93 0.01 15 300

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Calculation comparison between solid and flux cored wire

Schweiverfahren
Schweizusatz Ausfhrungen Nahtvorbereitung Lagenaufbau

MAG- Flldraht MAG- Massivdraht

Fluxofil 14 HD Halbmechanisiert Carbofil 1 halbmechanisiert

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90

Lagenzahl/Raupenzahl Schweinahtgewicht Hauptzeit Hauptzeit + Nebenzeit Schweizusatzkosten Schutzgaskosten Lohnkosten Gemeinkosten Fertigungskosten Gesamtkosten Ersparnis Ersparnis

SNG (Kg/m) Th ( min/m ) T ( min / m ) KZ (Euro/m) KS(Euro/m) KL (Euro/m) KG (Euro/m) KF (Euro/m) KGe (Euro/m)

3L/3R 1,20 24,00 53,33 3,96 0,87 11,56 34,67 46,22 51,05

3L/3R 1,20 48,00 106,67 1,12 0,87 23,11 69,33 92,44 94,43

Euro/m %

43,38 45,94
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Fluxofil 14 HD - Data sheet FLUXOFIL 14 HD

Rutile tubular cored electrode for MAG-welding, with fastfreezing slag

Standards: DIN EN 758 AW S/ASME SFA-5.20 T 46 2 P C 1 H5 / T 46 2 P M 1 H5 E71T-1 H4 / E71T-1M H4

Applications and properties : The higher filling degree of FLUXOFIL 14 HD results in higher current carrying capacity and deposition rate. Welding speed is thereby essentially increased which leads to a saving of time and reduction of costs. It can be used in all positions with only one setting of welding parameters (2 4 volts, wire feed = 9m/min, wire dia. 1,2 mm). FLUXOFIL 14 HD is em ployed in manual welding, as well as in fully mechanized w elding by me ans of the orbital welding unit CITOTRACK OSG-O1 or the vertical welding set CITOTRACK VSG-O1. It is preferably used under mixed shield ing gas and is characterized by low spatter loss, good slag removal and finely rippled, pore-free welds without undercutting into the base metal. Materials: EN-Designation S185 S235 to S355 P235 L210 to L415 L290, L320 DIN-Designation EN-Designation DIN-/AWS-Designation St 33 S235 to S355 St 37.0 to St 52.0 St 37-2 to St 52-3 P235 to P355 St 37.4 to St 52.4 St 35.8 P265 St 45.8 StE 210.7 to StE 415.7 L360 to L485 StE 360.7 TM-StE 480.7 TM StE 290.7TM, StE 320.7T M P235GH, P265GH HI, HII X42 to X65 P295GH 17 Mn 4 StE 255 S(P)275 to S(P)460 StE 285to StE 460 A, B, D, E AH 32 to EH 36 GS-38 GP240R GS-45 Please observe admissible operating temperature for welding consumable and base material. Qualification tests: T V Approvals: DB, ABS, DNV, GL, LRS Indications as to approvals, see appendix. Analysis of all-weld metal (typical values in %): C 0,05 Yield strength [N/mm] >460 Si 0,55 Elongation A5 [%] >22 Mn 1,2 Impact energy ISO-V [Joule] -20 C >80

Mechanical properties of all-weld metal (single values are typical values): Heat treatment AW AW = as-welded Tensile strength [N/mm] 550 650

Chemical composition and mechanical properties apply to the use of shielding gas: DIN EN 439 - M21 (82 Vol. % Ar + 18 Vol. % CO2 ) Shielding gas as to DIN EN 439: Consumption: Form of delivery: Wire diameters [mm] Further forms of delivery on req uest. Wire cage reel K300 (16 kg) 1,0 1,2 1,6 M21 (ARCAL 21), C1 (carbon dioxide) 12 15 l/min for 1,6 mm B 131

Welding parameters and deposition rate, see:

Type of current/Polarity/Welding positions:

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Fluxofil 14 HD - advantages Easy handling in all welding position

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High deposition rate in all welding position To use in fully mechanized welding processes One side welding on ceramic backing Less spatter during the welding process Easy slag removal Very good penetration Seamless wire Less fume and less hydrogen content High efficiency
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Application

Metal cored wire

Fluxofil M8

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Metal cored wire Fluxofil M8 - advantages -

Easy handling in H and F welding position Seamless wire Less fume and less hydrogen content High deposition rate in H and F welding position To use in fully mechanized welding processes One side welding on ceramic backing Less spatter during the welding process Very good penetration High efficiency Very good ristriking
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Application

Metal cored wire

Fluxofil M8

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Application

Metal cored wire

Fluxofil M8

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Application

Metal cored wire

Fluxofil M8

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Application

Metal cored wire

Fluxofil M8

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Application

Metal cored wire

Fluxofil M8

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Variable applications with flux cored wires

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Variable applications with flux cored wires

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Variable applications with flux cored wires

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