Product Catalogue ESAB

Welding Consumables - Equipments - Automation - Cutting Systems

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Welding Consumables

A CENTURY OF ESAB INNOVATIONS

In 1904, Oscar Kjellberg, a Swedish engineer, was working on ships and boilers in Gothenburg, Sweden. He was not satisfied with the quality of repair jobs. His quest for a better technology led to the invention of the world’s first covered electrode. And thus, Elektriska Svetsnings Aktie Bolaget (ESAB) was born. Today, ESAB leads the world in providing welding and cutting solutions. At ESAB, every problem is an opportunity, every sale start of an enduring relationship. From supplying welding equipment to consumables, cutting machines to working environment products, ESAB, today has established itself as one of the leading suppliers of welding, cutting and working environment solutions in the country. ESAB products are now an integral part of industries like Shipbuilding, Petrochemical, Construction, Transport, Offshore, Energy and Repair and Maintenance. The ESAB group belongs to the world renowned Charter Plc. Group, UK, and employs around 8000 people of which more than 600 are engaged in research and development at centres in Sweden, Holland, UK, Germany, USA, Brazil and India. In India, ESAB was formally incorporated on 10th November 1987, and it has expanded through a number of acquisitions. The organisation operates five manufacturing facilities backed by world-class R&D. All the manufacturing units of Esab India Limited, are ISO 9000 and 14000 certified the only company in India, in the welding field to receive such an honour. The entire ESAB group including ESAB India has achieved ISO 14001 and OHSAS 18001 certification for Environmental and Occupational Health and Safety Management system. This is believed to be the most comprehensive certification achieved by any global company till date

2001 First Modular Platform for Welding Equipments 2002 Copper Fee Wire - Aristorod 2005 The Q Set Function

Index

Welding Consumables
Carbon Steel Electrodes ESAB Ferrospeed ESAB Ferroarc ESAB Ferrospeed plus ESAB Vortic ESAB 28 ESAB Vordian ESAB 46 ESAB Ferroweld 1 ESAB 56 ESAB Ferroweld 2 ESAB 36 H OK 48.20 ESAB 36 H (Spl) OK 48.20 (Spl) ESAB 36 H Spl (M) ESAB Vortex - 1 Gas Welding Fluxes Gas Welding Fluxes Pipe Welding Electrodes Pipeweld 6010 R Pipeweld 6010 Plus OK 22.46 P OK 22.47 P OK 22.48 P Pipeweld 6011 Low Alloy Electrodes OK 48.08 Ok 73.08 OK 74.46 OK 76.18 OK 76.18 M ESAB 8018 B2 OK 76.18 G OK 76.28 OK 76.28 M ESAB KV 4 ESAB KV 7 ESAB KV 7M OK 73.68 OK 73.68 M ESAB 8016 C2 OK 74.78 3 3 4 4 5 5 6 7 7 8 8 9 9 10 10 11 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23

OK 74.86 ESAB 8018 - D3 ESAB 98 ESAB 98 G ESAB 118 ESAB 120 ESAB 130 ESAB Ferroweld W ESAB Ferroweld W2 Stainless Steel Electrodes OK 61.50 OK 61.30 ESAB 304 B ESAB 304 B (N) OK 61.80 ESAB RSSC (M) ESAB 308 H OK 63.50 OK 63.30 OK 63.35 ESAB 316 KCR OK 63.80 OK 64.30 ESAB 317 LN OK 67.67 ESAB 309 OK 67.60 ESAB 309 LC OK 67.70 ESAB 309 Mo ESAB 309 LMO OK 67.68 ESAB 309 Cb OK 67.13 Ok 67.45 ESAB RSW OK 67.50 OK 68.55 OK 68.10 OK 68.00 ESAB RSQ ESAB 430 ESAB Armoid 1 ESAB Chromweld G ESAB Chromweld G (Spl)

24 24 25 25 26 26 27 27 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46

GTAW Consumables OK Tigrod SG OK Tigrod S2 OK Tigrod S2 (Spl) OK Tigrod 12.64 OK Tigrod 13.09 OK Tigrod 13.16 OK Tigrod B2L OK Tigrod 13.17 OK Tigrod B3L OK Tigrod 13.23 OK Tigrod 13.28 OK Tigrod 13.32 OK Tigrod 13.37 OK Tigrod 13.38 OK Tigrod 16.10 OK Tigrod 308H OK Tigrod 16.11 OK Tigrod 16.30 OK Tigrod 16.35 OK Tigrod 16.53 OK Tigrod 16.54 OK Tigrod 16.86 OK Tigrod 16.88 OK Tigrod 16.13 OK Tigrod 1070 OK Tigrod 1100 OK Tigrod 1450 OK Tigrod 4043 OK Tigrod 4047 OK Tigrod 5087 OK Tigrod 5183 OK Tigrod 5356 OK Tigrod 5554 OK Tigrod 5556 OK Tigrod 5754 OK Tigrod 19.12 OK Tigrod 19.30 OK Tigrod 19.40 OK Tigrod 19.49 GMAW Consumables ESAB MW1 ESAB MW2 OK AristoRod 12.50 Ok Autrod 13.14

47 47 47 48 48 48 49 49 50 50 51 51 52 52 53 53 54 55 55 56 56 57 57 58 58 59 59 59 60 60 60 61 61 61 62 62 62 63 63 64 64 65 65
i

OK AristoRod 13.09 OK AristoRod 13.26 OK Autrod 13.16 OK Autrod 13.17 OK Autrod 13.28 OK AristoRod 13.29 OK AristoRod 13.13 OK AristoRod 13.31 OK Autrod 16.10 OK Autrod 16.11 OK Autrod 16.30 OK Autrod 16.53 OK Autrod 16.75 OK Autrod 16.13 OK Autrod 16.33 OK Autrod 16.43 OK Autrod 16.95 OK Autrod 1100 OK Autrod 4043 OK Autrod 5356 OK Autrod 5183 OK Autrod 5556 OK Autrod 19.12 OK Autrod 19.30 OK Autrod 19.40 FCAW Consumables Dual Shield 7100 LH OK Tubrod 15.00 A OK Tubrod 15.14A Dual Shield 7100 Dual Shield 7100 Ultra Dual Shield 7100 SR Dual Shield T-5 Dual Shield II 70 Ultra Coreshield 11 Coreshield 8 Ni 1 Coreweld 70 Coreweld Ultra Coreweld III Ultra Dual Shield 8100 W Dual Shield 7000 A1 Dual Shield 8000 B2 Dual Shield 9000 B3 Dual Shield II 81 K2 Dual Shield T - 115
ii

66 66 67 67 67 68 68 69 69 70 70 71 71 71 72 72 73 73 74 74 75 75 76 76 77 78 78 79 79 80 80 81 81 82 82 83 83 84 84 85 85 86 86 87

Dual Shield II 110 Dual Shield II 101 TC Dual Shield B9 OK Tubrod 15.22 OK Tubrod 15.24 OK Tubrod 15.27 OK Tubrod 14.30 Shield-Bright 308 L Shield-Bright 309 L Shield-Bright 309 LMo Shield-Bright 309 LCb Shield-Bright 316 L Shield-Bright 317 L Shield-Bright 347 Shield-Bright 308 H Shield-Bright 410 Shield-Bright 2209 Shield-Bright 312 Shield-Bright 410 Ni Mo Shield-Bright 308L Xtra Shield-Bright 309L Xtra Shield-Bright 309LMo Xtra Shield-Bright 316L Xtra Shield-Bright 347 Xtra Arcaloy T - 409 Ti SAW Wires OK Autrod 12.08 L OK Autrod 12.22 L ESAB SA 10K ESAB SA 13K OK Autrod 12.40 L OK Autrod 12.24 L OK Autrod 12.33 L OK Autrod 12.34 L OK Autrod 13.09 L OK Autrod 13.12 L OK Autrod 12.44 OK Autrod 13.10 SC OK Autrod 13.20 SC OK Autrod 13.40 OK Autrod 13.27 OK Autrod 13.43 OK Autrod 13.64 OK Autrod 13.22 L OK Autrod 16.10

87 88 88 89 89 90 90 91 91 92 92 93 93 94 94 95 95 96 96 97 97 98 98 99 99 100 100 101 101 102 102 103 103 104 104 105 105 106 106 107 107 108 108 109

OK Autrod 16.30 109 OK Autrod 16.53 110 OK Autrod 16.11 110 OK Autrod 16.13 111 SAW Flux OK Flux 10.61 L 112 OK Flux 10.62 112 OK Flux 10.62 L 113 OK Flux 10.71 114 OK Flux 10.71 L 115 OK Flux 10.81 L 115 OK Flux 10.81 LM 116 OK Flux 10.81 LS 116 OK Flux 10.92L 117 Strip Cladding Consumables OK Band / Flux for Stainless Steel 118 Hard Surfacing Consumables Wire & Flux Combinations 119 Consumables for Ni Steels 9% Ni Steels for LNG Tank Fabrication120 SMAW OK 92.26 121 OK 92.86 121 OK 92.59 122 GMAW OK Autrod 19.81 123 OK Autrod 19.82 123 GTAW OK TIgrod 19.81 124 OK Tigrod 19.82 124 OK Tigrod 19.85 125 OK Tigrod 19.93 125 SAW OK Flux 10.16 126 Storage & Handling of Electrodes Approval in accordance with classification society rules Calculation of Electrode Consumption 127 Data Sheet – Pipewelding General Recommendations GMAW FCAW SAW

Consumables Guide for ASTM Steels Quick guide for selection of consumables

158 176

Reclamation Consumables
Conventional Hardfacing Alloys Buffering Duroid 250 Duroid 350 Duroid 650 Duroid 650 B ESAB 600B Duromangan Low Heat Hardfacing Alloys Hardfacing Recommended Preheating Astra HTB OK Selectrode 83.28 ESAB 116 Ni OK Selectrode 83.40 OK Selectrode 84.84 OK Selectrode 84.78 Terroweld EWR ESAB 550 Astra MN Durobell Terroweld MN Terroweld SHR Terrowed 35 Terroweld 65 OK 84.80 OK 84.84 Cast Iron Electrodes Welding Cast Iron Ferroloid 1 Ferroloid 3 Ferroloid 4 Terroweld CLH OK Selectrode 92.18 OK Selectrode 92.58 OK Selectrode 92.60 ESAB 801KG ESAB 802KG Terroweld CP 189 190 190 190 191 191 191 193 195 196 196 196 197 197 198 198 199 199 200 200 200 201 201 202 202 203 204 204 204 205 205 206 206 207 207 208

Terroweld CF 208 Steel and Dissimilar Joining Alloys Welding Dissimilar Steels 209 Terroweld DMS 210 ESAB 116 210 OK 53.18 210 Terroweld DBL 211 Terroweld DLH 211 Durochrome 212 Terroweld DS1 212 Terroweld DS2 212 Terroweld DS3 213 Terroweld DS4 213 Terroweld DS5 214 Terroweld DS6 214 Terroweld S1 214 Terroweld S2 215 Terroweld S3 215 ESAB CSA 215 OK Selectrode 68.82 216 OK Selectrode 68.53 216 OK 69.33 217 Astra ZF 217 Non - Ferrous Alloys Welding Non - ferrous Alloys 218 ESAB CN1G 219 ESAB CN 182 219 ESAB Monel 219 OK Selectrode 92.35 220 OK Selectrode 93.66 220 OK Selectrode 93.62 221 OK Selectrode 93.66 221 Bronzoid 1 222 Cuttifng & Gouging Electrodes Cutting and Gouging 223 Terrocut 224 OK Selectrode 21.03 224 Cobalarc Cobalarc 225 Cobalarc 1M 226 Cobalarc 9 226 Cobalarc 4 227 Cobalarc MX 227 Flux Cored Wires OK Tubrod 14.17 228

OK Tubrod 14.18 OK Tubrod 14.70 OK Tubrod 14.71 OK Tubrod 15.40 OK Tubrod 15.41 OK Tubrod 15.52 OK Tubrod 15.60 OK Tubrod 15.73 OK Tubrod 15.80 OK Tubrod 15.86 Gas Brazing Alloys Brazing Rupatan 2 Rupatan 14 Rupatan 35 Rupatan 43 Rupatan 50 Rupatan 60 ESAB Silicon Bronze Ruf - Kut Tig Filler Wires Crystalloy 60 Crystalloy 61 Crystalloy 62 Crystalloy 80 Crystalloy 81 Crystalloy 82 Crystalloy 85 Crystalloy 90 Hot Metal Spray Powders Powder Welding Castcoat 20 Multiweld 40 Borostrength 60 Tungstrength 70 ESAB wear plates ESAB ETH 500 Plates Conversion Chart Comparative Hardness Scales Metal Selection Guide ESAB Consumables for Different Repair Work Selection of Hard Facing Consumables

228 228 229 229 229 230 230 230 231 231 232 233 233 233 234 234 234 234 234 235 235 235 235 236 236 236 236 237 238 238 238 239 239 240 241 242

243 244

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ESAB Consumables for Joining of Dissimilar Metals Metal Identification Chart

245 246

Arc Welding Equipment
MMA Transformers Transweld 400 249 THH 400/THH 630 249 MMA Rectifiers RS 400 250 Esayweld SSr 400 / 600 250 Origo Arc 4001i A22 / A24 252 Caddy Arc 251i A32 / A34 252 Origo Arc 410C / 650C / 810C 253 653 CVCC 253 EDW 350 / 400 / 500 254 Power Compact 255 Migmatic 1250 255 Smashweld 4000T 256 LAB 4000 256 Auto K 400 / 600 257 Auto K 400 Synergic 258 SCR 400 (S) 259 MIG 3000i MA6 MIG 3001i / 4001i 260 Aristo MIG 5000i 261 Aristo MIG U4000i / U5000i 262 Feed 3004 / 4804 U6 264 MIG Torches - Air / Water / cooled 265 Easyweld SSR 400-T / 400-T Pluse 266 Caddy TIG 1500i 266 Origo TIG TA 24 267 Aristo TIG 4000i TA4 / TA 6 268 Heliarc 252 / 352 AC / DC 269 Caddy TIG 2200i AC/DC TA33 / TA34 / AC/DC 270 Origo TIG 3000i AC/DC TA 24 AC/DC 271 Origo TIg 4300iW AC/DC TA 24 AC/DC 272 TIG Torches - Air water cooled 273 LPH 35 / 50 / 80 / 120 274 Powercut 650 / 900 / 1300 / 1600 274 CPRA 800 (S) / 1200 (S) 275 Welding Automation Thyristorised SAW

Power Sources - DC Thyristorised SAW Power Sources - AC A2 / A6 Process controller PEH Orbital TIG Welding Tractor Automates - Migsytrac Migsytrac - 2000 Migsytrac - 3000 Tractor Automates - Roultrac Tractor Automates - Trippletrac / Multitrac / Mastertac Roller Beds Positioners Friction Stir welding Robotics for Arc welding Range of Robats Accessories ARC Welding Accessories Armour Range of Electrode Holders Handyoven Fusion Welding Methods Choice of Fusion Welding Method Welding Methods MMA Manual Metal Arc Welding MMA Manual Metal Arc Welding MIG / MAG Gas Metal Arc Welding MAG Welding MIG Welding TIG (GTAW) Tungsten Inert Gas Welding TIG (GTAW Welding) Common Faults in Arc Welding Common Faults in Arc Welding

276 276 276 277 278 278 278 279 280 281 281 282 283 284 285 286 286 287 287

Special Regulators Cutting Blowpipes Welding & Heating Blowpipes Flash Back Arresters Small Cutting Machine Cutting Nozzies Welding Tips Accessories Accessories

311 312 314 316 318 320 322 324

PPF & Welding Accessories
Helments, Masks & Screens Respiratory Equipment Spectacles, Goggles & Visors Welding Curtains Welding Gloves Safety Foodwear Welding Tools and Accessories Welding Cables Electrode Holders & Clamps 330 332 334 336 337 338 339 340 341

289

291 292

293 295

Industrial Gas Equipment
Process Description Process Description Regulators Single Stage Regulators Double Stage Regulators High Pressure Regulators Pipe Line Regulators 301 304 306 308 310

iv

Welding Consumables
Welding Consumables

ISO 9000 & ISO 14000

Carbon Steel Electrodes
ESAB FERROSPEED
A rutile coated general-purpose electrode for MMAW Classification DESCRIPTION ESAB FERROSPEED is one of the most popular and wellknown welding electrodes in India for decades. ESAB FERROSPEED is a rutile-coated electrode for welding general-purpose structures that are not subjected to heavy dynamic loading, and is specially designed for higher tolerance to less cleaned plates and poor joint fit-ups. Unique balance of arc force and slag fluidity makes the electrode easily manoeuvrable in all positions and because of its versatility and economy, has found wide acceptance for welding mild steel. The weld provides good penetration and an easily detachable slag. The electrode has high current carrying capacity and produces relatively high strength weldmetal. APPROVALS BIS, BV, CIB, LRS. Gr.1, MMD, ABS, IRS, DNV WELDING CURRENT : DC+, AC 70V AWS A5.1 : E 6012 IS 814 : ER 4124 TYPICAL APPLICATIONS Chimney, machine building, repair-jobs, shaft reclamation, ship building, steel furniture and frameworks, storage tanks, bus and truck bodies, cement mills, rolling mills, barge - building etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.085 0.20 0.02 0.40 0.02 Mechanical Properties YS UTS EL Impact (CVN) at + 27oC 420 N/mm2 490 N/mm2 23% 70J

Welding Consumables

CURRENT RANGE & PACKING DATA

Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 450 95-125 150 600 4.00 450 125-175 100 400 5.00 450 165-250 65 260

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB FERROARC
A rutile coated general-purpose electrode for MMAW Classification AWS A5.1 : E 6013 IS 814 : ER 4211X DESCRIPTION ESAB FERROARC is a medium coated general-purpose mild steel electrode, which operates on low OCV (50 V) AC in all positions. ESAB FERROARC delivers smooth and stable welding arc with low spatter and smoke, excellent slag detachability and smooth weld bead appearance. The weld deposit is of radiographic quality. APPROVALS ABS Gr.2, BIS BV Gr.2, DNV Gr.2, IRS Gr.2, LRS Gr.2, MMD, MN Dastur, RDSO E1, CIB, TEIL WELDING CURRENT: DC+, AC 50V

TYPICAL APPLICATIONS Ideally suited for structural welding, welding of pipe sockets, general welding fabrication, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.08 0.25 0.02 0.40 0.02 Mechanical Properties YS UTS EL Impact (CVN) at + 0oC 410 N/mm2 490 N/mm2 26% 70J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 40-100 125 750 3.15 350 95-125 90 540 4.00 5.00 450 450 125-175 165-260 60 40 360 240

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

3

Welding Consumables

ESAB FERROSPEED PLUS
A rutile coated general-purpose electrode for MMAW Classification DESCRIPTION ESAB FERROSPEED PLUS is a medium-heavy coated mild steel welding electrode for all positions, having good mechanical properties and arc characteristics. ESAB FERROSPEED PLUS operates on low open circuit voltage and its good running characteristics result in excellent weld finish of radiographic quality. ESAB FERROSPEED PLUS is also known for its superior V-down welding capabilities. APPROVALS ABS Gr.2, BIS, BV Gr.2, CIB, DNV Gr.2, IRS Gr.2, LRS Gr.2, MMD,PDIL, BHEL, TElL WELDING CURRENT: DC+, AC 50V TYPICAL APPLICATIONS ESAB FERROSPEED PLUS is recommended in applications such as bogies and under-frame of railway carriages and wagons, chimney, construction AWS A5.1 : E 6013 IS 814 : ER 4211X

engineering job, pipe welding, sheet metal fabrication, ship building, steel structures and frame works, truck and bus bodies, tanks, boiler components etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.08 0.23 0.02 0.45 0.02 Mechanical Properties YS UTS EL Impact (CVN) at + 0oC 440 N/mm2 500 N/mm2 26% 70J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.5 350 40-105 190 760 3.15 350 85-135 140 560 3.15 4.00 4.00 5.00 450 350 450 450 85-120 120-175 120-160 160-240 140 85 85 55 560 340 340 220

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB VORTIC
A rutile coated general-purpose electrode for MMAW Classification DESCRIPTION ESAB VORTIC is a medium coated general-purpose mild steel electrode, especially designed for use in vertical and over head positions. This is a rutile coated, fast freezing slag type electrode with excellent slag detachability even in deep grooves. ESAB VORTIC is characterised by superior running characteristic and exceptionally low spatter and finely rippled weld bead deposit. APPROVALS ABS Gr.2, BV Gr.2, BIS, CIB, DNV Gr.2, IRS Gr.2, LRS Gr.2, MMD, RDSO A1. WELDING CURRENT: DC+, AC 5OV TYPICAL APPLICATIONS ESAB VORTIC is recommended for applications such as bogies and under frames of railway carriages and wag4

ons, boilers and pressure vessels, general engineering constructions, pipe welding, sheet metal fabrications, ship construction steel structure and frameworks, tanks and coaches, trucks, bus frames and bodies, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.07 0.2 0.02 0.4 0.02 Mechanical Properties YS UTS EL Impact (CVN) at + 0oC 430 N/mm2 490 N/mm2 26% 65J

AWS AS.1 : E 6013 IS 814 : ER 4224X

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 40-100 185 740 3.15 450 100-125 125 500 4.00 5.00 6.30 450 450 450 135-175 150-260 195-360 90 60 35 360 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB 28
A rutile coated radiography quality electrode for MMAW Classification DESCRIPTION ESAB 28 is a medium heavy rutile coated mild steel electrode designed for welding of unalloyed structural steels in all positions. The electrode gives smooth radiographic quality weld with low spatter and smoke. Bead shape is uniform and finely rippled and slag is self removal type. APPROVALS ABS Gr.2, BIS, BV Gr.2, CIB, DNV Gr.2, TElL, IRS Gr.2, LRS Gr.2, MMD, NPC, PDIL. WELDING CURRENT: DC (+), AC 50V TYPICAL APPLICATIONS It is recommended for welding structures of varying thickness of MS plates in different type of joints and welding ordinary grade ship steel as well as structural steel of similar strength and composition. Suitable for AWS A5.1 : E 6013 IS 814 : ER 4212X

welding of pipes, bridges, boilers and pressure vessels storage tanks, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.08 0.24 0.02 0.45 0.02 Mechanical Properties YS UTS EL Impact (CVN) at 0oC 430 N/mm2 500 N/mm2 26% 90J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-85 190 760 3.15 350 85-120 120 480 3.15 4.00 4.00 5.00 450 350 450 450 85-120 120-175 120-160 160-240 120 75 75 50 480 300 300 200

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB VORDIAN
A rutile coated high productivity electrode for MMAW Classification DESCRIPTION ESAB VORDIAN is an all position medium heavy rutile coated mild steel welding electrode of outstanding quality permitting use of low open circuit voltages. Since it can be touch welded, very little skill is required in obtaining quality welds. ESAB VORDIAN is extremely suitable for flat and horizontal-vertical position as well as for vertical and overhead welding. Excellent welding performance and mechanical properties with radiographic soundness is easily achievable. ESAB VORDIAN is also suitable for pipe welding jobs. APPROVALS ABSGr.2, BIS, BV Gr.2, CIB, DNV Gr.2, TElL, IRS Gr.2, LRS Gr.2, MMD, NPC, RDSO C2, BHEL. WELDING CURRENT: DC(+), AC 50V TYPICAL APPLICATIONS ESAB VORDIAN is recommended for applications such as boiler and pressure vessels, bogies and under AWS A5.1 : E 6013 IS 814 : ERR 4221X

frame of railway carriages and wagons, bridges and dam construction, cranes, machine building, plate and sheet metal fabrication, ship construction, framework, tankages, pipes, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.07 0.22 0.02 0.42 0.02 Mechanical Properties YS UTS EL Impact (CVN) at 0oC 410 N/mm2 490 N/mm2 26% 90J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 50-105 160 640 3.15 350 85-130 110 440 3.15 4.00 5.00 450 450 450 85-130 130-180 160-240 110 75 50 440 300 200

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

5

Welding Consumables

ESAB 46
A rutile coated general-purpose electrode for MMAW Classification DESCRIPTION ESAB 46 is a heavy rutile coated electrode of excellent performance characteristics for welding of mild steel, structural steel, pressure vessels and of quality ship plates. It has very good slag detachability and shiny bead appearance. Provides welds of high radiographic soundness. APPROVALS ABS Gr.2, BV Gr.2, CIB, DNV Gr.2, MMD, LRS Gr.2, IRS Gr.2. ELDING CURRENT: DC+, AC 50V TYPICAL APPLICATIONS Boiler and pressure vessels, bogies and under frames of carriages and wagons, cranes, shipbuilding, storage tanks, bridges and dams, machine building, heavy structural work, etc. AWS A5.1 : E 6013 IS 814 : ERR 4221X

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.07 0.22 0.02 0.5 0.02 Mechanical Properties YS UTS EL Impact (CVN) at + 0oC 440 N/mm2 520 N/mm2 26% 70J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.5 350 55-105 150 600 3.15 450 95-130 110 440 4.00 5.00 450 450 140-190 160-250 75 40 280 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB C23S
A rutile coated general-purpose electrode for MMAW (High Recovery) Classification AWS A5.1 : E 7024 IS 814 : ERR 5234KX DESCRIPTION ESAB C 23 S is a heavy coated rutile-iron powder electrode having a deposition efficiency of 130-140% and is specially designed for very fast welding of unalloyed steels in downhand position and for standing fillets by contact welding. It is also widely used in filling of butt welds. ESAB C 23 S is less sensitive to plate surface impurity and has excellent weld appearance with a selflifting slag at all speeds. Above all weld deposit is of radiographic quality. APPROVALS BVGr.2, IRSGr2, MMD WELDING CURRENT: DC+, AC 50V

TYPICAL APPLICATIONS Welding of thick plate in shipbuilding, penstock fabrication, air-receivers, compressors, boilers, structural works, heavy beams and girders etc. This electriode is ideal where superior final bead finish coupled with good radiographic and mechanical properties are required. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.09 0.6 0.025 0.8 0.02 Mechanical Properties YS UTS EL Impact (CVN) at 0oC 480 N/mm2 550 N/mm2 23% 65J

CURRENT RANGE & PACKING DATA

Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 350 120-150 75 300 4.00 450 180-210 55 220 5.00 450 260-340 30 120

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

6

ESAB FERROWELD 1
A basic coated low-hydrogen electrode for MMAW
Classification DESCRIPTION ESAS FERROWELD 1 is a basic coated, hydrogen controlled electrode for welding mild, medium carbon, low alloy, medium tensile steels, free cutting and difficult steels, and grey cast iron (non-machinable deposits) in all positions, using AC or DC power sources for complete absence of porosity and cracking. The composition of the coating ensures high weldmetal ductility, very low hydrogen and absence of other non-metallic inclusions. ESAB FERROWELD 1 allows touch welding and deposits weldmetal of highest radiographic soundness (IIW Black) free from under-bead cracking and high notch ductility at sub zero temperatures. . APPROVALS ASS Gr.3H, BV Gr.3, 3YH, BIS, CIB, DNV Gr.3YH15, IRS 3YH, LRS 3, 3Y, 3H, MMD WELDING CURRENT : DC+, AC 70V AWS A5.1 : E 7016 IS 814 : EB 5424H3X

TYPICAL APPLICATIONS Boiler and pressure vessels, penstock, structure and other components under restrained conditions and dynamic loading, ship building, steel of doubtful composition, grey cast iron, buffer layer prior to hard facing etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.07 0.55 0.02 1.3 0.02 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 440 N/mm2 540 N/mm2 30% 80J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-100 170 680 3.15 350 100-150 100 400 4.00 5.00 450 450 120-210 200-280 65 45 260 180

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB 56
A basic coated electrode for MMAW Classification DESCRIPTION ESAB 56 is a basic coated, hydrogen controlled allpurpose electrode that can be operated using both DC and AC power sources in all positions. The fairly thin coating provides good accessibility to the joint. ESAB 56 has very smooth running performance with low spatter, requiring minimum post weld cleaning on account of its excellent de-slogging properties. APPROVALS DNV GR 3YH15, MMD, CIB WELDING CURRENT: DC +, AC 70V TYPICAL APPLICATIONS For welding heavy section of mild and medium tensile steels that are subjected to dynamic loading. It is intended for welding carbon and C-Mn steels. It is also suitable for depositing non-machinable weld on Cast Iron, buffer layer for hard facing, etc. AWS A5.1 : E 7016 IS 814 : EB 5424H2X

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.06 0.45 0.025 1.2 0.02 Mechanical Properties YS UTS EL Impact (CVN) at 0oC 450 N/mm2 550 N/mm2 29% 110J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 50-100 135 540 3.15 450 85-120 95 380 4.00 5.00 450 450 100-170 180-250 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electriode is also available in moisture resistant vacuum packed cartons, which can be used without redrying.

7

Welding Consumables

ESAB FERROWELD 2
A basic coated low-hydrogen electrode for MMAW Classification DESCRIPTION ESAB FERROWElD 2 is a basic coated, hydrogen controlled iron powder (high metal recovery of minimum 110%) electrode for welding mild, medium carbon, low alloy, medium tensile steels, free cutting and difficult to weld steels, grey cast iron (non-machinable deposits) in all positions using AC or DC power sources. The addition of iron powder permits higher currents to be used and results in improved arc characteristics. ESAB FERROWElD 2 allow touch welding and deposit weldmetal of highest radiographic soundness free from under-bead cracking and high notch ductility at sub zero temperatures. APPROVALS ABS 3H10 3Y, BIS BV 3YHH, CIB, DNV 3YH10, TElL, IRS Gr.3YH, LRS Gr.3, 3Y 3H, MMD WELDING CURRENT: DC+, AC 70V AWS A5.1: E 7018 IS 814 : EB 5424H3JX

TYPICAL APPLICATIONS Boiler and pressure vessels, penstock, structural and other components under restrained conditions and dynamic loading, ship building, steel of doubtful composition, grey cast iron, buffer layer prior to hard facing etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.07 0.55 0.02 1.3 0.02 Mechanical Properties YS UTS EL Impact (CVN) at -30oC 470 N/mm2 570 N/mm2 26% 75J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 140 560 3.15 450 110-140 90 360 4.00 5.00 450 450 140-185 160-275 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

ESAB 36 H
A basic coated electrode for MMAW Classification DESCRIPTION ESAB 36H is a heavy basic coated hydrogen controlled iron powder electrode designed for welding in all positions. It gives tough, crack resistant weld on mild and low alloy steels. ESAB 36H deposits good X-ray quality welds and is ideal for welding rigidly resistant structures where stress cannot be avoided. ESAB 36H is designed to provides high recovery (>115%) with a thin easily detachable slag of excellent bead profile. Further has an extremely smooth and stable arc with good arc striking and re-striking characteristics even at acv down to 60V. APPROVALS ABS Gr.3H15, BIS, BV Gr.3YHH, CIB, DNV Gr.3YH15, LRS Gr.3, 3Y, H, MMD, NPC, PDIL, TElL, IRS GR.3YH, BHEL. WELDING CURRENT: DC+, AC 70V AWS A5.1: E 7018 IS 814 : EB 5426H3JX

TYPICAL APPLICATIONS ESAB 36H is ideally suited for welding boiler quality and pressure vessel steels and heavy structures as well as pipes, tankages, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.08 0.45 0.022 1.20 0.022 Mechanical Properties YS UTS EL Impact (CVN) at -30oC 470 N/mm2 540 N/mm2 28% 100J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 80-110 130 520 3.15 4.00 5.00 450 450 450 120-150 150-190 180-260 90 60 40 360 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. The electrodes are also available in moisture resistant vacuum packed cartons, which can be used without redrying.

8

OK 48.20
A basic coated low-hydrogen electrode for MMAW Classification DESCRIPTION OK 48.20 is a heavy basic coated, hydrogen controlled iron powder (high metal recovery of approximately 117%) electrode with excellent running performance and bead finish in flat and positional welding. It deposits a tough and crack-resistant weld of high radiographic quality. APPROVALS MMD WELDING CURRENT: DC+, AC 70V TYPICAL APPLICATIONS Boiler and pressure vessels, penstock, structure and other components under restrained conditions and dynamic loading, ship building, steel of doubtful composition, grey cast iron, buffer layer prior to hard facing etc.

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.06 0.50 0.018 1.15 0.018 Mechanical Properties YS UTS EL Impact (CVN) at -30oC 490 N/mm2 560 N/mm2 30% 100J

Welding Consumables

AWS A5.1: E 7018
IS 814 : ES 5424H3JX

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 140 560 3.15 450 100-150 95 360 4.00 5.00 450 450 130-190 180-260 65 40 260 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode are also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

ESAB 36 H (SPL)
A basic coated electrode for MMAW Classification DESCRIPTION ESAB 36H (SPL) is a basic coated low hydrogen iron powder electrode for low temperature applications. It is an all position electrode for welding medium tensile and fine grained carbon steels. ESAB 36H (SPL) deposits weldmetal of very low hydrogen content at a deposition efficiency of 115%. The weldmetal is of high radiographic soundness, providing good mechanical properties and excellent impact strength at -50°C. APPROVALS MMD, NPC, PDIL, CIB, ABSGr, TEIL WELDING CURRENT: DC+, AC 70V TYPICAL APPLICATIONS ESAB 36H (SPL) is ideal for welding of fine grained carbon manganese steels and medium tensile steels having UTS of 50-58 Kgf/mm2 and is recommended for welding of pressure vessels, boilers, hortonspheres, AWS A5.1: E 7018-1 IS 814 : EB 5626H3JX

mounded bullets, heavy fabrication work and for pipelines subjected to low temperature. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.08 0.42 0.02 1.40 0.02 Mechanical Properties YS UTS EL Impact (CVN) at -50oC 450 N/mm2 570 N/mm2 28% 75J

CURRENT RANGE & PACKING DATA

Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 80-110 140 560 3.15 450 120-150 90 360 4.00 450 450 150-190 180-260 60 40 240 160

5.00

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode are also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

9

Welding Consumables

OK 48.20 (SPL)
A basic coated low-hydrogen electrode for MMAW Classification DESCRIPTION OK 48.20 (SPL) is a heavy basic coated, hydrogen all position electrode for welding medium tensile & fine grained carbon steels. The electrode gives an extremely smooth arc, least spatter with good slag detachability. The weldmetal is of highest radiographic soundness with good mechanical properties and excellent impact strength. The electrode gives deposition efficiency of approx. 115%. TYPICAL APPLICATIONS OK 48.20 (Spl) is especially designed for welding of C-Mn steels such as ASTM A 106 Gr B, pipelines, etc. used for sour gas service. WELDING CURRENT: DC+, AC 70V

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.06 0.50 0.010 1.15 0.018 Mechanical Properties YS UTS EL Impact (CVN) at -30oC 510 N/mm2 590 N/mm2 26% 120J

AWS A5.1: E 7018

PASSES CORROSION TEST AS PER NACE STANDARD TM-01-077 and TM-02-84 (of NACE MR 0175 specification). Guaranteed Strees Value after SSCC Test: 357 Mpa Hardness of the weldmetal: 22 RC max CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 100-150 90 360 4.00 5.00 450 450 140-200 190-270 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a carboard box.

ESAB 36 H (SPL) M
A basic coated moisture resistant electrode for MMAW Classification DESCRIPTION ESAB 36H (SPL) M is a heavy basic coated extra low hydrogen, iron power, moisture resistant electrode designed for welding in all positions. It gives tough, crack resistant weld on mild and low steels. ESAB 36 H (Spl) M deposits good X-ray quality welds and is ideal for welding rigidly restrained structures where stress cannot be avoided. ESAB 36H (Spl) M is designed to provide high recovery (>115%) with a thin easily detachable slag of excellent bead profile. Further, it has an extremely smooth and stable arc with good arc striking and restriking characteristics even at OCV down to 70V. TYPICAL APPLICATIONS ESAB 36H (Spl) M is designed for welding C-Mn steels used in boilers, pressure vessels, spheres, storage tanks and piping used for sour gas service. AWS A5.1: E 7018-1 IS 814 : EB 5626H3JX

WELDING CURRENT: DC(+), AC (70V) TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si P Mn S 0.06 0.30 0.008 1.2 0.01 Mechanical Properties YS UTS EL Impact (CVN) at -46oC 440 N/mm2 540 N/mm2 34% 150J

PASSES CORROSION TEST AS PER NACE STANDARD TM-01-77 and TM-02-84 (of NACE MR 0175 specification). Guaranteed Stress Value after SSCC Test: 357 MPa Hardness of the weldmetal: 22 RC max CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 80-110 140 560 3.15 450 120-150 90 360 4.00 5.00 450 450 150-190 180-260 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box.

10

ESAB VORTEX -1
Heavy Coated Rutile Type Classification DESCRIPTION ESAB Vortex-1 is a heavy coated rutile type electrode with excellent slag detachability even in deep grooves. Has superior bead finish and low spatter. Suitable for low alloy and medium tensile steels, high radiographic quality. APPROVALS : BIS, ABS Gr3, MMD TYPICAL APPLICATIONS Boilers and pressure vessels, shipbuilding and heavy structurals. WELDING CURRENT: DC+

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni S P 0.05 0.50 0.23 0.4 0.020 0.020 Mechanical Properties YS UTS EL Impact (CVN) at -20oC 400 N/mm2 510 N/mm2 26% 65J

Welding Consumables

AWS A5.1 : E6013

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 450 450 450 No. of Electrodes in a Cardboard PCS box 600 1 400 1 240 140 1 1

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a carboard box.

11

Gas Welding Fluxes
Welding Consumables

Gas Welding Fluxes
DESCRIPTION ESAB welding and brazing fluxes are well known and are designed to obtain consistent and sound joints between steel, copper, brass, bronze and aluminium. Some of the common applications are found in manufacturing and repair of automobiles, refrigeration and air conditioning, tool manufacturing and other industries. ESAB WELDING AND BRAZING FLUXES Flux
ESAB Castox

REMOVAL OF FLUX RESIDUE: Aluminium and Aluminium alloys: Immediately after welding wash the joints in warm water and brush vigourously. When conditions allow, follow up by a rapid dip in a 5% solution of nitric acid; wash again, using hot water to assist drying. Copper and Brass:- Wash in boiling water followed by brushing. Where possible a 2% solution of nitric or sulphuric acid is prefered to help in tifting the glassy deposit, followed by a hot water wash. Cast Iron:- Residues may be removed easily by a chipping hammer or wire brush. Rupatam A:- Can be easily removed by soaking brazed components in hot water followed by wire brushing. In difficult situations, the work piece should be immersed in 5% to 10% sulphuric acid solution for a period of 2 to 5 minutes, followed by hot water rinsing and wire brushing. PACKING: ESAB Welding and Brazing Fluxes are packed in plastic containers and then in cardboard box totalling 25kg Net of 500g each.

Application
Cast Iron Welding Cast Irons by fusion welding technique.

ESAB Brazotectic Fusion welding of brass, brazing copper to steel sheets and tubes with Sillicon Bronze rods. Welding copper alloys with Nickel Bronze and other Bronze rods. However not suitable for braze welding cast iron or brazing stellite for tipping of tools. ESAB Bronzotectic Braze welding cast or mallesable iron and building up worn bearing surfaces with Manganese Bronze rods and Nickel Bronze rods. Welding alloys Alumium and Aluminium

ESAB Alotectic AWS A5.31 FBI-A ESAB Rupatam A AWS A5.31 FB3-F ESAB Albratectic AWS A5.31 FBI -A

For Silver Brazing

Brazing Aluminium and Aluminium alloys containing 2% Magnesium

12

Pipe Welding Electrodes
PIPEWELD 6010R
Cellulose coated electrode for Pipe Welding Classification DESCRIPTION PIPEWElD 6010R is high cellulose coated electrode for welding of pipes. The electrode is designed to provide deep and complete penetration and the weld bead obtained is smooth with a thin, fast freezing easily removable slag, giving x-ray quality weldmetal. APPROVALS: PDll, TElL, NPC. WELDING CURRENT: DC + TYPICAL APPLICATIONS PIPEWElD 6010R is designed for site welding of carbon steel pipes and pipelines in all positions using conventional techniques particularly for root run. It can be used where stringent NDT requirement and testing codes are involved. AWS A5.1 : E6010 IS 814: EC 4410 X TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn P Si S 0.10 0.50 0.02 0.25 0.02 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 420 N/mm2 500 N/mm2 27% 50J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 50-80 200 800 3.15 350 90-130 130 520 4.00 350 110-160 80 320

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Also available in 10kg sheet metal cans.

Pipeweld 6010 Plus
Cellulose coated electrode for Pipe Welding Classification : AWS A5.1 : E6010 DESCRIPTION Cellulosic - coated electrode designed for welding of pipes and pipelines in all positions using conventional and stovepipe techniques with AC or DC. APPROVALS: ABS Gr3, LR Gr3. WELDING CURRENT: AC, DC +

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S 0.09 0.2 0.35 0.02 0.02 Mechanical Properties YS UTS EL (L=5d) Impact (CVN) at -29oC 410 N/mm2 495 N/mm2 26% 40J

CURRENT RANGE
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amps) 50-70 65-120 90-180 150-240

PACKING: Available in 20Kg sheet metal cans.

13

Welding Consumables

OK 22.46 P
Classification Electrode AWS A5.5 : E7010-G DESCRIPTION Cellulosic - coated electrode designed for sitewelding of pipe and pipelines API 5L X52 and X56 in all positions using conventional stovepipe techniques, DC only. APPROVALS: BV Gr 3, 3Y; LR Gr 3, 3Y. WELDING CURRENT: DC +

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Ni Mo 0.105 0.14 0.45 0.03 0.03 0.425 0.30 Size (mm) 3.20 4.00 5.00 Mechanical Properties YS UTS EL Impact (CVN) at -20oC 476 N/mm2 544 N/mm2 24% 60J

CURRENT RANGE
Length (mm) 350 350 350 Current Range (Amps) 65-120 90-180 150-240

PACKING: Available in 20Kg sheet metal cans.

OK 22.47 P
Classification Electrode AWS A5.5 : E8010-G DESCRIPTION Cellulosic-coated electrode designed for sitewelding of pipe and pipelines API 5L X60 and X70 in all positions using conventioneal stovepipe techniques, DC only. APPROVALS: LR Gr 3, 3Y. WELDING CURRENT: DC +

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Cr Ni Mo V 0.085 0.175 0.055 0.03 0.03 0.05 0.75 0.375 0.05 Size (mm) 3.20 4.00 5.00 Mechanical Properties YS UTS EL Impact (CVN) at -30oC 513 N/mm2 600 N/mm2 24% 70J

CURRENT RANGE

Length (mm) 350 350 350

Current Range (Amps) 65-120 90-180 150-240

PACKING: Available in 20Kg sheet metal cans.

14

OK 22.48 P
Classification Electrode AWS A5.5 : E9010-G DESCRIPTION Cellulosic-coated electrode designed for sitewelding of pipe and pipelines. WELDING CURRENT: DC + TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.11 0.175 0.95 0.03 0.03 0.05 0.795 0.45 0.05 0.05 0.3 Mechanical Properties YS UTS EL Impact (CVN) at -20oC 560 N/mm2 700 N/mm2 22% 60J

CURRENT RANGE
Size (mm) 3.20 4.00 5.00 Length (mm) 350 350 350 Current Range (Amps) 65-120 90-180 150-240

Welding Consumables

PACKING: Available in 20Kg sheet metal cans.

PIPEWELD 6011
Cellulose coated electrode for Pipe Welding Classification DESCRIPTION PIPEWELD 6011 is a high cellulose coated, potassium base electrode for pipe welding in DC (+) as well as AC operation. The electrode gives complete penetration and weld bead is smooth. Weld joint is of x-ray quality. The immense welder appeal stems from the fact that weld puddle is easily controllable, with a slag system that is fast freezing, thin and easily removable resulting in excellent bead profiles and ease of operation. WELDING CURRENT: DC +, AC TYPICAL APPLICATIONS PIPEWELD 6011 is designed for site welding of pipes and pipelines in all positions using ‘Stove Pipe’ and conventional techniques particularly for root bead. It can be used where stringent NDT requirement and testing codes are involved. AWS A5.1 : E6011 IS 814: EC 4316X

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si 0.10 0.55 0.25 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 400 N/mm2 480 N/mm2 27% 50J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 50-80 160 640 3.15 350 90-130 110 440 4.00 5.00 350 350 110-160 130-180 70 50 280 200

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Also available in 10 kg sheet metal cans.

15

Low Alloy Electrodes
Welding Consumables

OK 48.08
A low alloy, low hydrogen electrode for MMAW Classification DESCRIPTION OK 48.08 is a basic coated Ni alloyed low hydrogen electrode for low temperature applications down to - 51°C. It is an all position electrode for welding medium tensile & fine grained carbon steels with AC and DC power supply. The electrode gives an extremely smooth arc, least spatter with good slag detachability. Weldmetal is of highest radiographic soundness with good mechanical properties and excellent impact strength. The electrode gives deposition efficiency of approx. 115%. WELDING CURRENT: DC +, AC 70V TYPICAL APPLICATIONS OK 48.08 is especially designed for the welding of low alloy steels such as steels containing up to 1% Nickel and also for structures to withstand low temperatures. AWS A5.5: E 7018-G IS1395: E49B-G126Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn S Si Ni P Cr 0.06 1.25 0.015 0.2 1.00 0.02 0.03 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 430 N/mm2 520 N/mm2 28% 125J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 75-110 130 520 3.15 450 105-150 90 350 4.00 5.00 450 450 140-200 190-270 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

OK 73.08
A low alloy, low hydrogen electrode for MMAW Classification DESCRIPTION OK 73.08 is a Ni-Cu co alloyed low hydrogen basic coated electrode which deposits a weldmetal with good corrosion resistance to sea water and flue gases, for the welding of weather proof steel and for ships hull structural steel. The weldmetal has excellent mechanical properties and good low temperature toughness. Approval:- DNA(IN), RDSO E2 WELDING CURRENT: DC (+), AC 70V TYPICAL APPLICATIONS Designed for welding of weather proof steel, ship’s hull, ice - breaker and similar applications. AWS A5.5: E 8018 G IS: 1395:E55B-G1Ni26

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn S Si Ni P Cu 0.06 1.05 0.02 0.35 0.5 0.02 0.45 Mechanical Properties YS UTS EL Impact (CVN) at - 50oC 490 N/mm2 580 N/mm2 28% 50J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 75-110 130 520 3.15 4.00 5.00 450 450 450 105-150 140-200 190-270 90 60 40 360 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

16

OK 74.46
A low alloy, low hydrogen electrode for MMAW Classification DESCRIPTION OK 74.46 is a low alloy, low hydrogen electrode depositing a ductile and creep-resistant 0.5% Mo steel deposit for welding of Carbon-Molybdenum creep resistant pressure vessel steel. The specially designed slag system allows excellent running in all positions with minimum amount of spatter. OK 74.46 deposits a weldmetal with good crack and creep resistance to temperature upto 525°C. The weld deposit is of radiographic quality. APPROVALS: PDlL, IBR, NPC, TEIL. WELDING CURRENT: DC +, AC 70V TYPICAL APPLICATIONS OK 74.46 is especially designed for the welding of 0.5% Mo and similar creep resistant steels. It is extensively used in high temperature pipelines, boiler tubes and plates where high creep resistance is a pre-requisite. AWS A5.5: E7018-A 1 IS 1395: E49B-A 1-26Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition(%) C Mn Si Mo S P 0.06 0.75 0.45 0.55 0.018 0.020 Mechanical Properties YS 460 N/mm2 UTS 550 N/mm2 EL 28% Hot Tensile Properties 300oC 390 N/mm2 400oC 360 N/mm2 500oC 340 N/mm2

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 75-110 135 540 3.15 450 105-150 95 380 4.00 5.00 450 450 140-200 190-270 60 35 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

OK 76.18
A basic AC/DC low alloy electrode for MMAW Classification DESCRIPTION OK 76.18 is a basic coated, hydrogen-controlled electrode; iron powder type used for welding creep resistant steels of 1.25% Chromium, 0.5% Molybdenum type. The slag system design is such that the electrode welds with a quite, stable arc and gives a minimum amount of spatter and a weld bead that is smooth and even. OK 76.18 welds without short-circuiting and deposits a weldmetal resistant to both cracking and porosity. Root runs can be made easily with the electrode. The weldmetal is resistant to scaling upto 775°C. The weld deposit is of radiographic quality. APPROVALS: PDlL, IBR, NPC, TEIL. WELDING CURRENT: DC +, AC 70V TYPICAL APPLICATIONS OK 76.18 is specially used to the welding of 1.25 Cr 0.5 Mo and similar creep resistant steels which find extensive use in high temperature components of power plants, boilers, oil-refineries, petrochemical plants etc. Use for steels of the type ASTM A 182-F2, F11, F12; AWS A5.5: E 8018-B2 IS 1395: E 55B-B226Fe

A387 -2, 12; A213-T2, T11, T12;A335-P2, P11, P12 and German steels 13 Cr Mo 44,15 Cr Mo 5 etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si P Mo Cr S 0.07 0.60 0.5 0.020 0.55 1.3 0.018 Mechanical Properties Hot Tensile Properties

YS 520 N/mm2 100oC 480 N/mm2 UTS 610 N/mm2 200oC 465 N/mm2 EL 24% 300oC 450 N/mm2 400oC 420 N/mm2 500oC 360 N/mm2

* Annealed 2H at 700OC, furnace cooled. CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 3.15 4.00 4.00 5.00 450 350 450 350 450 90-150 80 - 130 130-190 110-170 150-260 95 95 60 60 35 380 380 240 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.
17

Welding Consumables

OK 76.18 M
A basic AC/DC low alloy electrode for MMAW Classification DESCRIPTION OK 76.18 M is a basic coated, low carbon, hydrogen controlled iron powder type electrode used for welding creep resistant steels of 1.25% Chromium, 0.5% Molybdenum type. The slag system design is such that the electrode welds with a quite, stable arc and gives a minimum amount of spatter and a weld bead that is smooth and even. OK 76.18 M welds without shortcircuiting and deposits a weldmetal resistant to both cracking and porosity. Root runs can be made easily with the electrode. The weldmetal is resistant to scaling upto 575°C and of radiographic quality. WELDING CURRENT: DC (+), AC 50V APPLICATION OK 76.18 M is specially used to the welding of 1.25 Cr 0.5 Mo and similar creep resistant steels which find extensive use in high temperature components of power plants, boilers, oil- refineries, petrochemical plants, boilAWS A5.5: E 7018-B2L IS 1395: E 49 BB 2 L 26 Fe

ers etc. Steels of the type ASTM A 182-F2, F11 , F12, A387 -2, 11, 12, A213-T2, T11, T12, A335- P2, P11, P12 and German steels 13 Cr Mo 44, 15 Cr Mo 5 etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Mo Cr S P 0.03 0.60 0.4 0.55 1.25 0.02 0.02 YS UTS EL Mechanical Properties 450 N/mm2 540 N/mm2 24%

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 90-150 95 380 4.00 5.00 450 450 130-190 150-260 60 35 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying. CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-100 130 520 3.15 4.00 5.00 450 450 450 90-150 130-190 150-260 95 60 35 380 240 140

ESAB 8018 - B2
A low hydrogen basic electrode for welding 1.25 Cr, 0.5 Mo - Creep Resistant Steel Classification DESCRIPTION ESAB 8018 - B2 electrode is a basic low hydrogen electrode for welding creep resisting steels of the 1.25 Cr - 0.5 Mo types, such as SA 387 Grade 11/A 335 P11. The Weldmetal has extra low impurity level, and is designed for low temperature impact toughness down to - 18OC. WELDING CURRENT: DC (+) TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si S P Cr Mo 0.052 0.49 0.141 0.009 0.018 1.17 0.55 Mechanical Properties UTS 643 N/mm2 UTS 574 N/mm2 EL 22% CVN Impact Toughness at - 18OC, 100J Hardness : Vickers H30:280 Diffusible Hydrogen : 4.5 ml/100g

AWS/A 5.5 E 8018 - B2

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Vacuum packed cartons also are available.

18

OK 76.18G
A Rutile AC/DC low alloy electrode For MMAW Classification DESCRIPTION OK 76.18G is a rutile-coated electrode depositing a 1.0 Cr/0.45 Mo/0.25 V type low alloy deposit for high temperature service up to 550°C. OK 76.18G is specially designed for joining plant piping and are of radiographic quality. WELDING CURRENT: DC +, AC 70 V TYPICAL APPLICATION OK 76.18G are suitable for low alloy steel boiler and piping applications that are operated at elevated temperatures of up to 550OC. OK 76.18G it can also used for fabrication of boiler heads and spares of similar composition that find usage at petro-chemicals, refineries, thermal power plants etc. AWS A5.5: E 8013-G IS 1395: E55RG124

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Mo S P V 0.07 0.5 0.25 1.05 0.50 0.02 0.02 0.30 YS UTS EL Mechanical Properties 500 N/mm2 580 N/mm2 22%

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 75-110 130 520 3.15 4.00 5.00 450 450 450 105-150 140-200 190-270 90 60 40 360 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistance vacuum packed cartons, which can be used without redrying.

OK 76.28
A basic AC/DC low alloy electrode for MMAW of 2.25 Cr, 1 Mo type steels Classification DESCRIPTION OK 76.28 is a basic, medium-heavy coated, hydrogen controlled iron powder type, all position electrode depositing a weldmet of the type 2.25% Cr, 1 % Mo steels suitable for welding of similar Cr-Mo steels. The slag system design allows excellent stable arc characteristics in all positions with minimum spatter providing smooth and even bead. The weldmetal provides scaling resistance upto 600°C and is radiographically sound. APPROVALS: PDlL, CIB, NPC, TEIL. WELDING CURRENT: DC:(+), AC 65V TYPICAL APPLICATIONS OK 76.28 finds extensive use in fabrication of low alloy steel boilers and piping operating at temperature upto 600°C in oil refineries, thermal and chemical plants, preheater, super heaters, steam boilers and especially for hydro-crackers. Used for welding creep resistant steels of 2.25 Cr 1 Mo type similar to ASTM A335 Gr P22 or equivalent. AWS A5.5: E 9018-B3 IS 1395: 63 BB 3 26 Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si P S Cr Mo 0.07 0.80 0.45 0.018 0.018 2.30 1.00 Mechanical Properties YS 600 N/mm2 UTS 700 N/mm2 EL 22% Hot Tensile Properties* 400oC 500oC 550oC 600oC 500oC 480 N/mm2 445 N/mm2 415 N/mm2 360 N/mm2 360 N/mm2

* Annealed 1 H at 700°C, furnace cooled. CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 90-150 95 380 3.15 4.00 4.00 5.00 350 450 350 450 80-130 130-190 110-170 150-260 95 60 60 35 380 240 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.
19

Welding Consumables

OK 76.28 M
A basic AC/DC low alloy electrode for MMAW of 2.25 Cr, 1 Mo type steels Classification DESCRIPTION OK 76.28 M is a basic, medium-heavy coated, hydrogen controlled low carbon, iron powder type, all position electrode depositing a weldmetal of the type 2.25% Cr, 1% Mo steels suitable for welding of similar Cr-Mo steels. The slag system design allows excellent stable arc characteristics in all positions with minimum spatter providing smooth and even bead. The weldmetal provides scaling resistance upto 600OC and is radiographically sound. WELDING CURRENT: DC (+), AC 65V TYPICAL APPLICATIONS OK 76.28 M finds extensive use in fabrication of low alloy steel boilers and piping operating at temperature upto 600°C in oil refineries, thermal and chemical plants, preheater, super heaters, steam boilers and especially for hydro-crackers used for welding creep resistant steels of 2.25 Cr-1 Mo type similar to ASTM A 335 Gr P22 or equivalent. AWS A5.5: E 9018-B3

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si P S Cr Mo 0.03 0.8 0.45 0.018 0.018 2.25 1.00 YS UTS EL Mechanical Properties 600 N/mm2 490 N/mm2 23%

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 90-150 95 380 4.00 5.00 450 450 130-190 150-260 60 35 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons which can be used without redrying.

ESAB KV4
A basic coated low hydrogen electrode for welding 5 Cr-O.5 Mo steels Classification DESCRIPTION ESAB KV4 is a basic coated all positional electrode used for welding of creep resistant, Cr-Mo bearing steel. Deposited metal is highly resistant to heat and corrosion. The design of the slag system and the good arc characteristics allow maximum welder appeal with the arc stable in all positions, spatter to a minimum and a weld bead that is smooth and even. Weld deposit is of radiographic quality. WELDING CURRENT: DC+ TYPICAL APPLICATIONS ESAB KV4 is designed for welding 5 Cr /0.5 Mo or equivalent steels used for elevated temperature service. It finds extensive use in the chemical and petrochemical industries, oil industries where it has to resist corrosion and hydrogen attack at high temperatures. It is also used for welding parts of aircraft made out of SAE 4130 steels, heat treatable steels etc.
20

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Mo S P 0.06 0.80 0.30 5.60 0.60 0.018 0.018 YS UTS EL Mechanical Properties 490 N/mm2 575 N/mm2 25%

AWS A5.5: E 8018-B6 IS 1395: E 55 B-B 620

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 65-95 135 540 3.15 350 75-130 95 380 4.00 5.00 350 450 115-165 180-240 60 45 240 180

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

ESAB KV7
A basic coated low hydrogen electrode for welding 9 Cr-1 Mo steels Classification DESCRIPTION ESAB KV7 is basic coated all position electrode for welding of creep - resistant steels alloyed with 9Cr-1 Mo. The weldmetal obtained is ductile and resistant to impact. The weldmetal is highly resistant to corrosion and hydrogen attack at high temperatures. The arc and current carrying characteristics, minimum spatter and smoke level and stable arc in all positions appeal to the welder. The weldmetal is of radiographic quality and appearance is smooth and even. WELDING CURRENT: DC+, AC (70V) APPLICATIONS ESAB KV7 is intended for welding of steels with similar composition. These steels are otten found in oil refineries, chemical and petrochemical industries, power plants where it has to resist corrosion and hydrogen attack at high temperatures. AWS A5.5: E 8018-B8 IS 1395: E 55 B-B 820

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Cr S Mo Mn Ni P 0.06 0.30 9.1 0.018 1.00 0.70 0.20 0.018 YS UTS EL Mechanical Properties 490 N/mm2 600 N/mm2 22%

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-100 135 540 3.15 350 90-130 95 380 4.00 5.00 350 450 110-165 175-240 60 45 240 180

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

ESAB KV 7 M
A basic coated low hydrogen electrode for welding modified 9Cr-1 Mo steels Classification DESCRIPTION ESAB KV7 M is a low hydrogen electrode for welding of modified 9 Cr-1 Mo steels like P91/T91. The electrode is suitable for all positional welding of plates and tubes used in oil refineries, power plants, chemical and petrochemical industries where the steels have to resist corrosion and hydrogen attack at high temperatures. The electrode deposits x-ray quality weldment and have a diffusible hydrogen content of less than 5 ml/100g. WELDING CURRENT: DC+ REDRYING 250OC/2 hrs before use. Refer our standard recommendation for coated electrode storage, redry and usage for further information. AWS A5.5: E 9018-B9 IS 1395: E 63B B9 26

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si S P Cr Mo Ni V Nb Cu AI N 0.10 0.85 0.25 0.01 0.01 9.0 1.00 0.10 0.24 0.04 0.10 0.02 0.04 Mechanical Properties (PWHT 760OC / 2 hrs) YS 730 N/mm2 UTS 820 N/mm2 EL 20% Preheat / Interpass 250OC

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-100 135 540 3.15 350 90-130 95 380 4.00 5.00 350 450 110-165 175-240 60 35 240 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Vacuum packed electrodes, which do not need redrying before use, also are available.
21

Welding Consumables

OK 73.68
A basic coated 2.5% Ni alloyed electrode for welding low alloy steels Classification DESCRIPTION OK 73.68 is a medium coated, hydrogen controlled, Ni based electrode specially designed for welding Ni alloy steels used for high ductility, toughness and resistance to the embrittlement effects of sub-zero temperatures. The weld deposit contains 2.5% Ni which imparts good resistance to brittle fracture down to -60°C. The weldmetal is so designed to give good low temperature properties even when welded vertically up. OK 73.68 posseses excellent operating characteristics for its class and can be operated in both AC and DC. WELDING CURRENT: DC+, AC 70V(min) TYPICAL APPLICATIONS OK 73.68 is widely used for welding structures in low alloy steels, which must have good resistance to brittle fracture at temperatures down to - 60°C. This particular AWS A5.5: E 8018-C1 IS 1395: E55B-C 129Fe

alloy type is also noted for its good corrosion resistance to sea water and sulphuric acid fumes. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni S P 0.08 1.0 0.45 2.7 0.02 0.019 Mechanical Properties YS UTS EL (L=5d) Impact (CVN) at - 60oC 490 N/mm2 610 N/mm2 22% 40J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 140 560 3.15 450 95-130 95 380 4.00 5.00 450 450 130-170 180-250 60 35 220 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr P Ni Si S 0.08 1.0 0.02 0.02 2.7 0.45 0.02 Mechanical Properties YS UTS EL Impact (CVN) at - 60oC 490 N/mm2 610 N/mm2 22% 40J

OK 73.68M
A basic coated 2.5% Ni alloyed electrode for HSLA steels Classification DESCRIPTION OK 73.68M is a medium coated, hydrogen controlled, Ni based electrode yielding 2.5% Ni in the weld deposit, ideally suiting welding of fine grain steels and Ni steels especially for service temperature down to -60°C. The weld provides excellent strength combined with notch toughness at sub zero temperatures. OK 73.68M is superior in its class and can be operated on both AC and DC with excellent results. WELDING CURRENT: DC+, AC 70V(min) TYPICAL APPLICATIONS OK 73.68M is primarily designed for welding structures of low alloy steel applications including storage tanks, pressure vessels, containers and piping of liquified gases like propane, butane and ammonia. This particular alloy type is also noted for its good corrosion resistance to seawater and sulphuric acid fumes. AWS A5.5: E 8016-C1

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 135 520 3.15 450 95-130 95 380 4.00 5.00 450 450 130-170 180-250 60 35 220 140

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

22

ESAB 8016 C2
A basic coated 3.5% Ni alloyed electrode for HSLA steels Classification DESCRIPTION ESAB 8016 - C2 is a medium coated, hydrogen controlled all position electrode specially designed for welding nickel alloy steels. The electrode deposits a 3.5% Ni weld deposit which has a high tensile strength, ductility and resistance to low temperature embrittlement down to -101OC. The weldmetal is of radiographic quality. WELDING CURRENT: DC+, AC 70V(min) TYPICAL APPLICATIONS For welding 3 - 3.75% Ni steels like LPG / Ethane tankage, chemical tanks, etc. Also used for fabrication of components used in low temperature service, refinery, pressure vessels, valves, etc. AWS A5.5: E 8016-C2

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si S P Ni 0.06 1.10 0.25 0.02 0.018 3.35 Mechanical Properties YS UTS EL Impact 9CVN) at - 80oC - 101oC 510 N/mm2 600 N/mm2 26% 60J 50J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 90-150 95 380 4.00 5.00 450 450 130-190 150-260 60 35 240 140

PACKING: Electrodes are packed in cardboard cartons and four of these cartons are shrink wrapped in a cardboard box. The electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

OK 74.78
A basic coated low hydrogen electrode for Welding HSLA steels with good notch toughness Classification DESCRIPTION OK 74.78 is a basic coated low hydrogen electrode for welding high tensile steel with good notch toughness down to -50°C. OK 74.78 is therefore suitable for welding mild and low alloy steels for structures working at low temperatures, OK 74.78 is suitable for HSLA steels when preheating cannot be applied due to its very low hydrogen content. The risk of grain boundary cracking is very low when welding with OK 74.78. APPROVAL: RDSO C2 WELDING CURRENT: DC+, AC 70V(min) TYPICAL APPLICATIONS The good notch toughness makes OK 74.78 suitable for enclosed joint welding of rail and for cladding on rail especially when a hardness of about 250 HV is desired. OK 74.78 are therefore highly suitable for welding of ‘CONCOR’ wagon type applications of the Indian Railways. OK 74.78 are also suitable for following high tensile steels: DOMEX 400 TE, 450 & 480, FAMA 35, AWS A 5.5: E 9018-D1 IS 1395: E 63B-D126J

OX 540E, OX 542E, OX 602, OX 702, OX 802, and VSS-T1 steels and similar steel compositions. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C S Si Mn P Mo 0.08 0.02 0.6 1.5 0.02 0.35 Mechanical Properties YS UTS EL Impact (CVN) at - 50oC 530 N/mm2 640 N/mm2 22% 40J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

23

Welding Consumables

OK 74.86
A low hydrogen electrode for welding high StrengthMn-Mo Steel Classification DESCRIPTION A basic coated electrode for steels and castings demanding 690 N/mm2. Excellent weldability and radiography quality welding. WELDING CURRENT: DC+, AC TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Cr Ni Mo V Cu 0.075 0.525 1.825 0.025 0.020 0.10 0.225 0.35 0.05 0.10 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 610 N/mm2 690 N/mm2 16% 30J

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.20 4.00 5.00 Length (mm) 350 450 450 450 Current Range (Amps) 75-100 110-140 150-190 190-260

EN 757 E 62 4 Z B T 32 H5 AWSA 5.5 : E10018 - D2

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

ESAB 8018 - D3
A low hydrogen basic coated electrode for Mn-Mo Steel Classification DESCRIPTION An electrode for welding Mn-Mo steels of similar composition. The electrode is designed for all position welding and has excellent radiographic properties. WELDING CURRENT: DC+, AC 70V TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si P S Mo Ni 0.09 1.4 0.65 0.018 0.018 0.55 0.01 Mechanical Properties UTS YS EL Impact (CVN) at - 51oC 610 N/mm2 500 N/mm2 26% 40J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 450 90-150 95 380 4.00 5.00 450 450 130-190 150-260 60 35 240 140

AWS A5.5: E 8018-D3

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Electrodes are packed in vacuum pack also are available.

24

ESAB 98
A low alloy electrode for welding high tensile low alloy steels Classification DESCRIPTION ESAB 98 is a heavy coated, hydrogen controlled, iron powder type electrode for welding high tensile, low alloy steels depositing x-ray quality, crack resistant welds. The addition of iron powder permits higher currents to be used and results in improved arc characteristics coupled with higher metal recovery. The current characteristics are smooth with excellent operability in all positions and excellent slag removal. WELDING CURRENT: DC+, AC 70V(min) APPLICATIONS ESAB 98 finds extensive use in pressure vessels, piping, penstock, earth moving equipment, machinery parts, automobile parts, chemical plants where low alloy Ni-CrMo steels are used. Suitable for N-A-XTRA 55 and N-AXTRA 60 steels. AWS A5.5: E 9018-M IS 1395: E63B-M 126Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni Mo S P Cr V 0.05 1.00 0.4 1.5 0.30 0.02 0.02 0.1 0.01 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 580 N/mm2 690 N/mm2 26% 47J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-100 130 520 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Ni Mo P S 0.05 1.15 0.4 0.15 1.60 0.25 0.02 0.015 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 590 N/mm2 650 N/mm2 26% 50J

ESAB 98 G
A low alloy Electrode for welding High tensile low alloy steel. Classification DESCRIPTION ESAB 98 G is a heavy coated, hydrogen controlled, iron powder type electrode for welding high tensile, low alloy steels depositing x-ray quality, crack resistant welds. The addition of iron powder permits higher current to be used and result in improved arc characteristics coupled with higher metal recovery. The current characteristics are smooth with excellent operability in all position and excellent slag removal. WELDING CURRENT: DC +, AC 70V APPLICATIONS ESAB 98 G finds extensive use in pressure vessels and pressure part welding, chemical plants where low alloy Ni, Cr, Mo steels is used. Other applications are piping, penstock, automobile parts, earth moving equipment etc. AWS A5.5: E 9018G IS 1395 : E63B-G129 Fe

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

25

Welding Consumables

ESAB 118
A low hydrogen, low alloy electrode for welding low alloy, high strength structural steels Classification DESCRIPTION ESAB 118 is an extra low-hydrogen controlled, low-alloy high tensile steel electrode suitable for welding fully killed fine grained steel giving a tough weldmetal without the risk of temper brittleness. The all position electrode has excellent arc and current carrying characteristics, with an easily removable slag and excellent bead finish contributing to its immense welder appeal. WELDING CURRENT: DC, AC 70V APPLICATIONS ESAB 118 is widely used for welding of low alloy high strength structural steels including quenched and tempered steels such as USS T1 , heat treated fine grained steels like N-A-XTRA 70, HY80 and ASTM A517 grade F generally used for penstock, earth moving equipment and other heavy steel fabrications. AWS A5.5: E 11018-M IS 1395: E76B-M 326Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni Mo Cr S P V 0.05 1.60 0.35 2.00 0.40 0.1 0.018 0.018 0.015 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 750 N/mm2 810 N/mm2 22% 65J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 60-100 130 520 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Mo S Ni Cr V P 0.06 2.00 0.50 0.25 0.018 3.1 1.00 0.02 0.018 Mechanical Properties YS UTS EL Impact (CVN) at - 51oC 790 N/mm2 860 N/mm2 22% 60J

ESAB 120
A low hydrogen, low alloy electrode for welding low alloy, high strength structural steels Classification DESCRIPTION ESAB 120 is all positional low hydrogen electrode designed to give a tough Weldmetal avoiding risk of temper brittleness. The excellent operation in all positions with smooth arc, very little spatter, easily detachable slag, a final weld appearance that is smooth and fine rippled makes ESAB 120 highly popular among welders among these class of electrodes. The final weldmetal possess very low level of hydrogen (less than 3ml/100g of weldmetal) and is radiographically sound. WELDING CURRENT: DC, AC 70V TYPICAL APPLICATION Used for steels with a yield point of upto 740 N/mm2. The electrode is intended for welding low alloy high strength structural steel including quenched and tempered steels such as HY 80, N-A-XTRA70, USS T1 grades etc. Used for components of penstock, earth moving equipment and other steel fabrications made of high tensile steels. AWS A5.5: E 12018-M IS 1395: E83 B-M 426Fe

APPLICATIONS ESAB 120 is meant for the welding of very high tensiles. CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

26

ESAB 130
A low hydrogen, low alloy electrode for welding low alloy, high strength structural steels Classification DESCRIPTION AWS A5.5: E 13018-G BS 611 HJ IS 1395 E838 B-G 129Fe

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Mo S Ni Cr V P 0.08 1.70 0.45 0.50 0.025 2.80 0.90 0.05 0.025 Mechanical Properties YS UTS EL Impact (CVN) at - 27oC 0oC 880 N/mm2 970 N/mm2 18% 90J 60J

Welding Consumables

ESAB 130 is an all position low hydrogen electrode designed to deposit high strength as well as highly ductile and tough Weldmetal for welding of fully killed high strength steels. The electrode deposits finely rippled weldbead which is of radiographically quality. The weldmetal is also low in diffusible hydrogen. TYPICAL APPLICATIONS Recommended for welding very high strength steels like XABO-90, penstocks, earthmoving equipment, casting repair, etc.

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 3.15 450 90-125 90 360 4.00 5.00 450 450 120-180 160-240 60 40 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. This electrode can also be made available in moisture resistant vacuum packed cartons, which can be used without redrying.

FERROWELD W
A basic low alloy electrode for weathering steels Classification DESCRIPTION ESAB Ferroweld W is medium coated hydrogen controlled basic type all positional electrode with excellent striking and re-striking properties, easily detachable slag. The electrode deposits and smooth flat bead of fine ripples. WELDING CURRENT: DC+, AC 90V TYPICAL APPLICATIONS: ESAB Ferroweld W is designed for the welding of high tensile steels, Steels of Similar composition having greater resistance to atmospheric corrosion as compared to normal steels. ESAB Ferroweld W is specially recommended for weathering steels like CORTEN A & B and their equivalents. AWS A5.5: E 7018-W1

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Ni S P Cu V 0.10 0.50 0.45 0.20 0.3 0.02 0.02 0.40 0.04 Mechanical Properties YS UTS EL Impact (CVN) at - 20oC 460 N/mm2 550 N/mm2 28% 45J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 140 560 3.15 4.00 5.00 450 450 450 90-150 130-190 150-260 90 60 40 360 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Vacuum packed electrodes, which do not need redrying before use, also are available.

27

Welding Consumables

ESAB FERROWELD W2
A basic low alloy electrode for weathering steels Classification DESCRIPTION ESAB Ferroweld W2 is medium coated hydrogen controlled basic type all positional electrode with excellent striking and re-striking properties, easily detachable slag. The electrode deposits a smooth flat bead of fine ripples. WELDING CURRENT: DC+, AC 90V TYPICAL APPLICATIONS: ESAB Ferroweld W2 is designed for the welding of high tensile steels, Steels of Similar composition having greater resistance to atmospheric corrosion as compared to normal steels. ESAB Ferroweld W2 is specially recommended for weathering steels like CORTEN A & B and their equivalents. AWS A5.5: E 8018-W2

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Ni S P Cu 0.10 0.9 0.45 0.55 0.6 0.02 0.02 0.50 Mechanical Properties YS UTS EL Impact (CVN) at - 20oC 500 N/mm2 610 N/mm2 28% 45J

CURRENT RANGE & PACKING DATA
Size Length Current Range No. of Electrodes in a (mm) (mm) (Amps) Carton Cardboard box 2.50 350 70-110 130 520 3.15 4.00 5.00 450 450 450 90-150 130-190 150-260 90 60 40 360 240 160

PACKING: Electrodes are packed in cartons and four of these cartons are shrink wrapped in a cardboard box. Vacuum packed electrodes, which do not need redrying before use, also are available.

28

Stainless Steel Electrodes
OK 61.50
A low carbon 19/9 stainless steel electrode Classification DESCRIPTION OK 61.50 is an AC/DC rutile coated stainless steel electrode with unique low moisture absorption coating which deposits low carbon 19Cr, 10Ni type metal. The unique flux coating allows easy striking and restriking and is completely free from short-circuiting during welding. The arc is stable, very smooth, negligible spatter, and gives welds with a self-releasing slag cover that is finely rippled and shiny. APPROVALS: PDlL, TEIL, NPCIL WELDING CURRENT: DC+, AC 65V TYPICAL APPLICATIONS OK 61.50 finds extensive use in fabrication of austenitic stainless steels of 18Cr 8Ni type corresponding to AISI types 301, 304 and 308, German steel nos. 1.4016, 1.4501, 1.4300, 1.4301, Continental steels V2A, Sandvik OR-2, UHB stainless 33 etc. It also finds use in building up stainless steel surfaces on centrifugal pumps, AWS A5.4: E 308-16 IS5206: E 19.9 R26 impellers and shafts, valve seats and chemical plants and certain grades of armour steels that are difficult to weld otherwise. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Ni Si S P Size (mm) 2.50 3.15 4.00 5.00 0.06 0.90 19.00 10.00 0.70 0.015 0.020 Mechanical Properties YS UTS EL Ferrite Content 440 N/mm2 600 N/mm2 40% FN 4-10

Welding Consumables

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. 308, Werkstoff Nr: 1.4306, 1.4301, 1.4541, Swedish steels SS 2352, 2333 having a very low carbon content, BS: En 58, 58A, 58E grades. Widely used in industries like food and beverage, chemicals, etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr P Ni Si S 0.025 0.90 19.50 0.020 10.00 0.70 0.015 Mechanical Properties YS UTS EL Ferrite Content 570 N/mm2 450 N/mm2 42% FN 3-8

OK 61.30
A rutile coated extra low carbon AC/DC stainless steel electrode of the 19/9 type Classification DESCRIPTION OK 61.30 is a rutile based extra low carbon 19Cr/10Ni type stainless steel electrode with a controlled ferrite of 3-8 FN that provides excellent resistance to corrosion, cracking and high temperature scaling resistance upto 800°C. The enormous welder appeal that OK 61.30 enjoys is due to excellent weldability in all positions, easy striking and restriking, stable and quite are, a slag cover that is selfpeeling and a final bead appearance that is finely rippled and shiny. In most cases OK 61.30 gives acceptable results on niobium or titanium stabilised austenitic stainless steels with the carbon content low enough to eliminates the possibility of inter-granular cracking APPROVAL: PDIL, NPCIL, TEIL WELDING CURRENT: DC+, AC 65 V TYPICAL APPLICATIONS OK 61.30 is especially designed for welding austenitic stainless steels corresponding to AISI 304L, 304, 308L, AWS A5.4: E 308L-16 IS 5206: E 19.9 LR 26

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.
29

Welding Consumables

ESAB 304B
An extra low carbon, basic type 19/9 stainless steel electrode Classification DESCRIPTION ESAB 304B is an extra low carbon, basic coated stainless steel electrode with outstanding welding properties in the vertical and overhead position. The weldmetal is highly resistant to cracking and porosity and has good impact toughness at very low temperatures. The low carbon content prevents intergranular corrosion in the temperature range 425°C and 823°C. The slag system allows excellent welding characteristics in all positions, slag cover that is easily detachable, and a weldbead that is shiny and finely rippled. The weldmetal has excellent creep strength and is of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 304B is mainly used for welding stainless steels having a corresponding chemistry with high ductility and high impact values at low temperature cryogenic applications (-196°C working temperatures). Stainless steel conforming to grades AISI 301, 302, 304, 304L, 304 having very low carbon contents, BS: EN 58, 58A, 58E AWS A5.4: E 308L-15 IS 5206: E 19.9LB 20

etc. are some of the steels which are widely fabricated with ESAB 304B and they find extensive use in food and beverage industries, chemical and petrochemical industries etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Si Ni Mn S P Mo <0.03 19.0 0.40 10.50 1.6 0.015 0.018 0.05 Mechanical Properties YS UTS EL Impact (CVN) at - 196oC Lateral Expansion 420 N/mm2 570 N/mm2 45% 40J 0.42 mm

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

ESAB 304B (N)
An extra low carbon, basic type 19/9 stainless steel electrode Classification DESCRIPTION ESAB 304B (N) is an extra low carbon, basic coated stainless steel electrode with outstanding welding properties in the vertical and overhead position. The weldmetal is highly resistant to cracking and porosity and has good impact toughness at very low temperatures. The slag system allows excellent welding characteristics in all positions, slag cover that is easily detachable, and a weldbead that is shiny and finely rippled. The weldmetal has excellent creep strength and is of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 304B (N) is mainly used for welding stainless steels having a corresponding chemistry with high ductility and high impact values at low temperature cryogenic applications (-196°C working temperatures). Stainless steel conforming to grades AISI 301, 302, 304, 304L, 304 having very low carbon contents, BS: EN 58, 58A, 58E etc. are some of the steels which are widely AWS A5.4: E 308L-15

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. fabricated with ESAB 304B (N) and they find extensive use in food and beverage industries, chemical and petrochemical industries, nuclear power industry etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Si Ni Mn S P Mo Size (mm) 2.50 3.15 4.00 5.00 0.035 20.0 0.65 10.00 1.75 0.02 0.025 0.5 Mechanical Properties YS UTS EL Impact (CVN) at - 196oC 345 N/mm2 595 N/mm2 38% 40J

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

30

OK 61.80
A niobium stabilised stainless steel electrode of the 19/10 type Classification DESCRIPTION OK 61.80 is a rutile type low carbon 19Cr/10Ni stabilised stainless steel electrode. This electrode provides excellent resistance to scaling, corrosion and cracking at temperatures of upto 800°C. Niobium prevents harmful carbide precipitation to avoid intergranular cracking in the temperature range 425°C to 850°C. The weldability of OK 61.80 is outstanding with very easy striking and restriking properties. The slag system is designed to provide self-lifting slag, and a bead that is smoothly rippled and shiny. Weldmetal is of radiographic quality. APPROVALS: NPCIL, TEIL WELDING CURRENT: DC+, AC 65V TYPICAL APPLICATIONS OK 61.80 finds extensive application for welding of stabilised version of 19Cr/10Ni type steels corresponding to AISI 321 & 347, Werkstoff Nr: 1.4541,1.4543,1.4550, 1.4552. These steels are used widely in the food and beverage industries, chemical industries, petrochemical industries, power plants, aircraft industries, etc. AWS A5.4: E 347-16 IS 5206: E 19.9 Nb R 26

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si Nb P Size (mm) 2.50 3.15 4.00 5.00 0.03 0.75 19.50 0.015 10.00 0.8 0.60 0.02 Mechanical Properties YS UTS EL Ferrite Content 600 N/mm2 400 N/mm2 35% FN 5-9

Welding Consumables

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

ESAB RSSC (M)
A basic 19/9 Niobium stabilised stainless steel electrode Classification DESCRIPTION ESAB RSSC (M) is used for providing maximum resistance to cracking, corrosion at high temperature upto 800°C. Niobium provides resistance to intergranular cracking in the temperature range 425°C to 843°C by preventing harmful Chromium carbide precipitation. The weldmetal has excellent creep resistance and is of radiographic quality. The basic type slag reduces the risk of hydrogen induced cracking. The arc characteristics are smooth with the slag system designed to provide easy control and high welder efficiency. WELDING CURRENT: DC + APPLICATIONS ESAB RSSC (M) is used for welding of AISI 321 and 347 type steels. It is especially designed for the welding of 18Cr/8Ni steels stabilised with Ti or Nb. Used extensively in food, chemical and aircraft industries. It is also suitable for welding of turbine blades. AWS A 5.4: E 347-15 IS 5206: E 19.9 Nb B20+

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Cr Ni Nb S P 0.06 0.95 0.35 20.00 10.00 0.80 0.018 0.018 Mechanical Properties YS UTS EL Ferrite Content 610 N/mm2 410 N/mm2 37% FN 4-8

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

31

Welding Consumables

ESAB 308H
A high carbon 19/9 stainless steel electrode Classification DESCRIPTION ESAB 308H is specially designed for welding of stainless steels with carbon content corresponding to AISI 308H type. ESAB 308H possess excellent arc and current carrying characteristics and provides a smooth and stable arc in all welding positions. The slag system is so designed to allow for a controllable fluid slag cover that provides for excellent wetting and an easily removable slag cover. The weldbead is smooth, even and shiny. WELDING CURRENT: DC +, AC 65 V TYPICAL APPLICATIONS Esab 308H finds wide use in the fabrication of components made out of AIS 308H type steels that are used for their high tensile strength e.g. in agricultural implements, automobile industries, construction segment, etc. AWS A5.4: E 308H-16 IS 5206: E 19.9 R26

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Ni Si Mo S P 0.06 0.80 19.00 10.00 0.70 0.50 0.018 0.018 Mechanical Properties YS UTS EL Ferrite Content 440 N/mm2 600 N/mm2 42% FN 3-10

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. phosphoric, citric, tartaric acids that are found in paper and pulp industries, textile industries, chemical mixers, paint and dye industries, etc., TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Mo Ni Si P Size (mm) 2.50 3.15 4.00 5.00 0.06 0.60 19.5 0.015 2.5 12.5 0.6 0.020 Mechanical Properties UTS YS EL Ferrite Content 580 N/mm2 420 N/mm2 38% FN 5-10

OK 63.50
A low carbon 19/12/2 stainless steel electrode Classification DESCRIPTION OK 63.50 is a low carbon, rutile electrode with a unique low moisture absorption coating depositing a weldmetal of the type 18% Cr, 13% Ni, 2.8% Mo. The weldability of OK 63.50 is outstanding like any ESAB stainless steel electrodes with excellent striking and restriking properties, a self peeling slag and a weld that is extremely smooth and shiny. Its extreme ease of operation in all positions with exceedingly low spatter and stable arc makes it a favourite of welders. APPROVAL: NPC, PDIL WELDING CURRENT: DC+, AC 50 V TYPICAL APPLICATIONS OK 63.50 is especially designed for the welding of 18Cr/13Ni/Mo type steels corresponding to AISI 316 and 317 type stainless steels. Commonly used in chemical tanks, coils and vats that are exposed to severe corrosion by sulphuric, sulphurous, hydrochloric, acetic, AWS A5.4: E 316-16 IS 5206: E 19.12.2 R 26

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Vacuum packed cartons are also available on demand.

32

OK 63.30
A rutile based extra low carbon 19/12/2 stainless steel electrode Classification DESCRIPTION OK 63.30 is an extra low carbon, rutile electrode with a unique low moisture absorption coating depositing a weldmetal of the type 18% Cr, 13% Ni, 2.8% Mo. The weldability of OK 63.30 is outstanding in all positions with both AC and DC current. It is completely free from short-circuiting during welding coupled with excellent striking and restriking properties, a self-lifting slag and a final weld appearance that is extremely smooth and shiny. APPROVALS : PDIL, NPCIL, TEIL WELDING CURRENT: DC+, AC 50 V TYPICAL APPLICATIONS OK 63.30 is especially designed for the welding of 18Cr/13Ni/Mo type steels corresponding to AISI 316 and 316L, 317 type stainless steels. Commonly used in chemical tanks paper mill equipment, bleaching equipment, chemicals plants, textile plants, whose vessel surfaces are exposed to severe corrosion by sulphuric, sulphurous, hydrochloric, acetic, phosphoric, citric, tartaric acids etc. and also for components exposed to high temperatures for e.g. heat resistant castings. It is AWS A5.4: E 316L-16 IS 5206: E 19.12.2 R 26

also suitable for welding titanium and niobium stabilised 18-12 steels of the type SS 2344 and 2345 except when the corrosive conditions are severe. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Mo Ni Si P Size (mm) 2.50 3.15 4.00 5.00 0.025 0.90 19.0 0.015 2.4 12.5 0.70 0.020 Mechanical Properties UTS YS EL Ferrite Content 580 N/mm2 400 N/mm2 40% FN 5-10

Welding Consumables

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si S Ni Cr Mo P 0.025 1.5 0.5 0.018 12.0 18.5 2.8 0.020 Mechanical Properties UTS YS EL Ferrite Content 590 N/mm2 400 N/mm2 40% 5-10 FN

OK 63.35
A low carbon basic coated stainless steel electrode of the 19/12/2 type. Classification DESCRIPTION OK 63.35 is a low carbon basic covered stainless steel electrode of the 19% Cr, 12% Ni, 2.8% Mo type. It is highly resistant to cracking and porosity, and has excellent welding properties in the vertical and overhead positions. WELDING CURRENT: DC + APPLICATIONS OK 63.35 is mainly used for welding stainless steels having a corresponding analysis, but can also be used for welding certain air hardening steels, e.g. armour plate, and for butt welding stainless steel to unalloyed or low alloyed carbon steels. Its welding properties are particularly marked during vertical welding. OK 63.35 is intended for welding acid resisting austenitic steels corresponding to AISI 316 and similar steels. AWS A 5.4: E 316L-15 IS 5206: E 19.12.2 B 20

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

33

Welding Consumables

ESAB 316KCR
An extra low carbon stainless steel electrodes with nil ferrite in deposited weldmetal Classification DESCRIPTION ESAB 316KCR is a specially designed extra low carbon stainless steel electrode to deposit a ferrite free, fully austenitic weldmetal with better corrosion resistance to hydrochloric, nitric and sulphuric acids. The deposited weldmetal meets the corrosion test requirements of ASTM A262 Practice B, C and E. The arc and current carrying characteristics are excellent with a smooth and stable arc with very little spatter. The slag cover easily detaches and the final weldbead is smooth, shiny and finely rippled. APPROVALS: SNAMPROGETTI (CR.UR.510 rev 03), PDlL, TIEIL WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 316 KCR is especially designed for both welding and cladding of 316L UREA GRADE steels, used for Urea reactors, stainless steels used for pickling plates, AWS A 5.4: E 316L-16 (mod)

chemical plants where better corrosion resistance is required for hydrochloric acid sulphuric acid etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Ni Mo Si S P 0.025 1.30 18.00 15.00 0.025 0.35 0.015 0.018 Mechanical Properties UTS YS EL Ferrite Content 520 N/mm2 390 N/mm2 40% NIL

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. equipment, textile industries using equipment for dyeing and bleaching, heat resistant castings etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Nb Mo Ni Si P S 0.05 0.90 19.0 0.70 2.3 11.5 0.7 0.020 0.015 Mechanical Properties UTS YS EL Ferrite Content 580 N/mm2 430 N/mm2 30% FN 5-9

OK 63.80
A rutile based Nb bearing 19/12/3 stainless steel electrode Classification DESCRIPTION OK 63.80 is a rutile based, low carbon 19Cr/12Ni/3Mo type stainless steel electrode, stabilised with Niobium to resist intergranular corrosion between 425°C and 845°C. The electrode deposits a weldmetal that has a controlled ferrite content of 5-9 FN for maximum resistance to cracking, corrosion and scaling. The weldmetal has good creep strength and is of radiographic quality. OK 63.80 electrodes possess outstanding arc and current carrying characteristics in all positions with a slag that is self peeling and a bead that is finely rippled and shiny. WELDING CURRENT: DC+, AC 50 V TYPICAL APPLICATIONS OK 63.80 is especially designed for the welding of Ti and Nb stabilised stainless steels with similar base composition corresponding to AISI 316 and 318 types. Widely used in chemical plants handling corrosive acids like Sulphuric acid, hydrochloric acid, tartaric acid, acetic acid, formic acid, citric acid etc., in paper and pulp industries using paper mill equipment, bleaching
34

AWS A5.4: E 318-16 IS 5206: E 19.12.2 Nb R 26

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

OK 64.30
An extra low carbon AC/DC stainless electrode of the 19/12/3 type Classification DESCRIPTION OK 64.30 is an extra low carbon AC/DC stainless steel electrode of the type 19Cr, 13Ni, 3.5 Mo with controlled ferrite content of 5 to 10 for maximum resistance to intercrystalline corrosion, stress corrosion cracking, hot cracking and chemical corrosion. The weldmetal display excellent resistance to creep and the higher molybdenum reduces the susceptibility to pitting. OK 64.30 has excellent weldability in all positions, a slag cover that is self peeling and a weld bead appearance which is smooth and shiny. The welds are of radiographic quality. WELDING CURRENT: DC +, AC TYPICAL APPLICATIONS OK 64.30 is designed for welding stainless steel corresponding to AIS1317, 317L, DIN W Nr: 1.4438, British Standard: 317 S 12, Swedish Standard: SS-steel 2367. These find extensive use where severe corrosion AWS A 5.4: E 317L-16 IS 5206: E 19 123 LR 26

takes place involving sulphuric acid and sulphurous acids and their salts. OK 64.30 is also for steel fabrications in, which post weld heat treatment is to be avoided. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mo Si Ni Mn Cr S P Size (mm) 2.50 3.15 4.00 5.00 0.028 3.7 0.7 12.5 0.8 19.0 0.015 0.020 Mechanical Properties YS UTS EL Impact (CVN) at +20oC Ferrite Content 450 N/mm2 600 N/mm2 35% 55J FN 5-10

Welding Consumables

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. acids and their salts. ESAB 317 LN is also for steel fabrications in, which post weld heat treatment is to be avoided. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mo Si Ni Mn Cr S P 0.003 4.5 0.9 14.0 1.5 19.5 0.02 0.025 Mechanical Properties UTS EL Impact (CVN) at - 4OC 520 N/mm2 30% 27J

ESAB 317 LN
An extra low carbon AC/DC stainless electrode of the 19/12/3 type Classification DESCRIPTION ESAB 317 LN is an extra low carbon AC/DC stainless steel electrode of the type 19Cr, 13Ni, 3.5 Mo with controlled ferrite content of 5 to 10 for maximum resistance to intercrystalline corrosion, stress corrosion cracking, hot cracking and chemical corrosion. The weldmetal display excellent resistance to creep and the higher molybdenum reduces the susceptibility to pitting. ESAB 317 LN has excellent weldability in all positions, a slag cover that is self peeling and a weld bead appearance which is smooth and shiny. The welds are of radiographic quality. WELDING CURRENT: DC +, AC TYPICAL APPLICATIONS ESAB 317 LN is designed for welding stainless steel corresponding to AIS1317, 317L, DIN W Nr: 1.4438, British Standard: 317 S 12, Swedish Standard: SS-steel 2367. These find extensive use where severe corrosion takes place involving sulphuric acid and sulphurous AWS A 5.4: E 317L-16

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.
35

Welding Consumables

OK 67.67

A rutile type, 23% Cr, 12% Ni type stainless steel electrode Classification AWS A 5.4: E 309-16 IS 5206: E 23.12 R 26 DESCRIPTION OK 67.67 is a rutile based, medium coated, all position electrode depositing an alloy of 23 Cr, 12 Ni type which has excellent resistance to corrosion and oxidation at very high temperatures, up to 1100°C. OK 67.67 has an extremely stable and smooth arc with very easy striking and re-striking properties and a final slag that is selfpeeling to reveal a very finely rippled, smooth and shiny bead. Welds are radiographically sound. APPROVALS: PDIL, RDSO, NPCIL, TEIL WELDING CURRENT: DC +, AC 50V TYPICAL APPLICATIONS OK 67.67 is designed for applications requiring high strength and corrosion resistance at high temperatures upto 1100°C; for e.g. welding of heat resistant chrome steels and Cr-Ni steels of the 309 type in low sulphurous atmospheres. It is also widely used for joining of dissimilar steels like joining of mild steel to stainless steel, low alloy steels to stainless steels for welding root runs

in clad steels of 18/8 type. It is also used for surfacing to protect against severe environment e.g. on mild steel and wear resistant steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Ni Si S P Mo Size (mm) 2.50 3.15 4.00 5.00 0.06 0.8 24.0 12.5 0.70 0.015 0.020 0.02 Mechanical Properties YS UTS EL Ferrite Content 470 N/mm2 600 N/mm2 40% FN 12-24

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

ESAB 309
A basic 23/12-type stainless steel electrode Classification DESCRIPTION ESAB 309 is a basic, all position electrode depositing a 23Cr/12Ni type weldmetal which is extremely resistant to corrosion and oxidation at elevated temperatures of upto 1100°C. ESAB 309 welds with a very smooth and quite arc in all positions with a very low spatter. The slag is easily detachable and the final weld bead is smooth, finely rippled and shiny. Welds are of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 309 is specially designed for the welding of AISI 309 type steels, straight chrome steels dissimilar steels for e.g. welding of mild steels to stainless steels, low alloy steel to stainless steels etc. It is also used for surfacing and building up of components to improves its wear resistance. AWS A 5.4: E 309-15 IS 5206: E 23.12 B 20

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si P Mo 0.05 0.9 24.00 0.015 12.5 0.7 0.020 0.05 Mechanical Properties UTS YS EL Ferrite Content 610 N/mm2 480 N/mm2 37% FN 12-24

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 40-60 60-90 85-130 140-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

36

OK 67.60
An extra low carbon, 23% Cr, 12% Ni type stainless steel electrode Classification AWS A 5.4: E 309L-16 IS 5206: E 23.12LR 26 DESCRIPTION OK 67.60 is a rutile based, extra low carbon, all position electrode of 23Cr/12Ni type for joining of stainless steel to mild steel and for surfacing of mild steel. The extra low carbon content prevents carbide precipitation and hence avoids intergranular cracking. The weld deposit has excellent corrosion and oxidation resistance in continuous service upto 1000°C. OK 67.60 welds with a very smooth and stable are, with virtually no spatter and a slag cover that is self-releasing. The final weld bead is very finely rippled and shiny. The weldmetal is of radiographic quality. APPROVALS : NPCIL, TEIL, PDIL WELDING CURRENT: DC +, AC 50V TYPICAL APPLICATIONS OK 67.60 is essentially used for welding heat resistant straight Chrome steels and Cr-Ni alloyed steels for e.g. AISI 309 type steels, for working temperatures upto 1000OC, if sulphurous attack does not occur. It is especially useful for joining stainless to mild steel; stainless steels to low alloy steels and for welding root

runs in clad steels of 18/8 type. It is also used widely for surfacing of mild steel and for building up worn out parts for wear resistant steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Ni P Mn Si S Mo 0.03 24.0 12.5 0.020 0.9 0.75 0.015 0.05 Mechanical Properties YS UTS EL Ferrite Content 470 N/mm2 600 N/mm2 40% FN 12-22

Welding Consumables

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. 304L and 309L clad steels. It is also used as buffer in cladding. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr P Ni Si S Mo 0.03 0.9 23.5 0.020 12.5 0.7 0.015 0.05 Mechanical Properties YS UTS EL Ferrite Content 580 N/mm2 470 N/mm2 40% FN 12-22

ESAB 309LC
An extra low carbon, basic 23/12 type stainless steel electrode Classification DESCRIPTION ESAB 309LC is an extra low carbon all positional basic coated electrode giving austenitic weld deposit of 23Cr - 13Ni type suitable for welding heat resistant Cr-Ni alloyed steels for working temperatures upto 1000°C, If sulphurous attack does not occur. ESAB 309LC possess excellent weldability in all positions with a fine, stable, smooth arc with a slag system that allows good wetting and an easily removable slag. The final weldbead is shiny, finely rippled and smooth. Welds are of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS It is recommended for applications requiring superior corrosion resistance, high strength and oxidation resistance upto 1000°C where the sulphurous attack does not occur. It is also eminently suitable for welding stainless steel to unalloyed steel and also for welding of AWS A 5.4: E 309L-15 IS 5206: E 23.12 L B 20

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.
37

Welding Consumables

OK67.70
A rutile based, 23 Cr, 12 Ni, 2 Mo type stainless steel electrode Classification AWS A 5.4: E 309Mo-16 IS 5206: E 23.12.2 R 26 DESCRIPTION OK 67.70 is rutile based, medium-heavy coated, “overalloyed” stainless electrode for giving a 25 Cr, 12 Ni, 2.5 Mo deposit for use as a buffer layer in welding acid resisting clad steels and stainless steels to other types of steels. The addition of molybdenum to the 25 Cr, 12 Ni deposit improves tensile strength and corrosion resistance. The weldmetal possess excellent resistance to chemical corrosion and heat. OK 67.70 welds with a very smooth and quite arc which is stable in all positions and a slag system that allows a very easily removable slag and a final weld bead, very finely rippled, smooth and shiny. The weldmetal is of radiographic quality. APPROVALS: PDlL, NPCIL WELDING CURRENT: DC +, AC 50V TYPICAL APPLICATIONS OK 67.70 is especially designed for welding of acid resisting clad steels and stainless steels to other types of steels for e.g. welding of the root runs in the transition between the stainless layer in a clad steel and the unalloyed base material. OK 67.70 is also widely used for joining of dissimilar metals such as molybdenum bear-

ing austenitic stainless steels to carbon steel, for welding of 309 Mo types steels, and also for surfacing and building up on carbon steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr Ni Mo Si S P 0.05 0.80 24.5 12.5 2.5 0.70 0.015 0.020 Mechanical Properties UTS YS EL Ferrite Content 650 N/mm2 560 N/mm2 35% FN 12-24

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. welding buildup layer of turbine, runners made of ferritic chromium stainless steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si Mo P 0.06 0.7 23.50 0.015 12.5 0.7 2.5 0.018 Mechanical Properties UTS YS EL Ferrite Content 640 N/mm2 460 N/mm2 35% FN 12-22

ESAB 309Mo

A basic stainless steel electrode depositing a 23 Cr, 12 Ni, 2 Mo type weldmetal Classification AWS A 5.4: E 309Mo-15 IS 5206: E 23.12 2 B 20 DESCRIPTION ESAB 309Mo is a basic coated all position stainless steel electrodes giving an austenitic weld deposit of 23 Cr, 13 Ni, 2.5 Mo type. The addition of Mo to the normal AISI 309-type steel improves its tensile strength and corrosion resistance. The weldmetal has excellent resistance to corrosion and oxidation at elevated temperature upto 1100°C in continuous service. ESAB 309Mo welds with a quiet, smooth and stable arc in all positions with minimum spatter. The slag cover is easily detachable and the weldbead is shiny and smooth. The weldmet is of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 309Mo is especially suitable for welding of stainless steels where better toughness is required compared to the rutile based electrodes of the same class. ESAB 309Mo is used for the welding of 316 type clad steels as well as a buffer layer in welding of dissimilar metals e.g. mild steel to stainless steel, low alloy steel to stainless steel. Also suitable for surfacing and building up for wear resistance. Recommended for
38

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 40-60 60-90 85-130 140-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

ESAB 309LMo
An extra low carbon, basic stainless steel electrode depositing a 23 Cr, 13 Ni, 2.5 Mo type weldmetal Classification DESCRIPTION ESAB 309LMo is an extra low carbon, basic coated all position stainless steel electrode giving an austenitic weld deposit of 23 Cr, 13 Ni, 2.5 Mo type. The weldmetal has excellent resistance to corrosion and oxidation at elevated temperatures of upto 1100°C in continuous service, coupled with good strength. ESAB 309LMo welds with a quiet, smooth and stable arc in all positions with a minimum spatter. The slag cover is easily detachable and the weld bead is shiny and smooth. The weldmetal is of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 309LMo is especially suitable for welding of stainless steels where better toughness is required compared to the rutile based electrodes of the same class. ESAB 309LMo is used for the welding of 316 type clad steels as well as for joining and as a buffer layer in welding of dissimilar metals e.g. mild steel to stainless steel, low alloy steel to stainless steel. Also suitable AWS A 5.4: E 309LMo-15 IS 5206: E 23.12.2 L B 20

for surfacing and building up for wear resistance. Recommended for welding build-up layer of turbine, runners made of ferritic chromium stainless steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si Mo P 0.03 0.8 23.5 0.018 13.0 0.7 2.50 0.018 Mechanical Properties UTS YS EL Ferrite Content 620 N/mm2 440 N/mm2 35% FN 12-22

Welding Consumables

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 40-70 60-100 100-140 140-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si Nb P 0.07 0.80 24.0 0.015 12.5 0.60 0.80 0.020 Mechanical Properties UTS YS EL Ferrite Content 590 N/mm2 430 N/mm2 35% FN 12-25

OK 67.68
A rutilebased electrode giving 23 Cr/12 Ni / Nb stabilised deposit Classification DESCRIPTION OK 67.68 is a rutile based electrode for depositing Weldmetal that can withstand upto 1100°C in continuous service. The Nb stabilised 23Cr/12Ni weldmetal provides resistance to intergranular corrosion and also provides higher strength for elevated temperature service. OK 67.68 provide excellent resistance to chemical corrosion and heat. The excellent arc and slag characteristics ensure smooth welding performance with an excellent finish coupled with high deposition efficiency. WELDING CURRENT: DC +, AC 65V TYPICAL APPLICATIONS OK 67.68 is used for the welding of AISI 309 Nb type, straight chrome steels, joining stainless steels to low alloy steels and carbon steels. Also for building up on mild steel to improve wear resistance and for building up worn parts of wear resisting steels. AWS A 5.4: E 309Nb-16 IS 5206: E 23.12 Nb R 26

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

39

Welding Consumables

ESAB 309Cb
A basic type, stainless steel electrode depositing a 23 Cr/12 Ni, Nb Stabilised type weldmetal Classification DESCRIPTION ESAB 309Cb is a basic coated stainless steel electrode giving austenitic weld deposit of 23 Cr/12 Ni type containing columbium for immunity against weld decay. The C-Nb ratio is carefully controlled to provide stabilisation against intergranular corrosion and higher strength at elevated temperature service of upto 1100OC in continuous service. ESAB 309Cb welds with a very smooth, quite and stable arc in all positions with very little spatter. The slag system design allows for a fluid but controlled slag and a slag cover that is easily detachable to reveal a shiny, smooth and even weld bead. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 309Cb is especially designed for welding AISI 309, 309Nb steels and joining of dissimilar steels, stainless steel to mild steel, stainless steel to low alloy steel, for root runs in clad steel joints, surfacing on mild AWS A 5.4: E 309 Nb-15 IS 5206: E 23.12 Nb B 20

steel to improve wear resistance, building up on worn parts of wear resisting steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Nb Si P 0.06 0.90 23.0 0.015 13.00 0.85 0.70 0.020 Mechanical Properties UTS YS EL Ferrite Content 620 N/mm2 420 N/mm2 35% FN 12-24

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 40-70 80-100 100-150 140-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. ature furnace parts, annealing boxes, carburising pots, armour plates and welding stainless steels to unalloyed steels. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Ni Mn Si S P Mo 0.10 26.0 21.0 1.70 0.60 0.015 0.020 0.04 Mechanical Properties UTS YS EL Ferrite Content 580 N/mm2 430 N/mm2 35% FN 0

OK 67.13

A basic rutile, 25 Cr, 20 Ni type austenitic stainless steel electrode Classification AWS A 5.4: E 310-16 IS 5206: E 25.20 R 26 DESCRIPTION OK 67.13 is a medium heavy coated, semi basic type austenitic stainless steel electrode depositing a 25 Cr, 20 Ni type weld deposit which has excellent stability and oxidation resistance in continuous service upto 1100°C. OK 67.13 has excellent striking and restriking properties and do not run the problem of short-circuiting during welding. The very smooth and quite arc in all positions coupled with a slag cover that is self-detaching and a weld bead finely rippled and shiny contributes to its immense welder appeal. The weldbead is of radiographic quality. APPROVAL: NPCIL WELDING CURRENT: DC +, AC 65V TYPICAL APPLICATIONS OK 67.13 is used for the welding of heat resisting steels of 25 Cr /20 Ni type such as AISI 310 and Din werkst. Nr 1.4848. 1.4841, 1.4845, German steels like 4762, 4828, 4841, 4846 and 4848, cladding side of clad stainless steels, hydrogenation plants, polymerisation plants, gas turbine combustion chamber components, high temper40

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

OK 67.45
A basic coated stainless steel electrode of the 18 Cr-8 Ni-6 Mn type Classification DESCRIPTION OK 67.45 is a basic coated austenitic stainless steel electrode giving a weldmetal of the 18 Cr-8 Ni-6 Mn type. The tough weldmetal imparts excellent crack resistance, when welding steels of even poor weldability. OK 67.45 has excellent arc and current carrying characteristics in all positions giving a very smooth, quite, stable arc and very little spatter. The slag system is fluid but controllable, giving a slag cover that is self-peeling and a weldbead that is smooth, even and shiny. The weld is of radiographic quality. APPROVALS: CQA (Met), Ichapore, DGQA WELDING CURRENT: DC+, AC 70V TYPICAL APPLICATIONS OK 67.45 find extensive use for joining dissimilar steels, 13 Mn steels with reduced weldability and for cladding carbon steels. OK 67.45 can also be used as a buffer layer prior to hard surfacing. Also used for welding Armour steels. AWS A 5.4: E 307-15 (Nearest)

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Cr S Ni Si P Mo Size (mm) 2.50 3.15 4.00 5.00 0.05 6.00 19.0 0.015 9.5 0.5 0.020 0.45 Mechanical Properties YS UTS EL Impact (CVN) at +20OC Ferrite Content 450 N/mm2 650 N/mm2 40% 90J FN<5

Welding Consumables

CURRENT RANGE & PACKING DATA
Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

ESAB RSW

A high alloy ‘Universal’ electrode for joining steels of unknown composition Classification AWS A 5.4: E 312-16 IS 5206: E 29.9 R 26 DESCRIPTION ESAB RSW is a rutile coated all position electrodes for welding of complex dissimilar alloys and high strength steels with low heat input, giving sound joints free from any cracks and fissures. It is a specially designed high alloy electrode for joining steels of unknown composition. The weldmetal has high strength combined with excellent resistance against impact, heat (excellent scaling resistance upto 1150°C) and corrosion. The ferriticaustenitic duplex structure weldmetal is highly tolerant to dilution and stress corrosion. Also suitable for depositing buffer layers prior to surfacing on high strength and high alloy steels. ESAB RSW has excellent weldability characteristics in all positions giving a slag that is easily detachable and a final weldbead that is finely rippled, smooth and shiny. APPROVALS: CQA (Met), Ichapore, DGQA WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB RSW is especially designed for welding of high strength alloy steels and dissimilar joints especially where one or both the components are high in nickel. Also suitable for building up or cushioning prior to hard facing on very high strength and high hardness deposit

and hot working tools, dies for plastics etc. Other applications include rebuilding chemical agitator blades, shafts, rolling mill spindles, bucket lips, highly hardenable armour steels and for furnace parts etc. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Ni S Mn Si P Mo 0.10 30 10.0 0.015 2.20 0.40 0.020 0.15 Mechanical Properties UTS YS EL Impact (CVN) at +20oC Ferrite Content 800 N/mm2 700 N/mm2 28% 40J FN 50-75

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 50-80 70-110 100-140 140-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.
41

Welding Consumables

OK 67.50

A rutile based stainless electrode for welding Duplex Stainless Steels Classification AWS A5.4: E 2209-17 EN 1600 E2293 NLR32 Werkstoff Nr.1.4462 DESCRIPTION OK 67.50 is an acid rutile electrode specially designed for welding of UNS31500, UNS31803 types of ferriticaustenitic stainless steels (popular known as “Duplex stainless steels”). The composition of weldmetal is designed to give mechanical and corrosion properties that fully comply with these grades for example, high resistance to stress corrosion cracking and high yield strength. The arc and current carrying characteristics are in the best traditions of ESAB stainless steel electrodes of the highest standards coupled with its self-releasing slag and its outstanding weld bead finish makes OK 67.50 the welders favourite the world over for welding of Duplex Steels. APPROVALS: ABS, BV, CE, CWB, DNV, GL, RINA, CEPROZ, VdTUV WELDING CURRENT: DC +, AC APPLICATIONS OK 67.50 find extensive use in welding of duplex steels of the type UNS31500, UNS31803 which need high resistance to stress corrosion and high yield strength e.g.

in the ship building industry, chemical industries etc. OK 67.50 may also be used for joining of Duplex steels to mild steels. Welding of duplex steels should be made with low heat input. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Cr Ni Mo Cu N 0.03 0.8 0.7 0.018 0.01 22.5 8.9 3.00 0.1 0.16 Size Mechanical Properties YS UTS EL CVN Impact Value at +20OC Ferrite Content 660 N/mm2 820 N/mm2 25% 50J FN 25 - 40

CURRENT RANGE
(mm) 2.50 3.2 4.00 5.00

Length Current Range (mm) (Amps) 350 50-90 350 350 350 80-120 90-160 150-220

PACKING: Electrodes are available in ready to use vacuum pack cartons. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Mn P S Cr Ni Mo Cu N 0.04 0.45 0.8 0.025 0.015 25.25 9.75 4.0 0.75 0.27 Mechanical Properties YS UTS EL CVN Impact Tolyhress at - 60OC Ferrite Content 700 N/mm2 900 N/mm2 28% 45J FN 35-50

OK 68.55
A basic coated stainless steel electrode for welding Super Duplex Stainless Steels Classification AWS A5.4 : E2594-15 EN 1600 E 25 9 4 N L B 4 2 Werkstoff Nr. (1.4410) DESCRIPTION OK 68.55 is a basic coated electrode for welding austeniticferritic steels of the so-called “Super Duplex Steels” type. OK 68.55 deposits a weldmetal with high ductility that has very high resistance to pitting, crevice and stress corrosion cracking. OK 68.55 possess excellent welding characteristics in all positions providing a smooth and stable arc in all positions with very little spatter. The slag is self-peeling and the final weldbead is smooth, finely rippled and shiny. APPROVAL: DNV WELDING CURRENT: DC + TYPICAL APPLICATIONS OK 68.55 is especially designed for welding of the new range of super duplex stainless steels, such as SAF 2507, Zeron 100, Ferralium 255 UR 47 N, DP3 and similar steels which find increasing use for good corrosion resistance and high structural strength that are required compared to conventional stainless steel grades.

CORROSION DATA : Streicher Test, ASTMA 262P-B : 0.24 mm/year

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amps) 50-80 60-100 100-140 150-240

PACKING: Available in ready to use vacuum pack cartons.

42

OK 68.10
A basic coated stainless steel electrode for depositing a ferritic weldmetal Classification DESCRIPTION OK 68.1 0 is a basic coated stainless steel electrode giving ferritic weldmetal of 13% Cr type for welding of ferriticmartensitic chrome steels. OK 68.10 has excellent welding characteristics in all positions as it welds with a smooth and stable arc and the slag system design allows good wetting and washing to obtain a very finely rippled bead and a slag that is very easily detachable. WELDING CURRENT: DC + APPLICATIONS OK 68.10 is suitable for joining, surfacing, inlay and overlay applications on similar type of steels e.g. 410, 410S etc. Typical applications include Machine parts, Gears, Fasteners, Propeller Shafts, welding of cast parts in gas turbine construction, welding of similar corrosion resistant chrome steels and steel castings, pump parts components in oil refineries, coal washers, rebuilding of valves, etc. AWS A5.4: E 410-15 IS 5206: E 13 B 20

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Si Cr S Mn Ni Mo P 0.07 0.5 13.5 0.017 0.7 0.5 0.3 0.019 YS UTS EL Mechanical Properties 410 N/mm2 540 N/mm2 26%

Welding Consumables

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 70-100 90-130 120-170 150-220 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.

OK 68.00

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni Cr Mo S P 0.03 0.8 0.4 4.5 12.5 0.5 0.015 0.020 YS UTS EL Mechanical Properties 680 N/mm2 800 N/mm2 17%

A rutile based stainless steel electrode for depositing 13 Cr/4 Ni/O.5 Mo type weldmetal Classification AWS A 5.4: E 410Ni Mo-16 IS 5206: E 13 4 R 26 DESCRIPTION OK 68.00 is a specially designed rutile coated stainless steel electrode depositing 13 Cr, 4.5 Ni and 0.5 Mo weldmetal. It has excellent welding characteristics in flat, H-V positions and V-up position. The weldmetal provides very good resistance to corrosion, erosion and pitting. OK 68.00 has outstanding arc and current carrying characteristics with a quite and stable arc. The slag is easily detachable revealing a smooth, shiny and finely rippled bead. WELDING CURRENT: DC +, AC 65 V TYPICAL APPLICATIONS OK 68.00 is a suitable electrode for joining, surfacing applications of hydel turbine blades, valve seat runners, high pressure vessels, paper plant equipment, welding of guide vans and runners, similar corrosion resisting chromium steels, steel castings and martensitic-ferritic stainless steel of similar types.

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 70-100 90-130 120-170 150-220 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

43

Welding Consumables

ESAB RSQ
A specially designed stainless steel electrode for welding dissimilar and difficult to weld steel DESCRIPTION ESAB RSQ is a specially designed basic coated stainless electrode for welding dissimilar and difficult to weld steels. The weld deposit work hardens and provides good impact resistance and has excellent thermal shock resistance. ESAB RSQ welds with a smooth arc with very little spatter and has a slag system that provides good wetting with a slag cover that is easily detachable depositing a weldbead that is smooth, shiny and uniform. APPROVAL: CQA(Met), Ichapore, DGQA WELDING CURRENT: DC + APPLICATIONS ESAB RSQ deposits a weldmetal which is highly resistant to cracking and as well has good thermal shock resistance. The weldmetal will polish in service to provide excellent metal to metal wear resistance. Extremely suitable as a tough underlay for more brittle alloys in medium to high temperature applications. Recommended to use as a buffer layer for reconditioning of medium manganese steel rail crossing. Other typical applications: to weld difficult to weld steels, armour steels, carbon steels to stainless steels, as a buffer layer

for overlaying surfaces that take severe impact and pounding (ie) in steel mill wobblers and coupling boxes, armour mill hammers, bar mill guides and synter-plant parts. Also for welding 5Cr-1/2Mo steels where no heat treatment can be applied. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mo Cr S Ni Si Mn P 0.03 3.30 22.00 0.017 11.5 0.6 1.2 0.018 Mechanical Properties UTS EL Hardness As welded Work-hardened 640 N/mm2 36% 150-200VHN 400-430VHN

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 50-80 60-100 90-145 130-180 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni Cr Mo 0.08 0.9 0.5 0.4 17.0 0.4 YS UTS EL Mechanical Properties 430 N/mm2 520 N/mm2 20%

ESAB 430
A basic coated stainless steel electrode for depositing a 17 Cr Weldmetal Classification DESCRIPTION ESAB 430 is a basic coated stainless steel electrode giving ferritic weld of 17% Cr type for welding of ferriticmartensitic chrome steels. Welding with ESAB 430 electrode requires suitable post and preheats teatment for obtaining optimum weldmetal properties. The welds arc of radiographic quality. WELDING CURRENT: DC + TYPICAL APPLICATIONS ESAB 430 is designed for welding AISI 430 stainless steels and steels with similar composition. Typical applications include machine parts, gears, fasteners, propeller shafts, welding of cast parts in gas turbine construction, welding of similar corrosion resistant chrome steels and steel castings, pump parts cimponents in oil refineries, coal washers etc.
44

AWS A 5.4: E 430-15

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 60-90 80-120 120-170 150-240 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

ESAB ARMOlD 1
A specially designed stainless steel electrode for joining of armour plates and other crack sensitive steels DESCRIPTION ESAB ARMOlD 1 is a stainless steel electrode designed for joining of high strength and dissimilar alloys, armour plates and other crack sensitive steels. ESAB ARMOlD 1 is also suitable as a cushioning alloy under hard deposits and for repairing of carbon steel, alloy steel and stainless steel components. It deposits an austenitic weldmetal with sufficient residual ferrite to impart extreme crack resistivity. The electrode has excellent operating characteristics with superior arc stability at low current levels. The weldmetal has excellent work hardening rate without deformation. The slag cover is easily detachable and the weld bead is shiny smooth and finely rippled. APPROVAL: CQA (Met), Ichapore, DGQA WELDING CURRENT: DC +, AC 70V APPLICATIONS ESAB ARMOlD 1 is especially designed for welding of armour plates. Other than application on armour plates, the electrode is also suitable for joining of high strength steels such as high carbon steels, ChromeCarbon steels, Chrome-Moly steels and spring steels. Dissimilar steels such as Carbon & Alloy steels to Mn-

steels or Stainless Steels can also be welded with ESAB ARMOlD 1. The excellent work hardening characteristics displayed by ESAB ARMOID-1, makes it suitable for use in reinforcing rail steels, excavator bucket teeth, for surfacing of gear teeth and steel mills roll prior to hard metal deposition. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Cr Ni Mn Mo Si S P 0.08 20.30 8.50 1.8 2.60 0.50 0.015 0.020 Mechanical Properties UTS 735 N/mm2 EL 35% Hardness (As Welded Condition) 280VHN Hardness (Work Hardend Condition) 400VHN

Welding Consumables

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 55-75 90-110 120-160 140-205 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons. TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si S Ni Cr P Mo 0.10 6.20 0.75 0.015 8.0 18.00 0.020 0.2 UTS YS EL Mechanical Properties 650 N/mm2 500 N/mm2 35%

ESAB CHROMWELD G
A rutile coated 19/8/5 type electrode for joining dissimilar steels Classification DESCRIPTION ESAB Chromweld G is a rutile coated stainless steel electrode depositing 19Cr - 8Ni - 5Mn work hardening type weldmetal. The electrode is specially designed for applications involving good work hardening properties and joining of high tensile steels. It has smooth and stable characteristics with good bead appearances. WELDING CURRENT: DC +, AC 70V APPLICATIONS Chromweld G is specially designed for welding of High strength steels of unknown composition and also suitable as a cushioning layer prior to hard surfacing. Other applications include joining of manganese steel to manganese steel or mild steel, in marine shaft building, bucket lips, etc. IS 5206: E 18.8 Mn R 24

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 55-75 90-110 120-160 140-205 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a card board box. Also available in ready to use vacuum pack cartons.
45

Welding Consumables

ESAB CHROMWELD G (Spl)
A high alloyed electrodes for high strength applications DESCRIPTION ESAB Chromweld G (Spl) is a lime rutile coated stainless steel electrode depositing high strength 20Cr - 8.5Ni - 6Mn - 0.6Mo type work hardening austenitic weld deposit. The Electrode is especially suitable for high impact and corrosion resistance combined with moderate abrasion at elevated temperature. The design ensures excellent running performance with smooth stable arc with good wetting action and minimum spatter level. The weldmetal is designed to have optimum ferrite content to prevent hot cracking and suitable for welding of dissimilar steels and high tensile steels. WELDING CURRENT: DC +, AC 70V TYPICAL APPLICATIONS ESAB Chromweld G Special is designed for welding of high strength alloy steel and dissimilar joints. The unique composition enables this electrode to be most suitable for welding of Gun Carriage base plates, High Tensile Armour Plates, joining of austenitic manganese steel components, etc.

TYPICAL ALL WELDMETAL PROPERTIES
Chemical Composition (%) C Mn Si Ni Cr Mo P S 0.06 6.00 0.6 10.5 20.0 0.6 0.02 0.02 UTS EL Mechanical Properties 640 N/mm2 40%

CURRENT RANGE & PACKING DATA
Size (mm) 2.50 3.15 4.00 5.00 Length Current Range (mm) 350 350 350 350 (Amps) 55-75 90-110 120-160 140-205 Weight Per Box : 10 Kgs Weight Per carton (Packet) : 2 Kgs No. of Packets (Cartons) in a box : 5 Packing

PACKING: Electrodes are packed in heat sealed plastic cartons and five of these cartons are shrink wrapped in a Cardboard box. Also available in ready to use vacuum pack cartons.

46

GTAW Consumables
OK TIGROD SG
TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 425 MPa 515 MPa 26%

Welding Consumables

Classification : AWS A5.18: ER 70S-G DESCRIPTION & APPLICATION General purpose TIG Welding Wire suitable for C/C-Mn steel pipes, tubes, plates etc. WELDING CURRENT: DC SHIELDING GAS: Argon TYPICAL WIRE COMPOSITION (%) C Mn Si P S 0.08 1.3 0.60 0.014 0.024

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.2 1000 a 1.6 1000 a 2.0 1000 a 2.4 1000 a PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box. TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Al S P Ti Zr 0.06 1.00 0.6 0.08 0.015 0.015 0.07 0.07 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 420 N/mm2 515 N/mm2 26% 50J

OK TIGROD S2

A Copper coated rod for TIG welding Classification AW5 A5.18: ER 70S-2 DESCRIPTION & APPLICATION OK TIGROD S2 are copper coated rod for TIG welding process using Argon and is specially suitable for welding of light gauge mild steel in all position and for a variety of applications, including root run for pipes & tubes etc. APPROVALS : PDIL, NPCIL WELDING CURRENT: DC TYPICAL WIRE COMPOSITION (%) C Mn Si P S Ti Zr Al 0.06 1.15 0.6 0.015 0.015 0.08 0.07 0.08

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.6 1000 a 2.0 1000 a 2.5 1000 a PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box. TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Al S P Zr Ti 0.05 1.20 0.55 0.08 0.015 0.015 0.07 0.08 Mechanical Properties YS UTS EL Impact (CVN) at -51oC 415 N/mm2 510 N/mm2 27% 28J

A Copper coated rod for TIG welding meeting impact strength at -51°C Classification AW5 A5.18: ER 70S-2 DESCRIPTION & APPLICATION OK TIGROD S2 (Spl) are copper coated rod for TIG welding containing medium manganese and silicon to optimise strength and impact toughness at sub-zero temperatures of -51OC. OK TIGROD S2 (Spl) is designed for the welding structural steels, pressure vessels and boilers involving unalloyed and micro alloyed structural steels. Also recommended for rootruns of pipes & tubes of A5TM A 1 066-B steel used for offshore application. Passes NACE Tests as per TM - 02 - 84 (HIC) and TM - 01 - 77 (SSCC). WELDING CURRENT: DC TYPICAL WIRE COMPOSITION (%) C Mn Si P S Ti Zr Al 0.05 1.20 0.55 0.015 0.015 0.08 0.07 0.08

OK TIGROD S2 (Spl)

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.6 1000 a 2.0 1000 a 2.5 1000 a PACKING: The rods are packed in 5-kg cartons and four of them in a Cardboard box.

47

Welding Consumables

OK TIGROD 12.64
A Copper coated rod for TIG welding Classification DESCRIPTION OK TIGROD 12.64 is a copper-coated rod for GTAW of mild steels and carbon steels. A slightly higher silicon and manganese increases better yield and tensile strength of the weldmetal that is smooth and sound. TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 1.70 Si P S AW8 A5.18: ER 70S-6

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S P 0.10 1.70 1.00 0.020 0.023 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 470 N/mm2 590 N/mm2 25% 80J

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.90 0.020 0.015

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

OK TIGROD 13.09
A Copper coated rod for TIG welding of C-0.5 Mo Steel pipes/tubes Classification DESCRIPTION OK TIGROD 13.09 is copper coated rod for TIG welding C-0.5 Mo steel pipes and tubes used in boilers and pressure vessels with a temperature up to 500°C. Also used for high strength low alloy steel. APPROVALS : DB, DNV, VdTUV TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 1.95 Si 0.5 P S Mo Cu 0.15 AW8 A5.28: ER 80S - G

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S P Mo 0.07 0.9 0.55 0.01 0.08 0.50 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 410 N/mm2 580 N/mm2 26% 150J

PACKING DATA Size (mm) 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 Packing (5 Kg.) a a a a

0.01 0.010 0.50

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

OK TIGROD 13.16
Copper coated 1.25 Cr-0.5 Mo Tig Rod Classification DESCRIPTION OK TIGROD 13.16 is a tig filler rod suitable for welding pipes and tubes of 1.25 Cr-0.5 Mo Steels. It deposits notch free welds with excellent mechanical properties as well as high creep resistance and toughness.The weld deposit is of radiographic quality. AWS A5.28: ER 80S -B2

APPLICATIONS Recommended for welding of pipes and tubes of matching composition in Power Plants, Refineries, Fertilizer Plants, Chemical and Petrolium Plants. Suitable for ASTM A 335 Gr. P11, ASTM A387Gr.B, DIN 15 Cr Mo3, ASTM A 199-76, ASTM A 200-75, ASTM A 213-760 and similar steels. TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 0.60 Si 0.50 Cr 1.30 Mo 0.60 Cu S P

0.25 0.012 0.014 (Contd...)

48

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Cu P Mo 0.07 0.55 0.45 0.012 1.25 0.20 0.014 0.55

Mechanical Properties 510 N/mm2 620 N/mm2 26% 60J

PACKING DATA Size (mm) 1.6 2.0 2.4

Welding Consumables

Length (mm) 1000 1000 1000

Packing (5 Kg.) a a a

YS UTS EL Impact (CVN) at -29oC

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box. TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Cu P Mo 0.03 0.55 0.55 0.010 1.30 0.15 0.010 0.5 Mechanical Properties YS UTS EL Impact (CVN) at -20oC 470 N/mm2 550 N/mm2 23% 250J

OK TIGROD B2L

Copper coated low carbon 1.25 Cr-0.5 MoTig Rod Classification AWS A5.28: ER 70S - B2L DESCRIPTION OK TIGROD B2L is a TIG filler rod suitable for welding pipes and tubes of 1.25 Cr-0.5 Mo Steels. It deposits notch free welds with excellent mechanical properties as well as high creep resistance and toughness. The weld deposit is of radiographic quality. APPLICATIONS Recommended for welding of pipes and tubes of matching composition in Power Plants, Re1ineries, Fertilizer Plants, Chemical and Petrolium Plants. Suitable for ASTM A 335 Gr. P11, ASTM A 387 Gr. B, DIN 15 Cr Mo 3, ASTM A 199-76, ASTM A 200-75, ASTM A 213-76D, A335-76, A369-76, A387-76 and similar steels. Suitable for pipelines and pressure vessels with operating temperatures of about 500OC. SHIELDING GAS : 100% Ar TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Mo Cu S P Cu

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.03 0.60 0.60 1.30 0.50 0.15 0.010 0.014 0.015

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

OK TIGROD 13.17

Copper coated 2.25 Cr-1 MoTig Rod Classification AWS A5.28: ER 90SB - 3 DESCRIPTION OK TIGROD 13.17 is a tig filler rod suitable for welding pipes and tubes of 2.25 Cr-1.0 Mo Steels. It deposits notch free welds with excellent mechanical properties as well as high creep reistance and toughness. The weld deposit is of radiographic quality. APPLICATIONS Recommended for welding of pipes and tubes of matching composition in Power Plants, Re1ineries, Fertilizer Plants, Chemical and Petrolium Plants. Suitable for ASTM A 335 Gr. P22, ASTM A 387 Gr. D, DIN 10 Cr Mo 910-G3, ASTM A 199-76, ASTM A 200-75, ASTM A 36976D, DIN 10 CrMo910 and similar steels. TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 0.60 Si 0.50 Cr 2.5 Mo 1.05 Cu S P

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Cu P Mo 0.07 0.55 0.45 0.012 2.5 0.20 0.014 1.02 Mechanical Properties YS UTS EL Impact (CVN) at -29oC 600 N/mm2 710 N/mm2 24% 60J

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.25 0.012 0.014

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.
49

Welding Consumables

OK TIGROD B3L

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Cu P Mo 0.03 0.55 0.50 0.010 2.5 0.15 0.010 1.1 YS UTS EL Mechanical Properties 500 N/mm2 600 N/mm2 24%

Copper coated low carbon 2.25 Cr – 1 Mo Tig Rod Classification DESCRIPTION OK Tigrod B3L is a TIG filler rod suitable for welding pipes and tubes of 2.25 Cr-1 Mo Steels. It deposits notch free welds with excellent mechanical properties as well as high creep resistance and toughness. The weld deposit is of radiographic quality. TYPICAL APPLICATIONS Recommended for welding of pipes and tubes of matching composition in Power Plants, Refineries, Fertilizer Plants, Chemical and Petroleum Plants. Suitable for ASTM A 335 Gr. P22,ASTM A 387 Gr. D, DIN 10 Cr Mo 910-G3, ASTM A 199-76, ASTM A 200-75, ASTM A 36976D,DIN 10CrMo910 and similar steels. CURRENT: DC+ TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Mo Cu S P Cu

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.03 0.60 0.60 2.5

1.1 0.15 0.010 0.014 0.015

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

OK TIGROD 13.23
Classification DESCRIPTION A copper coated, Ni-alloyed (0.9% Ni), rod for GTAW of low - temperature fine-grained steels. The wire provides good impact toughness down to -50OC and is especially suitable for use in the offshore industry. APPROVALS : DNV ALLOY TYPE : Low alloyed steel (1% Ni) SFA/AWS A5.28 ER80S-Ni1

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Si Mn P S Cr Ni Mo 0.08 0.60 1.0 0.025 0.025 0.15 0.9 0.3 Mechanical Properties YS UTS EL Impact (CVN) at 0oC -20oC -46oC -60oC 500 N/mm2 600 N/mm2 25% 230J 200J 140J 90J

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.6 1000 a 2.0 1000 a 2.4 1000 a 3.2 1000 a PACKING: The rods are packed in 5-kg cartons and four of them in a Cardboard box.

50

OK TIGROD 13.28
Classification DESCRIPTION OK TIGROD 13.28 is 2.4 Ni-alloyed (ER80S-Ni2), copper-coated rod for the GTAW of low-temperature, finegrained steels in applications such as pressure vessels, pipes and the offshore industry, with a minimum yield strength of up to 470 MPa. The wire provides good impact toughness down to - 60OC. APPROVALS: VdTÜV WELDING CURRENT: DCSFA/AWS A5.28: ER80S-Ni2

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Ni 0.10 1.1 0.6 2.4 Mechanical Properties YS UTS EL Impact (CVN) at +20oC -40oC -60oC 540 N/mm2 630 N/mm2 30% 200J 180J 150J

Welding Consumables

PACKING DATA Size (mm) 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 Packing (5 Kg.) a a a a

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

OK TIGROD 13.32
A Copper coated 5 Cr, 0.5 Mo rod for TIG welding Classification DESCRIPTION OK TIGROD 13.32 is low alloyed 5 Cr, 0.5 Mo filler rod for GTAW of creep resistant steels. OK TIGROD 13.32 weld deposit has excellent mechanical properties with good Xray quality. The filler rod is developed for welding of pipes and tubes of similar composition, in refineries, petrochemicals, and fertiliser plants. OK TIGROD 13.32 is suitable for ASTM grades 199-76, 335-76, 369-76, and 387-76. The arc and current carrying characteristics are excellent and provides a high degree of welder appeal. The final weld bead is smooth, shiny and even. TYPICAL WIRE COMPOSITION (%) C 0.07 Mn 0.50 Si 0.40 Cr 5.70 Mo 0.60 AWS 5.28: ER 80S - B6

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Cr Mo 0.10 0.60 0.50 5.50 0.50 Mechanical Properties YS UTS EL Impact (CVN) at +20oC - 20OC 510 N/mm2 620 N/mm2 25% 200J 150J

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

PACKING: The rods are packed in 5-kg cartons and four of them in a Cardboard box.

51

Welding Consumables

OK TIGROD 13.37
GTAW ER80S-B8 Classification DESCRIPTION OK TIGROD 13.37 is a 9Cr-1 Mo-alloyed, copper-coated rod for the GTAW of high temperature steels and steels for hot hydrogen service, especially in oil refineries. SFA/AWS A5.28: ER80S-B8

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Cr Mo 0.08 0.60 0.40 9.00 1.00 Mechanical Properties YS UTS EL Impact (CVN) at -20oC 540 N/mm2 660 N/mm2 26% 140J

PACKING DATA Size (mm) 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 Packing (5 Kg.) a a a a

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

OK TIGROD 13.38
GTAW ER90S-B9 Classification DESCRIPTION OK TIGROD 13.38 is a 9CrMo VN-alloyed rod for the GTAW of high-temperature steels and steels for hot hydrogen service, especially in oil refineries. It should preferably be used for 9% Cr steels, such as P91/T91 steels. The alloy is modified in terms of the limits for impurity elements and is extremely “clean”. This produces improved strength levels both at room temperature and at higher temperatures. APPROVALS: VdTŰV, SFA/AWS A5.28: ER90S-B9

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Cr Ni Mo 0.10 0.50 0.26 8.90 0.70 1.00 Mechanical Properties YS UTS EL Impact (CVN) at 0oC -20oC 690 N/mm2 785 N/mm2 20% 180J 150J

PACKING DATA Size (mm) 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 Packing (5 Kg.) a a a a

PACKING: The rods are packed in 5-kg cartons and four of them in a Cardboard box.

52

OK TIGROD 16.10
An extra low carbon stainless steel rod of 18/8 type for TIG Welding Classification DESCRIPTION OK TIGROD 16.10 is 18 Cr - 8 Ni type rod for GTAW of austenitic corrosion resisting steels. OK TIG ROD 16.10 is suitable for welding of AISI 301, 304, 304L and equivalent grade. Also provides acceptable results on most niobium and titanium stabilised steels. APPROVALS: PDIL, NPCIL TYPICAL WIRE COMPOSITION (%) C 0.025 Mn Si Cr Ni S P Mo Cu AWS A5.9: ER 308L

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Ni P 0.025 1.75 0.4 0.018 20.0 10.0 0.008 Mechanical Properties YS UTS EL (L=4d) Impact (CVN) at -196oC 461 N/mm2 632 N/mm2 36% 84J

Welding Consumables

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

1.6 0.4

20 10

0.018 0.018 0.05 0.05

PACKING: The rods are packed in 5.5 kg cartons and four of them in a Cardboard box.

OK TIGROD 308H
Bare corrosion resisting chroumium - nickel rods for welding of austenitic chromium nickel alloys of 18% Cr - 8% Ni- type Classification DESCRIPTION OK TIGROD 308H has a good general corrosion resistance. The alloy has a high carbon content which makes this alloy suitable for applications used at higher temperatures. The alloy is used in chemical and petrochemical industry for welding of for tubes, cyclones and boilers. SFA/AWS A5.9: ER 308H

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Si Mn P S Cr Ni Mo Cu 0.06 0.4 1.6 0.015 0.012 20 9.5 0.25 0.15 YS UTS EL Mechanical Properties 390 N/mm2 590 N/mm2 32%

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

53

Welding Consumables

OK TIGROD 16.11
Extra low carbon stainless steel rods of the Niobium stabilised 18/8 type for TIG welding Classification DESCRIPTION OK TIGROD 16.11 are Niobium stabilised stainless steel rods of 18Cr-8Ni type for GTAW, providing excellent weld appeal. OK TIGROD 16.11 is suitable for AISI 321, 347 & 348 type grades that are commonly used in refinery, chemical and petrochemical industries, food and beverage industries etc. APPROVALS: NPCIL TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Ni Nb S P Mo Cu AWS A5.9: ER 347

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Nb Cr Ni S P 0.03 1.50 0.60 0.55 5.5 2.5 0.018 0.018 Mechanical Properties YS UTS EL (L=4d) Impact (CVN) at +20oC 430 N/mm2 640 N/mm2 35% 100J

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.04 1.5 0.4 19.5 9.5 0.55 0.018 0.018 0.05 0.03

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

OK TIGROD 347H
Classification SFA / AWS A5.9 : Er347 DESCRIPTION Bare, corrosion-resistant, chromium-nickel rods for welding stabilised austenitic chromium-nickel alloys of the 18% Cr-8% Ni type. The rods are stabilised with niobium, which provides good resistance to the intergranular corrosion of the weld metal. Due to the niobium content, this alloy is recommended for use at higher temperatures. WELDING CURRENT: DC (-)

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Si Mn Cr Ni Mo Nb Cu 0.06 0.4 2.1 20.0 10.0 <0.3 <1.0 <0.3 Mechanical Properties YS UTS EL (L=4d) 350 N/mm2 550 N/mm2 25%

PACKING DATA Diameter (mm) 1.6 2.0 2.5 3.15 Length (mm) 1000 1000 1000 1000 Weight of rods / box 5 Kg a a a a

54

OK TIGROD 16.30
An extra low carbon stainless steel rod of the 18 Cr, 12 Ni, 3 Mo type for TIG welding Classification AWS A5.9: ER 316L

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Nb Cr Ni S P 0.020 1.8 0.4 18.5 12 2.7 0.018 0.018 Mechanical Properties YS UTS EL Impact (CVN) at -196oC 470 N/mm2 650 N/mm2 35% 50J

Welding Consumables

APPROVALS: PDIL, NPC DESCRIPTION OK TIGROD 16.30 is an extra low carbon stainless rod for GTAW of corrosion resisting steels having composition corresponding to 18% Cr, 12% Ni and 3% Mo type, suitable for AISI 316, 316L & similar steels. TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Ni Mo S P Cu 0.03

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.025 1.8 0.40 18.5

12.0 2.7 0.018 0.018

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

OK TIGROD 16.35
An extra low carbon stainless steel rod of the 20 Cr, 14 Ni, 3.5 Mo type forTIG welding Classification DESCRIPTION OK TIGROD 16.35 are extra low carbon stainless rods of 20% Cr, 14% Ni, 3.5% Mo type for GTAW of AISI 317 and 317L or somewhat lower alloyed types normally employed for welding of corrosion esistant austenitic type and acid resistant steels. The wires are designed for providing excellent results with Argon as shielding gas. TYPICAL WIRE COMPOSITION (%) C Mn Si Cr 19 Ni Mo 14 3.5 S P CU AWS A5.9: ER 317L

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Cr Ni Mo S P 0.028 1.80 0.40 19 14 3.5 0.018 0.018 Mechanical Properties YS UTS EL Impact (CVN) at +20oC 450 N/mm2 600 N/mm2 32% 55J

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.025 1.8 0.4

0.018 0.018 0.04

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

55

Welding Consumables

OK TIGROD 16.53
An extra low carbon 24% Cr, 13% Ni stainless steel rods for TIG welding Classification DESCRIPTION OK TIGROD 16.53 are extra low carbon rods of 24% Cr, 13% Ni stainless steel for GTAW of similar composition and also dissimilar welding of 18/8 steels to Mild steels or for surfacing of steels for corrosion resistance. The weld bead is smooth, shiny and also of radiographic quality. APPROVALS: PDIL, NPCIL TYPICAL WIRE COMPOSITION (%) C Mn Si 0.4 Cr 24 Ni S P Mo Cu 0.03 AWS A5.9: ER 309L

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si Cr Ni S P 0.026 1.8 0.4 24.0 13.0 0.018 0.018 Mechanical Properties YS UTS EL Impact (CVN) at -60oC 440 N/mm2 630 N/mm2 35% 130J

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

0.025 1.8

13 0.018 0.018 0.06

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

OK TIGROD 16.54
Classification DESCRIPTION An over-alloyed, stainless, CrNiMo (ER309LMo type) electrode for the GTAW of stainless steels of the same type and for joining stainless to mild or low alloyed steels. OK Tigrod 16.54 is usually welded with Ar as the shielding gas. WELDING CURRENT: DC+ TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Ni Mo 2.6 S P Cu AWS A5.9: ER 309 LMo (Nearest)

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20OC 400 MPa 600 MPa 34% 110J

PACKING DATA Size (mm) 1.6 2.0 2.5 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

<0.02 1.5

0.5 24 14

0.015 0.015 0.04

PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.

56

OK TIGROD 16.86
Classification DESCRIPTION Bare corrosion resisting Duplex welding rods for welding of austenitic - ferritic stainless alloys of 22% Cr 5% Ni 3% Mo types. OK TIGROD 16.86 has a high general corrosion resistance. In media containing chloride and hydrogen sulphide the alloy has a high resistance to intergranular, pitting and especially to stress corrosion. The alloy is used in a variety of applications across all industrial segments. TYPICAL WIRE COMPOSITION (%) C Si Mn Cr Ni 8.5 Mo 3.3 Cu <0.3 SFA/AWS A5.9: ER 2209

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at 20oC -20oC -60oC 600 N/mm2 765 N/mm2 28% 100J 85J 60J

Welding Consumables

PACKING DATA Size (mm) 1.2 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 1000 Packing (5 Kg.) a a a a a

<0.03 0.5 1.7 22.5

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

OK TIGROD 16.88
Classification DESCRIPTION Bare corrosion resisting “Super Duplex” rods for welding of austenitic - ferritic stainless alloys of 25% Cr, 7% Ni 4% Mo, low C types. OK TIGROD 16.88 has high intergranular, pitting and stress corrosion resistance. The alloy is widely used in applications were corrosion resistance is of outmost importance. Plup & paper industry, offshore and gas industry are areas of interest. TYPICAL WIRE COMPOSITION (%) C Si Mn Cr Ni Mo 9.8 4.0 W <1.0 CU <0.03 EN ISO 14343 W 25 9 4 NL

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC -40oC Ferrite No. : FN 30-50 670 N/mm2 850 N/mm2 30% 150J 115J

PACKING DATA Size (mm) 1.6 2.0 2.4 3.2 Length (mm) 1000 1000 1000 1000 Packing (5 Kg.) a a a a

<0.02 0.4 0.4 25.0

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

57

Welding Consumables

OK TIGROD 16.13

TYPICAL ALL WELDMETAL PROPERTIES
Weldmetal Composition (%) C Mn Si S Cr Ni 0.10 1.80 0.40 0.018 26.0 21 Mechanical Properties YS UTS EL Impact (CVN) at +20oC 310 N/mm2 520 N/mm2 32% 200J

An austenitic stainless steel rod of 25 Cr, 20 Ni type for TIG welding Classification AWS A5.9: ER 310 DESCRIPTION OK Tigrod 16.13 is fully austenitic rod of heat resisting 25 Cr-20 Ni type for GTAW providing scaling resistance at temperatures upto 1100°C-1150°C. OK AUTROD 16.13 is suitable for AISI 310& DIN werkst Nr 1.4828, 1.4841 & 1.4845 type steels and deliver excellent weld performance. TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Ni S P Mo Cu 0.10 1.8 0.40 26.0 21.0 0.018 0.018 0.04 0.03

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.6 1000 a 2.0 1000 a 2.5 1000 a PACKING: The rods are packed in 5 kg cartons and four of them in a Cardboard box.
Typical Mechanical Properties of All Weld Metal YS UTS EL 35 N/mm2 75 N/mm2 33%

OK TIGROD 1070
Classification DESCRIPTION OK Tigrod 1070 is highly resistant to chemical attack and weathering. It is a relatively soft alloy that is very formable and it is used extensively in thin - gauge and foil products. It has good welding characteristics. One characteristic feature of the alloy is the bright finish obtained by anodising. Non - heat treatable. WELDING CURRENT: AC Chemical COMPOSITION (Wire) % Si Mn Cu V Al Ti Zn Fe EN ISO 18273: S AI 1070 (AI99,7)

PACKING DATA Size Length Packing (mm) (mm) (5 Kg.) 1.6 1000 a 2.0 1000 a 2.5 1000 a 3.2 1000 a PACKING: The rods are packed in 2.5 kg cartons and four of them in a Cardboard box.

<0.02 <0.03 <0.04 <0.04 >99.7 <0.03 <0.04 <0.25

58

OK TIGROD 1100
Classification DESCRIPTION OK Tigrod 1100 is highly resistant to chemical attack and weathering. It is a relatively soft alloy that is very formable and it is used extensively in thin - gauge and foil products. It has good welding characteristics. One desirable characteristic of the alloy is the bright finish obtained by anodising. Non-heat treatable. APPROVALS : CWB, WELDING CURRENT: AC SFA/AWS A5.10: R1100 EN ISO 18273 : S Al 1100 (Al 99, 0Cu)

CHEMICAL COMPOSITION (Wire) % Mn <0.05 V <0.5 Cu 0.13 Al >99 Ti <0.03 Zn <0.1

Welding Consumables

Typical Mechanical Properties of All Weld Metal YS UTS EL 30 N/mm2 75 N/mm2 35%

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

OK TIGROD 1450
Classification DESCRIPTION OK Tigrod 1450 is highly resistant to chemical attack and weathering. The alloy has a small addition of titanium, which has a grain-refining effect, which reduces cracking susceptibility. It has good welding characteristics. One characteristic feature of the alloy is the bright finishes obtained by anodising. Non-heat treatable. APPROVALS : VdTŰV WELDING CURRENT: AC EN ISO 18273: S AI 1450 (AI99,5Ti)

WIRE COMPOSITION (%) Si Mn Cu Al Ti Zn <0.07 Fe <0.40

<0.25 <0.05 <0.05

>99.5 0.15

Typical Mechanical Properties of All Weld Metal YS UTS EL 40 N/mm2 90 N/mm2 35%

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons. WIRE COMPOSITION (%) Si 5.0 Mn Cr Cu Ti Zn Fe <0.6

OK TIGROD 4043
Classification SFA/AWS A5.10: R4043 EN ISO 18273: S Al 4043 (AlSi5) EN ISO 18273 S Al 4043A (AlSi5(A))

<0.05 <0.05

<0.05 <0.15 <0.10

DESCRIPTION OK Tigrod 4043 is one of the most widely used welding alloys. It is used for welding AIMgSi types and AISi alloys with up to 7% silicon. Not recommended for anodising. Non-heat treatable. APPROVALS : CE, CWB, DB WELDING CURRENT: AC

Typical Mechanical Properties of All Weld Metal YS UTS EL 55 N/mm2 165 N/mm2 18%

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

59

Welding Consumables

OK TIGROD 4047
Classification DESCRIPTION OK Tigrod 4047 was originally developed as a brazing alloy to take advantage of its low melting point and narrow freezing range. In addition, it has a higher silicon content than OK Tigrod 4043, which provides increased fluidity and reduced shrinkage. Hot cracking is significantly reduced when using OK Autrod 4047 as a filler alloy. The alloy may be used in applications at sustained elevated temperatures. Non - heat treatable. APPROVALS : CWB WELDING CURRENT: AC SFA/AWS A5.10: R4047 EN ISO 18273 : S AI 4047 (AISi12)

WIRE COMPOSITION (%) Si Mn Cu Ti Zn Fe <0.6

12.0 <0.15 <0.05

<0.15 <0.20

Typical Mechanical Properties of All Weld Metal YS UTS EL 80 N/mm2 170 N/mm2 12%

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

OK TIGROD 5087
Classification DESCRIPTION Bare welding rod suitable for welding aluminium alloys with up to 5% Mg and alloys where a higher tensile strength is required. The alloying element Zr produces improved resistance to hot cracking during solidification. APPROVALS : DB VdTŰV, CE WELDING CURRENT: AC EN ISO 18273 : S AI 5087 (AIMg4, SMnZr)

WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zr Zn Fe Mg

<0.25 0.9 0.15 <0.05 <0.15 0.15 <0.25 <0.40 4.9
Typical Mechanical Properties of All Weld Metal YS UTS EL Impact (CVN) at + 20OC 130 N/mm2 280 N/mm2 30% 35J

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons. WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Mg

OK TIGROD 5183
Classification DESCRIPTION OK Tigrod 5183 was developed to provide the highest possible strength in tthe asweled condition of alloy AA 5083 and similar high magnesium alloys. The more common OK Tigrod 5356 will typically fail to meet the as-welded tensile requirements of AA 5083. The alloy is typically utilised in marine and structural applications where high strength, high impact fracture toughness and exposure to corrosive elements are important. The alloy is not recommended for elevated temperature applications due to its susceptibility to stress corrosion cracking. The alloy is non - heat treatable. APPROVALS : CWB, VdTŰV, CE, ABS, DNV, KR WELDING CURRENT: AC SFA/AWS A5.10 : R5183 EN ISO 18273: S Al 5183 (AlMg4, 5MnO, 7(A))

<0.25 0.8 0.15 <0.10 <0.15 <0.25 <0.40 4.8
Typical Mechanical Properties of All Weld Metal YS UTS EL Impact (CVN) at + 20OC 140 N/mm2 290 N/mm2 25% 30J

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

60

OK TIGROD 5356
Classification DESCRIPTION SFA/AWS A5.10: R5356 EN ISO 18273: S Al 5356 (AlMg 5Cr (A))

WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Mg

Welding Consumables

<0.25 0.15 0.13 <0.05 0.11 <0.10 <0.40 5.0
Typical Mechanical Properties of All Weld Metal YS UTS EL 120 N/mm2 265 N/mm2 26%

OK Tigrod 5356 is the most widely used welding alloy and can be classified as a general-purpose type filler alloy. OK Tigrod 5356 is typically chosen because of its relatively high shear strength. The 5XXX alloy base material, welded with OK Tigrod 5356, with a weld pool chemistry greater than 3% Mg and service temperatures in excess of 65OC, is susceptible to stress corrosion cracking. The alloy is non - heat treatable. APPROVALS : CE, CWB, DB, VdTŰV, ABS, DNV, KR WELDING CURRENT: AC

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

OK TIGROD 5554
Classification DESCRIPTION SFA/AWS A5.10: R5554 EN ISO 18273: S Al5554 (AIMg2,7Mn)

WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Mg

<0.25 0.75 0.13 <0.10 0.13 <0.25 <0.40 2.7
Typical Mechanical Properties of All Weld Metal YS UTS EL 110 N/mm2 230 N/mm2 17%

OK Tigrod 5554 is a solid aluminium rod with a content of 2.7% Mg. It is recommended for the welding of AlMg alloys like 5454. Typical applications include chemical storage tanks, automotive components like wheels and frame sections. The Weldmetal is not sensitive to stress corrosion cracking at elevated temperatures. APPROVALS : CWB WELDING CURRENT: AC

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons. WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Mg

OK TIGROD 5556
Classification DESCRIPTION Bare welding rod suitable for welding aluminium alloys with up to 5% Mg that are not age hardenable and alloys where a higher tensile strength is required. The corrosion resistance in a marine atmosphere is very good. APPROVALS : CWB, ABS, DNV WELDING CURRENT: AC SFA/AWS A5.10 : R556 EN ISO 18273: S AI 5556A (AIMg5Mn)

<0.25 0.8 1.3 <0.10 0.13 <0.20 <0.40 5.3
Typical Mechanical Properties of All Weld Metal YS UTS EL Impact (CVN) at + 20OC 140 N/mm2 295 N/mm2 25% 25J

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons.

61

Welding Consumables

OK TIGROD 5754
Classification DESCRIPTION OK Tigrod 5754 is a solid aluminium rod with a content of 3% Mg. It is recommended for welding Al-Mg alloys with less than 3% magnesium. The alloy has relatively high strength and corrosion resistance. APPROVALS : VdTŰV WELDING CURRENT: AC EN ISO 18273: S Al 5754 (AlMg3)

WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Mg

<0.25 <0.5 <0.3 <0.05 <0.15 <0.20 <0.40 3.1
Typical Mechanical Properties of All Weld Metal YS UTS EL 110 N/mm2 230 N/mm2 23%

PACKING: Sizes Available are in 1.6, 2.0, 2.4, 3.2 & 4.0 mm diard and 900 or 1000 mm lengths, packed in 4.54 kg (for 900 mm length) or 5.0 Kg (for 1000 mm length) cartons. Typical mechanical properties all weld metal
YS UTS EL Impact (CVN) at +20oC -20oC 75 N/mm2 220 N/mm2 30% 75J 40J

OK TIGROD 19.12
Classification DESCRIPTION Bare copper wire for the GTA joining of oxygen-free, pure copper and low-alloyed copper. OK TIGROD 19.12 is alloyed with tin and has good flow properties. Preheting is recommended when welding large pieces. OK TIGROD 19.12 is normally welded with pure Ar as the shielding gas. WELDING CURRENT : DC TYPICAL WIRE COMPOSITION (%) Si 0.3 Mn 0.3 Cu Sn SFA/AWS A5.7 ERCu EN 14640 S Cu 1898 (CuSn1)

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

>98.0 0.8 Typical mechanical properties all weld metal
YS UTS EL Impact (CVN) at +20oC 150 N/mm2 350 N/mm2 40% 30J

OK TIGROD 19.30
Classification DESCRIPTION Bare copper wire for the GTA joining of oxygen-zinc alloys and low-alloyed copper alloys. OK TIGROD 19.30 is alloyed with silicon and manganese and has good flow properties and wear resistance. The alloy is widely used in the joining of zinc-coated steel sheets and for joining low and non-alloyed steels and cast iron. OK TIGROD 19.30 is normally welded with pure Ar as the shielding gas. WELDING CURRENT : DC TYPICAL WIRE COMPOSITION (%) Si 3.4
62

SFA/AWS A5.7 ERCuSi-A EN 14640 S Cu 6560 (CuSi3mn1)

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

Mn 1.1

Cu

Sn

Zn

Fe

>94.0 <0.2

<0.2 <0.3

OK TIGROD 19.40
Classification DESCRIPTION An aluminium - bronze (CuAl8) rod for the GTAW of rolled and cast aluminium-bronze alloys. The alloy is noted for its high strength, good wear resistance and very good corrosion resistance, particularly in salt water. OK TIGROD 19.40 is normally welded with pure Ar as the shielding gas. WELDING CURRENT : DC TYPICAL WIRE COMPOSITION (%) Si Mn Al 8.3 Fe <0.5 Cu bal. SFA/AWS A5.7 ERCuAl-A1 EN 14640 S Cu 1600 (CuAl8)

Typical mechanical properties all weld metal
YS UTS EL Impact (CVN) at +20oC 175 N/mm2 420 N/mm2 40% 70J

Welding Consumables

PACKING DATA Size (mm) 1.6 2.4 Length (mm) 1000 1000 Packing (5 Kg.) a a

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

<0.1 <0.5

OK TIGROD 19.49
Classification DESCRIPTION Bare Cu-Ni rods for welding similar alloys, such as 90Cu10Ni, 80Cu20Ni and 70Cu30Ni alloys. The addition of nickel strengthens the weld metal and improves corrosion resistance, particularly to salt water. The alloy is used for the overlay welding of steels and is widely used for welding Cu-Ni components for desalination plants. WELDING CURRENT : DC TYPICAL WIRE COMPOSITION (%) C Si Mn 0.8 Fe 0.6 Cu bal. SFA/AWS A5.7 ERCuNi EN 14640 S Cu 7158 (CuNi30)

Typical mechanical properties all weld metal
YS UTS EL Impact (CVN) at +20oC 180 N/mm2 350 N/mm2 40% 90J

PACKING DATA Size (mm) 1.6 2.0 2.4 Length (mm) 1000 1000 1000 Packing (5 Kg.) a a a

PACKING: The rods are packed in 5 Kg cartons and four of them in a Cardboard box.

<0.05 <0.1

63

GMAW Consumables
Welding Consumables

ESAB MW1
A Copper coated wire for MIG/MAG welding Classification AWS A5.18: ER 70S-6 EN ISO 14341 - A : G3Si1 IS 6419 : S4

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at -30oC 440 N/mm2 520 N/mm2 26% 50J

DESCRIPTION ESAB MW1 is a copper - coated, Mn - Si alloyed solid wire for GMAW of non alloyed steel as used in general construction, automotives, ship building and pressure vessel fabrication. The wire has a carefully controlled wire chemistry and a unique surface technology providing superior Weldmetal quality at high wire feed speeds and at high welding currents. The wire can be used with both Ar/CO2 and pure CO2 shielding gas. WELDING CURRENT: DC+ APPROVALS: RDSO, LRS, MN DASTUR, ABS, NPCIL TYPICAL WIRE COMPOSITION (%) C 0.07 Mn 1.45 Si 0.80 S 0.02 P 0.02 Cu 0.2

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.2 1.6 2.0 Current (Amp) 60-220 90-330 120-440 150-550 Voltage Packing in Kg. (V) 12.5 15.0 100 250 17-25 18-30 20-36 21-41 a a a a a a a a a a a a r r r a

PACKING: The wires are supplied in plastic or wire basket spools packed in a cardboard box 12.5/15.0 kgs or 100/250 kgs Marathon pac or 100/250 kgs steel Bobbins.

ESAB MW2
A Copper coated low alloy wire for MIG/MAG welding of HSLA steels Classification DESCRIPTION ESAB MW2 a copper coated low alloy wire for GMAW of HSLA steels, such as tractor cylinder, automobile components, and medium and heavy fabrication workshops involving high strength materials. The wire is designed to produce excellent beads of radiographic quality with CO2 or CO2 / Argon mixtures in all position. TYPICAL WIRE COMPOSITION (%) C 0.09 Mn 1.7 Si 0.5 Mo P S CU 0.2 AWS A5.28 : ER 80S - G

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at -18oC 490 N/mm2 580 N/mm2 22% 30J

CURRENT RANGE & PACKING DATA Size (mm) 1.2 1.6 Current (Amp) 80-280 120-360 Voltage Packing in Kg. (V) 12.5 15.0 100 250 18-28 20-34 a a a a a a a a

PACKING: The wires are supplied in plastic or wire basket spools packed in a Cardboard box 12.0/15.0 Kgs or 100/250 kgs Marathon pac

0.45 0.018 0.02

64

OK ARISTOROD 12.50
Classification DESCRIPTION The non copper coated OK AristoRod 12.50 is a manganese-silicon alloyed solid wire for GMAW of unalloyed steels, such as general structural, pressure vessel, ship building and for fine - grained carbon manganese steels for the same purpose with a minimum yield strength of max 420 MPa. The electrode can be welded with Ar/20CO2 or with pure CO2 as the shielding gas. The AristoRod wires are suitable for operating at high currents with maintained disturbance free wire feeding giving a stable arc with a low amount of spatter. OK AristoRod 12.50 delivered in the unique ESAB Octagonal Marathon Pac is excellent in mechanised welding applications. SHIELDING GAS: CO2, 80Ar / 20 CO2 APPROVAL: ABS 3YSA; BV SA37M; DNV III YMS; LR 3S, 3YS; VDTUV 10052. TYPICAL WIRE COMPOSITION (%) C 0.1 Si 0.9 Mn 1.5 P S Cu Ti+Zr 0.10 SFA/AWS A5.18 ER70S-6 EN ISO 14341-A G3 Si1

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties As Welded YS UTS EL Impact (CVN) at -30oC 470 N/mm2 560 N/mm2 26% 70J

Welding Consumables

CURRENT RANGE & PACKING DATA Size (mm) 0.8 0.9 1.0 1.14 1.2 1.4 1.6 Current (Amp) 60-200 70-250 80-300 80-300 120-380 150-420 225-550 Voltage (V) 18-24 18-26 18-32 18-32 18-35 22-36 28-38

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18 kg.

0.025 0.025 0.15

OK AUTROD 13.14
A copper coated low alloy wire for MIG welding of HSLA steels Classification DESCRIPTION OK AUTROD 13.14 is a copper coated low alloy wire for GMAW of HSLA steels, such as tractor cylinder, automobile components, wagon manufacturing, light, medium and heavy fabrication workshops involving high strength materials. The wires are designed to produce excellent beads of radiographic quality with CO2 or Argon mixtures in all position. One of the significant applications of OK Autrod 13.14 is of welding ‘CONCOR’ type wagons of the Indian Railways. APPROVAL: RDSO TYPICAL WIRE COMPOSITION (%) C 0.09 Mn 1.7 Si 0.55 Mo 0.45 P 0.02 S 0.02 Cu 0.2 AWS A5.28: ER 90S-D2

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at -30oC 520 N/mm2 640 N/mm2 22% 30J

CURRENT RANGE & PACKING DATA Size (mm) 1.2 1.6 Current (Amp) 80-280 120-360 Voltage Packing in Kg. (V) 12.5 15.0 100 200 18-28 20-34 a a a a a a a a

PACKING: The wires are supplied in plastic or wire basket spools packed in a Cardboard box 12.5/15.0 kgs or 100/250 kgs Marathon pac or 100/250 kgs steel Bobbins.

65

Welding Consumables

OK ARISTOROD 13.09
Classification EN 440 : G2Mo EN 12070 : G MoSi SFA/AWS A5.28 : Er80S-G

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties As Welded YS UTS EL Impact (CVN) at 20OC -20OC -40OC 515 610 26% 117J 100J 57J PWHT - Stress Relieved 620OC 15h YS UTS EL Impact (CVN) at 20OC -20OC -40OC 430 545 30 150J 120J 90J

DESCRIPTION The non copper coated OK AristoRod 13.09 is a lowalloyed, molybdenum (0.5% Mo), solid wire for GMAW of creep resistant steels of the same type, such as pipes in pressure vessels and boilers with a working temperature of up to 500OC. The AristoRod wires are suitable for operating at high currents with maintained disturbance free wire feeding giving a stable arc with a low amount of spatter. OK AristoRod 13.09 delivered in the unique Esab Octagonal Marathon Pac is excellent in mechanised welding applications. Shielding Gas: CO2, 80 Ar/20 CO2 TYPICAL WIRE COMPOSITION (%) C 0.1 Si 0.5 Mn 1.1 P S Mo 0.5 Cu 0.15

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 60-170 80-280 120-350 225-480 Voltage (V) 18-22 18-28 20-33 26-38

0.02 0.02

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18 kg.

OK ARISTOROD 13.26
Classification DESCRIPTION The non copper coated OK AristoRod 13.26 is a lowalloyed, nickel-copper (0,8% Ni, 0,3% Cu), solid wire for GMAW of weathering steels, such as COR-TEN, Patinax, Dillicor etc. The Weldmetal composition and mechanical properties also make this product suitable for welding high strength steels with a minimum yield strength less than 470 Mpa. The AristoRod wires are suitable for operating at high currents with maintained disturbance free wire feeding giving a stable arc with a low amount of spatter. OK AristoRod 13.26 delivered in the unique Esab Octagonal Marathon Pac is excellent in mechanised welding applications. Shielding Gas: CO2, 80Ar / 20 CO2 ALLOY TYPE : CE EN13479, DB 42.039.92, DNV IIYMS (C1), III YMS (M21) SFA/AWS A5.28 ER80S-G

TYPICAL WIRE COMPOSITION (%) C Si Mn P S Ni Cu

0.095 0.8

1.4 0.025 0.025 0.85 0.425
Mechanical Properties As welded

TYPICAL ALL WELDMETAL PROPERTIES

YS UTS EL Impact (CVN) at -40oC

540 N/mm2 625 N/mm2 26% 83J

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.4 1.6 Current (Amp) 80-280 80-280 120-350 120-350 225-480 Voltage (V) 18-28 18-28 20-33 20-33 26-38

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18 kg.

66

OK AUTROD 13.16

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties PWHT - Stress Relieved 620OC 1h YS UTS EL 490 N/mm2 580 N/mm2 21%

Welding Consumables

Classification SFA/AWS A5.28 : ER 80S-B2 DESCRIPTION A copper coated, low - alloyed, chromium-molybdenum (1.3% Cr, 0.5% Mo), solid wire for GMAW of creep resistant steels like SA-387 Grade P11, A 335 Grade P11 or similar materials. OK Autrod 13.16 is a high purity wire with guaranteed Bruscato factor X<15. Shielding Gas: Ar/1-5O2, Ar/20CO2, CO2 TYPICAL WIRE COMPOSITION (%) C Si Mn P S Cr Mo Cu 0.095 0.6 0.55 0.025 0.20 1.35 0.525 0.35

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 80-170 80-280 120-350 225-480 Voltage (V) 18-22 18-28 20-33 26-38 Packing in 15 Kg Plastic Spools a a a a

OK AUTROD 13.17
Classification DESCRIPTION A copper coated, low - alloyed, chromium-molybdenum (2.5% Cr, 1.1% Mo), solid wire for GMAW of creep resistant steels like SA-387 Grade 22, A 335 Grade P22 or similar materials.High purity wire with a guaranteed Bruscato factor X<15. Shielding Gas: CO2, 80Ar/20CO2, Ar/1-5O2 TYPICAL WIRE COMPOSITION (%) C Si Mn P S Cr Mo Cu SFA/AWS A5.28 : ER 90S-B3

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties PWHT - Stress Relieved 690OC / 1h YS UTS EL Impact (CVN) at -40oC 590 N/mm2 720 N/mm2 22% >47J

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 80-170 80-280 120-350 225-480 Voltage Packing in 15 Kg (V) Plastic - Spools 18-22 18-28 20-33 26-38 a a a a

0.95 0.55 0.55 0.025 0.015 2.5

1.05 0.35

OK AUTROD 13.28
Classification SFA/AWS A5.28 : ER 80S-Ni2 DESCRIPTION A copper coated, Ni-alloyed (2.4% Ni), solid wire for GMAW of low-alloyed and low temperature steels in applications such as vessels, pipes and in the offshore industry with a minimum yield strength less than 470 Mpa. The wire provides a good impact thoughness down to - 60OC. Shielding Gas: Ar/1-5O2, Ar/20CO2 TYPICAL WIRE COMPOSITION (%) C Si Mn P S Ni 2.4 Mo Cu AI

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties PWHT - Stress Relieved 620OC 1h YS UTS EL Impact (CVN) at -60OC 540 630 29% 70J

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 80-170 80-280 120-350 225-480 Voltage Packing in 15 Kg (V) Plastic Spools 18-22 18-28 20-33 26-38 a a a a

0.095 0.6 1.125 0.02 0.02

0.15 0.35 0.02

67

Welding Consumables

OK ARISTOROD 13.29
Classification DESCRIPTION The non copper coated OK AristoRod 13.29 is a lowalloyed, chromium-nickel-molybdenum (0.3% Cr, 1.4% Ni, 0.25% Mo), solid wire for GMAW of high tensile strength steels requiring tougher Weldmetal for critical applications. Also suitable when fairly high impact strength at lower temperatures is required. The AristoRod wires are suitable for operating at high currents with maintained distrubance free wire feeding giving a stable arc with a low amount of spatter. Ok AristoRod 13.29 delivered in the unique Esab Octagonal Marathon Pac is excellent in mechanised welding applications. Shielding Gas: 80Ar/20CO2 TYPICAL WIRE COMPOSITION (%) C Si Mn P S Cr Ni Mo V SFA/AWS A5.28 : ER 100S-G EN ISO 16834-A : GMn3Ni1 Cr Mo

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties As Welded YS UTS EL Impact (CVN) at -20OC / -40OC 730 800 19% 70J / 55J PWHT - Stress Relieved 620OC 15 h YS UTS EL Impact (CVN) at -30OC 690 750 20% 60J

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 80-280 80-280 120-350 225-480

Voltage (V) 18-28 18-28 20-33 26-38

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18kg.

0.10 0.55 1.65 0.015 0.015 0.3

1.4 0.25 0.075

OK ARISTOROD 13.13
Classification DESCRIPTION The non copper OK AristoRod 13.13 is a low-alloyed, chromium-nickel-molybdenum (0.5% Cr, 0.5% Ni, 0.2% Mo), solid wire for GMAW of high strength steels. But, also suitable when welding steels where good impact toughness is required at lower temperatures. The AristoRod wires are suitable for operating at high currents with maintained disturbance free wire feeding giving a stable arc with a low amount of spatter. OK AristoRod 13.13 delivered in the unique Esab Octagonal Marathon Pac is excellent in mechanised welding applications. Shielding Gas: 80Ar/20CO2 SFA/AWS A5.28 : ER 100S-G

TYPICAL WIRE COMPOSITION (%) C Si Mn P S Cr Ni 0.6 Mo 0.2 Cu 0.30

0.105 0.7 1.55 0.015 0.015 0.6

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties As Welded YS UTS EL Impact (CVN) at -20OC / -30OC 690 770 20% 75J / 65J PWHT - Stress Relieved 570OC 1h YS UTS EL Impact (CVN) at -20OC 660 750 24% 60J

CURRENT RANGE & PACKING DATA Size (mm) 0.8 1.0 1.2 1.6 Current (Amp) 40-170 80-280 120-350 225-480

Voltage (V) 16-22 18-28 20-33 26-38

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18kg.

68

OK ARISTOROD 13.31
Classification DESCRIPTION The non copper OK AristoRod 13.31 is a low-alloyed, chromium-nickel-molybdenum (0.3% Cr, 1.9% Ni, 0.5% Mo), solid wire for GMAW of high strength steels, heat treated steels and fine grained constructional steels, such as XABO90 with a minimum yield strength less than 850 Mpa. The ArristoRod wires are suitable for operating at high currents with maintained disturbance free wire feeding giving a stable arc with a low amount of spatter. OK AristoRod 13.31 delivered in the unique ESAB Octagonal Marathon Pac is excellent in mechanised welding applications. Shielding Gas: 80Ar/20CO2 Alloy Type: 0.3% Cr, 1.9% Ni, 0.5% Mo SFA/AWS A5.28 : ER 110S-G

TYPICAL WIRE COMPOSITION (%) C Si Mn P S Cr Ni Mo Cu Ti 0.1 0.75 1.9 0.015 0.018 0.35 2.05 0.55 0.15 0.15 TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties As Welded YS UTS EL Impact (CVN) at -30oC 850 N/mm2 900 N/mm2 18% 50J

Welding Consumables

CURRENT RANGE & PACKING DATA Size (mm) 1.0 1.2 Current (Amp) 80-280 120-350 Voltage (V) 18-28 20-33

PACKING: Aristorod wires can be supplied on adapter free 18kg wire baskets or in Marathon Pac bulk drums charged with 250 or 475 kg, as well as plastic spools of 15kg or 18kg.

OK AUTROD 16.10
An extra low carbon stainless steel wire of 19/9 type for MIG welding Classification DESCRIPTION OK AUTROD 16.10 are 19 Cr - 9 Ni type bare stainless steel wires for GMAW of austenitic grades of the type AISI 302,304, 304L and equivalent types. In most cases OK AUTROD 16.10 gives fully acceptable results on niobium and titanium stabilised austenitic stainless steels. The wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.02 Mn 1.6 Si 0.4 Cr 20 Ni 10 P S AWS A5.9: ER 308L

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at -196oC 450 N/mm2 645 N/mm2 36% 70J

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 a a a

PACKING: The wires are supplied in plastic spools packed in a Cardboard box.

0.018 0.018

69

Welding Consumables

OK AUTROD 16.11
Stainless steel wires of Niobium stabilised 19/9 type for MIG welding Classification DESCRIPTION OK AUTROD 16.11 are Niobium stabilised 19 Cr-9 Ni type wires for GMAW of welding of Niobium and Titanium stabilised stainless steel type AISI 321, 347 and 348 grades. This steel finds extensive use in refineries, chemical and petrochemical Industries, food and beverage industries etc. The wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.07 Mn 1.5 Si 0.6 Cr 19.8 Ni 9.8 Nb 0.6 AWS A5.9: ER 347

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC 430 N/mm2 640 N/mm2 35% 100J

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 a a a

PACKING: The wires are supplied in plastic spools packed in a Cardboard box.

OK AUTROD 16.30
An extra low carbon stainless steel wire of the 19 Cr, 12 Ni, 3 Mo type for MIG welding Classification AWS A5.9: ER 316L DESCRIPTION OK AUTROD 16.30 are extra low carbon wire of 19% Cr, 12% Ni and 3% Mo type for GMAW of stainless steel grade AISI 316, 316L and somewhat lower alloyed types. The wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.02 Mn 1.8 Si 0.4 Cr 18.5 Ni 12 Mo 2.7 S P

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL (L=4d) Impact (CVN) at -196oC 470 N/mm2 650 N/mm2 35% 60J

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 a a a

0.018 0.018

PACKING: The wires are supplied in plastic spools packed in a Cardboard box.

70

OK AUTROD 16.53
An extra low carbon 24% Cr, 13% Ni type stainless steel wire for MIG welding Classification DESCRIPTION OK AUTROD 16.53 is an extra low carbon 24% Cr, 13% Ni wire for GMAW of similar alloys or dissimilar joining of 18/8 type to mild steel, carbon steel or low alloy steels. The wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.02 Mn 1.8 Si 0.4 Cr 24 Ni 13 P S AWS A5.9: ER 309L

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at -196oC 440 N/mm2 600 N/mm2 41% 130J

Welding Consumables

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 r r r

0.018 0.018

PACKING: The wires are supplied in plastic spools packed in a Cardboard box. TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC 650 N/mm2 800 N/mm2 22% 45J

OK AUTROD 16.75

A 30% Cr, 10% Ni stainless steel wire for MIG welding Classification AWS A5.9: ER 312 DESCRIPTION OK AUTROD 16.75 are 30% Cr, 10% Ni stainless steel wires for GMAW of complex dissimilar alloys and high strength steels with low heat input resulting in sound joints free of cracks and fissures. OK AUTROD 16.75 combine high strength with excellent resistance against impact, scaling upto 1150°C and corrosion. The ferriticaustenitic duplex structure is highly tolerant to dilution and hence can be used as buffer layers prior to surfacing on HSLA steels. OK AUTROD 16.75 provides excellent weld appeal with recommended shielding gas mixtures of Ar with CO2 or O2 TYPICAL WIRE COMPOSITION (%) C 0.11 Si 0.45 Mn P S Cr Ni 9.50

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 Current (Amp) 50-180 80-240 Voltage (V) 16-22 19-28 Packing in Kg. 12.5 r r

P ACKING: The wires are supplied in plastic spools packed in a Cardboard box.

2.00 0.020 0.009 29.6

An austenitic stainless steel wire of 25 Cr, 20 Ni type for MIG welding Classification AWS A5.9: ER 310 DESCRIPTION OK AUTROD 16.13 is fully austenitic 25 Cr - 20 Ni type wires for GMAW of AISI 310 and DIN werkst Nr. 1.4828, 1.4841, 1.4845 etc. the wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.09 Mn 1.80 Si 0.4 Cr 26 Ni 21 S P

OK AUTROD 16.13

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC 310 N/mm2 520 N/mm2 32% 120J

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 Current (Amp) 50-180 80-280 Voltage (V) 16-22 19-28 Packing in Kg. 12.5 a a

0.018 0.018

P ACKING: The wires are supplied in plastic spools packed in a Cardboard box.
71

Welding Consumables

OK AUTROD 16.33
A 13% Cr stainless steel wire for MIG welding Classification DESCRIPTION OK AUTROD 16.33 is a 13% Cr stainless steel wire for GMAW of AISI 410, 410S, 420 and steels of similar compositions. Also recommended for surfacing of machine parts, diesel motor pistons that are working in a corrosive environment or at elevated temperatures. The weldmetal is machinable and has good resistance to wear in a corrosive environment. The wires are designed to produce excellent weld appeal with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C 0.11 Mn 0.5 Si 0.3 Cr Ni Mo 0.6 Cu S P AWS A5.9: ER 410

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS E1 400 N/mm2 550 N/mm2 24%

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 a a a

PACKING: The wires are supplied in plastic spools packed in a Cardboard box.

12.5 0.5

0.10 0.019 0.018

OK AUTROD 16.43
A 17% Cr stainless steel wire for MIG welding Classification DESCRIPTION OK AUTROD 16.43 is a 17% Cr stainless steel wire for GMAW of AISI 430 type or for surfacing machine parts and to provide adequate corrosion resistance while retaining sufficient ductility in heat-treated condition. The wire is designed for weld beads that are shiny, finely rippled and uniform with Argon/O2 or CO2 mixtures as shielding gas. TYPICAL WIRE COMPOSITION (%) C Mn Si Cr 17 Ni 0.5 Mo 0.5 Cu S P AWS A5.9: ER 430

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 410 N/mm2 560 N/mm2 22%

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 1.2 1.6 Current (Amp) 50-180 80-280 100-380 Voltage (V) 16-22 19-28 19-33 Packing in Kg. 12.5 a a a

PACKING: The wires are supplied in plastic spools packed in a Cardboard box.

0.09 0.55 0.45

0.1 0.018 0.020

72

OK AUTROD 16.95
Classification DESCRIPTION A continous solid corrosion resisting chromium-nickelmanganese wire for welding of austenitic stainless alloys of 18% Cr, 8% Ni, 7% Mn types. OK Autrod 16.95 has a general corrosion ressistance similar to that of the corresponding parent metal. The higher sillicon content improves the welding properties, such as wetting. The product is a modified variant of ER307, basically with a higher Mn content to make the Weldmetal less sensitive to hot cracking. When used for joining dissimilar materials the corrosion resistance is of secondary importance. The alloy is used in a wide range of applications across the industry such as joining of austenitic, manganese, work hardenable steels as well as armourplate and heat resistant steels. TYPICAL WIRE COMPOSITION (%) C 0.07 Si 0.8 Mn 6.5 P S Cr Ni 8.4 Mo 0.2 Cu 0.1 EN ISO 14343 G 18 8 Mn

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC 450 N/mm2 640 N/mm2 41% 130J

Welding Consumables

CURRENT RANGE & TYPICAL PACKING DATA Size (mm) 0.8 0.9 1.0 1.2 1.6 Current (Amp) 55-160 65-220 80-240 100-300 65-220 Voltage (V) 15-24 15-28 15-28 15-29 15-28 Packing in Kg. 12.5 a a a a a

P ACKING: The wires are supplied in plastic spools packed in a Cardboard box.

0.02 0.01 19.2

OK AUTROD 1100
Classification DESCRIPTION OK Autrod 1100 is highly resistant to chemical attack and weathering. It is a relatively soft alloy that is very formable and is used extensively in thin gauge and foil products. It has good welding characteristics. A desirable characteristic of the alloy is the bright finish obtained by anodising. Non-Heat treatable. APPROVALS : CWB TYPICAL WIRE COMPOSITION (%) Mn V Cu Al Ti Zn Be Si+Fe Others each Others total < 0.05 < 0.05 0.13 99.00 (Min) < 0.03 < 0.10 0.0003 (Max) 0.95 (Max) 0.03 (Max) 0.15 (Max) SFA/AWS A5.10 : ER1100 EN ISO 18273 : S Al 1100 (Al99, 0Cu)

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 30 N/mm2 75 N/mm2 35%

CURRENT RANGE & PACKING DATA
Size (mm) 1.2 1.6 Current (Amp) 140-260 190-350 Voltage (V) 20-29 25-30 Weight of Packing 9.1 Kg 9.1 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. Also available in 22.7 Kg Mini Drum and 141 Kg Marathon Pac : these unique packaging is excellent for mechanised applications.

73

Welding Consumables

OK AUTROD 4043
Classification

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 55 N/mm2 165 N/mm2 18%

SFA/AWS A5.10 ER4043 EN ISO 18273 S Al 4043 (AlSi5) EN ISO 18273 S Al 4043A (AlSi5(A))

DESCRIPTION OK Autrod 4043 is one of the most widely used welding and brazing alloys and can be classed as a generl purpose filler alloy. The silicon additions result in improved fluidity (wetting action) to make the alloy a preferred choice by welders. The alloy is not sensitive to weld cracking and produces bright and almost smut free welds. Not recommended for anodizing. Non-Heat treatable. APPROVALS : CWB TYPICAL WIRE COMPOSITION (%) Si Mn Cu Ti Zn Fe Cr Mg Others each Others tot 5.00 < 0.05 0.05 0.15 0.10 < 0.6 < 0.05 0.05 (Max) 0.05 (Max) 0.15 (Max)

CURRENT RANGE & PACKING DATA
Size (mm) 0.8 0.9 1.0 1.2 1.6 2.0 2.4 Current (Amp) 60-170 60-170 90-210 140-260 190-350 280-400 280-400 Voltage (V) 13-24 13-24 15-26 20-29 25-30 26-31 26-31 Weight of Packing 6.4 Kg 7.3 Kg 7.3 Kg 9.1 Kg 9.1 Kg 7.3 Kg 7.3 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. Also available in 22.7Kg mini Drum and 141 Kg Marathon Pac : these unique packaging is excellant for mechanised applications.

OK AUTROD 5356
Classification DESCRIPTION OK Autrod 5356 is the most widely used welding alloy and can be classified as a general purpose type filler alloy. OK Autrod 5356 is typically chosen because of its relatively high shear strength. The 5356 alloy base material, welded with OK Autrod 5356, with a weld pool chemistry greater than 3% Mg and service temperatures in excess of 65OC are susceptible to stress corrosion cracking. The alloy is non-heat treatable. APPROVALS : ABS, BV, CE, CWB, DB, DNV, GL, LR, VdTÜV, KR TYPICAL WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Be Others each Others tot <0.25 0.15 0.13 <0.05 0.11 < 0.10 < 0.40 0.0003 (Max) 0.05 (Max) 0.15 (Max) SFA/AWS A5.10 ER5356 EN ISO 18273 S Al 5356 (AlMg5Cr(A))

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 120 N/mm2 265 N/mm2 26%

CURRENT RANGE & PACKING DATA
Size (mm) 0.8 0.9 1.0 1.2 1.6 2.4 Current (Amp) 60-170 60-170 90-210 140-260 190-350 280-400 Voltage (V) 13-24 13-24 15-26 20-29 25-30 26-31 Weight of Packing 6.4 Kg 7.3 Kg 7.3 Kg 9.1 Kg 9.1 Kg 7.3 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. Also available in 22.7Kg mini Drum and 141 Kg Marathon Pac : these unique packaging is excellant for mechanised applications.

74

OK AUTROD 5183
Classification SFA/AWS A5.10 ER5183 EN ISO 18273 S Al 5183 (AlMg4, 5Mn0, 7(A))

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20oC 140 N/mm2 290 N/mm2 25% 30J

Welding Consumables

DESCRIPTION OK Autrod 5183 was developed to provide the highest strengths possible in the as welded condition of alloy AA 5083 and other similar high magnesium alloys. The more common OK Autrod 5356 will typically fail to meet the as - welded tensile requirements of AA 5083. The alloy is typically utilised in marine and structural applications where high strengths, high fracture toughness for impact resistance and exposure to corrosive elements are important. The alloy is not recommended for elevated temperature applications due to its susceptibility to stress corrosion cracking. The alloy is non-heat treatable. APPROVALS : ABS, DNV, CWB, KR WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Be Mg Others each Others total <0.25 0.75 0.15 <0.10 <0.15 <0.25 <0.40 0.0003 (Max) 4.75 0.05 (Max) 0.15 (Max)

CURRENT RANGE & PACKING DATA
Size (mm) 1.0 1.2 1.6 2.4 Current (Amp) 90-210 140-260 190-350 280-400 Voltage (V) 15-26 20-29 25-30 26-31 Weight of Packing 7.3 Kg 9.1 Kg 9.1 Kg 7.3 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. Also available in 22.7 kg Mini Drum and 141 Kg Marathon Pac. These unique packaging is excellent for mechanised applications.

OK AUTROD 5556
Classification DESCRIPTION Continuous solid wire suitable for welding of aluminium alloys with up to approx. 5 % Mg that are not agehardenable and alloys where a higher tensile strength is required. The corrosion resistance in marine atmosphere is high. APPROVALS : ABS, CWB, DNV WIRE COMPOSITION (%) Si Mn Cr Cu Ti Zn Fe Be Mg Others each Others total 0.25 1.8 0.25 0.10 0.25 0.20 0.40 0.0003 5.25 0.05 0.15 SFA/AWS A5.10 ER5556 EN ISO 18273 S Al 5556A (AlMg5Mn)

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL (L=4d) Impact (CVN) at 20oC 145 N/mm2 295 N/mm2 25% 25J

CURRENT RANGE & PACKING DATA
Size (mm) 1.0 1.2 1.6 Current (Amp) 90-210 140-260 190-350 Voltage (V) 15-26 20-29 25-30 Weight of Packing 7.3 Kg 9.1 Kg 9.1 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. Also available in 22.7 kg Mini Drum and 141 Kg Marathon Pac. These unique packaging is excellent for mechanised applications.

75

Welding Consumables

OK AUTROD 19.12
Classification DESCRIPTION A continuous solid copper wire for welding of oxygen free, pure copper and low alloyed copper. OK Autrod 19.12 is alloyed with tin, and has good flow properties. The weld is easily workable. For welding of large work pieces and heavy thickness preheating is recommended. WIRE COMPOSITION (%) Si 0.3 Mn P Cu Al Sn Pb As Fe SFA/AWS A5.7 : ERCu EN 14640 : S Cu 1898 (Cusn1)

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL CVN Impact toughness at +20OC Size (mm) 0.8 1.0 1.2 1.6 2.4 Current (Amp) 60-120 90-180 120-200 150-280 250-370 Voltage (V) 20-24 22-26 22-28 24-30 26-32 75 N/mm2 220 N/mm2 30% 75J Weight of Packing 15 Kg 15 Kg 15 Kg 15 Kg 15 Kg

CURRENT RANGE & PACKING DATA

0.3 0.02 98.0 0.01 0.75 0.01 0.05 0 . 0 5 (Min) (Max) (Max) (Max)

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes. TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL 130 N/mm2 350 N/mm2 40%

OK AUTROD 19.30
Classification DESCRIPTION A continuous solid copper wire, for welding of copper Zinc alloys, low alloyed copper and for Mig brazing of Zinc coated steel sheets. OK Autrod 19.30 is alloyed with Silicon and manganese. The alloy is widely used in the automotive industry for Mig Brazing of galvanised steel in car body production. The wire is also suitable for overlay welding of un-alloyed and low alloyed steels. TYPICAL WIRE COMPOSITION (%) Si Mn P Cu Al Sn Pb Zn Fe Ni+Co others tot 3.4 1.1 0.020 94.0 (min) 0.01 (Max) <0.2 0.02 (Max) <0.2 <0.3 0.1 (Max) 0.4 (Max) SFA/AWS A5.7 ERCu EN 14640 S Cu 1898 (CuSi3 Mn1)

CURRENT RANGE & PACKING DATA
Size (mm) 0.8 1.0 1.2 Current (Amp) 60-165 80-210 150-320 Voltage (V) 13-17.5 12.5-18 16-29 Weight of Packing 15 Kg 15 Kg 15 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes.

76

OK AUTROD 19.40
Classification DESCRIPTION A continuous solid copper wire for welding of aluminium bronzes of the same type and over lay welding of un and low alloyed steels. OK Autrod 19.40 is alloyed with aluminium and is recognised for high strength, good wear resistance and very good corrosion resistance particularly in salt water. The alloy is widely used for joining corrosion - resistant pipes made of aluminium bronze or other speical brass alloys. Other common applications include the overlay welding of bearings, ship’s propellers and rails. OK Autrod 19.40 is normally welded with pure Ar as the shielding gas. TYPICAL WIRE COMPOSITION (%) Si Mn Ni Al Fe Cu <0.10 <0.50 0.3 7.8 <0.5 Balance SFA/AWS A5.7 ERCuAl-A1 EN 14640 S Cu 6100 (CuAl8)

TYPICAL ALL WELDMETAL PROPERTIES
Mechanical Properties YS UTS EL Impact (CVN) at +20OC 175 N/mm2 420 N/mm2 40% 40J

Welding Consumables

CURRENT RANGE & PACKING DATA
Size (mm) 0.8 1.0 1.2 Current (Amp) 60-165 80-210 150-320 Voltage (V) 13-17.5 12.5-18 16-29 Weight of Packing 15 Kg 15 Kg 15 Kg

PACKING: The wires are supplied in Plastic Spools packed in cardboard boxes.

77

FCAW Consumables
Welding Consumables

DUAL SHIELD 7100 LH
All Position rutile, low-hydrogen flux cored wire Classification DESCRIPTION Dual Shield 7100 LH is a multi purpose cored wire and is one of the most productive consumable for manual and mechanised positional welding, including vertical down and provides an excellent bead appearance. It is extremely welder - friendly with a soft, spatter - free arc and is easy to obtain flat welds with a good penetration. WELDING CURRENT: DC+ SHIELDING GAS: Pure CO2 (C1) Ar / CO2 (M21) APPROVALS: DNV III YMS (H10) (M21 and C1) LR 3, 3Y (M21, C1) IRS 3YS MHH (M21, C1) ABS 3SA, 3YSA (M21, C1) BV SA3M, SA3YMHH (M21, C1) SFA/AWS A5.20 E71T-1C SFA/AWS A5.20 E71T-1M

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical Properties of All Weldmetal

Ar/CO2 CO2 shielding Ar/CO2 CO2 shielding gas Shielding gas gas Shielding gas C Si Mn P S Cr Ni Mo V Nb Cu 0.06 0.45 1.2 0.025 0.030 0.2 0.5 0.2 0.08 0.05 0.3 C Si Mn P S Cr Ni Mo V Nb Cu 0.06 0.5 1.25 YS UTS EL 420 610 22% YS UTS EL Impact (CVN) at 54J -20OC 54J 460 640 22%

0.025 Impact 0.030 (CVN) 0.2 0.5 0.2 0.08 0.05 0.3 at -20 C
O

TYPICAL APPLICATIONS The wire is applied in all areas that involve positional welding of structural steel such as shipbuilding, offshose, civil construction and mobile machinery. CURRENT RANGE & PACKING DATA Size (mm) 1.2 1.4 1.6 Current Range (Amps) 150-350 150-350 150-450 Volts (V) 23-35 22-34 22-36

OKTUBROD 15.00A

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si S P 0.06 1.20 0.60 0.015 0.015

PACKING: Each spool is packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each. Also Available in 200 Kg Marathon Pac®.
Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -30oC 450 N/mm2 540 N/mm2 25% 80J

A fully basic flux cored wire Classification AWS A5.20: E71T-5 DESCRIPTION OK TUBROD 15.00A is a fully basic flux cored wire producing very low hydrogen quality weldmetal with high resistance to cracking in joints under restraint. The smooth metal transfer facilitates easy deposition even in position welding. Fillet contour is flat, with equal leg lengths & uniform sidewall wetting. The slag system alloys for excellent welding in all positions with virtually no spatter. The wire and slag system design prevents any absorption of moisture and very low levels of hydrogen are achieved in the weldmet. Compared to the seamless varieties, there is no inconsistency in fill-ratio and higher deposition rates are possible. Special surface coating of the wires ensures a long shelf life and trouble free feeding. Weldmet are radiographically sound. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar + 20% CO2 APPROVALS: ABS 3SA, 3YSA; DNV IIIYMS; BV SA, 3MH, LR 3S, 3YS H15
78

TYPICAL APPLICATIONS All general fabrication work involving the multi-pass welding of heavy sections in tensile strength up to 530 N/mm2 e.g. in construction, bridges, pressure vessels and offshore structures boiler quality steels like SA 51570, 285 Grade C, IS: 2002-2A and 28, IS: 2062, IS: 226 and DIN 17155 HIV, etc. CURRENT RANGE & PACKING DATA Size Current Range Volts Spool Weight Welding (mm) (Amps) (V) (Kg) Position 1.2 100-250 18-26 15 F.H.V.O 1.6 140-350 20-32 15 F.H. PACKING: Each spool is sealed in an airtight polythene bag and packed in a corrugated box of 15Kg. Also Available in 200 Kg Marathon Pac®.

OK TUBROD 15.14A
An all-positional rutile flux cored wire Classification DESCRIPTION OK TUBROD 15.14A is an all-positional flux cored wire designed for optimum performance when using 100% CO2 gas. The smooth metal transfer facilitates easy deposition even in positional welding. Fillet contour is flat, with equal leg lengths & uniform sidewall wetting. The slag coverage is complete and easy to remove. The slag system allows excellent welding in all positions with virtually no spatter. Compared to conventional low hydrogen electrodes, OK TUBROD 15.14A absorbs no moisture and ensures much lower H2 levels in the deposited weldmet. Compared to the seamless varieties available, OK TUBROD 15.14A due to its unique method of manufacture presents no inconsistency in fillratio and also has higher deposition rates. Further the special surface coating provided to the wires assures a very long shelf life and easier wire feeding. Weldmet are radiographically sound. WELDING CURRENT: DC + SHIELDING GAS: CO2 or Ar + 20% CO2 APPROVALS: ABS 3SA 3YSA, BV SA3YM, DNV IIIYMS, LR 3S 3YS FCAW wire for mild steel and 490/mm2 class high tensile strength steel Classification ASME SFA/AWS A5.20 E71T-1 DESCRIPTION Dual Shield 7100 is a multi purpose all position flux cored wire for use with CO2 gas. WELDING CURRENT: DC+ SHIELDING GAS: CO2 APPROVALS: ABS 2SA 2YSA H10 (C1) BV SA2YM HH (C1) DNV II YMS H10 (C1) GL 2YH10S (C1) KR RSW 51G(52G) HH (C1) LR 2S 2YS H15 (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (A) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-460 Vertical - up 160-280 AWS A5.20: E71T-1

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si S P 0.03 1.30 0.50 0.02 0.02 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -18oC - 29OC 480 N/mm2 580 N/mm2 30% 80J 50J

Welding Consumables

APPLICATIONS It is designed for all position single and multi-pass welding of mild and medium tensile carbon steels upto 510 N/mm2. For e.g. fabrication in chemical machinery equipment, structures and steel frames in construction, shipbuilding, automobile industry, building of heavy infrastructure such as bridges, towers, in steel industry, rolling stocks etc. It performs well over normal rust and mill scale. CURRENT RANGE & PACKING DATA
Size Current (mm) (Amp) 1.2 100-230 1.6 150-350 Voltage (V) 18-26 20-32 Weight of Packing 15 Kg 15 Kg

PACKING: Each spool is sealed in an airtight polythene bag and packed in a corrugated box of 15Kg each. Also Available in 200 Kg Marathon Pac®.
TYPICAL ALL WELDMETAL PROPERTIES Wire Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.040 0.572 1.270 0.013 0.008 0.028 0.017 0.005 0.019 0.012 0.017 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at 0oC -18oC 491 N/mm2 563 N/mm2 30% 101J 58J

DUAL SHIELD 7100

Volts (V) 22-34 22-28 23-35 22-28 24-36 23-28

Weight of Packing Spool (Kg) Pail (Kg) 5, 12.5, 15 12.5, 15 12.5, 15 100, 200 100, 200 300

PACKING: Each spool is sealed in an airtight polythene bag and packed in a corrugated box.

79

Welding Consumables

FCAW wire for mild steel and 490N/mm2 class high tensile steel Classification ASME SFA/AWS A5.20 E71T-1/ E71T-9 / E71T-9M DESCRIPTION Dual Shield 7100 Ultra is a multi purpose all position flux cored wire for use with CO2 or CO2 /Ar mixed gas. WELDING CURRENT: DC+ SHIELDING GAS: 100% CO2; Ar/CO2 mixtures up to 75% Ar APPROVALS: ABS 3SA 3YSA H10 (C1 and M21) BV SA3YM HH (C1 and M21) DNV III YMS H10 (C1 and M21) GL 3YH10S (C1 and M21) LR 3S 3YS H10 (C1 and M21) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-300 Vertical - up 140-240 1.4 Flat 160-360 Vertical - up 150-260 1.6 Flat 170-410 Vertical - up 160-270

DUAL SHIELD 7100 Ultra

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.038 0.546 1.305 0.013 0.007 0.029 0.022 0.003 0.019 0.013 0.016 Typical Mechanical properties of all Weldmetal As welded (CO2) YS UTS EL (L=4d) Impact (CVN) at -18oC -29oC 495 N/mm2 561 N/mm2 31% 84J 55J

Volts (V) 21-30 21-25 22-32 21-26 23-34 22-27

Weight of Packing Spool (Kg) Pail (Kg) 5, 12.5, 15 12.5, 15 12.5, 15 100, 200 100, 200 300

PACKING: The wires are packed is polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each.

DUAL SHIELD 7100 SR

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.038 0.528 1.289 0.014 0.005 0.022 0.370 0.002 0.017 0.014 0.019 Mechanical Properties As Welded PWHT - Stress Relieved (CO2) 621OC 8 hrs YS UTS EL Impact (CVN) at -18oC -29oC 518 N/mm2 YS 587 N/mm2 UTS 31% EL Impact (CVN at 95J -18oC 59J -29oC 470 N/mm2 550 N/mm2 32% 76J 47J

FCAW wire for mild steel and 490N/mm2 class high tensile steel Classification ASME SFA/AWS A5.20 E71T-9 DESCRIPTION Dual Shield 7100 SR is an all position flux cored wire with a uniquely balanced formulation to provide greater deposition and improved welding productivity. This wire has good mechanical properties in stress relieved condition as well as in as welded. WELDING CURRENT: DC+ SHIELDING GAS: CO2 APPROVALS: ABS, BV, DNV, GL, KR, LR, NK, CCS CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-460 Vertical - up 160-280

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) Pail (Kg) 5, 12.5, 15 12.5, 15 12.5, 15 100, 200 100, 200

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box.

80

Basic slag type FCAW wire for mild steel and 490N/ mm2 class high tensile strength steel Classification ASME SFA/AWS A5.20 E70T-5/T-5MJ DESCRIPTION Dual Shield T-5 is a basic slag flux cored wire which produces crack resiatant, highly ductile weld deposits. The small diameter wires, such as 1.2mm & 1.4mm diameters can be used out - of position. The arc characteristics are globular but can be improved with the use of argon mixtures. Weldmetal analysis is similar to an E7018 or E7018-1 low hydrogen electrode. WELDING CURRENT: DC RP SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS, BV, DNV, GL, LR CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-280 Vertical - up 140-240 1.4 Flat 160-300 Vertical - up 150-260 1.6 Flat 170-320 Vertical - up -

DUAL SHIELD T-5

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.058 0.637 1.368 0.013 0.008 0.027 0.016 0.004 0.002 0.003 0.018 YS UTS EL Impact (CVN) at -18OC -29OC -40OC -51OC Mechanical Properties As Welded (75% Ar / 25% CO2) 440 N/mm2 547 N/mm2 32% 130J 110J 95J 80J

Welding Consumables

Volts (V) 22-31 22-26 23-33 22-27 24-35 -

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

FCAW wire for mild steel and 490N/mm2 class high tensile strength steel Classification ASME SFA/AWS A5.20 E71T-1/1M/12M DESCRIPTION Dual Shield II 70 Ultra is an all - position flux cored wire that displays exceptional impact properties in both the as welded and stress relieved conditions when used with 75% Ar / 25% CO2. Weldmetal analysis is similar to E 7018 low hydrogen electrode. WELDING CURRENT: DC+ SHIELDING GAS: Ar / CO2 APPROVALS: ABS, BV, DNV, GL, LR CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-280 Vertical - up 140-250 1.4 Flat 160-320 Vertical - up 150-270 1.6 Flat 170-340 Vertical - up 160-280

DUAL SHIELD II 70 Ultra

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.042 0.418 1.079 0.013 0.007 0.027 0.016 0.004 0.021 0.014 0.015 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -18oC -29oC 486 N/mm2 545 N/mm2 33% 112J 88J

Volts (V) 22-30 22-26 23-32 22-27 24-33 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

81

Welding Consumables

Self - Shielded FCAW wire for mild steel and 490N/ mm2 class high tensile strength steel Classification : ASME SFA/AWS A5.20 E71T-11 DESCRIPTION Coreshield 11 is excellent for use on single or multiple pass, lap, fillet and butt welds on mile steels in all welding position. It meets the requirements for classification E71T-11 in AWS specifiction A5.20, and offers smooth arc action, full slag coverage, easy slag removal, and low spatter. Bead appearance and weld edges are smooth and no shielding gas is required. WELDING CURRENT: DC SHIELDING GAS: None (Self - shielding) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 170-240 Vertical - up 170-240 1.2 Flat 180-270 Vertical - up 180-270 1.6 Flat 200-300 Vertical - up 200-300

CORESHIELD 11

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V A1 Cu 0.210 0.370 0.610 0.013 0.003 0.040 0.020 0.010 0.009 1.600 0.013 YS UTS EL Typical Mechanical properties of all Weldmetal 440 N/mm2 600 N/mm2 25%

Volts (V) 17-23 17-23 19-25 19-25 22-28 22-28

Weight of Packing Spool (Kg) 12.5 / 15 12.5 / 15 12.5 / 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each.

Self - shielded FCAW wire for mild steel and 490N/ TYPICAL ALL WELDMETAL PROPERTIES mm2 class high tensile strength steel Weldmetal Typical Mechanical properties Classification: ASME SFA/AWS A5.29 E71T8-Ni1 Composition (%) of all Weldmetal DESCRIPTION C 0.030 YS 424 N/mm2 Coreshield 8Ni1 is a self - shielded flux cored wire deSi 0.260 UTS 560 N/mm2 signed to produce welds with outstanding impact toughMn 1.050 EL (L=4d) 29% ness at temperatures as low as - 60OF (-51OC). It is P 0.013 Impact (CVN) at suitable for all position welding and is especially suited S 0.003 -29OC 120J for making root passes of handling poor fit up. It should Cr 0.035 -51OC 38J only be run on DCEN (electrode negative). It should be Ni 0.990 used for welding offshore structures, bridges, storage Mo 0.020 V 0.002 tanks, and other applications where excellent impact A1 0.900 toughness is specified and where self-shielding proCu 0.013 vides an advantages. CURRENT RANGE & PACKING DATA Size Position Current Range Volts Weight of Packing (mm) (Amps) (V) Spool (Kg) 1.0 Flat 200-300 21-23 8 / 12.5 Vertical - up 200-300 21-23 1.2 Flat 220-320 22-24 8 / 12.5 Vertical - up 220-320 21-24 1.6 Flat 240-340 24-28 8 / 12.5 Vertical - up 240-340 23-28 PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 8Kg/12.5Kg each.

CORESHIELD 8 Ni 1

WELDING CURRENT: DC (-) SHIELDING GAS: None (Self - shielding)

82

Metal type FCAW wire for mild steel and 490N/mm class high tensile strength steel Classification : ASME SFA/AWS A5.18 E70C-6M DESCRIPTION Coreweld 70 is a metal cored wire that combines the high deposition rates of a rutile slag flux - cored electrode with the high efficiencies of solid wire. WELDING CURRENT: DC+ SHIELDING GAS: Ar / CO2 APPROVALS: ABS, BV, DNV, GL, LR
2

COREWELD 70

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.048 0.582 1.375 0.014 0.012 0.023 0.014 0.001 0.004 0.002 0.015 Typical Mechanical properties of all Weldmetal YS UTS EL Impact (CVN) at -18OC -29OC 448 N/mm2 549 N/mm2 31% 62J 48J

Welding Consumables

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 180-350 Vertical - up 140-220 1.4 Flat 200-430 Vertical - up 150-240 1.6 Flat 300-500 Vertical - up 2.0 Flat 350-550 Vertical - up 2.4 Flat 400-600 Vertical - up -

Volts (V) 24-33 20-24 26-34 21-25 27-35 28-36 29-37 -

Weight of Packing Spool (Kg) Pail (Kg) 12.5 / 15 100 / 200 12.5 / 15 12.5 / 15 25 25 100 / 200 300 -

PACKING: Each spool is sealed in an airtight polythene bags and then packed in a corrugated cardboard box of 15Kg/12.5Kg/25Kg each.

COREWELD ULTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.038 0.592 1.432 0.013 0.010 0.023 0.015 0.001 0.009 0.003 0.013 Mechanical Properties As Welded (CO2) YS UTS EL Impact (CVN) at -18OC -29OC 440 N/mm2 YS 530 N/mm2 UTS 31% EL 75J 48J -18OC -29OC As Welded (Ar / CO2) 449 N/mm2 545 N/mm2 30% 82J 52J

metal type FCAW wire for mild steel and 490N/mm2 class high tensile strength steel Classification: ASME SFA/AWS A5.18 E70C-6M/ E70C-6C DESCRIPTION Coreweld Ultra is a low fume metal - cored wire. The use of higher argon shielding gas further reduces fume, spatter and slag islands. The higher deposition efficiency and improved welder appeal minimizes post weld clean up. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS, BV, DNV, GL, LR CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 180-350 Vertical - up 1.4 Flat 200-430 Vertical - up 1.6 Flat 300-500 Vertical - up -

Volts (V) 24-33 26-34 27-35 -

Weight of Packing Spool (Kg) Pail (Kg) 12.5 / 15 100 / 200 12.5 / 15 12.5 / 15 100 / 200 300

PACKING: Each spool is seald in an airtight polythene bag and then packed in a corrugated cardboard box of 15Kg/12.5Kg each.
83

Welding Consumables

COREWELD 111 ULTRA
Semi - metal type FCAW wire for mild steel 490N/ mm2 class high tensile strength steel Classification : ASME SFA/AWS A5.20 E70T-9 DESCRIPTION Coreweld 111 Ultra is a low slag type cored wire with a bright surface finish that is specially designed to provide very high deposition rates, high deposition efficiency and low fume emission rates. This wire is most suitable for fillet welding of inorganic zinc primer coated steels in the shipbuilding industry. WELDING CURRENT: DC+ SHIELDING GAS: CO2 APPROVALS: ABS, BV, DNV, GL, KR, LR CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 1.4 Flat 160-390 Vertical - up 1.6 Flat 170-460 Vertical - up -

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.057 0.652 1.375 0.013 0.009 0.023 0.348 0.002 0.012 0.008 0.014 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -20OC -29OC 500 N/mm2 580 N/mm2 30% 67J 43J

Volts (V) 22-34 23-38 24-42 -

Weight of Packing Spool (Kg) Pail (Kg) 12.5 / 15 100 / 200 12.5 / 15 12.5 / 15 100 / 200 300

PACKING: Each spool is seald in an airtight polythene bag and then packed in a corrugated cardboard box of 15Kg/12.5Kg each.

DUAL SHIELD 8100 W

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.035 0.492 0.925 0.013 0.007 0.539 0.605 0.004 0.016 0.010 0.490 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -5oC -29oC 515 N/mm2 593 N/mm2 30% 98J 35J

FCAW wire for weather - proof steel Classification ASME SFA/AWS A5.29 E81T-W2 DESCRIPTION Dual Shield 8100 W is an all - position flux cored wire developed specifically to color match with the low alloy, high strength weathering grade steels such as ASTM 588 & 242. WELDING CURRENT: DC+ SHIELDING GAS: Pure CO2 or Ar / CO2 APPROVALS: ABS 3SA 3YSA H10 (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-300 Vertical - up 140-240 1.4 Flat 160-360 Vertical - up 150-260 1.6 Flat 170-410 Vertical - up 160-270

Volts (V) 21-30 21-25 22-32 21-26 23-34 22-27

Weight of Packing Spool (Kg) Pail (Kg) 12.5, 15 12.5, 15 12.5, 15 100, 200 100, 200

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 15Kg/12.5Kg each.
84

DUAL SHIELD 7000 A1

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.048 0.475 0.789 0.016 0.007 0.028 0.019 0.480 0.016 0.009 0.022 Mechanical Properties As Welded (CO2) YS UTS EL Impact (CVN) at 10oC -18oC PWHT - 620OC 1 hr (CO2) 470 N/mm2 550 N/mm2 32% 31J 20J

Welding Consumables

FCAW wire for 0.5% Mo heat resistant steel Classification ASME SFA/AWS A5.29 E81T-A1 DESCRIPTION Dual Shield 7000 - A1 is an all - position wire recommended for 0.5% Mo steels. It is used in the fabrication and erection of boilers, pressure piping and tubing and other pressure vessel applications. 75% Ar / 25% CO2 shielding gas mixture may be used to improve arc characteristics, increase wetting action, decrease penetration, and provide easier arc control for out - of - position welding. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar/ 25% CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-430 Vertical - up 160-280

503 N/mm2 YS 684 N/mm2 UTS 28% EL Impact (CVN at 43J 10oC 27J -18oC

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

DUAL SHIELD 8000 - B2

TYPICAL ALL WELDMETAL PROPERTIES Weld Matel Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.054 YS 0.512 UTS 0.589 EL 0.015 0.007 1.323 0.017 0.543 0.017 0.010 0.021 Mechanical Properties As Welded (CO2) PWHT - 690OC 1 hr (CO2) 520 N/mm2 610 N/mm2 24%

FCAW wire for 0.5 - 1.25% Cr - 0.5% Mo heat resistant steel Classification ASME SFA/AWS A5.29 E81T-B2 DESCRIPTION Dual Shield 8000 - B2 is an all - position flux cored wire which contains 1.25% Cr-0.5% Mo. The Weldmetal analysis is similar to an E8018-B2 low hydrogen electrode. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar / 25% CO2

565 N/mm2 YS 660 N/mm2 UTS 23% EL

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-430 Vertical - up 160-280

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

85

Welding Consumables

DUAL SHIELD 9000 - B3

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.053 YS 0.517 UTS 0.538 EL 0.015 0.006 0.268 0.019 1.066 0.015 0.011 0.024 Mechanical Properties As Welded (CO2) 717 N/mm2 YS 822 N/mm2 UTS 20% EL PWHT 690OC 1 hr 606 N/mm2 692 N/mm2 22%

FCAW wire for 2.25% Cr-1% Mo heat resistant steel Classification ASME SFA/AWS A5.29 E91T-B3 DESCRIPTION Dual Shield 9000 - B3 is an all - position flux cored wire which contains 2.25% Cr - 1% Mo. The Weldmetal analysis is similar to an E9018 - B3 low hydrogen electrode. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar/ 25% CO2

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-430 Vertical - up 160-280

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

FCAW wire for mild steel, 490N/mm2 class high tensile steel and 550N/mm2 class high tensile steel for low temperature service. Classification ASME SFA/AWS A5.29 E81T1-K2 DESCRIPTION Dual Shield II 81 - K2 is a high strength all position flux cored electrode designed to provide excellent low temperature impact toughness. WELDING CURRENT: DC+ SHIELDING GAS: CO2 APPROVALS: ABS 4Y400SA H5 (C1) BV SA5Y40M HHH (C1) DNV IVY40MS H5 (C1) GL 6Y40H5S (C1) LR 5Y40S H10 (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-320 Vertical - up 140-270 1.4 Flat 160-330 Vertical - up 150-280 1.6 Flat 170-350 Vertical - up 160-280

DUAL SHIELD II 81 - K2

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.038 0.413 1.141 0.012 0.008 0.026 1.553 0.002 0.017 0.012 0.015 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -18oC -29oC -51oC 517 N/mm2 581 N/mm2 30% 136J 121J 81J

Volts (V) 22-32 22-28 23-34 22-28 24-36 24-29

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.
86

Basic slag type FCAW wire for mild steel and 760N/ mm2 class high tensile strength steel Classification ASME SFA/AWS A5.29 E110T5-K4 DESCRIPTION Dual Shield T - 115 is a basic slag flux cored wire designed for applications requiring a high strength weld deposit. This wire produces weld deposits which are resistant to cracking in heavy sections or under high restraint. The metal analysis is similar to an E11018-M low hydrogen electrode. WELDING CURRENT: DC+ SHIELDING GAS: Ar / CO2 APPROVALS: ABS E110T5 - K4 (M21) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-460 Vertical - up 160-280

DUAL SHIELD T - 115

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.069 0.592 1.375 0.014 0.009 0.234 2.185 0.455 0.003 0.004 0.021 YS UTS EL Impact (CVN) at -29OC -51OC Mechanical Properties As Welded (75% Ar / 25% CO2) 702 N/mm2 813 N/mm2 21% 59J 38J

Welding Consumables

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

DUAL SHIELD II 110

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.053 0.298 1.600 0.014 0.007 0.027 1.813 0.375 0.018 0.013 0.016 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -18oC -29oC 705 N/mm2 830 N/mm2 19% 45J 38J

FCAW wire for mild steel and 760N/mm2 class high tensile strength steel Classification ASME SFA/AWS A5.29 E110T1-K3 DESCRIPTION Dual Shield II 110 is an all - position flux cored wire that combines a high stength deposit with excellent impact toughness. This wire was designed to join high strength steel such as HY-100 and T-1 in the as welded or stress relieved conditon. The Weldmetal analysis is similar to an E11018 - M low hydrogen electrode. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar / 25% CO2 APPROVALS: ABS E110T1 - K3 (M21) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-330 Vertical - up 140-270 1.4 Flat 160-390 Vertical - up 150-280 1.6 Flat 170-460 Vertical - up 160-280

Volts (V) 22-34 22-28 23-34 22-28 24-36 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.
87

Welding Consumables

FCAW wire for mild steel AND 620N/mm2 class high tensile strength steel Classification ASME SFA/AWS A5.29 E91T1-K2 (E91T1-K2) DESCRIPTION Dual Shield II 101TC is an all - position wire developed to meet the U.S. Navy qualification tests for hydrogen levels of less than 5ml / 100g of Weldmetal. This wire produces exceptional mechanical properties and low temperature impact toughness. It is intended for use on HY-80, ASTM A 70, A514 and A517 or other similar HSLA steels. WELDING CURRENT: DC+ CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 140-280 Vertical - up 140-250 1.4 Flat 160-300 Vertical - up 150-270 1.6 Flat 170-330 Vertical - up 160-280

DUAL SHIELD II 101TC

SHIELDING GAS: CO2 APPROVALS: ABS E91T1-K2(C1)
TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.058 0.637 1.368 0.013 0.008 0.027 0.016 0.004 0.002 0.003 0.018 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at -18oC -29oC -51oC 565 N/mm2 649 N/mm2 28% 112J 94J 65J

Volts (V) 22-32 22-27 23-32 22-28 24-34 24-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: Each spool is sealed in an airtight polythene bag and then packed in a corrugated cardboard box of 5Kg/15Kg/12.5Kg each.

DUAL SHIELD B9
Classification

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si P S Cr Ni Mo V Nb N Al Cu 0.1 0.9 0.2 0.010 0.008 9.0 0.2 1.0 0.22 0.035 0.034 0.002 0.02 Typical Mechanical properties of all Weldmetal PWHT 2 hrs @ 760OC YS UTS EL Impact (CVN) at 22oC 758 N/mm2 620 N/mm2 20% 34J

ASME SFA/AWS A5.29 Class E91T1 B9M - H8

DESCRIPTION Dual Shield B9 is an all - positional flux - cored electrode designed for the welding of modified 9% chromium creep resisting steels, such as ASTM A335 Grade P91 or ASTM A213 T91. This product is specially formulated with a combined Mn-Ni < 1.20% to meet a variety of customers’ specification. SHIELDING GAS: 75% Argon / 25% CO2 APPLICATION: This product operates well out - of - position, especially in the 6 O’clock position on pipe producing a flat to slightly convex weld bead. CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 170-290 Vertical 170-200 Overhead 180-230 1.6 Flat 200-365

Volts (V) 26-32 24-26 25-27 26-33

Weight of Packing Spool (Kg) 6.8 15

PACKING: All Dual Shield B9 product is layer level wound and packaged on wire spool basket to allow for the product to be placed in an heated storage oven. In addition, the wire is packaged in a vacuum sealed foil bag to prevent moisture pick up until such time the sealed bag has been opened.

88

OK TUBROD 15.22
A 2.25 Cr, 1 Mo alloyed basic flux cored wire Classification DESCRIPTION OK TUBROD 15.22 is a basic low hydrogen flux cored wire depositing a 2.25 Cr, 1 Mo alloy designed for creep resistant steels of similar composition and intended for service at around 600°C. Typical applications include fabrication and repair in the power generation field. Stress relief to be carried out at 690°C. The flux-cored wire welds with a very smooth and stable arc and deposits a very thin slag that is easily removable. The weldbead is smooth and shiny with a flat bead profile. SHIELDING GAS: CO2 or 80% Argon with 20% CO2 or 45% CO2 + 2.3% O2 APPLICATIONS OK TUBROD 15.22 is designed for single and multipass welding in the flat and for horizontal fillets of 2.25 AWS A 5.29: E90T5-B3

Cr-1 Mo steels, which are used principally in power piping and boiler work for the fabrication of plates, pipes, tubes, castings and forging conforming to ASTM specifications.
TYPICAL WELDMETAL PROPERTIES Weldmetal Mechanical Properties Composition As Welded PWHT - Stress Relieved (%) at 690OC / 1 hr C 0.06 YS 630 N/mm2 YS 550 N/mm2 Mn 0.637 UTS 730 N/mm2 UTS 650 N/mm2 Si 1.368 EL 20% EL 22% Mo 0.013 Cr 0.008 S 0.027 P 0.016 CURRENT RANGE & PACKING DATA Size (mm) 1.2 1.6 Current (Amp) 120-250 130-350 Voltage (V) 18-26 20-32 Weight of Packing 16 Kg 16 Kg

Welding Consumables

PACKING: The wires wrapped in polythene bags are packed in corrugated cardboard boxes.

A 1 Ni alloyed basic flux cored wire Classification AWS A 5.29: E80T5-G DESCRIPTION OK TUBROD 15.24 is a fully basic low hydrogen flux cored wire depositing a 1 Ni alloy designed for high strength combined with low temperature toughness for service down to -50°C and has good CTOD-performance. This applies to both the as welded and stress relieved condition. Shielding gas could be CO2 or Ar mixtures. Typical applications include fabrication and repair in the power industry. The flux-cored wire welds with a very smooth and stable arc and deposits a very thin slag that is easily removable. The weld bead is smooth and shiny with a flat bead profile. SHIELDING GAS: CO2 or Argon with 20% CO2 APPROVALS: IN (DVA), MOD APPLICATIONS OK TUBROD 15.24 is designed for good low temperature

OK TUBROD 15.24

impact properties and to help resist weld cracking. It can be used for single and multi-pass welding. One typical appli~ation is in the construction and repair of offshore platforms and containment vessels.
TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si Ni S P Size (mm) 1.2 1.6 0.06 1.5 0.5 0.8 0.02 0.01 Current (Amp) 100-250 140-350 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at - 50oC 540 N/mm2 600 N/mm2 28% 100J

CURRENT RANGE & PACKING DATA
Voltage (V) 18-26 20-32 Weight of Packing 16 Kg 16 Kg

PACKING: The wires wrapped in polythene bags are packed in corrugated cardboard boxes.

89

Welding Consumables

OKTUBROD 15.27
A basic flux cored wire for HSLA steels Classification DESCRIPTION OK TUBROD 15.27 is a fully basic low hydrogen flux cored wire depositing a 2.5 Ni alloy designed for welding of high tensile strength steels such as HY 100. It is also suitable for welding high tensile steels with a low temperature toughness requirement down to -50°C. The wire is capable of welding in all positions and uses the dip transfer mode for the vertical-up technique, which can be further enhanced by the synergic pulsed process. The flux-cored wire welds with a very smooth and stable arc and deposits a very thin slag that is easily removable. The weldbead is smooth and shiny with a flat bead profile. SHIELDING GAS: CO2 or Argon with 20% CO2 WELDING CURRENT : DCAPPROVALS : MOD, Q2N AWS A 5.29: E110T5-G

APPLICATIONS OK TUBROD 15.27 is used for the welding of quenched and tempered steels as N-A-XTRA 90, N-A-XTRA 100, HY100, etc. which are used for offshore jack-up structures and general structural fabrication of high tensile steels for low temperature service.
TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si Ni 0.06 1.6 0.5 2.5 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) Impact (CVN) at - 50oC 750 N/mm2 820 N/mm2 21% 80J

CURRENT RANGE & PACKING DATA
Size (mm) 1.2 1.6 Current (Amp) 100-250 140-350 Voltage (V) 18-26 20-32 Weight of Packing 16 Kg 16 Kg

PACKING: The wires wrapped in polythene bags are packed in corrugated cardboard boxes. stabilised grades 321 and 347 types, except when the corrosive conditions are very severe.
TYPICAL WELDMETAL PROPERTIES Wire Composition (%) C Mn Cr Si Ni 0.03 1.6 19.0 0.4 10.0 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) 410 N/mm2 535 N/mm2 40%

OK TUBROD 14.30
A rutile flux cored wire for welding 18 Cr, 8 Ni steels for welding of stainless steel Classification DESCRIPTION OK TUBROD 14.30 is a flux cored tubular wire designed for the welding of stainless steels containing 18-20% Cr and 8-12% Ni in all positions. It can also be used for welding the stabilised grades 321 and 347 types in most cases, except when the environmental corrosive conditions are very severe. The slag volume is thin and its removal effortless with a final weldbead that is smooth, shiny and with an exceptional finely rippled appearance. Due to the extremely stable DC+ arc, spatter levels are virtually nonexistent. SHIELDING GAS: Ar/CO2, CO2 APPROVALS: TUV, LR, DB, VdTÜV TYPICAL APPLICATIONS OK TUBROD 14.30 is intended for welding austenitic stainless steels corresponding to AISI 304L, 304, 308L, 308 etc. In most cases its also suitable for welding the AWS A5.22: E308LT0-1

CURRENT RANGE & PACKING DATA
Size (mm) 1.2 1.6 Current (Amp) 150-250 200-350 Voltage (V) 25-32 26-34 Weight of Packing 15 Kg 15 Kg

PACKING: The spools are packed in sealed polythene bags and then packed in corrugated carboard boxes.

90

FCAW wire for 18% Cr - 8% Ni stainless steel, For all - position welding Classification ASME SFA/AWS A5.22 E308LT1-1(4) DESCRIPTION For welding types 301, 302, 304, 304L, 308 and 308L of stainless steel. May be used for welding types 321 and 347 if service temperature does not exceed 500OF (260OC). Low carbon content minimizes carbide precipitation. Ferrite values will lower as impact toughness increases. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS E308LT1-1(C1) DNV 308L (C1) LR 304L (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

SHIELD - BRIGHT 308 L

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.024 0.752 1.118 0.020 0.005 19.21 10.00 0.101 0.052 0.022 0.140 Mechanical Properties As Welded (CO2) As Welded (Ar / CO2)

Welding Consumables

YS UTS EL Impact (CVN) at -0OC

400 N/mm2 YS 570 N/mm2 UTS 50% EL

403 N/mm2 593 N/mm2 50%

49J

Ferrite No. FN 3-9

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each. FCAW wire for 22% Cr - 12% Ni stainless steel, For all - Position welding Classification ASME SFA/AWS A5.22 E309LT1-1(4) DESCRIPTION Designed for welding type 309 wrought or cast forms, but used extensively for welding type 304 to mild or carbon steel. Also used for welding 304 clad sheets and for applying stainless steel sheet linings to carbon steel. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar / 25% CO2 APPROVALS: ABS E309LT1-1(C1) BV 309L (C1) DNV 309L MS (C1) LR SS / CMn (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 0.9 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

SHIELD - BRIGHT 309 L

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 0.805 1.093 0.022 0.007 22.70 12.66 0.080 0.067 0.022 0.145 Mechanical Properties As Welded (CO2) As Welded (Ar / CO2)

YS UTS EL Impact (CVN) at -0OC

450 N/mm2 YS 580 N/mm2 UTS 40% EL

459 N/mm2 589 N/mm2 40%

38J

Ferrite No. FN 9-20

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
91

Welding Consumables

SHIELD - BRIGHT 309 LMo

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 YS 0.632 UTS 0.967 EL 0.019 0.009 23.02 13.01 2.622 0.072 0.018 0.152 Mechanical Properties As Welded (CO2) As Welded (75% Ar / 25% CO2)

FCAW wire for dissimilar metals, For all - position welding Classification: ASME SFA/AWS A5.22E309LMoT1-1(4) DESCRIPTION Designed for welding type 316 clad steels on the first pass in cladding steels or for welding dissimilar metals such as Mo-containing austenitic stainless steels to carbon steels. Used in paper mills and in power plants. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or 75% Ar / 25% CO2 APPROVALS: DNV 309MoL (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 0.9 Flat 120-200 Vertical - up 100-150 1.2 Flat 150-270 Vertical - up 130-200 1.6 Flat 200-350 Vertical - up 160-250

517 N/mm2 YS 645 N/mm2 UTS 33% EL

550 N/mm2 700 N/mm2 33%

Ferrite No. FN 17-23

Volts (V) 24-30 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

SHIELD - BRIGHT 309 L Cb

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical properties of all Weldmetal As Welded (CO2) C Si Mn P S Cr Ni Mo V Nb Cu 0.024 0.750 1.062 0.022 0.007 24.20 12.84 0.080 0.067 0.778 0.145 YS UTS EL (L=4d) Impact (CVN) at 0oC 501 N/mm2 653 N/mm2 34% 52J

FCAW wire for dissimilar metals, For all - position welding Classification : ASME SFA/AWS A5.22E309LCbT1-1(4) DESCRIPTION Shield - Bright 309LCb is an all - position flux cored wire. It containes Nb alloy element which inhibits carbide precipitation to prevent intergranular corrosion at elevated temperatures. Shield Bright 309LCb is recommended for welding types 347 or 321 stainless clad steels, or type 347 stainless steel to carbon steel. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 0.9 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

Ferrite No. FN19-25

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

92

FCAW wire for low carbon 18% Cr - 12% Ni - 2% Mo stainless steel For all - position welding Classification: ASME SFA/AWS A5.22 E316LT1-1(4) DESCRIPTION For welding type 316 stainless. Contains molybdenum which resists pitting corrosion induced by sulphuric and sulphurous acids, chlorides and cellulose solutions. Used widely in the rayon, dye and paper making industries. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS E316LT1-1(C1) BV 316L (C1) DNV 316L MS (C1) LR 316L (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

SHIELD - BRIGHT 316 L

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 0.805 1.093 0.022 0.007 22.70 12.66 0.080 0.067 0.022 0.145 Mechanical Properties As Welded As Welded (CO2) (75% Ar / 25% CO2) YS UTS EL Impact (CVN) at -0OC 430 N/mm2 YS 570 N/mm2 UTS 42% EL 39J 456 N/mm2 595 N/mm2 42%

Welding Consumables

Ferrite No. FN 5-15

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

SHIELD - BRIGHT 317 L

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo Cu 0.03 0.75 1.05 0.02 0.01 19.5 12.9 3.5 0.15 Typical Mechanical properties of all Weldmetal YS UTS EL (L=4d) 421 N/mm2 560 N/mm2 43%

FCAW wire for 18% Cr - 12% Ni - 3% Mo - N Stainless steel For all - position welding Classification : ASME SFA/AWS A5.22 E317LT1-1(4) DESCRIPTION Recommended for welding type 317 stainless steel to give a maximum of 0.04% carbon in the weld deposit. The higher molybdenum content, as compared to type 316L, further reduces susceptibility to pitting corrosion. Used in the pulp and paper industry and in other severe corrosion applications involving sulfuric and sulfurous acids and their salts. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

Ferrite No. FN10-20

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 / 15 12.5 / 15 12.5 / 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

93

Welding Consumables

SHIELD - BRIGHT 347

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Cb Cu 0.02 0.8 1.1 0.02 0.01 19.3 10.0 0.4 0.15 Typical Mechanical properties of all Weldmetal As Welded (CO2) YS UTS EL (L=4d) 431 N/mm2 598 N/mm2 55%

FCAW wire for 18% Cr - 8% Ni - Cb Stainless steel Classification: ASME SFA/AWS A5.22E347T1-1(4) DESCRIPTION Developed to weld types 347, 304, 304L and 321 stainless, where service temperatures are below 316. The addition of columbium helps minimize chromium carbide precipitation while providing improved corrosion resistance. WELDING CURRENT: DC RP SHIELDING GAS: CO2 or Ar / CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

Ferrite No. FN 8-12

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 / 15 12.5 / 15 12.5 / 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each.

SHIELD - BRIGHT 308 H

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Mn Si S P Cr Ni Mo Cu 0.054 1.072 0.768 0.007 0.026 19.01 9.85 0.08 0.12 YS UTS EL Typical Mechanical properties of all Weldmetal 372 N/mm2 585 N/mm2 38%

Classification : AWS A5.22 E308HT1-1(4) DESCRIPTION For welding types 304H and 307H stainless when high temperature service is required. CO2 shielding is preferred to reduce silicon content at these elevated temperatures. Carbon content 0.04% minimum. WELDING CURRENT: DC RP SHIELDING GAS: CO2

Ferrite No. FN 7-10

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 LG 200

Volts (V) 29

Weight of Packing Spool (Kg) 12.5 / 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each.

94

SHIELD - BRIGHT 410

FCAW wire for 13% Cr stainless steel For all - position welding Classification: ASME SFA/AWS A5.22 E410T1-1(4) DESCRIPTION Shield Bright 410 is 13% Cr martensitic stainless steel flux cored wire. It is used for overlay welding on valve sheet surface of its martensite structure in as - welded condition which shows high hardness and wear resisting properties. It will be showed good ductility and excellent corrosion resistance after post weld heat treatment at 600-850 and it is suitable for welding of AISI 410, 403, 420J1, and 420J2. Recommended for welding remove dirt such as oil and dust from the groove. Normally, pre-heat is necessary at 200-400. CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical properties of all Weldmetal PWHT : 750OC / 1 hr (CO2) C Si Mn P S Cr Ni Mo V Nb Cu 0.055 0.484 0.597 0.021 0.008 12.701 0.219 0.010 0.071 0.013 0.036 YS UTS EL 480 N/mm2 570 N/mm2 25%

WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2

Welding Consumables

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

SHIELD - BRIGHT 2209

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical properties of all Weldmetal As Welded (CO2) C Si Mn P S Cr Ni Mo V Nb Cu 0.035 0.493 0.856 0.023 0.008 22.76 8.922 3.407 0.053 0.023 0.156 YS UTS EL Impact (CVN) at -46.5OC 650 N/mm2 825 N/mm2 26% 49J

Shield Bright 2209 is an all - position duplex flux cored electrode for use with CO2 gas. Classification : SFA/AWS A5.22 E2209T1-1(4) DESCRIPTION It is designed for the welding of 22Cr-5Ni-2Mo-0.15N duplex stainless steel (UNS S31803), commonly known as 2205. Commercial designations for such steels include SAF 2205(Sandvik), 2205(Avesta), UR 54N(Creusot), AF22(Mannesmann), NK Cr22(Nippon Kokan), SM22Cr (Sumitomo). WELDING CURRENT: DC+ SHIELDING GAS: CO2 APPROVALS: DNV CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat 130-220 Vertical - up 130-170 1.4 Flat 150-260 Vertical - up 150-210 1.6 Flat 170-300 Vertical - up 170-250

Volts (V) 25-30 25-28 25-31 25-28 25-32 22-28

Weight of Packing Spool (Kg) 5, 12.5, 15 12.5, 15 12.5, 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 5Kg/15Kg/12.5Kg each.
95

Welding Consumables

SHIELD - BRIGHT 312

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.075 YS 0.752 UTS 1.102 EL 0.023 0.003 28.50 9.65 0.097 0.088 0.026 0.156 Mechanical Properties As Welded (CO2) As Welded (75% Ar / 25% CO2)

FCAW wire for 29%Cr - 9%Ni stainless steel For all - position welding Classification: ASME SFA/AWS A5.22 E312T1-1(4) DESCRIPTION For welding type 312 stainless steel. Highly crack resistant of austenite - ferritic electrode with a ferrite content of 50%. Also highly suitable for stress compensating buffer layers on parent metals sensitive to cracking. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2

620 N/mm2 YS 810 N/mm2 UTS 24% EL

625 N/mm2 813 N/mm2 28%

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

Ferrite No. FN 50-60

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 FCAW wire for 13%Cr - 5%Ni-0.5%Mo stainless steel

SHIELD - BRIGHT 410NiMo

For all - position welding Classification : SFA/AWS A5.22 E410NiMoT1-1(4) DESCRIPTION Shield - Bright 410NiMo is composed of 13%Cr - 5%Ni - 0.5%Mo type stainless steel flux cored wire. It is not severely required to control pre-heating and interpass temperature during welding and it shows good impact property at low temperature compared with ShieldBright 410. There is no need to take care of delayed hydrogen cracking and temper brittleness, thereby it is used for welding and repairing of pump wheels and impeller of turbine, which are operating with high loading and pressure. Recommended for welding remove dirt such as oil and dust from the groove. Normally, pre-heat is necessary at 100-150. CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 100-170 Vertical - up 100-150 1.2 Flat 130-250 Vertical - up 130-200 1.6 Flat 170-320 Vertical - up 160-250

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%)

Typical Mechanical properties of all Weldmetal PWHT : 600OC @ 1 hr (CO2)

C Si Mn P S Cr Ni Mo V Nb Cu

0.055 0.484 0.597 0.021 0.008 12.701 0.219 0.010 0.071 0.013 0.036

YS UTS EL

720 N/mm2 840 N/mm2 20%

Volts (V) 23-27 21-25 25-31 23-28 25-33 24-30

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.
96

FCAW wire for 18%Cr - 8%Ni stainless steel For flat and horizontal position welding Classification: ASME SFA/AWS A5.22 E308LT0-1(4) DESCRIPTION Designed for welding types 301, 302, 304, 304L, 308, 308L steels. Ideal where service temperatures are below 500OF (260OC). Low carbon content helps minimize carbide precipitation. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS E308LT0-1(C1) DNV 308L (C1) LR 308L (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

SHIELD - BRIGHT 308L XTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 0.512 1.390 0.021 0.005 19.45 9.90 0.082 0.054 0.011 0.154 Mechanical Properties As Welded (CO2) As Welded (75% Ar / 25% CO2)

Welding Consumables

YS UTS EL Impact (CVN) at -100OC

427 N/mm2 YS 575 N/mm2 UTS 42% EL 30J

432 N/mm2 585 N/mm2 41%

Ferrite No. FN 5-15

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

SHIELD - BRIGHT 309L XTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 0.632 1.548 0.019 0.004 24.44 12.70 0.085 0.052 0.013 0.143 Mechanical Properties As Welded As Welded (CO2) (75% Ar / 25% CO2) YS UTS EL Impact (CVN) at -100OC 453 N/mm2 YS 579 N/mm2 UTS 38% EL 24J 473 N/mm2 592 N/mm2 38%

FCAW wire for 22%Cr - 12%Ni stainless steel For flat and horizontal position welding Classification : ASME SFA/AWS A5.22 E309LT0-1(4) DESCRIPTION Developed to be used when welding most mild or carbon steels to type 304. The higher percentages of Cr and Ni provide the necessary crack resistance. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS E309LT0-1(C1) DNV 309L MS (C1 and M21) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

Ferrite No. FN 17-29

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

97

Welding Consumables

SHIELD-BRIGHT 309LMo XTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical properties of all Weldmetal As Welded (CO2) C Si Mn P S Cr Ni Mo Cu 0.03 0.55 1.4 0.02 0.01 23.3 13.6 2.6 0.15 YS UTS EL (L=4d) Ferrite No 559 N/mm2 725 N/mm2 39% 18-26

FCAW wire for 22%Cr - 12%Ni-2%Mo stainless steel For flat and horizontal position welding Classification: ASME SFA/AWS A5.22 E308LT0-1(4) DESCRIPTION Designed for welding type 316 clad steels on the first pass in cladding steels or for welding dissimilar metals such as molybdenum-containing austenitic stainless steels to carbon steels. Used in paper mills and power plants. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 / 15 12.5 / 15 12.5 / 15

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 15Kg/12.5Kg each.

SHIELD - BRIGHT 316L XTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Cu 0.032 0.521 1.400 0.021 0.007 18.44 12.20 2.494 0.050 0.015 0.158 Mechanical Properties As Welded (CO2) YS UTS EL Impact (CVN) at -100OC As Welded (75% Ar / 25% CO2) 415 N/mm2 571 N/mm2 42%

FCAW wire for 18%Cr - 12%Ni-2%Mo stainless steel For flat and horizontal position welding Classification : ASME SFA/AWS A5.22 E316LT0-1(4) DESCRIPTION Designed specifically for applications where the service environment can produce pitting corrosion. Commonly used in the pulp and paper industry. Carbon content 0.04% maximum. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 APPROVALS: ABS E316LT0-1(C1) DNV 316L (C1) LR 316L (C1) CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

411 N/mm2 YS 565 N/mm2 UTS 42% EL 47J

Ferrite No. FN 4-15

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

98

SHIELD-BRIGHT 347 XTRA

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) Typical Mechanical properties of all Weldmetal As Welded (CO2) C Si Mn P S Cr Ni Mo V Nb Cu 0.029 0.512 1.390 0.021 0.005 19.45 9.90 0.082 0.054 0.47 0.154 YS UTS EL (L=4d) Impact (CVN) at -100OC Ferrite No 427 N/mm2 575 N/mm2 42% 30J 3-10

Welding Consumables

FCAW wire for 18%Cr - 8%Ni-Cb stainless steel For flat and horizontal position welding Classification: ASME SFA/AWS A5.22 E347T0-1(4) DESCRIPTION Developed to weld types 347, 304, 304L and 321 stainless, where service temperatures are below 316. The addition of columbium helps minimize chromium carbide precipitation while providing improved corrosion resistance. WELDING CURRENT: DC+ SHIELDING GAS: CO2 or Ar / CO2 CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.0 Flat 120-200 Vertical - up 1.2 Flat 150-270 Vertical - up 1.6 Flat 200-350 Vertical - up -

Volts (V) 24-30 25-31 25-33 -

Weight of Packing Spool (Kg) 12.5 12.5 12.5

PACKING: The wires are packed in polythene bags and then packed in corrugated cardboard boxes of 12.5Kg each.

ARCALOY T - 409 Ti

TYPICAL ALL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn P S Cr Ni Mo V Nb Ti 0.034 0.479 0.456 0.011 0.013 11.78 0.016 0.009 0.030 0.006 0.820 UTS EL Typical Mechanical properties of all Weldmetal 500 N/mm2 20%

Metal type FCAW wire for 12%Cr stainless steel Classification : SFA/AWS A5.22 E409T0-G DESCRIPTION Arcaloy T-409Ti is a metal cored wire designed to match the corrosion resistance and mechanical properties of type 409Ti stainless steel. This material is widely used in automotive exhaust systems. WELDING CURRENT: DC+ SHIELDING GAS: Ar or 98 Ar / 2% O2

CURRENT RANGE & PACKING DATA Size Position Current Range (mm) (Amps) 1.2 Flat & Horizontal Fillet 160-250

Volts (V) 19-24

Weight of Packing Spool (Kg) Pail (Kg) 12.5 / 15 100 / 200

PACKING: Each spool is seald in an airtight polythene bag and then packed in a corrugated cardboard box of 15Kg/12.5Kg each.

99

SAW Wires
Welding Consumables

OK AUTROD 12.08L

A copper coated mild steel wire for SAW Classification AWS A5.17: EL 8 DESCRIPTION OK AUTROD 12.08L is a copper-coated mild steel electrode for Submerged Arc Welding (SAW) of mild and medium carbon structural steels. APPROVALS: With OK FLUX 10.71L : ABS, IRS OK FLUX 10.81L : ABS, IRS, DNV, MND OK FLUX 10.81LM : IRS OK FLUX 10.71 : DNV, ABS, LR, IRS, BV

TYPICAL WIRE COMPOSITION (%) C Mn Si S P Cu 0.08 0.5 0.05 0.018 0.018 0.25 PACKING DATA Size Packing Packing Packing (mm) 25Kg 100/200 Kg 400/700 Kg 2.00 a a r 2.50 a a r 3.15 a a a 4.00 a a a 5.00 a a r

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Chemical Composition (%) Mechanical Properties OK Autrod Yield Stress Tensile EI. Impacts values 12.08LOK C Mn Si N/mm2 N/mm2 (%) Flux J Temp (OC) 10.71 L 0.06 1.05 0.5 405 500 32 80 -29 10.81L 0.07 1.4 0.7 440 550 25 10.81 LM 0.07 1.4 0.7 430 520 25 10.81LS 0.07 1.4 0.7 440 520 28 10.71 0.055 1.05 0.5 400 500 32 80 -29 PACKING: The wires are packed in corrugated cardboard boxes in case of 25kg packs. Also available in 400/700kg steel or fibre drums or 100/200 kgs steel bobbins.

OK AUTROD 12.22L

A copper-coated semi killed wire for SAW Classification AWS A5.17: EM12K DESCRIPTION OK AUTROD 12.22L is a medium manganese alloyed copper coated steel wire for submerged arc welding and electroslag welding of medium and high tensile steels. Provides exceptional high impact values of submerged arc welds, when combined with fluxes like OK Flux 10.62L, 10.71L, 10.61L, etc. APPROVALS: With OK FLUX 10.71 : LRS, DNV, ABS, IRS, BV OK FLUX 10.81 LS : IBR

TYPICAL WIRE COMPOSITION (%) C Mn Si S P Cu 0.10 1.0 0.20 0.018 0.018 0.25 PACKING DATA Size Packing Packing Packing (mm) 25Kg 100/200 Kg 400/700 Kg 2.00 a a r 2.50 a a r 3.15 a a a 4.00 a a a 5.00 a a r

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Chemical Composition (%) Mechanical Properties OK Autrod Yield Stress Tensile EI. Impacts values 12.22L OK C Mn Si N/mm2 N/mm2 (%) Flux J Temp (OC) 10.71L 0.08 1.5 0.5 440 530 30 50 -40 10.81 LS 0.08 1.5 0.8 450 540 26 30 -29 10.61 L 0.07 1.25 0.30 410 500 26 30 -51 10.81 L 0.07 1.7 0.7 500 580 24 30 0 10.81LS (FG) 0.08 1.7 0.7 500 580 26 35 -29 10.71 0.08 1.5 0.5 440 530 30 50 -40 10.62L 0.07 1.0 0.3 410 500 33 90 -40 PACKING: The wires are packed in corrugated cardboard boxes in case of 25kg packs. Also available in 400/700kg steel or fibre drums or 100/200 kgs steel bobbins.
100

ESAB SA10K
A copper-coated Mn alloyed wire for SAW Classification DESCRIPTION ESAB SA 10K is a copper coated manganese alloyed wire for submerged are welding (SAW) of medium and high tensile steels. To be used with OK Flux 10.61L / 10.62L / 10.71L depending on application and mechanical property requirement. AWS A5.17 : EH 10K

TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 1.45 Si 0.15 S 0.02 P 0.02 Cu 0.2

Welding Consumables

PACKING DATA Size (mm) 2.00 2.50 3.15 4.00 5.00 Packing 25Kg a a a a a Packing 400/700 Kg r a a a r

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod SA10K / OK Flux 10.71L 10.61 L 10.62 L Chemical Composition (%) Yield Stress C Mn Si N/mm2 0.08 0.07 0.06 1.71 1.35 1.25 0.56 0.4 0.3 478 465 412 Tensile N/mm2 557 555 550 Mechanical Properties EI. Impacts values (%) J Temp (OC) 30 50 -51 29 35 -40 34 35 -51

PACKING: The wires are supplied in rims packed in a cardboard box of 25Kg or steel drums of 400/700Kgs.

ESAB SA13K
A copper-coated Mn alloyed wire for SAW Classification DESCRIPTION ESAB SA 13K is a copper coated manganese alloyed wire for submerged are welding (SAW) of medium and high tensile steels. To be used with OK Flux 10.81LS / 10.71L / 10.62L depending on application and mechanical property requirement. AWS A5.17 : EM13K

TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 1.25 Si 0.4 S 0.02 P 0.02 Cu 0.2

PACKING DATA Size (mm) 2.00 2.50 3.15 4.00 5.00 Packing 25Kg a a a a a Packing 400/700 Kg r a a a r

PACKING: The wires are supplied in rims packed in a cardboard box of 25Kg or drums of 400/700Kgs.

101

Welding Consumables

OK AUTROD 12.40L

A copper-coated Mn alloyed semi killed wire for SAW Classification AWS A5.17: EH14 DIN 8557: S4 DESCRIPTION OK AUTROD 12.40L is a copper coated manganese alloyed semi-killed electrode for Submerged Arc Welding (SAW) of medium and high tensile steels. APPROVALS: With OK FLUX 10.71L : LRS, IRS, DNV, IBR, MND OK FLUX 10.71 : DNV, ABS, LR, IRS, BV OK FLUX 10.62L : IBR Chemical Composition (%) C 0.07 0.08 0.7 0.07 Mn 2.0 1.7 1.4 2.0 Si 0.45 0.45 0.4 0.45

TYPICAL WIRE COMPOSITION (%) C Mn Si S P Cu 0.12 1.8 0.08 0.018 0.018 0.25 PACKING DATA Size Packing Packing Packing (mm) 25Kg 100/200 Kg 400/700 Kg 2.00 a r r 2.50 a a a 3.15 a a a 4.00 a a a 5.00 a r r

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 12.40L OK Flux 10.71L 10.61 L 10.62L 10.71 Yield Stress N/mm2 460 460 488 460 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 540 28 40 -40 540 25 30 -62 548 28 60 -40 540 28 40 -40

PACKING: The wires are packed in corrugated cardboard boxes in case of 25kg packs. Also available in 400/700kg steel or fibre drums or 100/200 kgs steel bobbins.

OK AUTROD 12.24L
A copper-coated Mo alloyed solid wire for SAW and electroslag welding Classification DESCRIPTION OK AUTROD 12.24L is used for submerged arc welding and electroslag welding of unalloyed and low alloy steels with impact requirements higher than those obtainable with mild steel filler wires. Especially suitable for the two run technique. APPROVALS : With OK FLUX 10.71 : DNV, ABS, LR, IRS, BV AWS A5.23: EA 2

TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 1.2 Si 0.10 Mo 0.50 Cu S P

0.25 0.018 0.018

PACKING DATA Size (mm) 2.00 2.50 3.15 4.00 5.00 Packing 25Kg a a a a a Packing Packing 100/200 Kg 400/700 Kg r r r r a a a a r r

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Chemical Composition (%) OK Autrod 12.24 L OK Flux 10.71L 10.61 L 10.62 L 10.71 C 0.07 0.08 0.07 0.07 Mo 0.5 0.5 0.5 0.5 Mn 1.4 1.2 1.0 1.4 Si 0.45 0.45 0.22 0.45 Yield Stress N/mm2 530 510 500 530 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 590 38 30 -40 600 28 50 -29 580 25 60 -40 590 38 30 -40

PACKING: The wires are packed in corrugated cardboard boxes in case of 25kg packs. Also available in 400/700kg steel or fibre drums or 100/200 kgs steel bobbins.
102

OK AUTROD 12.33L
A copper-coated Mo alloyed solid wire for SAW Classification DESCRIPTION OK AUTROD 12.33L is used for submerged arc welding and electroslag welding of unalloyed and low alloy steels with impact requirements higher than those obtainable with mild steel filler wires. Especially suitable for the two run technique. AWS A5.23: EA3K

TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 1.80 Si S P Mo 0.5 Cu 0.25

Welding Consumables

0.55 0.018 0.018

PACKING DATA Size (mm) 2.00 2.50 3.15 4.00 5.00 Packing 25Kg a a a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 12.33L OK Flux 10.71 L 10.61L Chemical Composition (%) C 0.10 0.09 Mo 0.5 0.5 Mn 1.7 1.85 Si 0.4 0.2 Yield Stress N/mm2 530 600 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 630 26 40 -40 750 25 45 -46

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 12.34L
A Mn-Mo alloyed copper-coated wire for SAW and electroslag welding Classification DESCRIPTION OK AUTROD 12.34L is manganese - molybdenum alloyed copper-coated electrode for submerged arc welding and electroslag welding of high tensile steels and steels for low temperature application. AWS A5.23: EA4

TYPICAL WIRE COMPOSITION (%) C 0.12 Mn 1.5 Si 0.15 Mo 0.50 Cu S P

0.25 0.018 0.018

PACKING DATA Size (mm) 2.00 2.50 3.15 4.00 5.00 Packing 25Kg a a a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 12.34L OK Flux 10.71 L 10.61 L Chemical Composition (%) C 0.09 0.10 Mo 0.45 0.40 Mn 1.5 1.4 Si 0.4 0.2 Yield Stress N/mm2 550 580 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 640 25 50 -40 660 24 60 -40

PACKING: The wires are packed in corrugated cardboard boxes.

103

Welding Consumables

OK AUTROD 13.09L
A 0.5% Mo wire for SAW Classification DESCRIPTION OK AUTROD 13.09L is a copper coated, low-alloyed 0.5% Mo Wire for SAW of low-alloy and creep resistant steels used for pipes in pressure vessels and boilers with a working temperature of about 500°C. It can also be used for other high strength low-alloy steels. APPLICATIONS AWS A5.23 EG

TYPICAL WIRE COMPOSITION (%) C Mn Si Cr Ni Mo Cu S P

0.08 1.05 0.60 0.03 0.03 0.50 0.17 0.009 0.008 PACKING DATA Size (mm) 2.50 3.20 4.0 Packing 25Kg a a a

OK AUTOROD 13.09L is especially designed for the welding of HSLA steels. It is extensively used in high temperature pipelines; boiler tubes and plates where high creep resistance is a pre-requisite. Can be used in combination with OK Flux 10.61L OK Autrod 10.62L. TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Chemical Composition (%) OK Autrod 13.09 L OK Flux 10.61 L C 0.075 Mo 0.45 Mn 1.0 Si 0.45 Yield Stress N/mm2 500 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 600 24 75 RT

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 13.12L
A 1% Cr, 0.5% Mo wire for SAW DESCRIPTION OK AUTROD 13.12L are copper coated, low-alloyed 1% Cr, 0.5% Mo wires for SAW of creep resistant and other low-alloyed high strength steels. APPLICATIONS OK AUTROD 13.12L is specially used to the welding of 1 Cr 0.5 Mo and similar creep resistant steels which find extensive use in high temperature components of power plants, boilers, oil-refineries, petrochemical plants, boilers etc. Steels of the type ASTM A 182-F2, F11 , F12; A387 -2, 11,12; A213-T2, T11, T12; A335-P2, P11, P12 and German steels 13 Cr Mo 44, 15 Cr Mo 5 etc. The weldmetal is resistant to scaling up to 550°C. Can be used in combination with OK Flux 10.61L and OK Autrod 10.62L. Chemical Composition (%) C 0.08 Cr 1.05 Mo 0.45 Mn 0.75 Si 0.20

TYPICAL WIRE COMPOSITION (%) C 0.09 Mn 1.98 Si 0.65 Cr 1.15 Mo 0.49 Cu S P

0.17 0.009 0.009

PACKING DATA Size (mm) 2.50 3.20 4.0 Packing 25Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.12 L OK Flux 10.61L Yield Stress N/mm2 520 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 650 22 65 RT

PACKING: The wires are packed in corrugated cardboard boxes. Also available in bulk drums / spiders of 280/500/1000 Kgs.
104

OK AUTROD 12.44
Mn-Mo alloyed, copper coated wire for submerged arc welding Classification DESCRIPTION OK AUTROD 12.44 is a Mn-Mo-alloyed, copper coated wire for the submerged arc welding of high tensile steel and steel for low temperature work. Also for creep resistant steels (0.5% Mo), structural steels, ship building steels, pressure vessel steels, etc. If can be combined with OK Flux 10.62. Chemical Composition (%) OK Autrod 12.44 OK Flux 10.61 C 0.08 Mn 1.9 Si P S AWS A5.23: EA3

TYPICAL WIRE COMPOSITION (%) C 0.11 Mn 2.0 Si S P Mo

Welding Consumables

0.15 0.015 0015 0.5

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Mechanical Properties Yield Stress Mo N/mm2 600 Tensile N/mm2 700 EI. (%) 27 Impacts values J 65 Temp (OC) -50

0.21 0.015 0.015 0.5

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 13.10SC
Cr-Mo alloyed copper - coated wire for Submerged Arc Welding. Classification DESCRIPTION OK AUTROD 13.10 SC is a low-alloyed, copper coated wire designed for the submerged arc welding of creepresistant steels of the 1.25Cr 0.5Mo type, especially designed fo step cooling applications. It can be combined with OK Flux 10.62 and 10.63. APPROVALS : With OK Flux 10.62 : CE, DB, VdTÜV AWS A5.23: EB2R

TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 0.7 Si 0.15 Cr 1.2 Mo 0.5

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.10SC OK Flux 10.62 10.63 Chemical Composition (%) C 0.08 0.08 Mn 0.7 0.8 Si 0.22 0.2 Cr 1.1 1.2 Mo 0.5 0.5 Yield Stress N/mm2 500 480 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 610 26 80 -29 590 25 110 -29

PACKING: The wires are packed in corrugated cardboard boxes.

105

Welding Consumables

OK AUTROD 13.20SC
Low alloyed copper - coated wire of rsubmerged Arc Welding. Classification DESCRIPTION OK AUTROD 13.20 SC is a low-alloyed, copper coated wire designed for the submerged arc welding of creepresistant steels of the 2.25Cr 0.5Mo type, especially designed fo step cooling applications. It can be combined with OK Flux 10.62 and 10.63. AWS A5.23: EB3R

TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 0.6 Si 0.15 Cr 2.3 Mo 1.0

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.20SC OK Flux 10.62 10.63 Chemical Composition (%) C 0.08 0.07 Mn 0.6 0.8 Si 0.20 0.20 Cr 2.0 2.1 Mo 0.85 1.0 Yield Stress N/mm2 525 530 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 620 25 80 -29 630 25 110 -40

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 13.40
Classification DESCRIPTION OK AUTROD 13.40 is a nickel - molybdenum - alloyed, copper - coated wire designed for the submerged arc welding of higher tensile steel. It can be combined with OK Flux 10.62. APPROVALS : With OK Flux 10.62 : ABS, BV, CE, DNV, GL, VdTÜV, LR AWS A5.23: EG

TYPICAL WIRE COMPOSITION (%) C 0.10 Mn 1.5 Si 0.2 Ni 0.9 Mo 0.5

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.40 OK Flux 10.62 Chemical Composition (%) C 0.07 Mn 1.50 Si 0.26 Ni 0.9 Mo 0.5 Yield Stress N/mm2 650 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 730 23 60 -50

PACKING: The wires are packed in corrugated cardboard boxes.

106

OK AUTROD 13.27
Copper - coated, low-alloyed, 2% Ni electrode for the submerged arc welding Classification DESCRIPTION OK AUTROD 13.27 is a copper - coated, low - alloyed, 2% Ni electrode for the submerged arc welding of lowalloyed and low - temperature steels for applications in the offshore industry, for example. It can be combined with OK Flux 10.62 and OK Flux 10.71. APPROVALS : With OK Flux 10.62 : ABS, BV, CE, DNV, GL, LR, VdTÜV With OK Flux 10.71 : VdTÜV AWS A5.23: ENi2

TYPICAL WIRE COMPOSITION (%) C 0.08 Mn 1.0 Si 0.2 Ni 2.3

Welding Consumables

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.27 OK Flux 10.62 10.71 Chemical Composition (%) C 0.06 0.05 Mn 1.0 1.4 Si 0.25 0.4 Ni 2.1 2.2 Yield Stress N/mm2 510 500 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 605 27 60 -70 600 28 50 -51

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 13.43
A Cr, Ni, Mo-alloyed copper coated wire for submerged arc welding of high tensile steels Classification DESCRIPTION OK AUTROD 13.43 is used for the submerged arc welding of extra high tensile steels. The wire is a coppercoated Cr, Ni, Mo wire and the arc and current carrying characteristics in combination with OK FLUX 10.62 are excellent. APPROVALS : (In combination with OK FLUX 10.62) ABS, BV, LR, GL, DNV TYPICAL WELDMETAL COMPOSITION Chemical Composition (%) OK Autrod 13.43 OK Flux 10.62 C 0.08 Ni 2.2 Mn 1.35 Mo 0.5 Si Cr AWS A5.23: EG

TYPICAL WIRE COMPOSITION (%) C 0.11 Mn 1.4 Si 0.2 Mo 0.5 Cr 0.7 Ni S P Cu

2.4 0.015 0.015 0.17

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

Mechanical Properties Yield Stress N/mm2 700 Tensile N/mm2 795 EI. (%) 23 Impacts values J 50 Temp (OC) -62

0.25 0.6

PACKING: The wires are packed in corrugated cardboard boxes.

107

Welding Consumables

OK AUTROD 13.64
Low - alloyed and micro alloyed Ti-B-containing, solid wire designed for submerged arc welding Classification DESCRIPTION OK AUTROD 13.64 is a low - alloyed and micro alloyed Ti-B-containing, solid wire designed for submerged arc welding, specially in joins wih a high dilution, such as the seam welding of line pipes, where low - temperature impact toughness properties are required. AWS A5.23: EG

TYPICAL WIRE COMPOSITION (%) C 0.07 Mn 1.2 Si 0.25 Mo 0.5 Ti B

0.14 0.014

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 30Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES OK Autrod 13.64 C OK Flux 10.71 0.05 Chemical Composition (%) Mn 1.4 Si P S Mo Ti B Yield Stress N/mm2 610 Mechanical Properties Tensile EI. Impacts values N/mm2 (%) J Temp (OC) 680 22 47 -60

0.5 0.02 0.02 0.5 0.15 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 13.22L
A 2.25% Cr, 1 % Mo wire for SAW DESCRIPTION OK AUTROD 13.22L are copper coated, low-alloyed 2.25% Cr, 1 % Mo wires for SAW of creep resistant and other low-alloyed high strength steels. APPLICATIONS OK AUTROD 13.22L finds extensive use in fabrication of low alloy steel boilers and piping, operating at temperature of up to 600°C commonly found in oil refineries, thermal and chemical plants, pre-heaters, superheaters, for steam boilers and also for hydro-crackers. Can be used in combination with OK Flux 10.61L and OK Autrod 10.62L. Chemical Composition (%) OK Autrod 13.22 L OK Flux 10.61L C 0.06 Cr 2.30 Mo 0.95 Mn 0.75 Si 0.25

TYPICAL WIRE COMPOSITION (%) C 0.06 Mn 1.10 Si 0.60 Cr 2.45 Mo 1.05 Cu S P

0.17 0.009 0.009

PACKING DATA Size (mm) 2.50 3.2 4.0 Packing 25Kg a a a

TYPICAL WELDMETAL COMPOSITION WITH DIFFERENT FLUXES Yield Stress N/mm2 550 Mechanical Properties Tensile EI. Impacts values 2 N/mm (%) J Temp (OC) 690 22 60 RT

PACKING: The wires are packed in corrugated cardboard boxes.

108

OK AUTROD 16.10
An extra low carbon stainless steel wire of 18/8 type for SAW with OK Flux 10.92L Classification DESCRIPTION OK AUTROD 16.10 are 18 Cr-8 Ni type bare stainless steel wires for submerged arc welding of austenitic corrosion resisting steels. The arc and current carrying characteristics assure excellent welder performance of outstanding bead and surface finish. OK AUTROD 16.10 is intended for welding of austenitic corrosion resisting steels such as AISI, 301,304, 302L and equivalent types. TYPICAL WIRE COMPOSITION (%) C 0.025 Mn 1.8 Si 0.4 Cr 20 Ni 10 S P AWS A5.9: ER 308L

TYPICAL WELDMETAL COMPOSITION WITH OK FLUX 10.92L
Weldmetal Composition (%) C Cr Mn Ni Si S P 0.025 20.00 1.8 10.00 0.60 0.015 0.017 Mechanical properties YS UTS EL Impact (CVN) at - 196oC 365 N/mm2 580 N/mm2 35% 40J

Welding Consumables

PACKING DATA Size (mm) 2.50 3.15 4.0 Packing 25Kg a a a

0.015 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

OKAUTROD 16.30
An extra low carbon stainless steel wires of the 18 Cr, 8 Ni, 3 Mo type for SAW Classification DESCRIPTION OK AUTROD 16.30 are extra low carbon stainless bare rods for SAW of corrosion resisting steels having composition corresponding to 18% Cr, 12% Ni and 3% Mo type. The arc and welding characteristics of OK AUTROD 16.30 are excellent and possess a high degree of welder appeal. Used for AISI 316, 316L and equivalent steels. TYPICAL WIRE COMPOSITION (%) C 0.025 Mn 1.8 Si 0.4 Cr 19 Ni 12 Mo 2.7 S P AWS A 5.9: ER 316L

TYPICAL WELDMETAL COMPOSITION WITH OK FLUX 10.92L
Weldmetal Composition (%) C Cr Mn Ni Si Mo S P 0.025 19.00 1.8 12.00 0.60 2.7 0.015 0.017 Mechanical properties YS UTS EL Impact (CVN) at - 60oC 365 N/mm2 580 N/mm2 32% 55J

PACKING DATA Size (mm) 2.50 3.15 4.0 Packing 25Kg a a a

0.015 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

109

Welding Consumables

OK AUTROD 16.53
An extra low carbon 24% Cr, 13% Ni stainless steel wire for SAW Classification DESCRIPTION OK AUTROD 16.53 are 24% Cr, 13% Ni type bare stainless steel wires with extra low carbon for submerged arc welding and cladding of austenitic corrosion resisting steel. The arc and current carrying characteristics assure excellent weld appeal. OK AUTROD 16.53 is suitable for similar alloys in wrought or cast form and also for joining dissimilar steels such as “18 - 8” to mild steel or carbon steel or low alloy steel. TYPICAL WIRE COMPOSITION (%) C 0.02 Mn 1.6 Si 0.4 Cr 24 Ni 13 S P AWS A5.9: ER 309L

TYPICAL WELDMETAL COMPOSITION WITH OK FLUX 10.92L
Weldmetal Composition (%) C Cr Mn Ni Si S P 0.025 24.00 1.8 13.00 0.40 0.015 0.017 Mechanical properties YS UTS EL (L=4d) Impact (CVN) at - 60oC 440 N/mm2 600 N/mm2 35% 110J

PACKING DATA Size (mm) 2.50 3.15 4.0 Packing 25Kg a a a

0.015 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

OK AUTROD 16.11
A Niobium Stabilised 20 Cr-10 Ni Stainless Steel Wire for SAW Classification DESCRIPTION OK AUTROD 16.11 is intended for SAW of Stainless Steel corresponding to AISI 347 and AISI 321 with OK 10.92 Flux. TYPICAL WIRE COMPOSITION (%) C 0.05 Mn 1.5 Si 0.75 Cr 20 Ni 10 Nb 0.8 S P AWS A 5.9: ER 347

TYPICAL WELDMETAL COMPOSITION WITH OK FLUX 10.92L
Weldmetal Composition (%) C Cr Mn Ni Si Nb S P 0.07 19.00 1.75 9.8 0.70 0.70 0.015 0.017 Mechanical properties YS UTS EL (L=4d) Impact (CVN) at - 60oC 440 N/mm2 650 N/mm2 32% 70J

PACKING DATA Size (mm) 2.50 3.15 4.0 Packing 25Kg a a a

0.015 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

110

OK AUTROD 16.13
An austenitic stainless steel wire for welding 25 Cr, 20 Ni type of steels by SAW with OK Flux 10.92L Classification DESCRIPTION OK AUTROD 16.13 are fully austenitic welding wires for submerged arc welding of heat resistant steels of the 25 Cr-20 Ni type needing to withstand scaling at temperatures of upto 1100°C-1150°C. The arc and current characteristics of the wire help a smooth weld performance giving outstanding bead finish. TYPICAL WIRE COMPOSITION (%) C 0.11 Mn 1.90 Si 0.45 Cr Ni S P AWS A5.9: ER 310

TYPICAL WELDMETAL COMPOSITION WITH OK FLUX 10.92L
Weldmetal Composition (%) C Cr Mn Ni Si S P 0.10 26 1.7 21 0.40 0.015 0.017 Mechanical properties YS UTS EL Impact (CVN) at - 196oC 310 N/mm2 540 N/mm2 36% 60J

Welding Consumables

PACKING DATA Size (mm) 2.50 3.15 4.0 Packing 25Kg a a a

26.8 20.80 0.015 0.015

PACKING: The wires are packed in corrugated cardboard boxes.

111

SAW FLUXES
Welding Consumables

OK FLUX 10.61L
An agglomerated high basic non-alloying flux for SAW Classification AWS A5.17: AWS A5.23: DESCRIPTION OK FLUX 10.61 L is an agglomerated high basic non alloying flux for SAW and is designed for single wire multi run butt welding of mild, medium and high tensile steels TYPICAL WELDMETAL PROPERTIES Chemical Composition (%)
OK Flux 10.61L/OK Autrod 12.22 L 12.24 L 12.40 L

with impact strength requirements down to -51OC. BASICITY INDEX: 2.2 GRAIN SIZE: 0.2-1.6 mm REDRYING: 300OC/2 hrs APPLICATIONS OK Flux 10.61 L is designed for multi-run butt welding of mild, medium and high tensile steels with impact strength down to -51OC, when used on DC with an appropriate alloyed wire by SAW.

F7A4-F6P4-EM12K F7A6-F7P6-EH14 F8A2-F8P4-EA2-A2

C 0.07 0.08 0.08

Mn 1.25 1.2 1.7

Si 0.3 0.45 0.45

Yield Stress N/mm2 410 510 460

Mechanical Properties Impacts Values Tensile EI. Charpy V Notch N/mm2 (%) 500 600 540 26 28 25
J 30 50 30

Temp (OC) -51 -29 -62

Passes HIC Test as per NACE standard TM-02-84 and SSCC Test as per NACE Standard TM-01-77. PACKING: OK FLUX 10.61L are packed in plastic lined paper bags containing 25 kg.

OK FLUX 10.62
An agglomerated high basic Non-alloying flux for SAW Classification AWS A5.17: AWS A5.23: F7 A8/F6P8-EM12K F7A8/F7P8-EH12K F7A6/F7P6-EH14 F8A6/F7P6-EA2-A2 F8A6/F8P6-EA4-A4 F9A8/F9P8-EA3-A3 F8P2-EB2R-B2 F8P2-EB3R-B3 F7A6/F7P8-ENil-Nil F8A10/F8P8-EG-G F8A10/F8P10-EnI2-Ni2 F10A8/F9P6-EG-F3 F11A8/F10P8-EG-G EN760 SA FB 1 55 AC H5

ness, strength and CTOD values. Especially suitable for narrow gap welding due to good slag detachability and smooth side wall blending. Produces low oxygen weldmetal (approx 300 ppm) with hydrogen contents lower than 5ml/100g. Operates optimally at the lower end of the voltage range. This flux has a high current carrying capacity on both AC and DC. Especially suitable for narrow gap welding due to good slag detachability and smooth side wall blending. BASICITY INDEX: 3.2 HYDROGEN: 5ml/100g max of weldmetal (redried flux) GRAIN SIZE: 0.2-1.6 mm REDRYING: 300+/- 25OC/2-4 hrs APPLICATIONS For offshore constructions, pressure vessels including those for nuclear industries requiring good CTOD values, power generation, shipbuilding, pipe mills, civil constructions, transport industries, etc,. OK Flux 10.62 is designed for single and multiwire procedures for butt and fillet welds of mild, medium and high tensile steels as well as low alloyed steels. Works equally well on DC and AC current. Single layer and multilayer welding of unlimited plate thickness, with impact strength down to -40/60OC, when used with an appropriate alloyed wire by SAW. The Weldmetal can be suitably controlled.

Flux Classification

APPROVALS : ABS, LR, DNV, DV, GL, VdTÜV DESCRIPTION Agglomerated fluoride basic flux for Submerged Arc Welding, primarily for multi run welding. For highest demands on impact properties, low temperature tough-

112

TYPICAL WELDMETAL PROPERTIES Chemical Composition (%) OK Flux 10.62 C Mn Si Ni OK Flux Autrod 12.22 0.07 1.0 0.30 12.24 0.07 1.0 0.22 12.40 0.08 1.9 0.12 12.32 0.10 1.6 0.35 12.34 0.10 1.45 0.21 12.44 0.08 1.9 0.21 13.10SC 0.08 0.7 0.22 13.20SC 0.08 0.6 0.20 13.21 0.06 1.0 0.25 0.9 13.24 0.08 1.4 0.3 0.9 13.27 0.06 1.0 0.25 0.9 13.40 0.07 1.5 0.26 0.9 13.43 0.08 1.35 0.25 2.2

Welding Consumables

Cr

Mo

Yield Stress N/mm2 410 500 530 475 540 600 500 525 470 530 490 650 700

Mechanical Properties Tensile EI. Impacts values N/mm2 (%) Charpy V Notch J Temp (OC) -40 -40 -40 -40 -40 -50 -29 -29 -40 -60 -60 -50 -50 500 580 620 570 620 700 610 620 560 620 570 730 795 33 25 26 28 24 27 26 25 28 25 27 23 21 90 60 50 110 60 65 80 80 70 70 80 60 65

0.5 0.5 0.5 1.1 0.5 2.0 0.85 0.2 0.5 0.5 0.6 0.5

PACKING: OK FLUX 10.62 is packed in plastic lined paper bags containing 25 kg.

OK FLUX 10.62 L
An agglomerated high basic Non-alloying flux for SAW Classification AWS A5.A:17: F7 A8/F6P8-EM12K F7A8/F7P8-EH12K F7A6/F7P6-EH14 AWS A5.23: F8A6/F7P6-EA2-A2 F8A6/F8P6-EA4-A4 F9A8/F9P8-EA3-A3 F8P2-EB2R-B2 F8P2-EB3R-B3 F7A6/F7P8-ENil-Nil F8A10/F8P8-EG-G F8A10/F8P10-EnI2-Ni2 F10A8/F9P6-EG-F3 F11A8/F10P8-EG-G Flux Classification DESCRIPTION Agglomerated fluoride basic flux for Submerged Arc welding, primarily for multi run welding. For highest demands on impact properties, low temperature toughness, strength and CTOD values. Especially suitable for narrow gap welding due to good slag detachability and EN760 SA FB 1 55 AC H5

smooth side wall blending. Produces low oxygen weldmetal (approx 300 ppm) with hydrogen contents lower than 5ml/100g. Operates optimally at the lower end of the voltage range. This flux has a high current carrying capacity on both AC and DC. Especially suitable for narrow gap welding due to good slag detachability and smooth side wall blending. BASICITY INDEX: 3.2 HYDROGEN: 5ml/100g max of weldmetal (redried flux) GRAIN SIZE: 0.2-1.6 mm REDRYING: 300+/- 25OC/2-4 hrs APPROVALS: IBR APPLICATIONS For offshore constructions, pressure vessels including those for nuclear industries requiring good CTOD values, power generation, shipbuilding, piep mills, civil constructions, transport industries, etc, OK Flux 10.62L is designed for single and multiwire procedures for butt fillet welds of mild, medium and high tensile steels as well as low alloyed steels. Works equally well on DC and AC current. Single layer and multilayer welding of unlimited plate thickness, with impact strength down to 40/60OC, when used with an appropriate alloyed wire by SAW. The weldmetal can be suitably controlled.

113

TYPICAL WELDMETAL PROPERTIES Chemical Composition (%) OK Flux 10.62 L C Mn Si Ni OK Flux Autrod 12.22L 0.07 1.0 0.30 12.24L 0.07 1.0 0.22 12.40L 0.07 1.4 0.4 12.32 0.10 1.6 0.35 12.34 0.10 1.45 0.21 12.44 0.08 1.9 0.21 13.10SC 0.08 0.7 0.22 13.20SC 0.08 0.6 0.20 13.21 0.06 1.0 0.25 0.9 13.24 0.08 1.4 0.3 0.9 13.27 0.06 1.0 0.25 0.9 13.40 0.07 1.5 0.26 0.9 13.43 0.08 1.35 0.25 2.2

Welding Consumables

Cr

Mo

Yield Stress N/mm2 410 500 488 475 540 600 500 525 470 530 490 650 700

Mechanical Properties Tensile EI. Impacts values N/mm2 (%) Charpy V Notch J Temp (OC) -40 -40 -60 -40 -40 -50 -29 -29 -40 -60 -60 -50 -50 500 580 548 570 620 700 610 620 560 620 570 730 795 33 25 28 28 24 27 26 25 28 25 27 23 21 90 60 60 110 60 65 80 80 70 70 80 60 65

0.5 0.5 0.5 1.1 0.5 2.0 0.85 0.2 0.5 0.5 0.6 0.5

PACKING: OK FLUX 10.62 L is packed in plastic lined paper bags containing 25 kg.

OK FLUX 10.71
An agglomerated high basic non-alloying flux for SAW Classification AWS A5.17: F7A2-F6P2-EL8 F7 A4-F7P4-EM12K F7A4-F7P4-EH14 AWS A5.23 F8 A2-EA2-A4/F7P0 EA2-A4

BASICITY INDEX: 1.5 GRAIN SIZE: 0.2-1.6 mm (10 x 65 mesh) HYDROGEN: Max 5ml/100g of weldmetal (redried flux) REDRYING: 300 +/- 25OC / 2-4 hrs APPROVALS: LRS, IRS, ABS, DNV, CE, DB, NAKS/ HAKC APPLICATIONS For general constructions, pressure vessels, ship building, pipe mills, wind tower production, transport industries, etc. Designed for single and multi wire procedures for butt and fillet welds. Suitable for DC and AC welding. Single layer and multilayer welding of unlimited plate thickness. Mechanical Properties Impacts Values Tensile EI. 2 Charpy V Notch N/mm (%) 500 530 540 590 32 30 28 38
J 80

Flux Classification : EN 760 SA AB 1 67 AC H5 DESCRIPTION Agglomerated aluminate-basic flux for Submerged Arc Welding. General purpose flux with excellent welding performance suitable for all kinds of steels. High impact toughness values. Fits to a large range of SAW Wires. TYPICAL WELDMETAL PROPERTIES Chemical Composition (%)
OK Flux 10.71 / OK Autrod 12.08 L 12.22 L 12.40 L 12.24L

C 0.08 0.08 0.09

Mn 1.05 1.5 2 1.4

Si 0.5 0.5 0.45 0.45

Mo 0.5

Yield Stress N/mm2 400 440 460 530

Temp (OC) -29 -40 -40 -40

50 40 30

PACKING: OK FLUX 10.71 are packed in plastic lined paper bags containing 25 kg.

114

OK FLUX 10.71L
An agglomerated basic slightly Si and moderately Mn alloying flux for SAW Classification AWS A5.17: F7A2-F6P2-EL8 F7 A4-F7P4-EM12K F7A4-F7P4-EH14 AWS A5 23: F8A2 - EA2-A4/F7P0-EA2-A4 EN 760 SA AB 67 AC H5

BASICITY INDEX: 1.5 GRAIN SIZE: 0.2-1.6 mm Hydrogen : Max 5ml/100g of weldmetal (redried flux) REDRYING: 300 +/- 25OC/2-4 hrs APPROVALS: LRS, IRS, ABS, DNV, RDSO, F1, F2, F4, NPC, IBR APPLICATIONS For general constructions, pressure vessels, ship building, pipe mills, wind tower production, transport industries, etc. Designed for single and multi wire procedures for butt and fillet welds. Suitable for DC and AC welding. Single layer and multilayer welding of unlimited plate thickness. Mechanical Properties Tensile EI. Impacts values N/mm2 (%) Charpy V Notch J Temp (OC) 500 32 80 -29 530 30 50 -40 540 28 40 -40 590 38 30 -40

Welding Consumables

Fluck Classification DESCRIPTION

Agglomerated aluminate - basic flux for Submerged Arc Welding. General purpose flux with excellent welding performance suitable for all kinds of steels. High impact toughness values. Fits to a large range of SAW Wires. TYPICAL WELDMETAL PROPERTIES Chemical Composition (%) OK Flux 10.71 L C Mn Si Cr Ni OK Autrod 12.08L 0.06 1.05 0.5 12.22L 0.08 1.5 0.5 12.40L 0.07 2 0.45 12.24L 0.07 1.4 0.45 -

Mo 0.5

Yield Stress N/mm2 405 440 460 530

PACKING: OK FLUX 10.71 L are packed in plastic lined paper bags containing 25 kg.

OK FLUX 10.81L
An agglomerated Si and Mn alloying flux for SAW Classification DESCRIPTION OK FLUX 10.81 L is an agglomerated acid Si and Mn alloying flux for submerged arc welding, providing exceptional welding characteristics with a slag system that allows higher speeds. The easily removable slag and outstanding surface finish possible with this flux gives it a high degree of welder appeal. AWSA5.17: F7AZ-F7PZ-EL8 F7AZ-F7PZ-EM12K

BASICITY INDEX: 0.65 GRAIN SIZE: 0.2-1.6 mm REDRYING: 300OC/2 hrs APPROVALS: LRS, IRS, ABS, DNV, BV, NPC TYPICAL APPLICATIONS OK Flux 10.81 L is excellent for all types of general applications in low and medium tensile steels, in combination with a mild steel electrode of type OK Autrod 12.08L or OK Autrod 12.22L (for impact requirements down to O°C). It is especially suited for applications where the dilution of the base metal is high e.g. in fillet welding and butt welding of thin and medium thick plates with a small number of passes. Mechanical Properties Impacts values Tensile EI. Charpy V Notch N/mm2 (%)
J

TYPICAL WELDMETAL PROPERTIES Chemical Composition (%) C 0.07 0.07 Mn 1.4 1.7 Si 0.7 0.7

OK Flux 10.81 UOK Autrod 12.08 L 12.22 L

Yield Stress N/mm2 440 500

550 580

25 24

NA 30

Temp (OC) NA 0

PACKING: OK FLUX 10.81 L are packed in plastic lined paper bags containing 25 kg.

115

Welding Consumables

OK FLUX 10.81LM
An agglomerated Si and Mn alloying flux for SAW Classification DESCRIPTION OK FLUX 10.81 LM is an agglomerated flux specially designed for general-purpose applications, including structural welding. It has very good operative characteristics and is specially designed for butt and fillet welding at high speed. Compared to the fused fluxes the specific flux comsumption rate is 30% lesser and welding speed is at least 20% higher. Limited number of passes recommends it for fillet and butt welding of plate upto 20 mm thickness. It has very good slag detachability, excellent bead shape and a very smooth surface finish. TYPICAL WELDMETAL PROPERTIES
OK Flux 10.81 LM / OK Autrod 12.08 L

BASICITY INDEX: 0.65 GRAIN SIZE: 0.2-1.6 mm REDRYING: 300OC/2 hrs APPROVALS: IRS TYPICAL APPLICATIONS The excellent welding properties associated with the acid slag system of OK Fux 10.81 LM allow higher travel speeds required for manufacturing of LPG cylinders. Also used for joining carbon steels for structural use.

AWSA5.17:

F7AZ-F7PZ-EL8

Chemical Composition (%) C 0.07 Mn 1.4 Si 0.7

Mechanical Properties Yield Stress Tensile EI. N/mm2 N/mm2 (%) 430 520 25

PACKING: OK FLUX 10.81 L is packed in plastic lined paper bags containing 25 kg.

OK FLUX 10.81LS
An agglomerated Si and Mn alloying flux for SAW Classification DESCRIPTION OK FLUX 10.81 LS is an agglomerated acid, Si and Mn alloying flux of the aluminate rutile type. It has very good operative properties and is specially designed for butt and fillet welding at high speed. OK FLUX 10.81 LS is excellent for all types of general applications in low and medium tensile steels and for welding of pipes. Being an alloying flux with significant Si and Mn pickup, it is most suitable for applications where dilution of base metal is high, e.g. in fillet welding and butt welding of thin and medium thick plate with a small number of passes. The wide popularity of OK FLUX 10.81 LS TYPICAL WELDMETAL PROPERTIES Chemical Composition (%)
OK Flux 10.81 LS / OK Autrod 12.08 L 12.22 L

AWSA5.17:

F7AZ-F7PZ-EL8 F7A2-F7P2-EM12K

is mainly due to the welding adeptness possible, as it can be easily used over rust and primer at high welding speeds without running the risk of porosity etc. Excellent slag removl and the exceptional bead finish add up to its immense welder appeal. BASICITY INDEX: 0.75 GRAIN SIZE: 0.2-1.6 mm REDRYING: 300OC/2 hrs APPROVALS: IBR TYPICAL APPLICATIONS The excellent welding properties associated with the acid slag system of OK Fux 10.81 LS allows high travel speeds in butt welding i.e. spiral welding of pipes where good bead shape, excellent slag removal, good surface finish are essential. Mechanical Properties Impacts values Tensile EI. Charpy V Notch N/mm2 (%)
J

C 0.07 0.08

Mn 1.4 1.5

Si 0.7 0.8

Yield Stress N/mm2 440 450

520 540

28 26

40 30

Temp (OC) -18 -29

PACKING: OK FLUX 10.81 LS is packed in plastic lined paper bags containing 25 kg.

116

OK FLUX 10.92L
An agglomerated neutral chromium alloying flux for welding of stainless steel Classification DESCRIPTION OK FLUX 10.92L is a chromium alloying agglomerated flux specially designed for butt welding of stainless steels. The chromium alloying effect from OK FLUX 10.92L compensates for the chromium losses in the arc during welding. It is also excellent for strip cladding with stainless steel strips. The strip cladding process is stable over a wide range of currents and speeds. Very smooth overlapping between adjacent beads giving an outstanding aesthetic as well as mechanical finish. Direct current and positive polarity give maximum flexibility when choosing welding parameters. TYPICAL WELDMETAL PROPERTIES Chemical Composition (%)
OK Flux 10.92/ OK Autrod 16.10 16.30 16.53 16.11 16.13

BASICITY INDEX: 0.88 GRAIN SIZE: 0.2-1.6 mm REDRYING: 300OC/2 hrs APPROVAL: NPC TYPICAL APPLICATIONS OK FLUX 10.92L is especially suitable for butt welding of stainless steels and for strip cladding with stainless steel strips. Strip cladding can be carried out with strips of up to 100 mm in width. Due to the Chromium compensating effect of the flux, the typical weldmetal composition is close to the chemical composition of the wire used.

Welding Consumables

EN 760 SACS2Cr DC

C

Mn

Si 0.6 0.6 0.4 0.7 0.4

Cr 20 19 24 19 26

Ni 10 12
13 9.8

Mo 2.7 Nb=0.7 -

Yield Stress N/mm2 365 385 440 440 310

Mechanical Properties Impacts values Tensile EI. Charpy V Notch N/mm2 (%)
J

0.025 1.8 0.025 1.8 0.025 1.8 0.025 1.75 0.1 1.7

21

580 580 600 650 540

35 32 35 32 35

40 55 110 70 60

Temp (OC) -196 -60 -60 -60 -196

PACKING: OK flux 10.92L is packed in plastic lined paper bags containing 25 kg.

117

Strip Cladding Consumables
Welding Consumables

OK BAND/FLUX FOR STAINLESS STEEL
Stainless steel strips and Fluxes for Submerged Arc and Electroslag Cladding DESCRIPTION Nowadays, the two most productive systems for surfacing large components that are subject to corrosion or wear are submerged arc and electroslag cladding, using a strip electrode. Both processes are characterised by a high deposition rate and low dilution. TYPICAL APPLICATIONS They are suitable for surfacing flat and curved objects such as heat exchanger plates or pressure vessels of different kinds. Submerged arc welding (SAW) is the most frequently - used process, but if higher productivStainless welding strips for SAW Product OK Band 308L OK Band 347 OK Band 316L OK Band 309 L AWS A:5.9 EQ308L EQ347 EQ316L EQ309L %C <0.03 <0.03 <0.03 <0.03 %Si 0.5 0.5 0.5 0.5

ity and restricted dilution rates are required, electroslag welding (ESW) is used. These strips are finding increasing use in petroleum industry in hydrocracking, hydrosulphurisation and catalytic refining processes and in the chemical and petrochemical industries. Fluxes for SAW and ESW cladding Process SAW ESW Product OK Flux 10.05 OK Flux 10.10 Basicity Index 1.1 4.0 Density Kg/dm3 0.7 1.0

Dimension & packing Product Type Size Weight

Strips OK Band Fluxes OK Flux

60 x 0.5 mm 25 or 50 Kg coils 25 Kg bags

Other sizes available on request.

Typical strip composition %Mn %Cr %Ni 1.8 20.3 10.0 1.8 20.0 10.0 1.8 19.0 12.5 1.8 24.0 13.0

%Mo <0.03 <0.03 2.8 <0.03

Other Nb<1.0 -

Stainless welding strips for ESW Product OK Band 309L ESW OK Band 309L Nb ESW OK Band 309LMo ESW AWS A:5.9 EQ309L EQ309LNb EQ309LMo %C <0.03 <0.02 <0.02 %Si 0.3 0.3 0.3 Typical strip composition %Mn %Cr %Ni 1.8 21.0 11.0 1.8 21.0 11.0 1.8 20.5 13.5 %Mo <0.5 <0.5 3.1 Other Nb<1.0 -

Other welding strips for SAW To be used with AWS A:5.9 OK Band NiCrMo3 ERNiCrMo3 OK Band NiCr3 ERNiCr-3 OK Band NiCrMo13 ERNiCrMo-13 %C 0.03 0.05 <0.01 %Si 0.2 0.2 0.6 Typical strip composition %Mn %Cr %Ni 3.0 21.5 Bal. 3.0 20.0 Bal. 0.5 23.0 60.0 %Mo 9.0 1.8 16.0 Other Fe<2.0 Fe<3.0 Fe<1.5

Notes: 1) Other types of strips also available on demand. 2) OK 10.05,10.10 Flux is to be redried at 300-305°C for 2 hrs. before use. 3) Typical Weldmetal composition is available on demand. 4) OK Band 309L ESW together with OK 10.10 produces 308L type weld deposit (single layer). 5) OK Band 309L Nb ESW together with OK 10.10 produces 347 type weld deposit (single layer). 6) OK Band 309L Mo ESW together with OK 10.10 produces 316L type weld deposit (single layer).

118

Hard Surfacing Consumables
WIRE & FLUX COMBINATIONS
Wires and Fluxes for overlaying by SAW DESCRIPTION ESAB hardsurfacing Consumable are ideal for surfacing components that are worn-out or to resist wear against abrasion and impact with work hardening properties. WIRES ESAB WRAS has the following composition. OK AUTOROD 12.08L and 12.40L could also be used. TYPICAL WIRE COMPOSITION (%) WRAS C 0.35 Mn 1.5 Si 0.5 Cr 1 S 0.03 P 0.03 FLUXES ESAB AGGLOWELD HFG and AGGLOWELD HFG are agglomerated basic fluxes designed for hardsurfacing applications by providing necessary alloying elements to the weld deposit. ESAB AGGLOWELD HFG Weldmetal is a tough machinable alloy resisting compressive load, without micro fissuring and also has resistance to fatigue and impact. ESAB AGGLOWELD HFS can produce deposits of higher hardness with suitable wire. TYPICAL APPLICATIONS Suitable for overlaying of scraper blades, cane cutting knives, bucket body, chutes, guides, plough shear, cam rollers, gate valve seats, road graders, roll reclamation, crane wheels, earth moving equipment, crusher equipment etc. Suitable for building of machine components such as cams, gears, splines, sprockets, railway equalizer beams, sugar mill pinions, rims, tractor sprockets, gear teeth, wobblers, pump shafts, crane wheel, pulley brakes, cable drums skid wheels pulley brakes, track rollers, Crane wheels, ditcher rolls etc. PACKING: The Wires are available in standard sizes having net weight of 25 Kg, and Fluxes are packed in plastic lined paper bags containing 25 Kg. TYPICAL WELDMETAL PROPERTIES (After 3rd layer) FLUX / WIRE ESSAB WRAS VHN ESAB AGGLOWELD HFG ESSAB AGGLOWELD HFS OK FLUX 10.71L 400-440 480-550 220-250 RC 38-42 46-56 21-26 OK AUTROD 12.40L OK AUTROD 12.08L VHN 320-370 400-450 RC 31-35 48-43 VHN 260-300 RC 24-28 -

Welding Consumables
119

Consumables for Ni Steels
Welding Consumables

9% Ni STEELS FOR LNG TANK FABRICATION
DESCRIPTION LNG Storage tanks are usually fabricated from 9% Ni steels to provide a combination of properties at a reasonable price. Quenched & tempered 9% Ni Steels has excellent low temperature properties and is not susceptible to under bead cracking or excessive hardening in the HAZ on account of its low carbon. Esab offers a complete range of proven consumables, which have been used in over 30 global installations. Nickel Based Consumables The tensile strength of the high Nickel alloy Weldmetal is close to that of 9% nickel steels and has high resistance to brittle fracture, good impact strength at -196°C, lateral expansion, side bend test and yield strength properties. Special Stainless Steel Consumables are also available for LNG transport tanks and associated piping. Please refer section on stainless steel consumables elsewhere in this book. APPLICATIONS The MMA electrodes are designed to weld on AC, largely to eliminate the magnetic arc blow problem of 9% nickel steels. SAW is preferred for cicumferential welds and MMA for the vertical welds. Smaller diameter wires (1.6mm) deliver better impact values. 9% nickel steels can be welded without pre and post weld treatment up to 60 mm, as per ASME code, OK 92.55 is Preferred, when higher impact values are specified. TYPICAL WELDMETAL COMPOSTION (After 3rd Layer) Material/ESAB Product C 9% Ni Steels OK 92.45 OK 92.55 OK AUTROD 19.82 OK FLUX 10.16 *Including Tantalum TYPICAL ALL WELDMETAL MECHANICIAL PROPERTIES Material / ESAB Product Classification YS (N/mm )
2

Chemical Composition (%) Si 0.150.40 0.4 0.07 0.3 Mn 0.90 Max 0.4 3.0 0.25 Cr 22 13 22 Ni 8.5 9.5 64 70 Sal Mo 9.5 6.5 9.0 Nb 3.3 1.3 3.5* W 1.5 S&P 0.005 Max Fe Sal 3 4 1.5 0.13 Max 0.03 0.08 0.03

Mechanical Properties UTS (N/mm )
2

EI (%) (1=5d) 20 40 40 41

CVN Impact Values (J at -196°C) 27 50 85 80

9% Ni Steels OK 92.45 OK 92.55 OK AUTROD 19.82 + OK FLUX 10.16

A553-82 NiCrMo3 NiCrMo6 NiCrMo3

585 480 450 425

690-825 800 710 700

120

Consumables for Ni Steels
SMAW
OK 92.26
TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Nb Cu Ti Ta Fe 0.03 0.5 6.6 15.8 67 1.7 <0.5 <0.5 <0.3 8.8 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -196OC 410 N/mm2 640 N/mm2 40% 100J 80J

Welding Consumables

Classification SFA/AWS A5.11 ENiCrFe-3 DESCRIPTION A nickel - based electrode for welding nickel alloys such as inconel 600 and similar Inconel alloys, cryogenic steels, martensitic to austenitic steels, dissimilar steels, heat-resistant steels and castings with limited weldability. WELDING CURRENT: DC+ APPROVALS: ABS, SEPROS, UDT.

Welding Parameters
Diameter (mm) 2.5 3.2 4.0 5.0 Length mm 300 350 350 350 Welding Current, A 45-70 70-105 90-130 120-170 Arc voltage, V 22 23 24 25

OK 92.86

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Ni Nb Cu Al Ti Fe 0.01 0.3 2.1 66 <0.3 29 <0.5 0.2 1.6 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -196OC 410 N/mm2 640 N/mm2 40% 100J 80J

Classification SFA/AWS A5.11 ENiCu-7 DESCRIPTION A nickel-copper electrode for welding NiCu alloys to themselves and to steels and for corrosion resistant surfacing. The weld metal of OK 92.86 is crack resistant and ductile and meets rigorous requirements relating to corrosion resistance in sea water and in reducing and oxidising acids. OK 92.86 is used for welding corrosion - resistant monel alloys within the petroleum and ammoniun sulphate industry and in power plants. WELDING CURRENT: DC+

Welding Parameters
Diameter (mm) 2.5 3.2 4.0 Length mm 300 350 350 Welding Current, A 50-70 70-120 120-140 Arc voltage, V 22 26 28

121

Welding Consumables

OK 92.59

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Mo Fe <0.02 <0.2 <0.2 23.0 62 15.8 <1.0 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -196OC 430 N/mm2 770 N/mm2 40% 70J 60J

Classification SFA/AWS A5.11 ENiCrMo-13 DESCRIPTION OK 92.59 is designed for welding alloy 59, C-276 and 625 Ni-based materials. It is also suitable for welding superaustenitic steels like AISI/ASTM S31254 and S32654. WELDING CURRENT: DC+

Welding Parameters
Diameter (mm) 2.5 3.2 4.0 Length mm 300 350 350 Welding Current, A 50-70 60-90 80-120 Arc voltage, V 20 21 22

122

Consumables for Ni Steels
GMAW
OK AUTROD 92.81
TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Mo <0.01 0.3 2.1 66 <0.3 29 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values -110OC 550 N/mm2 750 N/mm2 45% 120J

Welding Consumables

Classification SFA/AWS A5.14 ERNiCrMo-13 DESCRIPTION A continous, solid, Ni-Cr-Mo electrode for welding highalloyed materials of the 20Cr-25Ni type with 4-6% Mo and Ni-based alloys of a similar type. It can also be welded in combination with carbon steels. The weld metal has very good corrosion resistance over a wide range of applications in oxidising and reducing media. WELDING CURRENT: DC+ APPROVALS: VdTÜV

Welding Parameters
Diameter (mm) 0.8 1.0 1.2 1.6 wire feed m/min 5-18 6-13 6-10 4-8 Welding Current, A 70-190 100-200 160-280 200-350 Arc voltage, V 20-27 21-27 24-30 25-32

OK AUTROD 92.82

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Mo Cu Al Ti Fe <0.01 <0.5 <0.5 21.5 >60.0 9.0 <0.5 <0.4 <0.4 <2.0 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -105OC -196OC 500 N/mm2 780 N/mm2 40% 130J 120J 110J

Classification SFA/AWS A5.14 ERNiCrMo-3 DESCRIPTION A continous, solid, corrosion and heat - resistant, NiCr electrode for welding high-alloyed heat-resistant and corrosion - resistant materials, 9% Ni steels and similar steels with high notch toughness at low temperatures. It is also suitable for joining dissimilar metals of the types mentioned above. The weld metal has very good mechanical properties at high and low temperatures. Good resistance to pitting and stress corosion. WELDING CURRENT: DC+ APPROVALS: UDT, VdTÜV

Welding Parameters
Diameter (mm) 0.8 1.0 1.2 1.6 wire feed m/min 5-18 6-13 6-10 4-8 Welding Current, A 70-190 100-200 160-280 200-350 Arc voltage, V 20-27 21-27 24-30 25-32

123

Consumables for Ni Steels
GTAW
Welding Consumables

OK TIGROD 19.81

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Mo <0.01 <0.1 <0.5 23.0 >56.0 15.7 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values -110OC 550 N/mm2 750 N/mm2 45% 120J

Classification SFA/AWS A5.14 ERNiCrMo-13 DESCRIPTION Bare Ni-Cr-Mo rod for welding high - alloyed materials of the 20Cr-25Ni typewith 4-6% Mo and Ni based alloys of a similar type. It can also be welded in combination with carbon steels. The weld metal has very good corrosion resistance over a wide range of applications in oxidising and reducing media. WELDING CURRENT: DC APPROVALS: VdTÜV

Welding Parameters
Diameter (mm) 1.6 2.0 2.4 Length mm 1000 1000 1000 Weight of rods / box, kg 5 5 5

OK TIGROD 19.82

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Mo Cu Al Ti Fe <0.01 <0.5 <0.5 21.5 >60.0 9.0 <0.5 <0.4 <0.4 <2.0 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -105OC -196OC 500 N/mm2 780 N/mm2 40% 130J 120J 110J

Classification SFA/AWS A5.14 ERNiCrMo-3 DESCRIPTION A nickel-based, corrosion - and heat - resistant, 22% Cr, 9% Mo, 3.5% Nb rod for the GTAW of high - alloyed steel, heat - resistant steel, corrosion - resistant steel, 9% Ni steels and similar steel with high notch toughness at low temperatures. It is also suitale for joining dissimilar metals of the types mentioned above. OK Tigrod 19.82 is normally welded with pure Ar as the shielding gas. WELDING CURRENT: DC APPROVALS: UDT, VdTÜV

Welding Parameters
Diameter (mm) 1.6 2.0 2.4 3.2 Length mm 1000 1000 1000 1000 Weight of rods / box, Kg 5 5 5 5

124

OK TIGROD 19.85

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Cr Ni Cu Ti Fe <0.01 <0.5 3.0 20 >67.0 <0.5 <0.7 <3.0 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC -196OC 440 N/mm2 670 N/mm2 40% 150J 100J

Welding Consumables

Classification SFA/AWS A5.14 ERNiCr-3 DESCRIPTION A nickel-based, corrosion - and heat - resistant, 20% Cr, 3% Mn, 2.5% Nb rod for the GTAW of high - alloyed steel, heat - resistant steel, corrosion - resistant steel, 9% Ni steels and similar steels with high notch toughness at low temperatures. It is also suitable for joining dissimilar metals of the types mentioned above. OK Tigrod 19.85 is usually welded with pure Ar as the shielding gas. WELDING CURRENT: DC APPROVALS: UDT, VdTÜV

Welding Parameters
Diameter (mm) 1.6 2.0 2.4 3.2 Length mm 1000 1000 1000 1000 Weight of rods / box, Kg 5 5 5 5

OK TIGROD 19.93

TYPICAL WELDMETAL PROPERTIES Weldmetal Composition (%) C Si Mn Ni Nb Cu Ti Fe 0.15 <1.0 3.0 65.5 >0.5 30.0 2.3 1.5 Typical Mechanical properties of all Weldmetal YS UTS EL Impact Values +20OC 0OC -20OC 300 N/mm2 530 N/mm2 45% 130J 140J 150

Classification SFA/AWS A5.14 ERNiCr-7 DESCRIPTION A nickel-based, rod alloyed with about 30% Cu, 2% Ti and 1% Fe for the GTAW of base materials of the same type. It can also be used for joining these alloys to steels. OK Tigrod 19.93 is normally welded with pure Ar as the shielding gas. WELDING CURRENT: DC APPROVALS: UDT, VdTÜV

Welding Parameters
Diameter (mm) 1.6 2.0 2.4 Length mm 1000 1000 1000 Weight of rods / box, Kg 5 5 5

125

Consumables for Ni Steels
SAW
Welding Consumables

OK FLUX 10.16
Classification OK Autrod 19.82 S Ni 6625 (NiCr22Mo9Nb) ERNiCrMo-3 OK Autrod 19.85 S Ni 6082 (NiCr20Mn3Nb)

welding with nickel-based alloy wires. Reverse polarity (DC-) should preferably be used in order to minimise the dilution for the base material and the risk of hot cracking in the weld metal. APPROVALS: OK Autrod 19.82 - ABS, LR, DNV, BV, GL, RS, CL, VdTÜV OK Autrod 19.85 - ABS, LR, DNV, BV, GL, RS, CL, VdTÜV BASICITY INDEX: 2.4

DESCRIPTION OK Flux 10.16 is an agglomerated, non-alloying flux for submerged arc welding. OK Flux 10.16 is specially designed for butt welding with nickel based alloyed wire and cladding with nickel based alloy strips. The well - balanced flux composition minimises silicon transfer from the flux to the welding metal, thereby minimising the risk of hot cracking when welding with nickel - based alloys. OK Flux 10.16 can only be used on DC when butt TYPICAL WELDMETAL PROPERTIES Chemical Composition (%) OK Flux 10.16 / C Si Mn Cr Ni OK Autrod 19.82 0.01 0.35 0.3 21.0 bal. 19.85 0.3 3.2 19.0 bal.

Mo 9.0 2.0

Yield Stress N/mm2 425 360

Mechanical Properties Tensile Impacts values N/mm2 Charpy V Notch J Temp (OC) 700 100 -140 80 -196 600 140 +20 100 -196

PACKING: OK FLUX 10.16 are packed in plastic lined paper bags containing 25 kg.

126

STORAGE AND HANDLING
RECOMMENDATIONS FOR THE STORAGE, REDRYING AND HANDLING OF ESAB COVERED ELECTRODES. General Information All covered electrodes are sensitive to moisture reabsorption to a greater or lesser degree. Care must be taken during storage and handling to prevent moisture being re-absorbed. Storage Covered electrodes of any type will pick up moisture only very slowly if they are stored under the following climatic conditions: At Temperatures During winter, it is possible to have low relative humidity by keeping the temperature in the storeroom at least 10OC above the outdoor temperature. During certain periods in the summer and in a tropical climate, sufficiently low relative humidity can be maintained by air dehumidification. Redrying Low-hydrogen basic electrodes should be redried before use whenever there are application requirements relating to weldmetal hydrogen content and / or radiographic soundness (not needed for VacPac®). Acid rutile stainless electrodes and all types of basic electrodes may produce pores in the weld if they have not been stored in sufficiently dry conditions. Redrying the electrode will restore their usability. Mild steel rutile and acid electrodes normally need no redrying. Cellulose electrodes must not be redried. Electrodes which are seriously damaged by moisture can normally not be redried. These electrodes should be scrapped. Redrying Conditions Redrying temperatures and holding times are specified on the label and in the product specification. The redrying temperature is the temperature in the bulk of the electrodes. The redrying time is measured from the point at which the redrying temperature has been reached. Do not stack more than four layers of electrodes in the redrying oven.

It is recommended not to redry covered electrodes more than three times. Holding Oven The holding oven is used for intermediate storage to avoid moisture pick-up in the coating of low - hydrogen electrodes and acid rutile stainless electrodes. The electrodes which should be stored in the holding oven are: 1. Electrodes that have been redried. 2. Electrodes that have been removed from thier hermetically - sealed container. 3. Electrodes that are considered to be in good condition and are transferred directly from the store room after unpacking. Holding over temperature : 120 - 150OC Precautions on Site Keep the electrodes in electrically - heated quivers at a minimum temperature of 70OC. After work return the remaining electrodes to the holding oven. Damaged Coating Mechanically damaged electrodes on which parts of the coating are missing will not perform correctly and should be scrapped. VacPac® Electrodes in VacPac® will not pick up any moisture during storage. They require no redrying before use, provided the package is undamaged. This is indicated by a vacuum in the package. Handling VacPac® Electrodes Protect VacPac® from damage at all times. The outer board packaging offers extra protection from mechanical damage to the metal foil. Handle the single inner, metal foil, VacPac® with special care. Do not use a knife or any other sharp object to open the outer board packaging. Before using VacPac® Electrodes Check if the protective foil still contains a vacuum. If the vacuum has been lost, redry the electrodes before use. Cut open the protective foil at one end. Do not take out more than one eletrode at a time, thereby, ensuring that the remaining electrodes are still protected inside the package. Put the top back on the plastic capsule. Discard or redry electrodes that have been exposed to the atmosphere in an opened VacPac® for more than 8 hours.

Welding Consumables
127

Welding Consumables

STORAGE AND HANDLING RECOMMENDATIONS FOR OK TUBROD / DUALSHIELD / COREWELD / CORED WIRES. Cored wire should be stored in conditions which prevent the accelerated deterioration of products or packaging. All cored wires should avoid direct contact with water or moisture. This could take the form of rain or the condensation of moisture on a cold wire. Cored wires must be stored in dry conditions. The relative humidity and temperature should be monitored and the temperature should not fall below the dew point. To avoid condensation, the wire should be kept in the original packaging and, if necessary, left to warm up to at least the ambient temperature before opening the package. Other hydrogen-containing substances, such as oil, grease and corrosion, or substances that could absorb moisture must also be avoided on the wire surface. Products must be stored in such a way as to avoid damage during storage. STORAGE AND HANDLING RECOMMENDATIONS FOR OK FLUX ESAB fluxes, have a guaranteed as-manufactured moisture content from the factories. This moisture content is well - controlled by internal ESAB specifications. Before transport, each pallet is shrink wrapped in plastic foil. This precaution action is done in order to maintain the as-manufactured moisture content as long as possible. Flux should never be exposed to direct wetness such as rain or snow. Storage
l

l

Addition of new flux must be done with the proportion of at least one part new flux to three parts recycled flux. Foreign material such as millscale, dross etc. should be removed by a suitable system such as sieving.

Redrying When handled and stored as above, the ESAB fluxes can normally be used as they are. If, however, a severe application is considered, as given by the applicable material specification, redrying of the flux is recommended. Furthermore, if the flux, due to unfavourable handling or storage, has picked up moisture, redrying can return the flux to its original state regarding moisture. Redrying shall be performed as follows: Agglomerated fluxes : 300 +/- 25OC for about 2-4 hours. Redrying must be done on shallow plates with a flux height not exceeding 50 mm. Redried flux, not immediately used, must be kept at 150 +/- 25OC before use.

Unopened flux bags must be kept under properly maintained storage condition as follows: Temperature : 20 +/- 10OC Relative humidity : as low as possible - not exceeding 60%. The content of unprotected flux hoppers should after an 8 hours shift be placed in a drying cabinet or heated flux hopper at a temperature of 150 +/25OC. Remaining flux from opened bags should be placed at a temperature of 150 +/- 25OC

l l

l

l

Recycling
l

Moisture and oil must in a suitable way be removed from the pressure air used in the recycling system.

128

HANDWELDING ELECTRODES
Official approval In addition to the official approval given in this catalogue, many electrodes are approved by shipping societies, Defence authorities, railway boards, private companies and so on. Information about the different types of approval is available on request. Tensile properties Unless otherwise stated, tensile properties refer to all weld metal test pieces prepared according to the rules of the classification societies using 4 and 5 mm diameter electrodes. Welding current Maximum and minimum values are given. The most suitable welding current depends largely on the size of the workpiece, the welding position and the type of joint. Small workpieces require a lower current, larger workpieces a higher current, depending on the dissipation of heat from the joint. Cold cracking Cold cracking will only occur if the following three factors are present at the same time: 1. Hard phases in the weld, preferably martensite 2. Sufficient stress 3. Hydrogen dissolved in the weld metal Hard phases form when the weld is cooled rapidly from melting temperature to room temperature. Alloying elements, mostly carbon, are forced to dissolve in the weld metal and make it brittle. The following formula describes this process in the case of standard carbon - manganese steel:%Mn %(Cr+Mo+V) %(Ni+Cu) EC=%C+ + + 6 5 15 Steels with EC=0.35 and below are usually weldable without any problems at normal steel sizes. For the more highly alloyed steels and steels with thicker dimensions, an elevated working temperature is necessary in order to reduce the cooling rate. The elevated temperature also allows the hydrogen to diffuse. To determine elevated working temperatures, please

consult BS 5135: 1984 or SS 064025. If the EC dimension of the plates and heat input are known, these standards will state whether heating is necessary and the level at which it should take place. Tension cannot be avoided when welding, as steel expands when heated, although correct planning and heat treatment can reduce tension considerably. Hydrogen forms from water in the surroundings and from the electrode coating. The water is divided into oxygen and hydrogen in the arc and the hydrogen in particular has a strong tendency to dissolve in the weld metal and initiate cold cracking. Conclusion : Dry basic electrodes when there is risk of cold cracking. Labelling The electrode type is clearly marked on the coating of each electrode near the grip end, e.g. ESAB 36H.

Welding Consumables
129

Welding Consumables

GENERAL INFORMATION
Choice of suitable electrode The electrodes in this catalogue are placed into groups according to the type of alloy deposited. Within each group of electrodes for welding mild, low-alloy and stainless steels, there are several cases in which many different electordes are designed for welding the same type of steel. So, for each steel grade, there are often a large number of electrode types to choose from, all of which produce similar weld metal compositions but have different coatings, welding properties, welding speeds and weld metal quality. This large choice makes it possible to choose the electrode which produces the right weld metal quality at the lowest cost. When selecting an electrode, the first rule is to select one which produces a weld metal quality equal to or better than that of the base material and, when necessary, is approved for the material in question. Welding position and type of joint are other factors which influence the choice of electrode, as different welding positions and types of joint. General information about the influence of coating type on welding properties, welding speed and weld metal quality Rutile electrodes giving about 100% weld metal recovery are easy to strike and use and are particularly suitable for short welds in mild steel, for fillet welds, for welding sheet steels and for bridging large joint gaps. The welds have a fine finish and spatter losses are negligible. The welding speed is moderate. Unalloyed electrodes Unalloyed rutile electrodes are not normally recommended for welding steel with a nominal tensile strength exceeding 440 MPa (45 kg/mm2). Rutile electrodes are relatively insensitive to moisture. High-efficiency rutile electrodes High-efficiency rutile electrodes generally produce a higher welding speed, which increases as the weld metal recovery increases. Eg. ESAB C23S. They are all easy to use, produce excellent slag detachability, fine bead appearance and are particularly suitable for welding horizontal/vertical fillets. The weld metal has tensile properties which are as high as, or somewhat higher than, those of the weld metal from unalloyed basic electrodes but have lower elongation and impact strength.

The evenness of the weld and the smooth transition of the base material make joints produced with rutile electrodes at least as good in terms of fatigue strength as unmachined joints produced with rutile electrodes at least as good in terms of fatigue strength as unmachined joints produced using basic electrodes. Unalloyed rutile electrodes, irrespective of thier efficiency, can be recommended for welding mild steel with a nominal tensile strength of 440 MPa (45 kg/mm2). When it comes to the tensile strength of the deposit, rutile electrodes can also be used for welding steels with a nominal tensile stength of more than 440 MPa (45 kg/mm2), but, as a general rule, only electrodes producing a weld metal with a low hydrogen content, e.g. basic, rutile basic or zircon-basic electrodes, should be used to weld these steels. Unalloyed basic electrodes Unalloyed basic electrodes give moderate welding speed in the flat position but are faster than other types when welding vertically upwards. The reason for this is that basic electrodes can be deposited at a higher current in the vertical position than other types of electrode. In addition, the amount of weld metal deposited per electrode is greater than that of other electrodes which can be used in this position. This results in a smaller number of electrode changes. The normal result is therefore a higher fusion rate and higher arctime factor when welding vertically upwards with basic electrodes compared with other types. The slag is normally not quite as easy to remove as the slag from acid or rutile electrodes, but, in spite of this, it can be classed as easily detachable. The slag from basic electrodes has a lower melting point than that from rutile or acid electrodes. The risk of slag inclusions during normal production welding is therefore unusually small when basic electrodes are used, even if the slag is not completely removed between beads during multirun welding. The weld metal from basic electrodes has a low hydrogen content and usually has good toughness even at low temperatures. Basic electrodes are less likely to produce either hot cracks or cold cracks compared with other types of electrode. The superiority of basic electrodes from this point of view appears when welding manganese alloyed structural steels, pressure-vessel steels and ship’s plate with a nominal tensile strength of 490-530 MPa (50-54 kg/mm2). The higher the hardenability of the steel to be welded, the greater the necessity to use basic electrodes and the greater the need for low moisture content in the coating.

130

Cellulose electrodes

Welding Consumables

Cellulose electrodes are easy to use in all welding positions and are particularly good for vertical and overhead welding. Cellulose electrodes are recommended for allpositional welding where the mechanical properties of the deposit are of the greatest improtance and radiographic requirements must be met. Vertical and overhead welding often require an electrode one size larger in comparison to electrodes with other types of coating. Cellulose electrodes are extremely good for verticaldown welding. Higher tensile steel requires preheating and higher interpass temperatures than when the welding is done with low-hydrogen electrodes.

131

Welding Consumables

Approval in accordance with classification society rules
Welding materials are normally classified by ESAB in accordance with a standard, e.g. AWS and EN. To verify mechanical properties they are also approved in accordance with the rules of the classification societies. Classification The Classification of welding products refers to standards and, when a welding product is classified, its type, properties and field of application are given. The manufacturer verifies the correct classification of a product by internal testing and / or by witness of an outside orgainisation. Approval Shipowners and partners in offshore enterprises require welding consumables to be approved in accordance with the rules of the classification societies. Approval is also required by clients in accordance with national or international standards for boiler and pressure vessels as well as other standards to be verified by an authorized approval institutute. Approved welding products are entered on the “List of Approved Welding Consumables: distributed annually by the societies and other institutes. This catalogue provides information about the welding position, current/polarity, low hydrogen and grading. Non-alloyed and low-alloyed steels Consumables are divided into three categories based on their tensile strength level: Normal stength steel : Indicated by the numbers 1, 2 or 3 (e.g. 3.3M) that the electrode is to be used in steel with a minimum yield strength (ReH) of 305 and a tensile strength (Rm) of 400-560 MPa. High strength Steel : Indicated by 2Y, 3Y, 4Y, 5Y (ReH min 375 and Rm 490-660 MPa) and 2Y40,3Y40, 4Y40 (ReH min 400 and Rm 510-690 MPa) Extra high strength steel : Indicated by 3Y42, 4Y42, 5Y42 up to 5Y69 and so on for the different strength steel categories, where the numbers 42....69 symbolize a yield strength in MPa indicating that the electrodes can be used for extra high tensile steels.

Toughness level Each steel category is divided into three to five toughness levels represented by the first digit in the grade (1, 2, 3, 4 or 5) -1 suitable for grade A steel (impact tested at 20OC) -2 suitable for grade A, B and C steels (impact tested at 0OC) -3 suitable for grade A, B, D and E steels (impact tested at -20OC) -4 suitable for grade A, B, D, E and F steels (impact tested at -40OC) -5 suitable for grades A, B, D, E and F steels (impact tested at -60OC) Other frequently used abbreviations T M two-run welding (submerged arc welded with one run from each side) multi-run welding (submerged arc or automatic gas-shielded arc welding) semi-automatic, gas-shielded and flux - flux - cored arc welding low - hydrogen welding consumables deep penetration

S H5, H10, H15 DP

Stainless steel and other high-content alloyed steels Grades of stainless steel for which the welding consumable is approved are indicated with respect to one or more of the types of stainless steels : 304L, 304LN, 316LN and so on. The abbreviation SS/CMn indicates approval for joining any of the austenitic types of stainless steel to any ofthe normal strength or higher tensile ship steels. Dup/CMn indicates approval for joining any of the duplex types of stainless steel to any of the normal strength or higher tensile ship steels. The system described for grading the consumables in accordance with the rules of the classification societies changes as new steels appear on the market and sometimes there are changes to the approval ratings which might mean that the handbook may not be currently upto date. To ensure that valid information is used, please request the latest issued Product Data Sheet for the consumables and / or the latest edition of the “List of Approved Consumables” and approval certificates from the most recent annual repeat test.

132

Calculation of electrode consumption
In the tables, joint cross section, theoretical joint volume and kg weld metal per metre length of welded joint are given. The electrode consumption per metre of welded joint is obtained by dividing the number of kg of weld metal by N, where N is the kg of weld metal per kg of electrode and is given for each electrode on thier respective pages.

Welding Consumables

Square butt joints: Joint volumes and weld metal weights
Position Plate thickness mm
1 1.5 2 3 4 5 6 7 1 1.5 2 3 4 5 6 7 4 5 6 7 4 5 6 7

Gap mm
0 0.5 1 1.5 2 2 2.5 3 0 0.5 1 1.5 2 2.5 3 3 2 2 2.5 3 2 2 2.5 3

Volume/length cm3/m
2 3 4 7 17 21 27 36 2.5 4 5 9.5 22 25 32 42 9 10.5 13 16 10.5 16 18 21

Weight/length weld metal kg/m
0.02 0.02 0.03 0.05 0.13 0.16 0.21 0.28 0.02 0.03 0.04 0.07 0.17 0.20 0.25 0.33 0.07 0.08 0.10 0.13 0.08 0.13 0.14 0.16

Flat

Flat

Horizontal-Ver tical

Horizontal-Ver tical

Overhead

133

134

Welding Consumables

Calculation of electrode consumption Single V-joints: volumes and weld metal weights
60° 60° 70° 80°

50°

Plate thickness mm Flat Vertical 3 1
15 22.5 31 45 16.5 24.5 37 49 59.5 75.5 96.5 113 134 171 197 223 276 334 510 2.17 2.62 4.00 308 376 577 320 396 606 2.51 3.11 4.76 1.05 1.34 1.55 1.75 145 193 219 247 157 204 231 257 1.23 1.60 1.81 2.02 107 141 160 180 223 271 411 0.47 0.59 0.76 0.89 65.5 81.5 104 124 70 87.5 109 130 0.55 0.69 0.86 1.02 49 60.5 77.5 92 56 65 81 96.5 113 159 171 186 233 281 425 0.13 0.19 0.29 0.38 17.5 26 36 51.5 18 28 38.5 56 0.14 0.22 0.30 0.44 13 19.5 27 39 14.5 21 30 42 57 70 90 107 125 165 188 211 263 320 488 0.11 0.16 0.24 0.33 0.44 0.51 0.64 0.76 0.89 1.17 1.34 1.46 1.83 2.21 3.34 0.10 0.15 0.20 0.30 0.37 0.44 0.57 0.66 0.77 1.02 1.15 1.23 1.60 1.94 2.94

Gap mm 1 2
12.5 19 25.5 38 46.5 56 72 83.5 97.5 130 146 157 204 247 375

Flat Overhead 3 1 2 3 1 2 3 Horizontal-Vertical 2
13 19.5 27 39 49 60.5 77.5 92 107 141 160 180 223 271 411

1

2

3

4 5 6 7

1 1 1 1.5

11.5 16.5 23 33.5

11 16 21.5 32.5

0.09 0.13 0.17 0.26

8 9 10 11

1.5 1.5 2 2

42 51 66.5 78.5

40 48 62 71.5

0.31 0.38 0.49 0.56

12 14 15 16

2 2 2 2

91 120 135 151

83 110 123 132

0.65 0.86 0.97 1.04

18 20 25

2 2 2

189 227 341

170 208 313

1.33 1.63 2.46

1 Theoretical volume cm3/m 2 Actual joint volume cm3/m (taking account of transverse shrinkage) 3 Deposited weld metal kg/m

The first run and backing run V-joints: Weld metal weights
Electrode diam mm
3.25 4 3.25 3.25 3.25

Position
0.10 0.15 0.15 0.15 0.10

Plate thickness mm

Weight/length kg/m

Flat Flat Vertical Horizontal-Vertical Overhead

6–12 > 12 > 8 > 8 > 10

Calculation of electrode consumption Corner welds: Actual joint volumes and weld metal weights

Welding Consumables

Plate thickness mm
2 3 4 5 6 7 8 9 10 11 12 15 18 20 22 25

Section size mm2
2 4.5 8 12.5 18 24.5 32 40.5 50 60.5 72 113 162 200 242 323

cm3/m
3.5 7 9 13 18.5 25.5 33 41.5 51.5 63 74.5 116 167 206 248 329

kg/m
0.03 0.05 0.07 0.10 0.15 0.20 0.26 0.33 0.40 0.49 0.58 0.91 0.31 1.62 1.95 2.58

cm3/m
3 7 9 13.5 19.5 26.5 34.5 43 53.5 67 79 123 174 206 255 331

kg/m
0.02 0.05 0.07 0.11 0.15 0.21 0.27 0.34 0.42 0.53 0.62 0.97 1.37 1.62 2.00 2.60

cm3/m
3.5 7 9.5 14.5 21 27.5 36 45.5 56 72 84.5 132 190 227 275 370

kg/m
0.03 0.05 0.07 0.11 0.16 0.22 0.28 0.36 0.44 0.57 0.66 1.04 1.49 1.78 2.16 2.90

cm3/m
3.5 7.5 10.5 16 22 31.5 40.5 51 64 78.5 93 141 204 252 204 405

kg/m
0.03 0.06 0.08 0.13 0.17 0.25 0.32 0.40 0.50 0.62 0.73 1.11 1.60 1.98 2.39 3.18

Fillet welds: Actual joint volumes and weld metal weights

Throat thickness mm
2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 9 10 11 12 13 14 15

Section size mm2
4 6.5 9 12.5 16 20.5 25 30.5 36 42.5 49 56.5 64 81 100 121 144 169 196 225

cm3/m
5 7.5 10.5 14 18 22.5 27.5 33.5 40 46.5 54.5 60.5 70 88 108 131 155 179 207 237

kg/m
0.04 0.06 0.08 0.11 0.14 0.18 0.22 0.26 0.31 0.37 0.43 0.47 0.55 0.69 0.85 1.03 1.22 1.41 1.62 1.86

cm3/m
6 8.5 12.5 16 21 26 31.5 37 42 49.5 57 65 73.5 94 114 138 162 190 224 248

kg/m
0.05 0.07 0.10 0.13 0.16 0.20 0.25 0.29 0.33 0.39 0.45 0.51 0.58 0.74 0.89 1.08 1.27 1.49 1.76 1.95

cm3/m
5.5 8 11 15 19.5 24.5 30.5 36 43 51 56 64 76.5 95 116 143 169 195 227 264

kg/m
0.04 0.06 0.09 0.12 0.15 0.19 0.24 0.28 0.34 0.40 0.44 0.50 0.60 0.75 0.91 1.12 1.33 1.53 1.78 2.07

cm3/m
5.5 8.5 12 16.5 22 26.5 33 40.5 47.5 56 65 73.5 82.5 109 130 157 188 220 257 294

kg/m
0.04 0.07 0.09 0.13 0.17 0.21 0.26 0.32 0.37 0.44 0.51 0.58 0.65 0.86 1.02 1.23 1.48 1.73 2.02 2.31

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Welding Consumables

The weight of welding electrodes or welding wire necessary to complete a given weld joint may be calculated by the formula: P = WL E Weight of electrode or wire required Weight per unit length of weldmetal Length of weld (meter) Deposition efficiency

PROCESS Submerged Arc Gas Metal Arc (98% Ar, 2% O2) Gas Metal Arc (75%Ar, 25% CO2) Gas Metal Arc (CO2) Metal Cored Wires Gas Shielded Flux Cored Wires Self Shielded Flux Cored Wires

DEPOSITION EFFICIENCY 99% 98% 96% 93% 93% 85% 82%

P = W = L = E =

WEIGHT PER UNIT LENGTH OF WELDMETAL Calculating the weight of weldmetal requires than we consider the following items. 1. Area of cross-section of the weld 2. Length of the weld 3. Volume of the weld in cubic centimetre 4. Weight of the weldmetal per cubic centimetre The area of the cross-section (the triangle) in the fillet weld shown below is equal to one half the base times the height. The volume of the weld is equal to the area times the length, and the weight of the weld then, is the volume times the weight of the material (steel) per cubic centimetre.

* Shielded Metal Arc (Stick 300 mm long) 59% * Shielded Metal Arc (Stick 350 mm long) 62% * Shielded Metal Arc (Stick 450 mm long) 66% * Includes 2” stub loss.
It must be remembered that when deposition tests are performed in the laboratory, the deposition efficiency is calculated by the formula: Weight of metal deposited Deposition Efficiency = Weight of electrode consumed

This does not take stub loss into consideration. The chart below shows how the length of the stub effects the laboratory-established efficiency. STUB LOSS CORRECTION TABLE FOR COATED ELECTRODES
Deposition 50mm Efficiency STUB 75mm 100 mm 125mm STUB STUB STUB

This example is for a fillet weld with no reinforcement. Similar calculations can be made for butt or lap joint. The table on following pages lists the weight per metre of fillet and the more common butt joints. DEPOSITION EFFICIENCY The deposition efficiency of an electrode or welding wire indicates the portion of that product you can expect to be deposited as weldmetal. Losses due to slag, spatter, fume and in the case of semi automatic or automatic welding processes, the ends cut before each weld and the wire left in the feed cable make no process 100% efficient. For estimates of electrode or wire consumption, the following average values of deposition efficiency may be used.

300 mm ELECTRODE

60% 65% 70% 75% 80%

50.00% 45.00% 40.00% 35.00% 54.20% 46.70% 43.30% 37.90% 58.30% 52.50% 46.60% 40.80% 62.50% 56.20% 50.00% 43.70% 66.60% 60.00% 53.30% 46.60% 51.40% 47.10% 42.90% 38.30% 55.70% 51.1 0% 46.40% 41.00% 60.00% 55.00% 50.00% 45.00% 64.30% 56.90% 53.60% 46.20% 68.50% 62.80% 57.10% 51.40% 53.30% 50.00% 46.60% 43.30% 57.70% 54.20% 50.50% 46.90% 62.20% 56.30% 54.40% 50.50% 66.60% 62.50% 56.30% 54.20% 71.10% 66.60% 62.20% 57.70%

350 mm ELECTRODE

60% 65% 70% 75% 80%

450 mm ELECTRODE

60% 65% 70% 75% 80%

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The following tables show the estimated weight of consumables for some of the common weld joints.

Welding Consumables

Fillet Size L (mm)

Weldmetal Required Kg/m

Weight of electrode/Wire required per unit length of weld (Kg/m) SMAW GMAW 0.04 0.10 0.17 0.26 0.38 0.67 1.06 1.53 2.70 FCAW 0.05 0.11 0.19 0.29 0.43 0.76 1.18 1.70 3.02 Metal Cored 0.04 0.10 0.17 0.27 0.39 0.70 1.09 1.57 2.79

3 5 6 8 10 Horizontal Fillet Weld 13 16 19 25

0.04 0.09 0.16 0.25 0.36 0.64 1.00 1.44 2.56

0.06 0.15 0.26 0.40 0.58 1.04 1.62 2.33 4.14

Joint Dimensions (mm) T 5 6 8 B 1.5 1.5 2.5 Square Butt Joint 1.5 2.5 13 A 10 11

Weldmetal Required kg/m 0.14 0.17 0.21 0.20 0.25

Stick Electrode Required kg/m 0.22 0.28 0.34 0.33 0.40

Joint Dimensions (mm) T 6 8 10 13 16 Single - V Butt Joint 19 25 B 2.0 2.5 3 3 3 3 3.2 A 8 10 13 16 21 24 32

Weldmetal Required kg/m 0.19 0.34 0.53 0.80 1.31 1.84 3.18

Stick Electrode Required kg/m 0.31 0.54 0.86 1.27 2.12 2.96 5.12

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WElGHT PER METER OF WELDMETAL FOR FILLET WELDS AND ELEMENTS OF COMMON BUTT JOINTS

Welding Consumables

INSTRUCTION 1. Make a drawing of the cross-section of the joint to exact scale. 2. Divide the cross-section into right triangles, rectangles and sketch in the desired reinforcement. 3. Dimension the thickness, angles, angle leg length, root opening and the length and height of the reinforcement. 4. Total the weight per meter of each of the elements from the chart for the weight per meter of the weld.

ANGLE ‘V’ JOINT - 60O Included Angle ‘V’

FILLET WELD

PLATE THK Mm 4 5 6 7 8 9 10 11 12 14 15 16 18 20 25
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ROOT THEORETICAL Weld GAP mm 1 1 1 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2 VOLUME mm 13 19.5 27 39 49 60.5 77.5 92 107 141 160 180 223 271 411 cm3/m 12.5 19 25.5 38 46.5 56 72 83.5 97.5 130 146 157 204 247 375

WEIGHT WELD METAUm kg/m 0.1 0.15 0.2 0.3 0.37 0.44 0.57 0.66 0.77 1.02 1.15 1.23 1.6 1.94 2.94

FILLET THEORETICAL WELD VOLUME cm3/m SIZE mm L 2 3 4 6 8 10 12 15 18 20 25 4.5 8.0 18.0 32.0 50.0 72.0 112.0 162.0 200.0 312.5 T 6.0 12.5 21.0 42.0 73.0 114.0 162.0 248.0

WEIGHT WELD METAUm kg/m L 0.036 0.064 0.142 0.252 0.394 0.567 0.887 1.277 1.576 2463 T 0.05 0.10 0.16 0.33 0.58 0.89 1.27 1.85

The figures above are for accurate weld volumes of exact dimensions. In practice it is difficult to obtain mitre shaped fillet welds, actual welds are generally convex in profile and an allowance of approximately 15% should be made when calculating consumable requirements.

DATA SHEETS - PIPE WELDING
ESAB Pipe Welding Electrodes The following electrodes are specially designed for pipeWeldin
Designation Pipeweld 6010 Pipeweld 6010 OK 22.46 P OK 22.47 P E 7010 E 8010-G X46,X52,X56 X60,X65 AWS classification E 6010 For line pipe steels API 5 LX X42,X46

Welding Consumables

Root pass Pipeweld 6010 3.20 or 4 mm dia.

Filler passes Pipeweld 6010 OK 22.46 P OK 22.47 P 4 or 5 mm dia.

Pipeweld 6010 is ideally suited for root bead welding. The welding technique, Le. the use of Pipeweld 6010 for the root bead and also in some cases for the hot pass, together with a high strength electrode for the other passes, gives maximum resistance to cracking. The practical technique is described in detail in the following pages. Joint Preparation Careful joint preparation, as shown in fig.1, is of utmost importance to achieve a perfect weld. With flame-cut edges the required tolerance are in general not obtained, so it has become common practice to machine the pipe ends. To avoid porosity and lack of fusion the weld faces must be free from foreign matter, such as oil, grease, mill scale, dirt and other destructive material.

Hot pass Citoflex OK 22.46 P OK 22.47 P 4 or 5 mm dia.

Capping pass Pipeweld 6010 OK 22.46 P OK 22.47 P 4 or 5 mm dia. ESAB Pipe Welding Electrodes Welding the hot pass

Fig. 1 Recommended joint preparation for pipe diameters up To 300 mm. Pipeweld 6010, 3.20 mm dia. for root bead. Welding the root bead, filler And capping passes For pipe diameters larger than 300 mm. Electrode Pipeweld 6010, 3.20 or 4 mm dia. for root beads. Welding Procedure and Technique The following schedule shows the range of application for all the electrode grades indicated. Selection of these electrodes depends on the line pipe steel grade used. Line Pipe Steel Grades The most common steels used for oil and gas crosscountry pipelines conforming to API 5 L, 5 LS, and 5 LX.
139

Welding Consumables

Table 1, shows the chemical requirements to API Standard 5 LX for the individual line pipe steel grades. Chemistry of the pipe material is an important consideration prior to welding; otherwise difficulties may be experienced on high strength pipe material from the high carbon and manganese contents, particularly in cold weather. It is therefore advisable, depending on the surrounding temperature and weather conditions, to preheat the entire pipe circumference before applying the stringer bead. Table 2, Shows the physical requirements to API 5 LX. line electrodes

Table 1: Chemical requirements
API 5 LX Grade Cmax. X42 X46 X52 X56 X60 X65 X70 0.28 0.28 0.28 0.26 0.26 0.26 0.23 Ladle analysis % Si Mn <1.25 <1.25 <1.25 <1.35 <1.350 <1.35 <1.60 Nbmin. 0.005 .005 0.005 Vmin. Ti 0.02 0.02 0.02

-

0.03 0.03 -

Composition and characteristics of cellulose pipe-

- -

Cellulose electrodes contain a high amount of organic material; about 35% of the coating consist of cellulose powder, which in the arc is transformed into a shielding gas at high pressure. This results in a fierce, concentrated arc giving deep penetration. This is one of in large electrode diameters - can be used for vertical down welding with excellent results. Welding current ranges (DC positive or negative)
ESAB AWS Electrode diameters (mm) and currents (amp) 3.25 Pipeweld 6010 A5.1:E 6010 OK 22.46 P 4.0 5.0

Table 2: Physical requirements
API 5 LX Yield stress min. Grade X42 X46 X52 X56 X60 X65 X70 N/mm2 (psi) 290 (42) 315 (63) 360 (66) 385 (56) 415 (60) 450 (65) 485 (70) Tensile strength Elongation min. N/mm2 (psi) 410 (60) 430 (63) 450 (66) 490 (71) 520 (74) 550 (77) 580 (85) min.% 25 23 22 22 22 20 20

the reasons why cellulose pipeline electrodes

-

even

Designation Classification

50-150 120-200 160-250

A5.1:E 7010-G 50-150 120-200 160-250

OK 22.47 P A5.1 :E 8010-G 5O-150 120-200 160-250

Selecting the correct electrodes for API 5 LX steels
Esab Pipe Welding Electrode Pipeweld 6010 OK 22.46 P OK 22.47 P API 5 LX root hot filler root hot filler root hot filler Grade bead pass and bead pass and bead pass and cover cover cover X42 X46 X52 X56 X60 X65 X70 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

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General recommendations GMAW
GMAW - Gas Metal Arc Welding The electrodes and joint faces should be clean. This is particularly important when welding aluminium and aluminium alloys. The shielding gasses which are used must be of a purity suitable for welding. Moisture in the gas can produce porous welds. Shielding gas for mild and low-alloy steels Carbon dioxide, CO2, is the cheapest and most commonly used gas and, in most cases, it produces satisfactory welds in both mild and low alloy steel. Mixed gas, of which the most commonly used consists of 80% Ar + 20% CO2, is clearer than pure CO2 but produces a softer arc, quieter welding, better bead appearance and less spatter. It is therefore often used, in spite of its higher price, for welding sheet steel 0.8-1.5 mm thick, which is more difficult to weld with pure CO2. A further advantage of mixed gas is the higher quality, in particular notch toughness, compared with CO2. For this reason, mixed gas is often recommended for welding low-alloy steels, such as creep-resistant steels, even in thicknesses greater than 1.5 mm. Mixed gas of the 80/20 type, in which the argon is of a lower purity, is also available. These gases are less expensive than those based on pure argon and can often be used with equally good results. One drawback of argon/CO2 mixtures is that they lead to increased ozone formation, compared with pure CO2, when used as shielding gas in arc welding. Another drawback when using the mixture is that the current load capacity of the welding gun is reduced by about 30% compared with welding with CO2. Shielding gas for stainless and heat resistant steels Argon containing 1% oxygen is normally used for welding stainless and heat-resistant steels, but argon containing 2% O2 or 5% O2 is also available. The latter produces a more fluid weld pool.A shielding gas which consists of 98% argon + 2% CO2 has gained favour for MIG welding stainless steels. It can often replace argon/ helium mixtures, Which are used to help fusion when welding thick stainless steel, and can very often replace argon/oxygen mixtures.

Choice of welding Process
Short arc or spray arc The electrodes for gas metal arc welding listed in these pages are suitable for short arc welding in the smallest diameters and for spray are welding in diameters 1.22.4 mm. Short arc welding (welding with short circuiting droplet transfer) can be carried out in all positions and is the best jprocess for welding sheet material approximately 0.8-3 mm thick and for making the root run in prepared butt joints. Spray arc welding (welding with finely divided free flight drop transfer) is carried out at higher currents and voltages than short arc welding and is therefore generally faster and more economical than short arc welding for plate thicknesses exceeding 2 - 3 mm. It is only used for weldingin the horizontal or horizontal/vertical positions. The gas consumption is 6-10 litres/min for short arc welding and 12-20 litres/min for spray arc welding. The higher the welding current, the higher the gas flow required. Welding technique The welding gun is normally held in the right hand, which means that the weld is made from right to left with the gun directed away from the deposited weld at an angle of 75-80O between the electrode and the workpiece, thereby giving the operator a good view of the weld pool and the joint. This produces a smoother weld bead than if the gun is directed towards the finished weld. Abbreviations MIG welding = metal inert gas welding = metal arc welding in an atmosphere consisting mainly of an inert gas such as argon. MAG welding = metal inert gas welding = metal arc welding in an atmosphere consisting mainly of an inert gas such as argon. MAG welding = metal active gas welding = metal arc welding in an atmosphere consisting of an active gas, usually carbon dioxide. Gas mixtures containing 20% or more CO2 are usually classified as active.

Welding Consumables
141

Welding Consumables

Solid wire classification for GTAW/GMAW

DATA SHEET - GTAW/GMAW
Indicates in 1000 PSi increments the minimum tensile strength of the weldmetal produced by the electrode when tested acco-diy to A5.18 specification. In this case 70 indicate 70,000 PSi.

ER 70 S - X
E indicates a filler wire/rod

Indicates chemical compsition (%) of Solid electrode indicates that the filler metal is solid

Indicates that the filter metal is solid

x
2 3 4 6 7

C
0.07 0.06 /0.15 0.06 /0.15 0.06 /0.15 0.07 /0.15

Mn 0.90 /1 .40 0.90 /1.40 1.00 /1.50 1.40 /1.85 1.50 /2.00

Si 0.40 /0.70 0.45 /0.75 0.65 /0.85 0.80 /1.15 0.50 /0.80

S 0.035 0.035 0.035 0.035 0.035

P 0.025 0.025 0.025 0.025 0.025

Ti 0.05 -0.15 -

Zr 0.02 -0.12 -

AI 0.05 -0.15

Cu 0.5 0.5 0.5 0.5 0.5

-

G

Chemical Compositions are not specified, however requirements shall be agreed to by the purchaser & supplier.

Note : Cr, Ni & Mo content not to exceed 0.15 each.

142

GENERAL RECOMMENDATIONS
FCAW
Introduction In recent years, pressure to increase productivity and reduce costs has been the main diving force behind the adoption of flux cored wires by fabricators. Productivity, ease of use and quality are the three main virtues on which the increasing popularity of Flux cored wires rest. The welding processes with which flux cored wire must mainly compete are MMAW and semi automatic welding with solid wire (MIG/MAG). The superior productivity and the accompanying improved economics of flux cored wire welding over MMAW are very apparent. Even at the same duty cycle as MMAW cored wire process can give much higher productivity because it can operate at much higher current densities. The deposition data of around 83 - 93% may be less convincing in case of flux-cored wire welding in comparison to MIG/MAG welding. which is nearly 96-98%. The ease of use of flux cored wires in out of position welding coupled with its greater process tolerance and comfort is an important aspect. The amount of time and money spent on reworking defects are less in flux cored welding in comparison to MIG welding and it becomes a very viable alternative to MIG/MAG welding. Possible elimination of quality problems like lack of fusion, cold laps, danger of hydrogen embrittlement etc. through the use of flux-cored wires has been a very important criterion for its selection all around the world for critical fabrication. THE CORED WIRE PROCESS Main Features Fundamentally the process of MIG/MAG welding and utilises the same equipment as that for solid wire albeit of larger capacity in some cases. The important difference between MIG/MAG welding with solid wire and cored wire is performance, productivity, welding characteristics and Weldmetal integrity. Variations to suit a particular application or physical requirement are more easily achieved than with solid wire. This involves changes in the filling formulation and percentage in a similar way to that of manual arc electrodes. The coating formulation and thickness can have a significant effect, whereas little can be done with the electrode core wire alone to improve aspects of performance. Economics Whilst there are higher productivity processes available, such as submerged arc and robotics, cored wire semiautomatic MIG offers the fabricator a more flexible process with genuine increases in productivity for the least capital expenditure. Where solid wire is already in use this may only involve a change of accessories such
143

as feed rolls and torch consumables. A move to cored wire MIG/MAG from the use of manual arc will obviously involve the purchase of new equipment but the undisputed increase in productivity will usually guarantee a return on capital invested in less than one year. Deposition The higher deposition rate from cored wires relies upon the I2R heating effect that is greater than with solid wires, for a given current. With the solid wire the total cross section carries all of the current but with metal cored wires a partial amount is carried by the core and in the case of flux cored wire all of the current is conducted by the tube. Thereby the current density and heating effect ensures a higher burn-off rate from cored wires.

Welding Consumables

SOLID

METAL CORED

FLUX CORED ESAB Cored Wire Range The ESAB range consist of rutile and fully basic flux cored wires, some of which are self-shielded, and a range of metal cored wires. For general fabrication work the metal cored type could satisfy the majority of applications, so the need for three principal types may be questioned.

Welding Consumables

There are a number of factors to be considered and can be summarised as follows:
l

Downhand Rutile Flux Cored Wires are easy to usewith a smooth arc action giving excellent weld appearance with easy slag detachment. Positional Rutile Flux Cored Wires when used with Argon rich gas offer spray transfer welding with a high level of operator appeal. Basic Flux Cored Wires produce a higher and more consistent level of mechanical properties. They also produce radiographic standard deposits with ease when compared to both rutile and metal cored wires. Metal Cored Wires when used on good quality clean plate will produce very little slag-similar to that of solid wires. Self-Shielded Wires produce their own gas shield via decomposition in the arc of various elements within the core.

for a given wire size will cater to 90% of flat and HV applications. The weld cross-section is controlled by the travel speed whereas solid wire would require considerable current resetting to achieve the same flexibility. Plate preparation Due to superior sidewall fusion obtained particularly from the metal cored wires the combined angles of preparations can generally be reduced. A V-butt joint for instance that would normally need a 60° included angle for manual arc welding can be reduced to 45° thereby saving plate and hence weldmetal to fill the joint.

l

l

l

l

OPERATING CONDITIONS Polarity DC electrode positive is recommended for the cored wires since the use of the negative pole produces inferior running characteristics and can occasionally produce porosity. Some Cored wires however, are designed to operate on both DC positive & negative polarity. Voltage Arc voltage has a direct influence on the arc length that controls the weld shape depth of penetration and spatter level. As the arc voltage is reduced the penetration increases and this is particularly important in V butt joints. An increase in voltage will result in a long arc length and increase the risk of porosity and undercut. When operating on dip transfer for positional welding at comparatively low currents the arc voltage should be kept at the highest practicable level to ensure adequate sidewall fusion. Amperage With flux cored wires the amperage used is ideally at the top half of the range specified for a particular size, except when positional welding with 1.0mm, 1.2mm, and 1.4 mm wires, and when the dip transfer mode is used at current below 220 amps. Metal cored wires eliminate the need for current variations relative to plate thickness since one current setting
144

The higher levels of de-oxidation and higher current density available with cored wires allows them to be used where mill scale and primer have to be tolerated. This is particularly so with the metal and basic cored wires, since the rutile types are the least tolerant. However, in case of primer the degree of success will depend on the type and thickness, but generally Tubrod basic wires will achieve porosity free welds at speeds 45% faster than solid wires and the Tubrod metal cored wires are approximately 35% faster For optimum radiographic standards with flux cored wires excessive rust and scale should be removed by grinding which will also serve to reduce slag formation to a minimum when using metal cored wires. Further economies can be achieved from a reduction in Weldmetal required on single pass fillet joints. The often-greater depth of fusion can increase the effective throat thickness and consequently allow a reduction in leg length by up to 20%. The savings in Weldmetal are considerable as can be seen from FIG.6 and some certification authorities will permit a reduction of 50% in weld dimensions for single pass fillets when produced fully automatically.

WELDING TECHNIQUES

Welding Consumables

Torch angles Flux cored wires With OK Tubrod / Dualshield flux cored wires the torch angle has a significant effect on slag control and weld deposit profile. For both fillet and butt joints the recommended angle between the wire axis and the line of joint is between 60° - 70° and using a backhand technique i.e. pulling, with the wire pointing toward the completed weld. In this way the arc force prevents the slag from running in front of the line of the weld pool and reduces the risk of slag traps. For HV fillets the wire tip should be directed toward the bottom plate at approximately 3-mm from the line of the joint with a torch angle of 45° from the vertical plate. In certain circumstances the forehand technique i.e. pushing can be used to advantage. On small fillet welds where penetration is not of paramount importance the higher welding speeds required are such that the molten slag is prevented from running ahead of the weld pool. This also has the advantage of producing a mitre fillet where as the backhand method tends to produce a more convex profile. Metal cored wires Maximum penetration is obtained using a backhand (pulling technique with a torch angle of 70/80° between the wire axis and the joint line. This will also serve to optimise gas coverage and is particularly relevant to multipass butt welds.The fillet and lap welds superior weld appearance is achieved using a torch angle of 60/70° and a forehand technique (push). This results in a more even distribution of Weldmetal, accompanied by a reduction in penetration.

145

Torch angles and manipulation

Welding Consumables

Vertical butt-welds

Vertical fillet welds

Preparation with root face

A torch angle of 100 above the horizontal may be used for root passes to assist arc stability and penetration control.

Triangular weaves for single pass fillets. If necessary subsequent weld runs should be deposited using techniques similar to that for Filling vertical butt joints. No weaving is necessary for single pass fillets when using OK Tubrod 15.15

Single Pass

Preparation with feather edges Torch angles and manipulation

Restrict vertical down technique to thin plate or leg lengths of 6 mm maximum. May be used for first pass of multipass joints.

146

Travel Speed Travel speed has an important influence on penetration. For example when using a 1.6mm metal cored wire at 305A an increase in travel speed from 30cms/min to 60cms/min approximately doubles penetration beyond the root of a fillet. At speeds in excess of 80/100 cms/ min penetration will decrease. Similarly a reduction in penetration will occur if the welding speed should fall to below 30cms/min, as the arc can impinge on the molten pool in preference to the base material. In addition the use of slow travel speeds should be avoided when low temperature impact properties are required. While the joint may be filled in fewer passes the individual weld deposits will be of large cross-section and therefore impact resistance will be reduced. Apart from this, in the case of flux cored wires there is the obvious difficulty of slag control to be considered. Positional Welding The majority of Tubrod cored wires are capable of positional welding in the smaller sizes. However, the choice of consumable must be given careful consideration in relation to the proposed applications because the various ranges require quite different manipulation techniques for optimum results. Rutile (EX1 T-1) Types This type of wire allows the use of the spray transfer mode in all positions including overhead and as such affords very high deposition rates. In addition, the exceptional fusion Characteristics that results will have significant effect on the production of defect free welds. This is particularly relevant when compared to solid wire that by necessity can only be used for positional welding in the dip transfer mode. The reduced depth of fusion involved together with the greater degree of skill and concentration demanded will increase the risk of fusion related defects. Dualshield 7100 LH can achieve in excess of 4kg/hr in the vertical position compared to manual arc at approximately 2kg/ hr. The required techniques for vertical up welding is almost identical to those employed by manual metal arc for both fillet and butt joints. However, root panes in open butt welds where a uniform bead of penetration required, when welded from one side are not recommended. This is due to the high arc energy and fluidity of the weld pool as well as the need to maintain highly accurate joint preparation that is considered not practical. In such circumstances the use of non-fusible back-

ing is recommended and this type of wire is eminently suitable for use with these materials and the speed of welding will be significantly higher. Metal Cored (EX1T-G) and Fully Basic (EX1T-5) These two groups may be treated as one with regard to positional welding techniques. To maintain optimum control welding is limited to the 1.0mm and 1.4mm sizes and is restricted to the dip transfer mode where greater welder skill is involved. The manipulation required be similar to that used for solid wire in that initial passes in the vertical position are completed using a triangular weave motion. This is to ensure that the weld profile remains flat and not peaked, which would otherwise occur leading to possible lack of fusion defects at the edges after further welding as in the case of multipass joints. The conventional straight weave may be used but only in circumstances when the face of the previous pass is wide enough such that the effect of heat sink will maintain a flat profile automatically. Whilst the dip transfer method is slow and often demanding in terms of operator concentration the arc energy is greater than with solid wire and the possibility of defects, especially cold lapping is substantially reduced. The root pass in an open butt weld, where full penetration is required from one side is always the most difficult regardless of welding process or position. However, when using Tubrod metal and basic cored wires the use of dip transfer and vertical down welding can be used to good advantage. Excellent results can be achieved more easily if it is rapid and dispensing with a root face can reduce plate preparation costs. Fillet joints may be welded using either the vertical up or vertical down techniques. The choice will depend on the thickness of material and degree of root penetration desired. Multi-pass joints should be completed on a similar basis to that of butt welds using the vertical up technique.

Welding Consumables
147

Welding Consumables

Metal cored wire
Electrode extension This term describe the distance between the contact tip of the torch and the work piece, some times described as ‘electrode stickout’. The current conditions should be set for the job in hand but during welding it may be nec-

essary to reduce the amount of heat in the weld pool to accommodate poor fit-up or out of position welding. An increase in the stickout length and the extra electrical resistance that results will produce a cooler less fluid weld pool. Similarly any decrease in electrode extension will have the effect of increasing welding current and this characteristic can be of benefit in controlling penetration; especially where inconsistent fit-up is encountered.

148

When operating with dip transfer an extension of 12 mm will suffice for most applications whereas spray transfer produces a greater amount of radiated heat and should have an extension of approximately 20-30 mm. During actual welding any large variation will produce an inconsistent weld deposit and excessive electrode extension has the effect of reducing the amperage drawn from the power source. Increasing the wire feed speed to compensate for the current drop will result in a significant increase in weldmetal deposition.

Welding Consumables

ELECTRODE EXTENSIONS RELATED TO DEPOSITION RATE

EXTENSION MM WIRE FEED M/Min CURRENT AMPS DEP RATE KGS/HR

12 5.8 350 4.7

18 5.8 320 4.7

25 5.8 280 4.7

25 8.4 350 6.5

149

Welding Consumables

DATA SHEET - FCAW

Flux cored wires classification E 71T-X E80T-X Indicates the primary welding conditions for which the electrode is designed; 0 - Flat and horizontal positions 1 - All positions Designates an electrode Designator identifying as flux cored electrode
Indicates usability and performance capabilities 1. Electrode classified for used with CO2 or CO2+Ar mixture to improve usability especially for out of position welding. Designed for single and multi-pass welding characterized by spray transfer, low spatter loss and a moderate volume of slag. Generally are rutile based and operate on DC+ Self-shielded electode for single and multi pass welding in the flat and hoizontal verticals positions. Operates on DC+ and gives globular transer. Dsigned for use with CO2 (Ar based gases may be used) for single and multi pass welding in the flat and hoizontal verticals positions. Electrodes of this group have a lime fluoride based slag and produce weldmet having improved impact properties and crack resisrtance in comparison to rutile type. Self shielded electrode operating on DC with negative polarity. Designed for all positions and provides a weldmet with very good low temperature impact properties. Used for single and multi pass welding.

E X X T-X

X

4.

Tensile Strength designator in units of 10 KSi Shielding Gas Designator C=100% Co2, M = 80% Ar 20% Co2 in AWS + 5.20 Deposit Composition Designator in AWS A5.29)

5.

8.

x
A1 B2 B2L B3 B3L Ni1 Ni2 Ni3 D1 D2 D3 K2 K4 W2

C
0.12 0.05 - 0.12 0.05 0.05 - 0.12 0.05 0.12 0.12 0.12 0.12 0.15 0.12 0.15 0.15 0.12

Mn
Carbon 1.25 1.25 1.25 1.25 1.25

- Molybdenum steel electrodes
-

Ni

Cr

Mo

V
0.05 0.05 0.03 -

AI
1.80* 1.80* 1.80* 1.80* Cu = 0.3-0.75

0.40-0.65

Chromium - Molybdenum steel electrodes 1.0-1.5 0.40-0.65 2.0-2.5 0.90-1.20 2.0-2.5 0.90-1.20 2.0-2.5 0.90-1.20 Nickel steel electrodes 1.50 0.80-1.10 0.15 0.35 1.50 1.75-2.75 1.50 2.75-3.75 Manganese - Molybdenum steel electrodes 1.25-2.00 0.25-0.55 1.65-2.25 0.25-0.55 1.00-1.75 0.40-0.65 All other low alloyed electrodes 0.50-1.75 1.20-2.25 0.5-1.3 1.00-2.00 1.75-2.60 0.4-0.8 0.15 0.20-0.60 0.45 - 0.70 0.35 0.20-0.65 -

* Refer applicable code for detaily.

150

Cored Wire Fault Finding
POSSIBLE CAUSE POROSITY Insufficient shielding gas Excessive electrode extension Gas Nozzle too short Plate condition and impurities Equipment fault on gas control POOR WIRE FEED Incorrect tip size Damaged liner or tip Incorrect types, size and pressure of feed rolls Spool brake too tight Blocked liner SLAG INCLUSIONS Incorrect welder technique Direction of travel UNDERCUT Travel speed too fast parameters Incorrect torch angle Voltage too high Refer to notes on torch angels Reduce voltage Reduced travel speed or check Refer to notes Refer to recommended technique Check and replace Replace Refer equipment manual Check tension and slacken if necessary Remove obstruction or replace Check recommended flow rate Reduced extension Replace Remove non-metallic substances Check for leaks and air ingestion REMEDY

POSSIBLE CAUSE LACK OF FUSION Current too low Electrode extension too long for current being used Incorrect or inconsistent travel speed Torch angel or direction of travel Narrow joint preparation Root face too large LACK OF FUSION Direction and speed of travel Incorrect torch angle Incorrect parameters or torch manipulation

REMEDY

Welding Consumables

Refer to notes on electrode extension Adjust travel speed to suit desired degree of penetration Refer to welding techniques Modify preparation Modify preparation

. refer notes

Refer to notesillustration Refer to noteslillustration Check against recommended values for the wire in question and notes on torch manipulation

EXCESSIVE SPATTER Dirty plate Voltage too high for amperage being used Shielding gas pressure too high Poor current pick-up Clean plate-wire brush or grinding Check against recommended values Check against recommended flow rates Check size or replace worn contact tip.

151

Welding Consumables

General recommendations for Submerged Arc Welding
1. The flux must be dry. Agglomerated fluxes must be protected from moisture pick-up. In tropical, humid areas, re-drying agglomerated fluxes at 250-350OC before use is recommended. The remaining flux in the welding machine container should be removed and stored in a dry cabinet and should therefore not be left in the open container durifng the night. During the transport of fluxes, a maximum of two pallets should be stacked to prevent the grains being crushed. 2. The fusion faces and the plate in the vicinity of the joint should be clean and dry. The cleaner the joint, the better the chances of obtaining a satisfactory weld. Rust, mill scale, paint, oil and residue from arc-air gouging or grining can adversely affect the quality of the weld metal. The more impurities on the fusion faces, the greater the risk of weld metal defects.

3. The arc voltage must be kept constant. Increased arc voltage results in higher flux consumption. If the flux contains alloying elements, the amount transferred to the weld metal will increase as the arc voltage increases. 4. As a general rule, multi-run deposits made at moderate welding currents have better mechanical properties than one-or two-layer deposits made at high currents in similar plate thicknesses. N.B. The chemical analyses given in this catalogue are for all weld metal deposited with DC+, 580 A, 29 V, 33 m/h, except for OK Flux 10.92, where DC+, 420 A, 27 V and 30 m/h has been used (wire Ø4 mm) and for OK Flux 10.90, where DC+, 300A, 30V, 24 m/h has been used (wire Ø2.4 mm). The mechanical properties are obtained according to the welding conditins given in EN 756 (i.e. the same welding data as in EN 760). Other welding conditions may produce weld metal analyses and mechanical properties which differ from those given in the handbook.

152

DATA SHEET - SAW
SAW Classification Indicates the minimum tensile strength of the weldmetal, welded in accordance with AWS specifictions. Indicates a solid electrode

Welding Consumables

F X X X
Indicates Flux Designed the condition of heat treatment in which tests were conducted. “A” as welded “P” Post weld heat treated

-

E X X X

Digit F Z 0 2 4 5 6 8 10 15

Test Temperature C -18 -29 -40 -46 -51 -62 -73 -101

Average Energy Level (min)

No impact rquirements 0 -20 -40 -50 -60 -80 -100 -150

27J

xxx
EL8 EL8K EL12 EM12 EM12K EM13K EM14K EM15K EH11 K EH12K EH14

C
0.10 0.10 0.04/0.12 0.06/0.15 0.05/0.15 0.06/0.16 0.06/0.19 0.10/0.20 0.07/0.15 0.06/0.15 0.10/0.20

Mn Low Manganese Electrodes 0.25/0.60 0.25/0.60 0.25/0.60 0.80/1 .25 0.80/1.25 0.90/1.40 0.90/1.40 0.80/1.25 1.40/1.85 1.50/2.00 1.70/2.20

Si 0.07 0.10/0.25 0.10 0.10 0.10/0.35 0.35/0.75 0.35/0.75 0.10/0.35 0.80/1.15 0.25/0.65 0.10
153

Medium Manganese Electrodes

Hi91:1 Manganese Electrodes

Welding Consumables

Welding data and joint preparation
Typical welding data and recommended joint preparation for submerged arc welding mild steel and carbon-manganese structural steels with OK Flux 10.40, OK Flux 10.47, OK Flux 10.70, OK 10.71, OK Flux 10.72, OK Flux 10.76 and OK Flux 10.81.

Type of joint

Plate thickness mm
6 8 10

Wire diameter mm
3 4 4 4 4 4 4 4 6 6 6 6 2 2.5 3 3 3 4

Run No
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1 1 1 1 1 2 3 X 1 2 3, 4 5 X 1 2 3-5 6 7-8 X

Arc voltage V
33 33 34 34 34 35 35 35 35 35 32 35 34 35 36 35 36 36 36 36 36 36 36 36 28 30 31 32 33 29 32 34 30 29 30 32 36 30 29 30 32 34 36 30

Welding current A
400 430 480 550 550 650 650 700 700 750 600 650 700 650 750 650 700 850 800 850 850 950 900 1000 325 450 510 525 600 650 750 750 550 650 700 750 750 550 650 700 750 750 750

Welding speed cm/min.
80 60 55 50 40 50 50 40 30 25 20 15 125 70 50 45 35 50 50 40 50 50 50 40 40 50 50 50 50 40 40

1

2

12 14

70° 1 10 2 70° 1 6-8 2

16 18 20 18 20 25 30 2 4 6

Cu

8 10 20

60°

1-n 6 X

25

4

30

4

154

Typical welding data and for submerged arc fillet welding mild steel and carbon-manganese structural steels with OK Flux 10.47, OK Flux 10.71 and OK Flux 10.81.

Welding Consumables

Type of joint

Plate thickness mm
≥6 ≥8 ≥10 ≥8 ≥12 ≥15 ≥15 ≥20 Twin wire – – – – – –

Wire diameter mm
3 4 4 4 4 4 4 4

Throat thickness mm
3 4 5 4 4 7 – –

Arc voltage V
30–32 30–32 30–32 32–34 32–34 36 36 36

Welding current A
500 450 650 700 800 800 750 750

Welding speed cm/min.
100 60 50 115 140 45 45 40

Single welding head

2x1.6 2x2.0 4 4 4 4

4 5 4 4 4 5

32 34 +32 ~38 +32 ~38 +32 ~38 +32 ~35

800 300 800 700 800 700 800 700 800 700

120 110 140 140 140 90

Two welding heads + ~

155

Welding Consumables

Submerged arc welding “18/8” stainless steel. Joint preparation and typical welding data for filler materials OK Autrod 16.10 + OK Flux 10.92, 10.93 and similar OK - combinations.

Type of joint
1

Plate thickness mm
6 8

Wire diameter mm
3 4

Run No
1 2 1 2 1 2 1 2 1 2 3 1 2 3 4 1 2 1 2 1 2 1 2

Arc voltage V
34 34

Welding current A
400 500 500 600 600 600 600 600 600 600 600 600 600 600 600 450 550 500 600 500 600 550 600

Welding speed m/h
80 60 80 60 40 60 35 50 35 30 40 40 35 35 40 55 50 40 50 35 40 35 35

2

Manual welded root bead
60°

10
1.3 1

4 4 4

34 34 34

12
2 2 gap: 0-2 mm

20

60°

1.4 2

25

4

34 34 34 34 34 34 34 34 34 34

0-2 mm gap: 2 mm 90°

2.3

8
5

4 4 4 4

10 12

70°

5

14

156

Table 3: Typical welding data for different types of joint OK Flux 10.61 Land 10.62

Welding Consumables

Type of Joint

Plate Thickness mm 6 8 10 12 16 20 25 30 35

Wire mm 3 3 3 3 4 4 5 5 5 5 6 6 6 6 6 6 6 6 6

Run No. 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 5.1 :1* 2 5.2:1** 2

Arc Voltage V 29 30 31 31 30 30 30 30 32 32 31 32 31 31 31 30 30 32 30 32

Welding Current A 350 425 450 500 500 575 600 650 750 800 950 950 1000 1000 1000 1050 1050 900 1100 900

Welding Speed m/h 40 40 40 40 40 40 40 40 35 35 23 23 21 21 20 20 23 30 25 30

* First side ** Second side

Fillet

Throat Thickness a-mm
6.0 6.5 7.0 3.5 4.5 5.5

Wire Dia. mm

Arc Voltage

Welding Current A

Welding Speed m/h
30 30 30 60 50 40

V

5 5 5 4 4 4

32 31 30 29 29 29

800 850 900 650 650 650

157

CONSUMABLES GUIDE FOR ASTM STEELS
Welding Consumables
ASTM Designation A-27/A-27M A-36/A-36M Class or grade All All Recommended Consumables SMAW ESAB 36H, OK 74.46, ESAB 56 ESAB 28, ESAB 36H, ESAB 56 GTAW/GMAW FCAW SAW ESAB MW1, OK Dualshield 7100 Tigrod S2 LH ESAB MW1, OK Dualshield 7100 Tigrod S2 LH, OK Tubrod 15.00 ESAB MW1, OK Dualshield 7100 Tigrod S2 LH, OK Tubrod 15.00 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

A-53/A-53M

Type F Grade A Type E and S Grade A Type E and S Grade B

OK 53.18 , ESAB 36H, ESAB 28

ESAB 28,OK 53.18 ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK 53.18 , ESAB 36H, ESAB 28 ESAB 28, ESAB 36H , Pipeweld 6010 R ESAB 28, Pipeweld 6010 R ESAB MW1, OK Dualshield 7100 Tigrod S2 LH, OK Tubrod 15.00 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1,OK Aristorod 12.50 Dualshield 7100 LH OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.81L, OK Autrod 12.08L

A-105/A-105M

All

A-106/A-106M

Grade A

Grade B and C

ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl ESAB 36H

OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.71 / 10.74/10.81LS, OK Autrod 12.08L/12.24L OK Flux 10.81L, OK Autrod 12.08L

A-134/A-134M

A-135/A-135M

Grade A and B

ESAB 28, Pipeweld 6010 R

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1,OK Tigrod S2 Dualshield 7100 LH

A-178/A-178M

Grade A

ESAB 28

OK Flux 10.81LS, OK Autrod 12.08L/12.22L OK Flux 10.81LS, OK Autrod 12.08L/12.22L OK Flux 10.81LS, OK Autrod 12.08L/12.22L OK Flux 10.81LS, OK Autrod 12.08L/12.22L OK Flux 10.81LS, OK Autrod 12.08L/12.22L

Grade C and D A-179/A-179M Grade C and D Class 60

ESAB 36H

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 , LH , OK Tubrod OK Tigrod S2 15.00 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 , LH , OK Tubrod OK Tigrod S2 15.00 ESAB MW1,OK Tigrod S2 Dualshield 7100 LH

ESAB 36H

A-181/A-181M

ESAB 28

Class 70

ESAB 36H

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 , LH , OK Tubrod OK Tigrod S2 15.00

158

ASTM Designation A-182/A-182M F1

Class or grade

Recommended Consumables SMAW OK 74.46 GTAW/GMAW FCAW SAW OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.32 OK Tigrod 13.37 OK Tigrod 13.38 Dualshiled B9 OK Tigrod 13.17, OK Tigrod B3L OK Tigrod 410 OK Tigrod 410 NiMo OK Tigrod 430 OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod 16.10N OK Tigrod 16.13 OK Tigrod 16.13NF OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L OK Flux 10.71, OK Autrod 12.40L OK Autrod 16.30 , OK Flux 10.92L OK Autrod 13.35, OK Flux 10.93 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

Welding Consumables

F2 , F11, F12 OK 76.18, OK 76.18 M F5, 5a F9 F91 F22 ESAB KV4, ESAB KV4L ESAB KV7 ESAB KV7M, OK 76.98 OK 76.28 , OK 76.28M OK 68.10 , OK 68.15 OK 68.00 , OK 68.25 ESAB 430 OK 61.50, ESAB 308H OK 61.30 , ESAB 304B ESAB 304B(N) OK 67.67 OK 67.13 OK 310 MoL OK 63.50 OK 63.30 OK 64.30 OK 61.80

Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62 Arcaloy 409-Ti PZ 6166 / Shieldbright 410NiMo Arcaloy 436 Shieldbright 308, 308L Shieldbright 308L, 308L Xtra OK Autrod 410, OK Flux 10.92L OK Autrod 16.79, OK Flux 10.93 OK Autrod 430, OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L

F6a F6NM F430 F304 , 304H

F304L

F304N, F304LN F309H F310 F310MoLN F316, 316H F316L F317L F321, 347 , 348

OK Tigrod 16.11 Shieldbright 347 OK Tigrod 347H Shieldbright 347 ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Tigrod / Autrod 13.16 OK Tigrod / Autrod 13.17

F321H, 347H OK 61.80 , 348H A-192/A-192M A-202/A-202M Grade A Grade B ESAB 28, ESAB 36H OK 76.18 OK 76.18

Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20, OK Flux 10.62

159

Welding Consumables

ASTM Designation A-203/A-203M

Class or grade Grade A and B Grade D, E and F

Recommended Consumables SMAW Filarc 75S , OK 73.68 OK 73.79 OK 74.46 OK 76.18 OK Tigrod / Autrod 13.09 OK Tigrod / Autrod 13.09 OK Tigrod / Autrod 13.09 GTAW/GMAW OK Tigrod / Autrod 13.28 FCAW OK Tubrod 15.27 SAW OK Autrod 13.27 , OK Flux 10.62 OK Autrod 13.49 , OK Flux 10.63 Dualshield 7000A1 OK Autrod 13.09 , OK Flux 10.62 Dualshield 7000A1 OK Autrod 13.09 , OK Flux 10.62 Dualshield 7000A1 OK Autrod 13.09 , OK Flux 10.62 OK Autrod 12.22/12.40L , OK Flux 10.71

A-204/ A-204M

Grade A and B Grade C

A-209/ A-209M A-210/ A-210M

Grade T1, OK 74.46 T1a, T1b Grade A1, ESAB 28, ESAB C 36H T2, T11, T17 T5b, T5c T9 T91 T21 , 22 OK 76.18, OK 76.18 M ESAB KV4, ESAB KV4L ESAB KV7 ESAB KV7M, OK 76.98 OK 76.28 , OK 76.28M OK 61.50 OK 61.50, ESAB 308H ESAB 304B(N) ESAB 309Cb OK 67.67 OK 67.13 OK 63.50 OK 63.30 OK 64.30 OK 61.80 OK 61.80

ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.32 OK Tigrod 13.37 OK Tigrod 13.38 Dualshiled B9 OK Tigrod 13.17, OK Tigrod B3L

A-213/ A-213M

Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

OK Autrod 13.35, OK Flux 10.93

Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62 OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L

TP201, 202, 304 TP304H

OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10N OK Tigrod / Autrod 16.53 OK Tigrod 16.13 OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra Shieldbright 309L Shieldbright 308, 308L

TP304N, LN TP309Cb TP309S TP310S TP316, 316H TP316L TP317L TP321, 347, 348 TP321H, 347H, 348H

OK Autrod 16.53 , OK Flux 10.92L

OK Autrod 16.30 , OK Flux 10.92L

OK Tigrod 16.11 Shieldbright 347 OK Tigrod 347H Shieldbright 347

OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L

160

ASTM Designation A-214/ A-214M

Class or grade

Recommended Consumables SMAW ESAB 28, ESAB 36H GTAW/GMAW FCAW SAW OK Autrod 12.22L, OK Flux 10.71/10.81L ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Autrod 13.16 OK Tigrod / Aristorod 13.29 OK Tigrod / Autrod 13.09 OK Tigrod / Aristorod 13.29 OK Tigrod / Autrod 13.17 OK Tigrod / Autrod 13.16 OK Tigrod / Autrod 13.32 OK Tigrod / Autrod 13.37 OK Tigrod / Autrod 13.38 OK Tigrod / Autrod 410 OK Aristorod 13.29 Dualshield B9 Arcaloy 409-Ti Dualshield T-115 Dualshield 8100W OK Autrod 13.35, OK Flux 10.93 OK Autrod 410, OK Flux 10.92L OK Autrod 13.43, OK Flux 10.62

Welding Consumables

A-216/ A-216M

Grade WCA Grade WCB and WCC

OK 76.18 ESAB 98

Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 OK Autrod 13.44, OK Flux 10.62 Dualshield 7000A1 OK Autrod 13.09, OK Flux 10.62 OK Autrod 13.44, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20, OK Flux 10.62 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

A-217/ A-217M

Grade WC1 Grade WC4 Grade WC5 and WC9 Grade WC6 and WC11 C5 C12 C12A CA15

OK 74.46 ESAB 98 OK 76.28

OK 76.18

ESAB KV4 ESAB KV7 ESAB KV7M OK 68.10 ESAB 118 Ferroweld W2

A-225/ A-225M A-234/ A-234M

Grade C and D Grade WPB, WPC Grade WP1

OK 74.46

OK Tigrod / Autrod 13.09 OK Tigrod 13.16, OK Tigrod B2L

Dualshield 7000A1 OK Autrod 13.09, OK Flux 10.62 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

Grade OK 76.18, OK WP1276.18 M CL1, WP12CL2, WP11CL1, WP11CL2, WP11CL3 Grade OK 76.28 , OK WP2276.28M CL1, WP22CL3 Grade WP5 ESAB KV4, ESAB KV4L

OK Tigrod 13.17, OK Tigrod B3L OK Tigrod 13.32

Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62

161

Welding Consumables

ASTM Designation

Class or grade Grade WP9 Grade WP91

Recommended Consumables SMAW ESAB KV7 ESAB KV7M, OK 76.98 OK 61.50 GTAW/GMAW OK Tigrod 13.37 OK Tigrod 13.38 Dualshield B9 OK Tigrod 16.10 Shieldbright 308, 308L OK Autrod 13.35, OK Flux 10.93 OK Autrod 16.10, OK Flux 10.92L FCAW SAW

A-240

Grade 201, 202, 301, 302, 304 Grade 304H Grade 304L Grade 304N, LN Grade 309S Grade 309Cb Grade 310S Grade 310MoLN Grade 316, 316L Grade 317, 317L, 317LN Grade 321, 347, 348 Grade 321H, 347H, 348H

OK 61.50, ESAB 308H OK 61.30 ESAB 304B(N) OK 67.67 ESAB 309Cb OK 67.13 OK 310 MoL OK 63.30 OK 64.30,ESAB 317L(N)

OK Tigrod 16.10, OK Tigrod 308H

Shieldbright 308, 308L

OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10 / OK Flux 10.92L

OK Tigrod 16.10 Shieldbright 308L OK Tigrod 16.10N OK Tigrod / Autrod 16.53 Shieldbright 309L

OK Autrod 16.53 , OK Flux 10.92L

OK Tigrod 16.13 OK Tigrod 16.13NF OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L /N Shieldbright 317L Xtra OK Autrod 16.30 , OK Flux 10.92L

OK 61.80

OK Tigrod 16.11 Shieldbright 347

OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L

OK 61.80

OK Tigrod 347H Shieldbright 347

Grade OK 68.10 405, 409, 410, 410S Grade 430 A-249/ A-249M TP201, 202, 304 TP304L, 304H TP304N, LN TP309S ESAB 430 OK 61.50 OK 61.50, ESAB 308H ESAB 304B(N) OK 67.67

OK Tigrod 410

Arcaloy 409-Ti

OK Autrod 410, OK Flux 10.92L

OK Tigrod 430

Arcaloy 436 OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L

OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10N OK Tigrod / Autrod 16.53 Shieldbright 309L Shieldbright 308, 308L

OK Autrod 16.53 , OK Flux 10.92L

162

ASTM Designation

Class or grade TP309Cb TP310S TP316, 316L TP317, 317L TP321, 347, 348 TP321H, 347H, 348H

Recommended Consumables SMAW ESAB 309Cb OK 67.13 OK 63.30 OK 64.30 OK 61.80 OK 61.80 OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L OK Autrod 16.30 , OK Flux 10.92L GTAW/GMAW FCAW SAW

Welding Consumables

OK Tigrod 16.11 Shieldbright 347 OK Tigrod 347H Shieldbright 347

A-250/A-250M

Grade T1, OK 74.46 T1a, T1b Grade T2, OK 76.18, OK T11, T12 76.18 M Grade T22 OK 76.28 , OK 76.28M ESAB 36H OK 76.18

OK Tigrod / Autrod 13.09 OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.17, OK Tigrod B3L

Dualshield 7000A1 OK Autrod 13.09 , OK Flux 10.62 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62 OK Autrod 12.40 and OK Flux 10.71

A-266/A-266M

Grade 1 Grade 2 , 3 and 4

ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 410 OK Tigrod 410NiMo OK Tigrod 430

Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Arcaloy 409-Ti PZ 6166 / Shieldbright 410NiMo Arcaloy 436 OK Autrod 410, OK Flux 10.92L OK Autrod 16.79, OK Flux 10.93 OK Autrod 430, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10 / OK Flux 10.92L

A-268/A-268M

TP405, 409, 410 TP410 (UNS S 41500) TP429, 430

OK 68.10 , OK 68.15 OK 68.25

ESAB 430 OK 61.50

A-276

Type 201, 202, 302, 304, 308

OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10 Shieldbright 308L OK Tigrod 16.10N OK Tigrod / Autrod 16.53 Shieldbright 309L

Type 304L OK 61.30 Type 304N, LN Type 309, 309S Type 310, 310S Type 314, 316 Type 317 Type 327, 347, 348 ESAB 304B(N) OK 67.67 OK 67.13 OK 63.30 OK 64.30 OK 61.80

OK Autrod 16.53 , OK Flux 10.92L

OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra

OK Autrod 16.30 , OK Flux 10.92L

OK Tigrod 16.11 Shieldbright 347

OK Autrod 16.11, OK Flux 10.92L

163

Welding Consumables

ASTM Designation

Class or grade Type 405 Type 429, 430 UNS S41500

Recommended Consumables SMAW OK 68.10 , OK 68.15 ESAB 430 OK 68.25 ESAB 28, ESAB 36H GTAW/GMAW OK Tigrod 410 OK Tigrod 430 OK Tigrod 410NiMo FCAW Arcaloy 409-Ti Arcaloy 436 PZ 6166 / Shieldbright 410NiMo SAW OK Autrod 410, OK Flux 10.92L OK Autrod 430, OK Flux 10.92L OK Autrod 16.79, OK Flux 10.93 OK Autrod 12.22L / 12.40L, OK Flux 10.71 OK Autrod 12.22L / 12.40L/SA10K, OK Flux 10.71/10.61L OK Autrod 12.24, OK Flux 10.71 OK Autrod 12.34, OK Flux 10.71 OK Autrod 12.34/12.24, OK Flux 10.71/10.62 OK Autrod 12.34 and 12.44 , OK Flux 10.62 OK Autrod 13.40, OK Flux 10.62 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10; OK Flux 10.92L OK Autrod 16.30 , OK Flux 10.92L OK Autrod 16.30 , OK Flux 10.92L OK Autrod 317L, OK Flux 10.92L OK Autrod 16.11, OK Flux 10.92L OK Autrod 12.24, OK Flux 10.62

A-283/A-283M

Grade A and B

ESAB MW1, OK Dualshield Tigrod S2, OK 7100LH, OK Aristorod 12.50 Tubrod 15.14A, Dualshield T5 ESAB MW1, OK Dualshield 7100LH, OK Tigrod S2, OK Aristorod 12.50 Tubrod 15.14A, Dualshield T5 OK Tigrod 13.09, OK Autrod 13.14 OK Aristorod / Tigrod 13.29 OK Aristorod / Tigrod 13.29 OK Tigrod / Aristorod 13.08 and 13.09 OK Autrod 13.25 OK Tubrod 15.24

Grade C and D

ESAB 36H

A-285/A-285M

Grade A

ESAB 8018-G

Grade B and C A-299/A-299M

ESAB 98 ESAB 8018-G

Dualshield II101TC Dualshield II101TC OK Tubrod 14.02

A-302/A-302M

Grade A

OK 74.78

Grade B , C and D A-311/A-311M 1018, 1117

OK 74.86

-

ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 36H , OK 48.20 Spl Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK 61.50, ESAB 308H ESAB 304B(N) OK 63.50 OK 63.30 OK 64.30 OK 61.80 ESAB 36H(Spl) OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10 OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra Shieldbright 308, 308L

A-312/A-312M

TP304 ,TP304H TP304L , TP304N TP316, 316H TP316L, 316LN TP317, 317L TP321, 347, 348

OK Tigrod 16.11 Shieldbright 347 OK Tigrod S2(Spl)/ OK Autrod 13.23 Dualshield 7100HI /OK Tubrod 15.19

A-333/A-333M

Grade 1 and 6

164

ASTM Designation

Class or grade Grade 3 and 4 Grade 7 and 9 Grade 8

Recommended Consumables SMAW ESAB 8016 C2 , OK 73.79 Filarc 75S OK 92.45, OK 92.55 Filarc 88S ESAB 36H(Spl) GTAW/GMAW OK Tigrod / Autrod 19.81 FCAW SAW OK Autrod 13.27, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 19.82/19.85, OK Flux 10.16 / 10.90 OK Autrod 13.27, OK Flux 10.62 OK Autrod 12.24, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 19.82/19.85, OK Flux 10.16 / 10.90

Welding Consumables

OK Tigrod 13.28 OK Tigrod / Autrod 19.82 ; 19.85 -

Grade 10 A-334/A-334M Grade 1 and 6 Grade 3 Grade 7 Grade 8

OK Tigrod 13.28 Filarc PZ 6138 OK Tigrod S2(Spl)/ OK Autrod 13.23 OK Tigrod / Autrod 19.81 Dualshield 7100HI /OK Tubrod 15.19 -

ESAB 8016 C2 Filarc 75S OK 92.45, OK 92.55 OK 74.46

OK Tigrod 13.28 OK Tigrod / Autrod 19.82 ; 19.85 -

A-335/A-335M

Grade P1 and P2

OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Tigrod 13.32 OK Tigrod 13.37 OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.17, OK Tigrod B3L Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20, OK Flux 10.62 OK Autrod 13.35, OK Flux 10.93

Grade P5, ESAB KV4, ESAB P5b, P5c KV4L Grade P9 Grade P11, P12 Grade P21, P22 Grade P91 A-336/A-336M F1 F3V F11 classes 2&3, F12 F5, F5A F6 F9 F91 ESAB KV7 OK 76.18, OK 76.18 M OK 76.28 , OK 76.28M ESAB KV7M, OK 76.98 OK 74.46 ESAB KV11 OK 76.18, OK 76.18 M ESAB KV4, ESAB KV4L OK 68.10 , OK 68.15 ESAB KV7 ESAB KV7M, OK 76.98

OK Tigrod 13.38 Dualshiled B9

OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Tigrod 13.16, OK Tigrod B2L Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

OK Tigrod 13.32 Dualshiled B6 OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410, OK Flux 10.92L OK Autrod 13.35, OK Flux 10.93 OK Autrod 13.35, OK Flux 10.93

OK Tigrod 13.37 Dualshiled B9 OK Tigrod 13.38 Dualshiled B9

165

Welding Consumables

ASTM Designation

Class or grade

Recommended Consumables SMAW GTAW/GMAW OK Tigrod 13.17, OK Tigrod B3L OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod 16.10N OK Tigrod / Autrod 16.53 OK Tigrod 16.13 OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 16.11 Shieldbright 347 OK Tigrod 347H Shieldbright 347 OK Autrod 16.30 , OK Flux 10.92L OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L OK Autrod 12.40 and OK Flux 10.71L OK Autrod 12.24, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 13.27, OK Flux 10.62 OK Autrod 12.24, OK Flux 10.71 OK Autrod 13.43, OK Flux 10.62 OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.30, OK Flux 10.92L Shieldbright 309L OK Autrod 16.53 , OK Flux 10.92L FCAW SAW Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62 Shieldbright 308, 308L Shieldbright 308L, 308L Xtra OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L

F21, F22 - OK 76.28 , OK classes 1 76.28M and 3 F304 , 304H F304L OK 61.50, ESAB 308H OK 61.30 , ESAB 304B ESAB 304B(N) OK 67.67 OK 67.13 OK 63.50 OK 63.30

F304N, F304LN F309H F310 , F310H F316, 316H F316L

F321, 347 OK 61.80 , 348 F321H, 347H , 348H A-350/A-350M LF1 , LF2 Class 2 OK 61.80

ESAB 36H

OK Tigrod S2 OK Tigrod S2(Spl)/ OK Autrod 13.23 OK Tigrod / Autrod 19.81

Dualshield T5 Dualshield 7100HI /OK Tubrod 15.19 -

LF2 Class ESAB 36H(Spl) 1 LF3 Class ESAB 8016 C2 1 and 2 , LF9 LF5 Class Filarc 88S 1 and 2 LF6 Class Filarc 88S 1 and 2 LF6 Class OK 73.08 3 LF787 Class 2 A-351/A-351M CF3, CF3A CF3M, CF3MA, CF3MN OK 75.75 OK 61.30 , ESAB 304B OK 63.30

OK Tigrod 13.28 Filarc PZ 6138 OK Tigrod 13.28 Filarc PZ 6138 OK Tigrod 13.09 OK Tubrod 15.24 OK Aristorod 13.26 OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod 16.30, OK Autrod 16.30 Dualshield T-115 Shieldbright 308L, 308L Xtra Shieldbright 316L, 316L Xtra

166

ASTM Designation

Class or grade CF8, CF8A, CF8C, CF10 CF8M, CF10M CH8, CH10, CH20 CK20, HK30, HK40

Recommended Consumables SMAW OK 61.50, ESAB 308H GTAW/GMAW OK Tigrod 16.10, OK Tigrod 308H FCAW Shieldbright 308, 308L SAW OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.53 , OK Flux 10.92L -

Welding Consumables

OK 63.50 OK 67.67

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod / Autrod 16.53 OK Tigrod / Autrod 16.13 Shieldbright 309L

OK 67.13

Shieldbright 310 Extra -

A-352/A-352M

LCA, Ferroweld W2 LCB, LCC LC1 LC2 LC2-1 LC3 LC9 OK 74.46 OK 73.68 ESAB 120 OK 73.79 OK 92.45, OK 92.55 OK 68.00 , OK 68.25, ESAB 410NiMo OK 92.45, OK 92.55 Grade OK 61.50, ESAB 304, 304H 308H Grade 304L Grade 304N, LN Grade 309S Grade 309Cb Grade 316, 316L Grade 321, 347, 348 OK 61.30 ESAB 304B(N) OK 67.67 ESAB 309Cb OK 63.30 OK 61.80

-

OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Tigrod 13.28 OK Tigrod / Autrod 19.82 ; 19.85 OK Tigrod 410 NiMo OK Tigrod / Autrod 19.82, 19.85 OK Tigrod 16.10, OK Tigrod 308H -

CA6NM

PZ 6166 / Shieldbright 410NiMo -

OK Autrod 16.79, OK Flux 10.93 OK Autrod 19.82, 19.85/OK Flux 10.16, 10.90 OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10 / OK Flux 10.92L

A-353/A-353M

A-358/A-358M

Shieldbright 308, 308L

OK Tigrod 16.10 Shieldbright 308L OK Tigrod 16.10N OK Tigrod / Autrod 16.53 Shieldbright 309L

OK Autrod 16.53 , OK Flux 10.92L

OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 16.11 Shieldbright 347

OK Autrod 16.30 , OK Flux 10.92L OK Autrod 16.11, OK Flux 10.92L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

A-369/A-369M

FPA, FPB

ESAB 28, ESAB ESAB MW1, OK Dualshield 7100 36H , OK 48.20 Spl Aristorod 12.50 LH

167

Welding Consumables

ASTM Designation

Class or grade FP1,FP2 FP11, FP12 FP21, FP22 FP5 FP9 FP91

Recommended Consumables SMAW OK 74.46 OK 76.18, OK 76.18 M OK 76.28 , OK 76.28M ESAB KV4 ESAB KV7 ESAB KV7M , OK 76.98 ESAB 36H GTAW/GMAW FCAW SAW OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.17, OK Tigrod B3L OK Tigrod / Autrod 13.32 OK Tigrod / Autrod 13.37 OK Tigrod / Autrod 13.38 OK Tigrod S2, ESAB MW1 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62 Dualshield B6 Dualshield B9 Dualshield B9 Dualshield 7100 LH OK Autrod 13.35 and OK Flux 10.93 OK Autrod 13.35 and OK Flux 10.93 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

A-372/A-372M

Grade A

Grade B

OK 73.08

OK Tigrod 13.09, OK Autrod 13.14

Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Autrod 13.43 and OK Flux 10.62 OK Autrod 13.43 and OK Flux 10.62

Grade C ,D

ESAB 118

OK Tigrod / Aris- Dualshield T-115 torod 13.13 OK Tigrod / Aris- Dualshield T-115 torod 13.13 OK Aristorod 13.31

Grade E, ESAB 118 F, G, H, J (Class 55) Grade E, F, G, H, J (Class 65), Grade K, M Class A,B A-376/A-376M TP304, TP304N TP304H ESAB 120

OK 61.50 OK 61.50, ESAB 308H OK 61.30 , ESAB 304B OK 63.50 OK 63.30

OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Autrod 16.10 Shieldbright 308, 308L Shieldbright 308L, 308L Xtra

OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L

TP304LN

TP316, TP316H TP316L, 316LN

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.30 , OK Flux 10.92L OK Autrod 16.11, OK Flux 10.92L

TP327, OK 61.80 327H, 347, 347H, 348

168

ASTM Designation A-387/A-387M

Class or grade Grade 2,12,11 Grade 22, 22L Grade 5 Grade 9 Grade 91

Recommended Consumables SMAW OK 76.18, OK 76.18 M OK 76.28 , OK 76.28M ESAB KV4, ESAB KV4L ESAB KV7 ESAB KV7M , OK 76.98 GTAW/GMAW OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.17, OK Tigrod B3L FCAW SAW Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield 9000B3 OK Autrod 13.20 and OK Flux 10.62

Welding Consumables

OK Tigrod 13.32 Dualshield B6 OK Tigrod 13.37 Dualshield B9 OK Tigrod 13.38 Dualshield B9 OK Tigrod 16.10 Shieldbright 308 OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod 308H OK Tigrod / Autrod 16.53 Shieldbright 308L, 308L Xtra Shieldbright 308L Shieldbright 309L OK Autrod 13.35, OK Flux 10.93 OK Autrod 13.35, OK Flux 10.93 OK Autrod 16.10 / OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 308H, OK Flux 10.92L OK Autrod 16.53 , OK Flux 10.92L

A-403/A-403M

WP/CR OK 61.50 304, 304N WP/CR 304L WP/CR 304H WP/CR 309 OK 61.30 , ESAB 304B ESAB 308H OK 67.67

WP/CR OK 63.50 316, 316N WP/CR 316L, 316LN WP/CR 317L, 317LN WP/CR 321, 347, 348 WP/CR 347H, 348H A-409/A-409M TP304 TP304L OK 63.30

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 317L Shieldbright 317L Xtra OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.53 , OK Flux 10.92L OK Autrod 16.30 , OK Flux 10.92L

OK 64.30

OK 61.80

OK Tigrod 16.11 Shieldbright 347

OK 61.80

OK Tigrod 347H Shieldbright 347

OK 61.50 OK 61.30 , ESAB 304B OK 67.67 ESAB 309Cb OK 67.13 OK 63.50 OK 63.30

OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod / Autrod 16.53 OK Tigrod 16.13 OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra Shieldbright 308L, 308L Xtra Shieldbright 309L

TP309S TP309Cb TP310S TP316 TP316L

OK Autrod 16.30 , OK Flux 10.92L

169

Welding Consumables

ASTM Designation

Class or grade TP317 TP321, 347, 348

Recommended Consumables SMAW OK 64.30 OK 61.80 ESAB 28, ESAB 36H ESAB 28, OK 48.20 Spl GTAW/GMAW OK Tigrod 317L FCAW Shieldbright 317L Xtra OK Autrod 16.11, OK Flux 10.92L SAW

OK Tigrod 16.11 Shieldbright 347 ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Tigrod S2 / S2 spcl Dualshield 7100 LH

A-414/A-414M

Grade A, B, C,D, E and F WPL 6

A-420/A-420M

OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Autrod 13.10, OK Flux 10.62

WPL 9 A-423/A-423M Grade 1

OK 73.08 OK 76.18, OK 76.18 M OK 73.08 OK 76.18, OK 76.18 M OK 67.67, ESAB 309 OK 61.50, ESAB 308H OK 63.50

OK Tigrod 13.16 OK Tubrod 15.24 OK Tigrod 13.16, OK Tigrod B2L OK Tigrod 13.16, OK Tigrod B2L OK Autrod/Tigrod 16.53 OK Tigrod 16.10, OK Tigrod 308H Dualshield 8000B2, OK Tubrod 15.24 OK Tubrod 15.24 Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Shieldbright 309L OK Autrod 16.53 , OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L

Grade 2 A-426/A-426M CP2, CP11, CP12 CP5, CP5b, CP21 A-430/A-430M FP304, FP304H, FP304N FP316, FP316H, FP316N FP321, FP321H, FP347 FP347, FP347H FP16-82H A-451/A-451M CPF3, CPF3A CPF8, CPF8A CPF3M CPF8M

Shieldbright 308, 308L

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11, OK Flux 10.92L OK Autrod 347H, OK Flux 10.92L

OK 61.80

OK 61.80

OK Tigrod 347H Shieldbright 347

OK 61.30 OK 61.50 OK 63.30 OK 63.50

OK Tigrod 16.10 Shieldbright 308L OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.11 Shieldbright 347 OK Tigrod / Autrod 16.53 Shieldbright 309L

OK Autrod 16.10 / OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.30 , OK Flux 10.92L

CPF10MC OK 63.80 CPF8C CPH8, CPH20 CPK20
170

OK 61.80 OK 67.67

OK Autrod 16.11, OK Flux 10.92L OK Autrod 16.53 , OK Flux 10.92L

ASTM Designation A-479/A-479M

Class or grade 302, 304, 304H, 304N 304L, 304LN 309S 309Cb 310S

Recommended Consumables SMAW OK 61.50 GTAW/GMAW FCAW SAW OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L OK Autrod 16.53 , OK Flux 10.92L OK Tigrod 16.10 Shieldbright 308, 308L OK Tigrod 16.10, OK Autrod 16.10 OK Tigrod / Autrod 16.53 OK Tigrod 16.13 OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.30 , OK Flux 10.92L OK Autrod 16.11, OK Flux 10.92L OK Autrod 410, OK Flux 10.92L OK Autrod 13.43, OK Flux 10.62 Shieldbright 308L, 308L Xtra Shieldbright 309L

Welding Consumables

OK 61.30 , ESAB 304B OK 67.67 ESAB 309Cb OK 67.13

316, 316N OK 63.50 316L, 316LN 321, 321H, 347, 348 403, 410, 414, 405, 430 A-487/A-487M 11A, 12A, 16A, 4B, 4D, 4E, 8B 8C, 9B, 9D, 10A, 11B, 12B, 13B, 6A, 6B, 7A, 14A, 10B A-508/A-508M 1, 1A, 2, 3, 2A, 3A, 4B 4,5 4A, 5A A-513/A-513M 10081035 All OK 63.30 OK 61.80

OK 68.10 , OK 68.15 ESAB 118

OK Tigrod 410

Arcaloy 409-Ti

OK Aristorod 13.29

Dualshield T-115

ESAB 120

ESAB 98

OK Tigrod / Aristorod 13.29 OK Aristorod 13.29 Dualshield T-115

OK Autrod 13.44, OK Flux 10.62 OK Autrod 13.43, OK Flux 10.62

ESAB 118 ESAB 120 Pipeweld 6010R, Pipeweld 6010 plus, ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl ESAB 118, ESAB 120

ESAB MW1, OK Dualshield 7100LH OK Autrod 12.24, Tigrod S2 OK Flux 10.71 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Aristorod 13.29 Dualshield T-115 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Autrod 13.43, OK Flux 10.62

A-515/A-515M

A-516/A-516M

All

A-517/A-517M

All

171

Welding Consumables

ASTM Designation A-533/A-533M

Class or grade Type A Type B Type C and D

Recommended Consumables SMAW OK 74.46 ESAB 118 OK 73.08 ESAB 36H, OK 73.08, OK 48.20 (spl) Filarc 75S , OK 73.68 ESAB 36H, OK 74.46, ESAB 56 OK 73.08 ESAB 98 ESAB 118 GTAW/GMAW FCAW SAW OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09 OK Aristorod 13.29 Dualshield T-115 OK Autrod 13.43, OK Flux 10.62

OK Tigrod 13.16 OK Tubrod 15.24 ESAB MW1, OK Dualshield 7100LH Tigrod S2 OK Tigrod / Autrod 13.28 OK Tubrod 15.27 OK Autrod 13.27 , OK Flux 10.62

A-537/A-537M

Class 1

Class 2 A-541/A-541M 1,1A 2,3,4 3V, 22b 2A, 3A, 7B, 22C, 7,8 22D, 7A, 8A A-543/A-543M 1B, 1C, 3B, 3C 2B, 2C A-556/A-556M A2

ESAB MW1, OK Dualshield 7100 Tigrod S2 LH OK Tigrod 13.16 OK Tubrod 15.24 OK Tigrod / Aristorod 13.29 OK Aristorod 13.29 Dualshield T-115 OK Autrod 13.44, OK Flux 10.62 OK Autrod 13.43, OK Flux 10.62

ESAB 120 ESAB 118 ESAB 120 Pipeweld 6010R, Pipeweld 6010 plus, ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl ESAB MW1, OK Dualshield 7100LH OK Autrod 12.24, Tigrod S2 OK Flux 10.71 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Aristorod 13.29 Dualshield T-115 OK Autrod 13.43, OK Flux 10.62

A-557/A-557M

B2, C2

A-562/A-562M

A-568/A-568M

All

Pipeweld 6010R, Pipeweld 6010 plus, ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl OK 73.08 ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl OK 73.08

ESAB MW1, OK Dualshield 7100LH OK Autrod 12.24, Tigrod S2 OK Flux 10.71 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Tigrod 13.16 OK Tubrod 15.24 ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Tigrod 13.16 OK Tubrod 15.24 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

A-572/A-572M

42, 50, 55, 60

65 A-573/A-573M 58,65

70

172

ASTM Designation A-592/A-592M A-612/A-612M A-638/A-638M A-645/A-645M A-649/A-649M

Class or grade A,E,F All

Recommended Consumables SMAW ESAB 118 Filarc 75S , OK 73.68 GTAW/GMAW OK Aristorod 13.29 OK Tigrod / Autrod 13.28 FCAW Dualshield T-115 OK Tubrod 15.27 SAW OK Autrod 13.43, OK Flux 10.62 OK Autrod 13.27 , OK Flux 10.62

Welding Consumables

2,4

ESAB 28, ESAB 36H , Pipeweld 6010 R, OK 48.20 Spl OK 76.18, OK 76.18 M ESAB 118 ESAB 36H ,OK 48.20 Spl

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Tigrod 13.16, OK Tigrod B2L OK Aristorod 13.29

OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

1A2 , 3

Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62 Dualshield T-115 OK Autrod 13.43, OK Flux 10.62 OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L

1B2 A-660/A-660M All

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Tubrod 15.24 OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Autrod 16.10 Shieldbright 308, 308L Shieldbright 308L, 308L Xtra

A-662/A-662M

A&B

ESAB 36H ,OK 48.20 Spl

C A-666/A-666M 201, 202, 301, 302, 304 304L, 304LN 316, 316M 316L A-671/A-671M A-672/A-672M A45, A50, ESAB 36H ,OK A55, B55, 48.20 Spl B65, B70, C55, C60, C65, C70, D70, D80, E55, E60 H75, H80 OK 74.46 OK 61.50, ESAB 308H OK 61.30 , ESAB 304B OK 63.50 OK 63.30

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Autrod 16.30 , OK Flux 10.92L OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L

OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 , OK Autrod 13.09

173

Welding Consumables

ASTM Designation

Class or grade J80, J90, J100, K75, K85, L65, L70, L75, M70, M75, N75

Recommended Consumables SMAW ESAB 118, OK 76.18, OK 76.18 M GTAW/GMAW OK Tigrod 13.16, OK Tigrod B2L FCAW SAW Dualshield 8000B2 OK Autrod 13.10, OK Flux 10.62

A-675/A-675M

45, 50, 55, 60

ESAB 36H ,OK 48.20 Spl

ESAB MW1, OK Dualshield 7100 Aristorod 12.50 LH , OK Tigrod S2 / S2 spcl OK Tigrod / Aristorod 13.29 OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Tigrod 308H OK Tigrod 16.10, OK Autrod 16.10 Shieldbright 308, 308L Shieldbright 308, 308L Shieldbright 308L, 308L Xtra

OK Flux 10.81L /10.71, OK Autrod 12.08L/12.22L / 12.40L OK Autrod 13.44, OK Flux 10.62 OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10 / 308H, OK Flux 10.92L OK Autrod 16.10, OK Flux 10.92L

65,70 A688-88a TP304

ESAB 98 OK 61.50, ESAB 308H OK 61.50, ESAB 308H OK 61.30 , ESAB 304B OK 63.50 OK 63.30 ESAB 317 LN OK 74.46 OK 73.08

TP304L, 304H TP304LN

TP316 TP316L TP316LN A691-85a CM-65, CM-70 CM-75, CMSH-70 CMSH-80 0.5CR., 1CR 1.2 CR 2.25 CR

OK Tigrod 316H Shieldbright 316, Xtra OK Tigrod 16.30 Shieldbright 316L, Xtra OK TIGROD 13.09 OK TIGROD 13.09 OK TIGROD 13.14 OK TUBROD 15.24 OK TUBROD 15.22 OK Autrod 16.30 , OK Flux 10.92L

OK 76.18

OK TIGROD 13.16

OK TUBROD 15.20 OK TUBROD 15.20

OK 76.28

OK Tigrod 13.17, OK Tigrod B3L ESAB MW1, OK Dualshield 7100 Tigrod S2 Ultra OK Tigrod S2 OK Tigrod S2 Dualshield 7100 Ultra Dualshield 7100 Ultra

A695-81

A,B,C,D Grades 35&40

ESAB 36H, OK 48.20 ESAB 36H, OK 48.20 Pipeweld 6010R, Citoflex, Pipeweld 6011

A696-85

B

174

ASTM Designation

Class or grade C

Recommended Consumables SMAW ESAB 36H, OK 48.20 Esab 118 OK 74.46 OK 73.08 Esab 118 Ferroweld W OK 76.18 GTAW/GMAW FCAW SAW ESAB MW1, OK Dualshield 7100 Tigrod S2 Ultra OK Tubrod 15.24 OK Tigrod 13.09 DS 7000 A1 OK Tigrod 13.14 OK Tubrod 15.24A OK Tubrod 15.27A DS 8100W DS 8100W OK Tigrod 13.16 OK Tubrod 15.20

Welding Consumables

A-724-88 A727-87 A737-87 A738-87a

All B C A B&C B11

A739-81a OK 76.28 B22 A-765-87 I II OK 73.08 OK 73.68 OK Tigrod 13.14 OK Tubrod 15.24 OK Tubrod 14.04 OK Tigrod 13.17 OK Tubrod 15.22

175

176

Welding Consumables

1. MMA electrodes for mild and low-alloyed steels
Normal quality level
Higher quality level (X-ray) Not specified 420 MPa (70 000) 560 MPa (80 000) 630 MPa (90 000) 700 MPa (100 000) 770 MPa (110 000) 850 MPa (115 000) ESAB 120 OK 74.46 OK 76.18 OK 76.18, OK 76.18 M OK 76.28, OK 76.28 M ESAB K V4, ESAB KV 4L ESAB KV7, ESAB KV7 M ESAB 36H ESAB 36H Spl OK 73.08 OK 73.68 ESAB 7018 C3L 0.5 Mo 0.5 Mo 0.5 Cr 0.5 Mo 1.2 Cr 1.0 Mo 2.25 Cr 0.5 Mo 5 Cr 1.0 Mo 9 Cr –20°C Charpy V –40°C Charpy V –60°C Charpy V –70°C Charpy V ESAB 118 OK 74.78 ESAB 98 ESAB 28 ESAB 46 ESAB 36H ESAB VORDIAN ESAB VORTEX 1 ESAB 36H ESAB 36H (Spl)

Mild steel

Yes

Requirements

QUICK GUIDE

No

Medium & hightensile steel

Yes

Requirements Tensile strength

No

Low-alloyed High temperature

Yes

Requirements Base metal composition

No

Quick Guide & General Information

Low temperature

Yes

Requirements Temp. °C

2. Solid wires
Normal quality level
Higher quality level (X-ray) Not specified 420 MPa (70 000) 560 MPa (80 000) 630 MPa (90 000) 700 MPa (100 000) 770 MPa (110 000) OK AristoRod 13.31 OK Autrod 12.51/ESAB MW1/OK/Tigrod S2 OK AristoRod 12.50 OK Tigrod S2 (Spl)

Mild steel

Yes

Requirements

No

Medium & hightensile steel

Yes

Requirements Tensile strength

No

OK Autrod 12.51/ESAB MW1/OK/Tigrod S2 OK AristoRod 12.50 OK Tigrod S2 (Spl) OK AristoRod/Tigrod 13.08 / ESAB MW2 OK AristoRod/Tigrod 13.09 OK AristoRod/Tigrod 13.12 OK AristoRod/Tigrod 13.13 / OK Autrod 13.14 OK Autrod 13.25/OK AristoRod 13.29

High temperature 0.5 Mo 0.5 Cr 0.5 Mo 1.2 Cr 1.0 Mo 2.25 Cr 0.5 Mo 5 Cr: 1 Mo 9 Cr

Yes

Requirements Base metal composition

0.5 Mo

OK AristoRod/Tigrod 13.09 OK AristoRod/Tigrod 13.12 OK AristoRod/Tigrod 13.12 / OK Tigrod B2L OK Autrod/Tigrod 13.16/13.17 OK AristoRod/Tigrod 13.22 / 13.17 / B3 L OK Tigrod 13.32 OK Autrod/Tigrod 13.37 OK Tigrod 13.38

No

Low temperature –40°C Charpy V

Yes

Requirements Temp. °C

–20°C Charpy V

OK Autrod 12.51 / ESAB MW1 OK Autrod/Tigrod 12.64 OK AristoRod 12.50/12.63 OK Tigrod 12.61 / OK Tigrod S2 OK Autrod/Tigrod 13.23/13.28 / OK Tigrod S2 (Spl) OK AristoRod/Tigrod 13.26

Weathering steels

Yes

Reistance against corrosion

COR-TEN, Patinax, Dillicor etc.

Welding Consumables

177

178

Welding Consumables

3. Fluxes and submerged arc wires
Normal quality level OK Flux 10.81LM / OK Autrod 12.08L

Mild steel Higher quality level (X-ray) OK Flux 10.81L / OK Autrod 12.22L OK Flux 10.81LS / OK Autrod 12.22L OK Flux 10.71L / OK Autrod 12.22L OK Flux 10.71L / OK Autrod 12.22L OK Flux 10.71L / OK Autrod 12.34 OK Flux 10.62L / OK Autrod 13.40 OK Flux 10.62L / OK Autrod 13.43

Yes

Requirements

No

Not specified 420 MPa (70 000 psi) 560 MPa (80 000 psi)

Medium & hightensile steel

Yes

Requirements Minimum yield stress

No

700 MPa (100 000 psi)

Low-alloyed high temperature 0.5 Mo 0.5 Cr 0.5 Mo 1.2 Cr 1.0 Mo 2.25 Cr –20°C Charpy V –40°C Charpy V –50°C Charpy V –60°C Charpy V –70°C Charpy V

Yes

Requirements Base metal composition

0.5 Mo

OK Flux 10.71L / OK Autrod 12.24L OK Flux 10.62L / OK Autrod 13.10 OK Flux 10.62L / OK Autrod 13.10 OK Flux 10.62L / OK Autrod 13.20 OK Flux 10.63 / OK Autrod 13.20SC OK Flux 10.81LS / OK Autrod 12.22L OK Flux 10.71 / OK Autrod 12.40L OK Flux 10.61 / OK Autrod 12.22L OK Flux 10.72 / OK Autrod 12.22L OK Flux 10.62L / OK Autrod 12.40L OK Flux 10.62 / OK Autrod 13.40 OK Flux 10.62 / OK Autrod 13.43 OK Flux 10.62 / OK Autrod 13.27

No

Low temperature

Yes

Requirements Temperature °C

4. Cored wires
375 MPa (55 000) OK Tubrod 15.00/Dualshield T5 OK Tubrod 14.12 Coreweld 70 Ultra

Mild steel

Yes

No

Requirements min. yield stress

metal-cored all positions basic all positions rutile flat & HV

Medium & hightensile steel OK Tubrod 15.14 rutile all positions Dualshield 7100LH/Ultra rutile all positions OK Tubrod 15.24 basic all positions 550 MPa (80 000) OK Tubrod 15.19 Dualshield II 81 K2 OK Tubrod 14.03 OK Tubrod 15.27 Dualshield T115 OK Tubrod 14.02 Dualshield 7000A1 OK Tubrod 15.20 Dualshield 8000B2 OK Tubrod 15.22 Dualshield 9000B3

Yes

Requirements min. yield stress 450 MPa (65 000)

OK Tubrod 15.12 OK Tubrod 15.18 OK Tubrod 15.14A rutile all positions Dualshield 7100LH/Ultra OK Tubrod 14.02 metal-cored all positions Coreweld Ultra/70

No

rutile all positions rutile all positions metal-cored all positions basic all positions basic all positions metal-cored all positions rutile all positions basic all positions rutile all positions basic all positions rrutile all positions

650 MPa (95 000)

Creep-resistant Yes High temperature 0.5 Mo 0.5 Cr 0.5 Mo 1.2 Cr 1.0 Mo 2.25 Cr

Requirements Base metal composition 0.5 Mo

No

Low temperature –40°C Charpy V –60°C Charpy V –70°C Charpy V

Yes

Requirements Temp. °C –20°C Charpy V (47J)

OK Tubrod 15.00 basic all positions OK Tubrod 15.14A rutile all positions Dualshield 7100 LH/Ultra rutile all positions OK Tubrod 14.03 metal-cored all positions OK Tubrod 15.17 rutile all positions Dualshield T5 basic all positions OK Tubrod 14.04 metal-cored all positions OK Tubrod 15.11 rutile all positions OK Tubrod 15.25 basic all positions

Welding Consumables

179

180

Welding Consumables

5. Submerged arc cored wires and fluxes

Mild steel

Yes 375 MPa (55 000 psi) OK Tubrod 14.00S/OK Flux 10.71 OK Tubrod 15.00S/OK Flux 10.71 OK Tubrod 14.00S/OK Flux 10.71 OK Tubrod 15.00S/OK Flux 10.71 OK Tubrod 15.24S/OK Flux 10.62, 10.47

No
420 MPa (60 000 psi) 450 MPa (65 000 psi) 550 MPa (80 000 psi)

Requirements min. yield stress

Medium & hightensile steel

Yes

Requirements min. yield stress

No

Low-alloyed High temperature 0.5 Mo 1.2 Cr 1.0 Mo 2.25 Cr

Yes

Requirements Base metal composition

0.5 Mo

OK Tubrod 14.02S/OK Flux 10.71 OK Tubrod 15.21S/OK Flux 10.71 OK Tubrod 14.07S/OK Flux 10.63

No

Low temperature

Yes –40°C Charpy V –50°C Charpy V –60°C Charpy V

Requirements Temp. °C

–20°C Charpy V

OK Tubrod 14.00S/OK Tubrod 15.00S OK Flux 10.71 OK Tubrod 15.00S/OK Flux 10.62 OK Tubrod 15.24S/OK Flux 10.62 OK Tubrod 15.25S/OK Flux 10.62

6. Wires for stainless steels. Selection by wire classification
C Cr Ni TIG OK Tigrod Mo Other elements MIG OK Autrod

EN 10088-1 Designation Werkstoff. No AISI

Austenitic X10CrNi18-8 X5CrNi18-10 X6CrNiTi18-10 X6CrNiNb18-10 X8CrNiS18-9 X2CrNi18-9 X2CrNiN18-10 Ti 0.7 Nb 0.7 S 0.2 N 0.15 N 0.15 2.5 2.5 2.5 2.5 2.5 2.5 Ti 0.7 N 0.5 Mn 8 Cu 1.5 Cu 0.8, N 0.2 Cu 1.5 Cu 0.5, N 0.5 N 0.17 + Ce 3.5 4.5 6.2 3.5 7.3 16.38 318Si, 16.30 16.30 16.95 317L 385 19.81, 19.82 19.81, 19.82 19.81 310 302 304 321 347 303 304L 304LN 304N 316 316 316L 316L 316Ti 316LN 202 S31703 N08904 S31254 N08028 S32654 S30815 16.38 318Si, 16.30 16.30 16.95 317L 385 19.81, 19.82 19.81, 19.82 19.81 310 < 0.12 < 0.07 < 0.08 < 0.08 < 0.12 < 0.03 < 0.03 < 0.08 < 0.05 < 0.05 < 0.03 < 0.03 < 0.08 < 0.03 < 0.15 < 0.03 < 0.03 < 0.02 < 0.02 < 0.02 < 0.10 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 20 20 27 24 21 8 10 11 11 9 10 10 9 12 12 12 13 12 12 5 16 25 18 31 22 11 16.10 16.10 16.11 16.11 16.53 16.10 16.10 16.10 16.30 16.10 16.10 16.11, 16.10 16.11, 16.10 16.53, 309L 16.10 16.10 16.10 16.30

1.4310 1.4301 1.4541 1.4550 1.4305 1.4307 1.4311

X3CrNiMo17-13-3 X5CrNiMo17-12-2 X2CrNiMo17-12-2 X2CrNiMo18-14-3 X6CrNiMoTi17-13-2 X2CrNiMoN17-13-3 X12CrMnNiN X2CrNiMo18-15-4 X1NiCrMoCuN25-20-5 X1CrNiMoCuN20-18-7 X1NiCrMoCu31-27-4 X9CrNiSiNCe21-11-2

1.4436 1.4401 1.4404 1.4435 1.4571 1.4429 1.4372 1.4438 1.4539 1.4547 1.4563 1.4652 1.4835

Austenitic-ferritic (Duplex) 1.5 4 5 7 6 3 4 3 S32101 S32304 S31803 S32750 S32760 0.03 < 0.03 < 0.03 < 0.03 < 0.03 21.5 23 22 25 25 Mn 5 N 0.10 N 0.10 N 0.25 N 0.25 W 0.7 16.86 16.86 16.86 16.88 16.88 16.86 16.86 16.86 16.88 16.88

X2CrNiN23-4 X2CrNiMoN22-5-3 X2rNiMoN25-7-4 X2CrNiMoCuWN25-7-4

1.4162 1.4362 1.4462 1.4410 1.4501

Welding Consumables

181

182

Welding Consumables
C Cr Ni Mo TIG OK Tigrod Other elements MIG OK Autrod

EN 10088-1 Designation Werkstoff. No AISI

1.4000 1.4003 1.4006 403 S41050 410 0.7 430 Ti, Nb Ti 2 441 439 S44400 446 < 0.03 < 0.8 < 0.03 < 0.20 18 17 18 26 < 0.08 16.5 < 0.08 13 < 0.03 12 0.1 13 16.10 16.10 16.53 16.10 16.10 16.53

Ferritic-martensitic X6Cr13 X2CrNi12 X12Cr13 Ferritic X6Cr17 430Ti, 430LNb, 16.10 16.10 430Ti, 430LNb 430Ti 16.30 16.13 430Ti, 16.10 16.10 430Ti 430Ti 16.30 16.13

1.4016

X6CrTiNb18 X6CrTi17 X2CrMoTi18-2 -

1.4509 1.4510 1.4521 -

7. The most common fluxes and wires for SAW of stainless steels

German DIN 17440

European standard EN 10082-1 Designation steel
1.4000 1.4006 1.4021 1.4028 1.4016 1.4057 1.47491) 1.44601) 430 S 17 431 S 29 – – – – – – 302 S 31 304 S 31 (304 S 15) 321 S 31 347 S 31 (316 S 33) (316 S 31) 316 S 11 Z 6 CNNb 18.10 (Z 6 CND 17.12) (Z 6 CND 17.11) Z 2 CND 17.12 Z 6 CNDT 17.12 Z 2 CN 18.10 Z 2 CND 17.13 (Z 12 CN 25-20) 320 S 31 304 S 11 316 S 3 (310 S 24) – – – 2338 2343 2347 2348 2350 2352 2353 2361 347 (316) (316) 316 L 316 Ti 304 L 316 L 310 S Z 10 CN 18.09 Z 6 CN 18.09 (Z 6 CN 18.09) Z 6 CNT 18.10 2331 2332 2333 2337 302 304 (304) 321 Z 8 C 17 Z 15 CN 16.02 Z 10 C 24 – – – – – 2320 2321 2322 2324 2327 2377 2328 – 430 431 446 329 S32304 S31803 S32750 S32760 403 S 17 410 S 21 420 S 37 420 S 45 Z 6 C 13 Z 12 C 13 Z 20 C 13 Z 30 C 13 2301 2302 2303 2304 403 410 420 – 10.92L+16.10 or 308H/10.92L+16.10 10.92L+16.10 or 308H/10.92L+16.10 10.92L+16.10 or 308H/10.92L+16.10 10.92L+16.10 or 308H/10.92L+16.10 10.92L+16.11 or 308H/10.92L+16.10 10.92L+16.11 or 10.92L+16.11 10.92L+16.13 10.92L+2209 or 2509/10.94+2509 10.92L+2209 or 2509/10.94+2509 10.92L+2209 or 2509/10.94+2509 10.94+2509 10.94+2509 10.92L+16.10 /10.92L+16.10 10.92L+16.10 /10.92L+16.10 10.92L+16.10 /10.92L+16.10 10.92L+16.11 or 10.92L+16.11 10.92L+16.11 or 10.92L+16.11 10.92L+16.30 or 10.92L+16.30 10.92L+16.30 or 10.92L+16.30 10.92L+16.30 or 10.92L+16.30 (10.92L+16.30) or (10.92L+16.30) 10.92L+16.10 or 308H/10.92L+16.10 10.92L+16.10 or 10.92L+16.10 10.92L+310

No

Designation steel

England France AFNOR Werkst. BS 970; NFA 35-572 to 1=Part 1 NFA 35-578 Nr. BS 1449; 2=Part 2 SS USA steel AISI No Recommended SAW consumables OK Flux + OK Autrod

X 6 Cr 13 X 12 Cr 13 X 20 Cr 13 X 30 Cr 13

1.4000 1.4006 1.4021 1.4028

X 7 Cr 13 X 10 Cr 13 X 20 Cr 13 X 30 Gr 13

X 6 Cr 17 X 17 Cr Ni 16-2

1.4016 X 6 Cr 17 1.4057 X 20 Cr Ni 17 2 – X 8 Cr Ni Mo 27 5 21) X 2 Cr Ni N 23-4 1.4362 X 2 Cr Ni Mo N 22-5-3 1.4462 X 2 Cr Ni Mo N 25-7-4 1.4410 X 2 Cr Ni Mo Ca WN 25-7-4 1.4501 – 1.4301 (1.4301) 1.4541 1.4550 1.4436) (1.4401) 1.4404

X 10 Cr Ni 18-8 X 5 Cr Ni 18-10 X 5 Cr Ni 18-10 X 6 Cr Ni Ti 18-10

1.4310 – 1.4301 X 5 Cr Ni 18 10 (1.4301) (X 5 Cr Ni 18 10) 1.4541 X 6 Cr Ni Ti 18 10

X 6 Cr Ni Nb 18-10 X 3 Cr Ni Mo 17-13-3 X 5 Cr Ni Mo 17-12-2 X 2 Cr Ni Mo 17-12-2

1.4550 X 10 Cr Ni Nb 18 10 1.4436 (X 5 Cr Ni Mo 17 13 3) (1.4401) (X 5 Cr Ni Mo 17 12 2 1.4404 X 2 Cr Ni Mo 17 13 2

X 6 Cr Ni Mo Ti 17-12-2 X 2 Cr Ni 18-9 X 2 Cr Ni Mo 18-14-3 (EN 10095) X 8 Cr Ni 25-21

1.4571 1.4307 1.4435 1.4845

X 6 Cr Ni Mo Ti 17 12 2 1.4571 X 2 Cr Ni 18 10 1.4306 X 2 Cr Ni Mo 18 14 3 1.4435 X 12 Cr Ni 25 211) 1.48451)

X 2 Cr Ni Mo 18-15-4 X 2 Cr Ni N 18-10 X 2 Cr Ni Mo N 17-13-3

1.4438 X 2 Cr Ni Mo 18 16 4 1.4438 1.4311 X 2 Cr Ni N 18 10 1.4311 1.4429 X 2 Cr Ni Mo N 17 13 3 1.4429

2367 317 L 10.92L+317L or 10.92L+317L Z 2 CND 19.15 Z 2 CN 18.10 Az 2371 304 LN (10.92L+16.10) or (10.92L+16.10) Z 2 CND 18.10 Az 2375 316 LN (10.92L+16.30) or (10.92L+16.30)

1) not standard

Welding Consumables

183

Welding Consumables

9. MIG and TIG wires for aluminium Base material
EN 573 Alloy designation Numerical EN AW-1050A EN AW-1070A EN AW-1100 EN AW-1200 EN AW-3003 EN AW-3103 EN AW-3004 EN AW-4045 EN AW-5005 EN AW-5019 EN AW-5050 EN AW-5052 EN AW-5083 EN AW-5086 EN AW-5454 EN AW-6013 EN AW-6060 EN AW-6061 EN AW-6063 EN AW-6082 EN AW-7005 EN AW-7021 EN AW-7029 EN AW-7039 EN AW-7050 Chemical symbols EN AW-Al 99,5 EN AW-Al 99,7 EN AW-Al 99,0Cu EN AW-Al 99.0 EN AW-Al Mn1Cu EN AW-Al Mn1 EN AW-Al Mn1Mg1 EN AW-Al Si10 EN AW-Al Mg1(B) EN AW-Al Mg5 EN AW-Al Mg1,5(C) EN AW-Al Mg2,5 EN AW-Al Mg4,5Mn0,7 EN AW-Al Mg4 EN AW-Al Mg3Mn EN AW-Al Mg1Si0,8CuMn EN AW-Al MgSi EN AW-Al Mg1SiCu EN AW-Al Mg0,7Si EN AW-Al Si1MgMn EN AW-Al Zn4,5Mg1,5Mn EN AW-Al Zn5,5Mg1,5 EN AW-Al Zn4,5Mg1,5Cu EN AW-Al Zn4Mg3 EN AW-Al Zn6CuMgZr The Aluminum Association AA 1050A AA 1070A AA 1100 AA 1200 AA 3003 AA 3103 AA 3004 AA 4045 AA 5005 AA 5019 AA 5050 AA 5052 AA 5083 AA 5086 AA 5454 AA 6013 AA 6060 AA 6061 AA 6063 AA 6082 AA 7005 AA 7021 AA 7029 AA 7039 AA 7050 ESAB filler metal OK Autrod/Tigrod 1070,1100, 1450 1070,1100, 1450 1070,1100 1070,1100 4043, 4047 4043, 5356 4043, 5356 4043,4047 5356 5356 5356 5356 5183 5356 5554 4043, 5356 4043, 5356 5356 5356 4043, 5356 5356 5356 5356 5356 5356

184

CHOOSE THE CORRECT OK ELECTRODES, WIRES AND FLUXES FOR HARFACING AND MAINTENANCE.
Recommendations for the right choice and electrodes for joining dissimilar materials can be found in Figs 1 and 2 on the next page. The conditions to be considered when choosing the correct electrode, wire and flux for hardfacing and maintenance are summarised in the following outline. A classification of weld metal resistance to different kinds of working condition can be found in Table 1. The working conditons for an object that is going to be repaired are often known. The table provides information about suitable electrodes and the different kind of attack which must be taken into account. The recommended OK electrodes, wires and fluxes for some of the most common objects for hardfacing and maintenance by welding can be found in Table 2. Short rules for choosing the correct type of weld metal alloy for hardfacing and cladding With regard to: 1. Type of wear 2. Working conditons 3. Machinability requirements Useful information when choosing the correct type of alloy 1. The compositon of the material to be welded when deciding. a) Which types of welding alloy are usable and suitable b) If preheating is favourable c) If welding a buffer layer is necessary 2. Conditions for welding a) Is preheating possible or not? If it is not possible, hardenable welding alloys can only be used to a very limited extent. For steel and cast iron weldments: austenitic or non-ferrous alloys are preferable: OK 67.45, OK 67.75 - austenitic

OK 68.81 and OK 68.82 - austenitic - ferritic

Welding Consumables

OK 92.18, OK 92.58, OK 92.35 - non-ferrous. b) The welding positon c) Can submerged arc welding or gas metal arc welding be applied? d) For which of the applicable welding processes is suitable filler material available? 3. Working conditons for the repaired workpiece a) Type of wear : abrasive, erosive or cavitation To resist abrasive wear by sharp - edged blast stone and ore, a hard surface or a work-hardening surface is required or desirable. Recommended: OK 84.78, OK 84.80 OK 84.58, OK 83.65 OK 86.28, OK 86.08 To resist erosive wear, a hard surface and a fine-grained microstructure in the weld metal is required. Recommended : OK 84.80 OK 84.78 OK 85.65, OK 84.58 OK 83.65 OK 84.52 Cavitation attacks in water turbines can usually be prevented by cladding with austenitic electrodes. OK 63.35 is the most frequently - used electrode for this purpose, but the following are also suitable : OK 67.70, OK 67.71 4. Environment a) Corrosive or non-corrosive? b) The temperature, high or low? c) To resist wear in a corrosive environment, the weld metal must be resistant to both corrosion and wear. So, depending on the severity of the corrosion attacks, an alloy with some degree of corrosion resistance is required.

185

Reclamation Consumables

ISO 9000 & ISO 14000

Reclamation Consumables

Conventional Hardfacing Alloys
BUFFERING
Buffer layers are used as intermediate deposits between the base material and the actual hardfacing weldmetal so that the following aspects are taken care of: l Good bonding with the base material l Hydrogen-induced underbead cracking is avoided, even on preheated workpieces l Stress consequences are minimized l Effect of dilution is limited l Spalling in subsequent hard layers is avoided l Prevention of cracks or relief checks from the hardfaced layers running into the base material

Generally, austenitic consumables are widely used as ductile buffer layers in hardfacing applications. The choice of consumables depends on the base material and the type of hardfacing alloy given the wear factors. The hardfacing layer tends to sink under high load con­ ditions if the base material is a soft one like mild steel. This can result in the hardfacing layer spalling off. A tough and strong buffer layer is applied to prevent this occurence.

In case of hardfacing with very hard and brittle alloys like the ones containing chromium carbides or with cobalt­ based alloys, there should be a buffering by an austen­ itic consumable for one or two layers. The compression stresses generated in the subsequent hard layers dur­ ing cooling are thus accommodated, reducing the risk of cracks in the hard weld metal. The “relief checks” present in many hardfacing depos­ its can propagate into the base metal under heavy im­ pact or flexing. High strength steels are most prone to such crack propagation. This is prevented by applying a tough buffer layer. BUILD-UP LAYERS In case of heavy wear, the component has to be built­ up to its original dimensions. But hardfacing layers are limited to 2­3 layers. In that case, a similar type of alloy can be used to build it up before applying the hardfacing deposit. Otherwise, alternate layers of hard and ductile deposits can be made finishing off with the hard layer. E.g. hammers, crushers, cold shearing tools, and exca­ vator teeth.

Reclamation Consumables
189

DUROID 250
Machinable Build-up Prior to Hardfacing A smooth running rutile coated general­purpose harcl­ facing electrode, depositing a tough air­hardening al­ loy weld metal, suitable for resisting moderate friction, abrasion and impact. ALLOY BASE Fe, Cr, Mn SPECIAL FEATURES l Smooth arc with low spatter. l Normally machinable weld metal. l Deposits a weld with self­lifting slag.

tion of all worn out carbon steel parts requiring subse­ quent matching. Other applications are pump housing, rail ends (medium Mn steel) for railways and tramways, forging dies, wheels, axles, and couplings. Suitable for use as a supporting buffer between a top layer of harder weld metal and a soft mild steel base. Recommended for hardfacing components and ma­ chine parts, which must be easily machinable after hardfacing. PROPERTIES Hardness : 24-27 HRC CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-120 130-170 155-200

Reclamation Consumables

APPLICATIONS Track links, rollers and sprockets, ropeway pulleys, trun­ ion wearing plates, gears, shafts and general reclama­

DUROID 350
Machinable Buffer for Impact and Moderate Abrasion A smooth running rutile coated hardfacing electrode de­ positing a tough air hardening type weld metal for re­ sisting moderate abrasion and impact. The deposit is machinable with suitable carbide tipped tools. ALLOY BASE Fe, Cr, Mn SPECIAL FEATURES l Good for build­up and buffering. l Excellent weld bead appearance. l Deposits a weld with fine bead appearance and easy de­slagging properties.

APPLICATIONS Roller, tractor idler wheels, brake shoes, crane wheels, wobblers, gears, shafts, forging dies, ploughshares, conveyor parts, track rollers, drive sprockets, tie tamp­ ing bars and picks, cams, cold punching dies, etc. where resistance to abrasion combined with toughness is needed. PROPERTIES Hardness : 33-36 HRC CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-120 130-170 155-200

DUROID 650
Abrasion Resistant Hardfacing This rutile­coated electrode gives an air­hardening type weld deposit, which is resistant to severe abrasion and moderate impact between metal to mineral wearing stresses. It provides moderate resistance to corrosion and scaling. ALLOY BASE Fe, Cr, Mn SPECIAL FEATURES l Smooth arc with low spatter. l It is very easy to use in all positions. · Excellent weld bead appearance.

APPLICATIONS Bulldozer blades, excavator teeth, metal cutting & form­ ing tools, hot & cold punching dies, bucket lips, chutes, conveyors, shears & croppers, oil expellers, pulping knives, ploughshares, road graders, crusher hammers, caterpillar treads, cane & bamboo cutting knives, etc. Recommended for applications involving metal to min­ eral wear. PROPERTIES Hardness : 55-58 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-120 130-170 160-240

190

DUROID 650B
No-Problem Abrasion Resistance even for Thicker Plates A high alloyed basic hardfacing electrode depositing a nonmachinable air­hardening weld metal. The weld deposit is resistant to severe abrasion and moderate impact between metal to mineral wearing stresses. It also resists scaling upto temperatures around 300°C and also moderate corrosion. Apart from applications on mild and medium carbon steels Duroid 650B, being basic coated, can also be used over high carbon and alloy steel base metals and on jobs of thicker cross­section. Requirement of pre­ heat can be lowered or avoided altogether to obtain weld deposit free from cracks, porosity and slag inclusions when normal welding practice for basic coated electrode is followed. ALLOY BASE Fe, Cr, Mn, Mo, V SPECIAL FEATURES l Can be used on thicker sections without the need of buffering.

Smooth arc with low spatter. l It is very ea$y to use in all positions. · Excellent weld bead appearance. APPLICATIONS Coal cutter blades, rock drills, drill bits, oil expeller worms, cane & bamboo cutting knives, excavator teeth, hot & cold punching dies, bucket lips, dipper teeth, impellers, muller ploughs, chutes, conveyors, shears & croppers, pulping knives, ploughshares, road graders, crusher hammers, caterpillar treads & shoes, etc. This electrode is specially recommended for applications involving metal to mineral wear. PROPERTIES Hardness : 57-59 HRC
l

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 100-140 120-180 160-250

Reclamation Consumables

ESAB 600B
Self-Buffering Abrasion Resistant Deposit ESAB 600B is a basic coated electrode meant for depositing hard surface having high resistance to wear caused by scouring action or rolling friction. It is insensitive to cracking tendency so the deposit does not require any additional buffering. The weld metal consists of uniformly distributed hard carbides in a martensitic matrix which make this electrode ideally suited for hardfacing parts, subjected to severe service conditions involving a combination of abrasion, moderate impact, and friction. Transverse relief cracks are welcome in the weld metal. ALLOY BASE Fe, Mn, C, Cr SPECIAL FEATURES l Excellent weld bead appearance. l Slag is easily detachable.

The deposit, hard as it is, can only be finished by grinding. APPLICATIONS Used for hardfacing of dredger buckets, draught bucket, working edges and surfaces of earth­moving equipment used in rocky soils, chain link, agricultural implements, vibrating shafts, steel sleeves, hammer mills, press tools, dies, punches and shears, tip of excavator, mill hammers for pulverizing coal & disintegrating chrome ore, iron ore, bucket teeth, shear blades, chutes and conveyors etc. PROPERTIES Hardness : 58-61 HRC
l

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 85-120 90-160 150-240

DUROMANGAN
Work Hardening for Extreme Impact and Abrasion A basic coated electrode depositing an austenitic manganese steel weld metal. The deposit is highly resistant to heavy impact and abrasion. The deposit is work hardenable. The electrode is recommended for surfacing of worn­out austenitic manganese steel parts. It can also be used to give impact protection on carbon

steels. ALLOY BASE Fe, Mn, Ni, Cr SPECIAL FEATURES l Build­up is free from cracks (with proper welding procedure). (Contd...)

191

Reclamation Consumables

Superior arc stability than available grades of Mn Steel electrodes. l It is very easy to use in all positions. APPLICATIONS Austenitic manganese steel components, crusher jaws, crusher hammers, crusher mantles, dredger bucket teeth, cement grinder rings, manganese steel railway points & crossings, manganese steel components used in the mining industry. PROPERTIES Hardness : As deposited : 24-26 HRC Work hardened : 43-45 H RC WELDING PROCEDURE l The surface to be welded should be without prior work hardening.
l

l

l

l

l

14% Mn steel should never be preheated for welding. Welding should be done in stringer beads directing the arc towards the weld pool keeping the heat input to the base metal minimum. Skip welding/back step welding can also be adopted. The weld bead can be peened with ball pen hammer immediately after welding. Quenching has no adverse effect on welding and should be adopted whenever possible after slag removal and peening. If possible the Mn steel job can be submerged in water during welding.
Size (mm) 4.00 5.00 Length (mm) 450 450 Current Range (Amp) 130-170 160-220

CURRENT RANGE : (AC 70, DC+/-)

192

Low Heat hardfacing Alloys
HARDFACING
Hardfacing involves protecting parts exposed to different types of wear in order to obtain a certain specific wear resistance. Hardfacing is primarily used to restore worn out parts back to usable condition in order to extend their service life but it can be successfully employed in new component manufacture as well. This technique will help in manufacturing a component from cheaper material with a wear resistant overlay providing the surface properties. A higher hardness level does not necessarily imply improved wear resistance or longer life. The effectiveness of any hardfacing alloy depends of its suitability in the operating conditions. So the appropriate hardfacing alloy has to be selected considering the following aspects:
l l l l

non­metallic particles. Abrasion may be classified into three types: a) Gouging abrasion: This class of abrasion involves the removal of sizable particles from a metallic surface by the action of a coarse material. The high pressure and impact cause the particles to cut into the surface and produce large gouge marks and scratches. Eg. shovel diggers, chute impact areas, pulveriser mills. Low stress abrasion: This form of wear results from the sliding action of free moving hard particles along a surface. Material is removed by scratching or micro­machining process. Eg. chutes, mineral conveyors. High stress abrasion: It occurs where abrasive particles are forced between two metal parts and crushed under heavy loads. The wear involves surface damage accompanied by plastic deformation. Eg. rock drills, scraper blades, ball mills.

b)

Reclamation Consumables

c)

the wear factors the base material of the component the surface finish required the process to be used Erosion

WEAR FACTORS Wear factors are the action of different agents on the metallic surface leading to degeneration and disintegration of the metal. A number of wear factors exist, which act individually or in combination. The weld metals have to be selected properly to counter these factors effectively. The major types of wear factors are as follows: Friction Wear from metal parts that roll or slide against each other. It accounts for 15% of the total spectrum of industrial wear. This type of wear is likely to be most severe when parts rub together under load with little or no lubrication. Generally, contact between surface materials of the same hardness will result in excessive wear. E.g. shafts against bearing surfaces, chain links against a roll, sprockets, steel mill rolls. The sudden action of a very large force for a very short time period gives rise to wear after some time. The mechanism is attributed to fatigue failure that has an incubation period prior to the appearance of surface damage. E.g. crusher rolls, impact hammers, railway points and crossings. About 50% of all industrial wear is abrasion in different forms. The wear takes place when metal is removed from a surface by the cutting or gouging action of hard

This wear is similar to abrasion but the particles are carried by a fluid stream like water, steam, etc., generally at a higher velocity compared to low­stress abrasion. Eg. slurry transport systems, shot blasting equipment. When a liquid is subjected to rapid changes of pressure, vapour or gas bubbles form in the lower pressure regions of the liquid. Entering high pressure areas at any metal/ liquid interface, these bubbles collapse and the immense force causes cyclic stress and fatigue on the metal surface. E.g. ship propellers, pump impellers. When metals are exposed to high temperature for long periods, they lose their durability mainly due to thermal fatigue cracking. Moreover, the metals tend to lose their strength and hardness at higher temperatures. These factors add up to wear. Eg. hot forging dies, extrusion dies, stamping dies, sinter crushing equipment. It involves reaction between a metallic surface and a corrosive environment whence the former is dissolved away leading to wear. In the presence of any mechanical force, the corrosion products may be removed leading to virgin surface coming in contact with the (Contd...)

Cavitation

Heat

Impact

Corrosion

Abrasion

193

corrosive environment again causing continued wear. E.g. valves, seating rings, screw conveyors. Oxidation In an oxidizing atmosphere, possibly aided by high temperatures, the metal surface builds .uP an oxide layer, which is mostly brittle in nature. This may break due to expansion and the entire oxidation operation is repeated. E.g. blast furnace parts, exhaust valves of internal combustion engines, hot working shears.

BASE MATERIAL The two main groups of base materials for hardfacing are: l Carbon or low­alloy steels: These steels require preheating, post­weld heat treatment, slow cooling for hardfacing according to the chemical composition and the section thickness. The general guidelines for preheating are given at the end of this section. l Austenitic manganese steels: These steels should be welded without any preheating or post­weld heat treatment at all. The interpass temperature should be kept as low as possible. SURFACE FINISH The surface finish requirements must be kept in mind while selecting the hardfacing alloy as they cover the entire range from easily machinable to non­machinable. Additionally, many of these deposits will contain “relief

checks”, which are formed across the bead as the bead releases the stress generated while the hard weld metal cools. These relief checks are not harmful to the deposit but may propagate into the base metal if the component is subjected to heavy impact or flexing. So, the issues of acceptability of relief checks and fin­ ishing requirements should be addressed to when the hardfacing deposit is decided. WELDING PROCESSES Shielded Metal Arc Welding : Covers the widest range of weld metals is a versatile process for on ­ site repairs and out­ of­position work is inexpensive Flux - Cored Arc Welding : the same range of alloys available as in case of coated electrodes on­site use is possible self­shielded wires do not require any additional shielding gas high deposition rate Submerged Arc Welding : high deposition rate no spatter loss product range limited positional welding not possible

Reclamation Consumables
194

RECOMMENDED PREHEATING TEMPERATURES IN OC
This chart is given as an indicative guide Base Material Filler material Low-alloy Steel 20 20-60
95 HRS

Plate thickness (mm)

Steel <90 HRB N N 100 N N 125 N 100 200 N N N N N N 100
300 400 N N NIL

Low alloy

Tool steel

Cr-steel 5-12% Cr

Cr-steel >12% Cr 30 HRC

Stainless steel -96 HRB N N N N L N N 150 200 N N 100 N N N 100
400 400 NL NL NL

14% Mn steel 25-51 HRC N N N N N L X X X N N N N N N X
X X NL NL NL

95 HRB- 30-43 HRC 32-51 HRC 95 HRB30 HRC 100 150 180 100 125 180 150 200 250 N 100 150 N N N 200
400 400 NIL 100 200

150 200 250 180 250 300 200 275 350 N 125 200 N *100 *100 250
*450 *500 NL 200 250

150 250 300 200 250 350 200 300 375 N 150 250 X X X 200
400 *500 NL *200 *200

100 200 200 100 200 250 150 200 250 N 200 200 X X X 200
350 400 NL *200 *200

Reclamation Consumables

- 30 HRC

60 20 20-60

Tool Steel

32 - 47 HRC 12% Cr Steel

60 20 20-60

32

- 51 HRC

60 20 20-60

Stainless Steel

95 HRS Mn Steel

60 20 20-60

20 HRC Co. based Gr.6

60 20
20-60

40 HRC Carbide type

60 20 20-60

55 HRC

60

N = Not necessary L = Preheating when large areas are surfaced X = This combination is not used

195

ASTRÄ HTB
Resistance to Corrosion, Cavitation and Erosion Astra HTB is the only machinable alloy that resists corrosion, cavitation alongwith erosion by suspended particles on the strength of the unique recipe of this electrode. The alloy also shows great resistance to deform in service and hence maintains shape and angularity of the original machined component at room temperature and also upto 700°C. Astra HTB endures in high temperature service as well. It offers best combination of machinability, friction and fatigue resistance, and shape retention at high temperature. ALLOY BASE Fe, Cr, Mo, Mn, Ni, C SPECIAL FEATURES l Smooth running characteristics.

l

Oxidation resistance retained upto 1100OC. APPLICATIONS Joining and surfacing of hydel turbine blades, valve seats, pump casings, gates, key­ways, machine components exposed to corrosive atmosphere, matching parts for which shape retention in service is of paramount importance. PROPERTIES UTS : 85­90 kg/mm2 Elongation : 18-24% Hardness : 42-45 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 80­150 110-170 160-220

Reclamation Consumables

ESAB 116 Ni
High Strength Joining A basic coated electrode suitable for build­up and repair of open and closed hot forge dies, moulds and tools. The deposit is insensitive to hot cracking. The electrode has very good strength and hardness upto 400°C. It can also be used for high strength joining. ALLOY BASE Fe, Mn, Ni SPECIAL FEATURES l Resists annealing. l Excellent weld bead appearance. l Resists metal­to­metal wear and deformation at high temperatures. APPLICATIONS Recommended for joining of high tensile steels of Hot Forge Die Repair

strength of the order of 80 kg / mm2. It is suitable for build­up and repair of new, worn out or cracked steel structures, components, and heavy equipment. Repair of forge dies, moulds and tools, high strength joining of carbon­steel earth moving equipments, truck frames, penstocks. PROPERTIES UTS : 62-70 kg/mm2 Elongation : 32-36% Hardness : 37-41 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 4.00 5.00 6.30 8.00 Length (mm) 450 450 450 450 Current Range (Amp) 120-175 150-230 200-260 240-300

OK SELECTRODE 83.28
Joining and Build-up on Rails A basic coated electrode suitable for hardfacing in metalto­metal wear applications. It has got very good resistance to impact and therefore can be used as a build­up and support layer for subsequent harder deposits. It is a special electrode, having good machinability, for special build­up on carbon­manganese steel rail tracks. ALLOY BASE Fe, Cr, Si, Mn SPECIAL FEATURES l Superb resistance to metal­metal friction. l Extreme impact toughness for heavy build-up.

APPLICATIONS Parts of rolling mills, grooved rolls and clutches, shafts, cog wheels, links and rollers for tractors, bearing journals. Joining and build­up of machinable carbon­ manganese steel railway tracks. This electrode can also be used for joining hardenable steels. PROPERTIES Hardness : 29-31 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 450 450 450 Current Range (Amp) 60-90 100-140 130-180 170-230

196

OK SELECTRODE 83.40
Infinite Fissure-Free Build-up for Impact Loading A smooth running touch welding low heat input electrode depositing a tough air hardening machinable multi­al­ loyed weld metal for low stress abrasion and good im­ pact. The deposit is free from surface micro­cracks even for higher build­up. It has high endurance limit and is suit­ able for compressive and fatigue loading. Special additives in electrode coating make it smooth running and easily maneuverable. Superior bead finish is obtained independent of welder skill. The flux is devoid of hygroscopic elements, making it ideal for site conditions. ALLOY BASE Fe, Mn, Cr, Ni SPECIAL FEATURES l Micro­crack free surface even for higher build­up. l Very good resistance to metal­to­metal wear and fatigue.

Smoothest running electrode of its class. l Low tendency to moisture absorption. l Marginal work hardening. APPLICATIONS Hammers, wobblers, railway equalizer beams, crane wheels, excavators, sprockets, rollers, pump shafts, gear teeth, concrete mixer blades, rims, carbon-alloyed rails, dies, striking tools and other machine parts subjected to heavy shock loading and pounding in service. It is the right consumable to use for providing buffer layers where impact and abrasion occur together. PROPERTIES Hardness : 28-33 HRC
l

CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-130 120-170 150-220

Reclamation Consumables

OK 84.76C
Sugar mill roller dry and wet arcing OK 84.76C is a basic coated high efficiency high chro­ mium carbide type electrode for roughening the wet mill rollers used in the sugarcane crushing. It provides an electric arc of spray type, depositing weld metal in the form of fine globules in the grooves of the mill roll thus increasing its gripping and dragging power. Enormous rollers are used in the sugarcane crushing process, which are subjected to excessive wear dur­ ing the season. These rollers have to be continuously roughened, even when the crushing is in full swing. These are smothered in crushed, sludgy cane and the surface is wet. OK 84.76C accommodate these condi­ tions and deposit a dispersion of small, hard and wear­ resistant globules that fastens to the sidewalls of the ridges of the roller. It can be observed that the roughness created on the surface of the mill roll increases its productivity consid­ erably, permitting better utilization of the grounded ma­ terial, which in turn increases the quantity of the sugar­ cane to be processed.

SPECIAL FEATURES: l Spray type arc for better distribution of the globules l Good bonding with the rollers, even in wet condi­ tion HARDNESS: 57 – 64 HRC WELDING PROCEDURE: l Hold the electrode at right angles to the flans of the profile. l Use "cold welding" technique; avoid excessive heat in the weld area. l Use DC positive, for better results. DEPOSITION DATA Deposition rate : 2.2 kg/hr Deposition Efficiency : 69% Metal Recovery : 205% WELDING CURRENT: DC +/-, AC 70
Size (mm) 3.15 4.00 Length (mm) 450 450 Current Range (Amps) 110-130 160-210

197

OK SELECTRODE 84.78
Maximum Abrasion Resistance OK Selectrode 84.78 gives an alloy rich deposit, which offers best resistance to high­pressure abrasion by gritty particles. The stainless bead is temper resistant upto 600°C. The deposit resists corrosion and oxidation even at elevated temperature. Relief cracks, transverse to the weld bead, are desirable. ALLOY BASE Fe,C,Cr SPECIAL FEATURES l Weld bead is convex and dilution is negligible. l Weld metal is having good corrosion resistance and can withstand high temperatures. l Smooth arc.

APPLICATIONS Highly recommended for earthmoving, construction, cement and agriculture industries. Road rippers, earth moving parts, excavator blades, crushing mills, edge runners, chutes, mixer blades, screw conveyors, asphalt phasing screws, coal mill exhauster fan blades, plough shares, tampers, scrapers, feeding screws, grader blades, pug mill knife etc. PROPERTIES Hardness : 57-60 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 110-160 120-170 150-220

Reclamation Consumables

TERROWELD EWR
Ultimate Resistance to Any Type of Wear Terroweld EWR deposits a low dilution, high abrasion resistant alloy that is stainless and does not tarnish even in presence of aggressive chemicals. The deposit is ripple­free and uniform. The electrode performs well even in out­of­position surfacing. Oxidation resistance of the deposit is maintained upto a temperature of 1100OC. Hardness retention at high temperature is also remarkable. ALLOY BASE Fe, C, Cr, Mn, V, Ti SPECIAL FEATURES l Stainless bead with high volume of complex carbide. l Temper resistant weld metal.

State­ot­art bead tinish. APPLICATIONS For critical machine part hardtacing which does not require machining. For complex wear involving simultaneous abrasion and corrosion. For high lite at elevated temperatures. PROPERTIES Hardness : 63-65 HRC
l

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 100­150 120-160 150­200

198

ESAB 550
Super Hot Hardness and Edge Retention A basic coated hardfacing electrode giving a weld deposit suitable for rebuilding of hot working tools, forging tools etc. Intended for hardfacing of hot trimming blades, hot bar shears etc. Resistance to scaling and tempering is upto 600°C. The weld-metal gives extremely good spalling resistance, hot hardness due to grain boundary pinning by fine carbides. ALLOY BASE Fe, Cr, Mn, W, V, Mo, Co SPECIAL FEATURES l Weld metal is resistant to scaling upto 600°C. l The weld deposit gives extremely high secondary hardening. l An excellent edge-retention property for repairing cutting and shearing tools.

APPLICATIONS Highest metal-to-metal wear resistance in upto 500°C along with good impact resistance. To be used where cutting, shaving, and piercing proprieties are required to be maintained. Typical applications are shear blades, roll face repairs, tools for hot trimming and cold punching, lifting tongs for billets, high­speed steel dies and tools. PROPERTIES Hardness : As deposited : 49-52 HRC After tempering at 600°C for 1 hr. : 53-56 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 80­120 120-170 170-230

Reclamation Consumables

ASTRÄ MN
Ductile Crack-Free Deposit for Mn Steel Build-up High efficiency electrode with special coating, to resist massive impact by mineral or metal along with moderate to good resistance to mineral abrasion. Despite the common tendency of cracking in manganese steel, this high purity bead remains ductile and crack­ free even after die penetration tests. The alloy also shows reluctance to necking in tensile specimen. In abrasion area also it is superior to all the above except high-density pre-formed carbides. ALLOY BASE Fe, Mn, Ni

SPECIAL FEATURES Ripple free deposit. Auto slag detachment, free from slag inclusion. Low heat input even at high current capacity. APPLICATIONS Crushers, earthmoving equipment, hammers, shovel track pads, wear plates, building up manganese steel components, buffering before carbide hardfacing de­ posit. PROPERTIES Hardness : As deposited : 22-23 HRC Work hardened : 42-44 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350/450 350/450 350/450 Current Range (Amp) 110-165 140-200 180-250

199

DUROBELL
Blast Furnace Bell Reclamation Durobell is a hardfacing electrode which deposits an alloy steel deposit that is both impact and abrasion resistant. The electrode is the only one for blast furnace bell repair as it gives rise to good resistance to abrasion at those temperatures. ALLOY BASE Fe, C, Ni, Mo SPECIAL FEATURES l Smooth arc with low spatter. l Excellent weld bead appearance. l Slag is easily detachable.

APPLICATIONS Seat area of blast furnace bells & hoppers, tong-pins, hot shears, furnace rollers, knives, valve seat, idler rollers of hot strip mills etc. PROPERTIES Hardness : As deposited : 53-55 HRC At 500°C : 46-50 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-120 115-175 160-225

Reclamation Consumables

TERROWELD MN
Low Heat Build-up on Manganese Steel This is a low heat input electrode suitable for surfacing, building up and joining of austenitic manganese steels of plain & alloy types. The austenitic deposit is more resistant to cracking, deformation and heat embrittlement. The deposit is tough to witbstand metal to metal impact. It resists wear under rolling abrasion at high contact pressures. ALLOY BASE Fe, C, Mn, Ni SPECIAL FEATURES l Graphite free coating avoids carbon pick­up. l Deposit gives high strength, combined with excellent resistance against impact. l Smooth are, fine ripples and a fluid but controlled slag, which is easily detachable. APPLICATIONS Manganese steel shovel bucket teeth & lips, pulverizing hammers, beaters, grinding ring & rollers, gyratory crusher mantle and liners, cone and ring, jaw crusher plates etc.

PROPERTIES Hardness : As deposited : 22-24 HRC Work hardened : 42-45 HRC WELDING PROCEDURE l 14% Mn steel should never be preheated for welding. l Welding should be done in stringer beads directing the towards the weld pool. l Heat input to the base metal should be kept minimum, if required skip welding/back step welding can be adopted. l The weld bead must be peened with ball pen hammer immediately after welding. l Quenching has no adverse effect on welding and should be adopted whenever possible after slag removal and peening. If possible the Mn steel job can be submerged in water during welding. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 80-100 110-160 180-225

TERROWELD SHR
Rare Earth Fortification for High Temperature Abrasion A low heat input electrode depositing a weld deposit alloyed with metals and rare earths, ideal for applications involving excessive wear and abrasion at light to moderate impact loads. Presence of special metals offer excellent resistance to oxidation at high temperatures, whereas the rare earth alloy additions helps the deposit to retain its hardness upto 600°C.

High volume of fine dispersed carbide is ideal to sustain life in service condition subjected to wear by fine particles. The deposit is non­machinable and transverse relief cracks are accepted. ALLOY BASE Fe, C, Cr, Mo, V, W, Nb, Ta SPECIAL FEATURES l Temper resistance at high temperature upto 600°C. l Oxidation resistance till 1000°C. l High deposition efficiency. (Contd...)

200

TYPICAL APPLICATIONS
Blast furnace parts, railway tampers, pump casing & impellers, ore breaker teeth, rolling mill guides, furnace parts, sinter plant disintegrators, screw conveyors cold forming dies, chain saw, coal burner nozzles, mechanical stackers, steam valve flanges etc.

PROPERTIES Hardness : As deposited At 600OC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 Length (mm) 450 450 Current Range (Amp) 110-130 150-185

: 56-58 HRC : 46-48 HRC

TERROWELD 35
Low Heat Deposit for Impact and Pressure A hardfacing electrode for operation at low heat input depositing a tough air hardening alloy, giving a combination of moderate abrasion and good impact resistance as encountered in rolling, reciprocating and sliding systems. ALLOY BASE Fe, Cr, Mn SPECIAL FEATURES l Low heat formulation. l Tough machinable deposit.

APPLICATIONS Hardfacing of rollers, tractor idler wheels, brake shoes, mine car wheels, drive sprockets, conveyor parts, gear teeth, briquette press, crane wheels, concrete mixer blades, mill pinions, knife edges etc. PROPERTIES Hardness : 33-36 HRC CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 75-110 110-160 140-185

Reclamation Consumables

TERROWELD 65
Multipass Electrode for Abrasion and Moderate Impact A low heat input hardfacing electrode, specially designed for repairing of worn­out components to withstand high metal to metal and mineral abrasion with moderate impact. The weld deposit is a tough air hardening type complex alloy. Two-layer deposit exhibits an average hardness of around 57 HRC. Depositing larger number of layers is also permissible. Deposit on mild/medium carbon steel is normally crack­ free even after attaining full hardness. ALLOY BASE Fe, Mn, Cr, V, Mo

SPECIAL FEATURES l Weldmetal is crackfree even at 58 HRC. l Good combination property for impact and abrasion. l Multipass build­up is possible. l Performs equally well in all­position welding. APPLICATIONS Scraper blades, cane cutting knives, bucket lips, chutes, guides, plough shear, earn, rollers, gate valve seats, road grades, conveyor screws, drills, fibrizer hammers etc. PROPERTIES Hardness : 55-58 HRC CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 80-110 110-160 140-240

201

OK 84.80
DIN 8555 E-10-65-GZ l Maximum abrasion resistance. l Zero dilution convex bead. Deposits a high carbon high chromium alloy, which offers best resistance to hih ­ pressure abrasion by gritty particles. The stainless bead is temper resistant up to 700OC. It resists corrosion and oxidation even at elevated temperature. Relief cracks transverse to the weld bead are allowed. SPECIAL FEATURES l Weld bead is convex and dilution is negligible. l Weld metal has good corrosion resistance and can withstand high temperatures. l Smooth arc.

TYPICAL APPLICATIONS Blast furnace bell & Hopper, BLT chutes, sinter crusher, crushing mills, edge runners, chutes, mixer blades, screw conveyors, asphalt phasing screws, scrapers, coal mill exhauster fan blades, feeding screws, grader blades, ploughshares, tampers pug mill knives, etc. CHEMICAL COMP.: C - 50, Si-2.0, Mn-0.7, Cr-23.0, Mo-7.0, Nb-7.0, W-2.0, V-1.0. HARDNESS: 62-65 HRC HIGH TEMP WEAR RESISTANCE - Very good. CORROSION RESISTANCE - Excellent.

Reclamation Consumables

OK 84.84
Classifications : DIN 8555 E10-UM-60-GP OK 84.84 is a hardfacing electrode depositing a weld metal with a high volume fraction of fine carbides in a martensitic matrix. It is designed for protection of component subjected to severe abrasive wear. Typical applications: earth ­ drilling equipment, hammers, scrapes and knives, shovel buckets and shovel teeth. WELDING CURRENT : DC(+-), AC OCV 45 V TYPICAL ALL WELD METAL COMPOSITION C Si Cr V Ti 3.0 2.0 5.8 5.7 4.8 TYPICAL PROPERTIES ALL WELD METAL Machinability Impact resistance Abrasion resistance
Weld metal hardness, a w 60-62 HRC

CURRENT RANGE :
Size (mm) 2.50 3.25 4.00 Length (mm) 350 350 350 Current Range (Amp) 70-100 100­150 115-200

Supplied in VacPacTM vacuum packed wrappers.

Grinding only Very good Excellent

202

Cast Iron Electrodes
WELDING CAST IRON
Cast iron is an alloy of iron with a carbon content of 2­ 5%, silicon content of 1-3% and upto 1 % manganese. The major types of cast iron are: l grey cast iron l nodular cast iron l malleable cast iron l white cast iron Cast iron has very low ductility, low strength and is very brittle. It is generally alloyed or heat­treated for improv­ ing these properties. The high carbon content adversely affects the weld­ ability of cast iron. Out of the grades mentioned above, white cast iron is considered unweldable for all practical purposes. The other types can be welded successfully with the consumables available. PREPARATION FOR WELDING The following steps should be kept in mind before com­ mencing the welding of cast iron: l Joint angles should be wider than for mild steel. l All sharp edges should be rounded off. l Preferably use U­grooves. l For repairing cracks, either gouge/grind the entire crack or drill small holes at each end of the crack. l The welding should start from the centre of the crack and proceed in both directions. l The absorbed oil and liquid should be removed be­ fore welding. If that is not possible, use an electrode giving a spray transfer for an anchoring buffer layer. l In critical welds, buttering by a ductile layer helps in absorption of the contractional stresses, thus saving the crack-susceptible HAZ.

Reclamation Consumables
203

FERROLOID 1
Excellent colour match with all cast irons Ferroloid 1 is a monel­cored electrode depositing a weldmetal, which bonds easily and matches in colour with cast iron. Weld deposit is soft, ductile and machinable. It is very effective for defect correction in foundries. It is excellent for joining cast iron to steel. ALLOY BASE Ni, Cu, Fe SPECIAL FEATURES l Smooth and stable arc with low spatter. · Excellent colour match. l Good machinability. l Slag is easily detachable. SPECIFICATION: AWS 5.15: E NiCu­B

APPLICATIONS Repairing of cracks and for depositing buffer layer prior to building up with nickel­copper types of weld metal, rebuilding of broken, cracked, worn­out cast iron castings, gear teeth, pumpimpellers, pump casing etc. Pipes, especially with heavy wall thickness, can be welded in circumferential positions without cracks. PROPERTIES UTS : 35-40 kg/mm2 CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 75-95 100-130 130-160

Reclamation Consumables

FERROLOID 3
Strength Joints in Grey and Nodular Cast Iron A nickel­alloyed machinable electrode for welding and repairing of all cast irons. The electrode deposits a high strength weld metal combined with good toughness of the weld joint, thus making it suitable for joining cast iron to mild steel. ALLOY BASE Ni, Fe, Si SPECIAL FEATURES l Strength joints with low heat. l Good machinability. l Slag easily detachable. SPECIFICATION: AWS 5.15: E NiFe­CI APPLICATIONS Joining of cast iron components, welding of cast iron to steel, rectification and build-up of defective castings giving good colour matching. Repairing of complicated and cracksensitive castings involving hydrostatic

pressure and dissimilar thickness, heavy sections and joints under restraint such as pumps, differential housing, cast iron dies etc. PROPERTIES UTS : 37-43 kg/mm2 WELDING PROCEDURE l Clean the weld area of all scales, grease and dirt. l The smallest possible electrode diameter and thelowest possible current should be used. l Skip welding sequence may be used. l When welding thick sections and malleable irons, preheating to about 250­300°C is advisable to minimize the shrinkage stresses and cracking. l On completion the casting should be allowed to cool slowly. CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 65-95 85-115 140-160

FERROLOID 4
Nickel Based Ductile Electrode for Cast Iron A Nickel­cored electrode depositing an almost pure nickel weld metal suitable for joining and repairing gray cast irons as well as for joining cast iron to steel, giving an easily machinable deposit. ALLOY BASE Ni,Si

SPECIAL FEATURES l Smooth and stable arc with low spatter. · Excellent weld bead appearance. l Slag is easily detachable. SPECIFICATION: AWS 5.15: E Ni­CI APPLICATIONS Reclamation of castings and machine parts, filling-in of blow holes in castings, joining cast iron to steel etc. (Contd...)

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PROPERTIES UTS : 28­31 kglmm2

CURRENT RANGE & PACKING DATA
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 65-95 80-130 90-140

TERROWELD CLH
Buffer for Oil Soaked & Dirty Cast Iron A cast iron welding electrode for operation at low heat input depositing a non­machinable weld. The electrode is recommended for buttering of oily, greasy, and dirty cast iron to avoid contamination in the final welding. It is suitable for non­critical welding in cast iron with high preheat. It is also suitable for welding in deep holes and tight cor­ ners for all types of sections giving good colour match­ ing as the deposit oxidizes in a similar fashion. ALLOY BASE Fe, Mn, Si SPECIAL FEATURES l Spray type deposit insensitive to contamination. l Good colour match. l Can be used in final layer to give hardness and wear resistance.

APPLICATIONS Pump housing, machine casing, rotor bodies, cast frames & cover, gear box, flywheel, oil soaked castings, ash pipes, oxidized cast iron furnace equipment, discs, etc. PROPERTIES UTS : 55-60 kglmm2 Hardness : 42-45 HRC WELDING PROCEDURE l Preheat the job uniformly to 250°­350°C. l Stringer bead to be used. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 100-130 130-170 160-200

Reclamation Consumables

OK SELECTRODE 92.18
State-of-the-Art Fail-safe Cast Iron Electrode OK Selectrode 92.18 is the latest generation low heat electrode for most fail­safe welding of cast iron. It de­ posits an extremely soft and ductile weld metal. The weld metal has very high crack­resistance and easy machinability. The welding arc is smooth, stable and with a controlled penetration to ensure reduced base metal dilution. ALLOY BASE Ni,Si, Fe, Conforms to AWS A5.15 ENi­Cl SPECIAL FEATURES l Superb slag detachability. l Excellent weld bead appearance. l Preheat is seldom necessary. l Barium Free APPLICATIONS Ductile repairs and build­up of cast iron components, salvaging of casting defects like blowholes, pit marks & scratches, reclaiming gears and pulleys, water pump housings, cylinder blocks, lathe beds. Buttering cast iron sections before joining with iron­nickel alloy con­ sumables.

PROPERTIES UTS : 36-38 kg/mm2 WELDING PROCEDURE l Welding area should be cleaned of scales, grease, oil impurities and dirt. l Cracks should be absolutely removed by gouging or cutting with OK Selectrode 21.03. l Welding should be done in stringer beads/skip weld­ ing/backstep welding. l When welding thick sections, preheating upto 150­ 200°C will keep the weld more ductile. l Reinforcing studs should be used when the volume of weld metal required is more. l Light peening of the weld metal is advisable at hot stage to minimize shrinkage stresses. CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.20 4.00 Length (mm) 350 350 Current Range (Amp) 90-140 110-170

205

OK SELECTRODE 92.58
Strength Welding for all Cast Irons OK Selectrode 92.58 is a new generation alloy electrode for welding and repairing of malleable and grey cast irons, and difficult-to-weld cast irons viz. S.G. iron. The weldmetal is machinable, possesses high strength coupled with good toughness, thus making it suitable for joining cast iron to steels and filling-up cavities in castings. ALLOY BASE Ni, Fe, Mn, Si Conforms to AWSA5.15 ENi ­ Fe CI SPECIAL FEATURES l Smooth bead consists of fine ripples. l Excellent slag peel-off. l Barium Free APPLICATIONS Joining of cast iron components, welding of cast iron to steels, rectification and build-up of defective castings giving good colour match. Repairing of complicated and cracksensitive castings involving hydrostatic pressure and dissimilar thickness, heavy sections and joints under restraint such as pumps, differential housings,

Reclamation Consumables

cast iron dies, etc. Other applications are cast iron gears and pulleys, sliding tables for machine tools, cylinder blocks. PROPERTIES UTS : 44-47 kg/mm2 WELDING PROCEDURE l Clean the weld area of all scales, grease and dirt. l The smallest possible electrode diameter and the lowest possible current should be used. l Skip welding sequence may be used to limit the heating of the base metal. l Although mostly preheating is not required, when welding thick sections and malleable irons, preheat­ ing to about 250­300°C is advisable to minimize the shrinkage stresses and cracking. l Just after welding the joint can be lightly peened and should be allowed to cool slowly. CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.20 4.00 Length (mm) 350 350 Current Range (Amp) 60-120 90-150

OK SELECTRODE 92.60
The Last Word in Cast Iron Welding OK Selectrode 92.60 is latest development in cast iron welding. With a specially designed slag it can weld extremely difficult to weld cast irons, in all positions. The refining action of the slag prevents hot shortness in high sulphur cast iron, giving a sound radiographic joint. The weld deposit produced has exceptional strength over those created by run­of­the­mill cast iron electrodes. For repairing thick joints in cast iron it provides fail­proof performance and prolonged service life. It can also be used for radiographic quality joints between cast iron and stainless steel/mild steel/manganese steel/ Inconel alloys. ALLOY BASE Ni, Fe, Mn SPECIAL FEATURES l High quality joints in any critical cast iron repairs. l Nitrogenous slag gives clean inclusion­free joint. l Barium Free. APPLICATION OK Selectrode 92.60 is applicable for any cast iron application ­ joining buffering and surfacing. Applications involving high joint strength and fatigue in service condition should be welded only with this grade.

PROPERTIES UTS : 56-61 kg/mm2 WELDING PROCEDURE l Clean the weld area of all scales, rust, grease and dirt. l Use the smallest possible electrode diameter. l OK Selectrode 92.60 has high current capacity, so for big jobs use sufficient current for proper base metal fusion and bonding. l One may use skip welding sequp.nce to limit the heating of the base metal. l Although preheating is not required in most cases, when welding complicated castings preheat to about 250­300OC to minimize the shrinkage stresses gen­ erated in the base metal. l Just after welding peen the joint lightly with ball pen hammer and cool slowly. CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.25 4.00 Length (mm) 350 350 Current Range (Amp) 75-150 90-175

206

ESAB 801 KG
Nickel Base Ductile Electrode for Cast Iron Welding A nickel­cored electrode depositing an almost pure nickel weld metal suitable for joining and repairing gray cast irons giving a perfectly machinable deposit. The electrode performs well even in areas that are difficult to reach. While rebuilding machine components, ESAB 801 KG does not overheat the job. For welding thicker sections and bigger jobs, should be used with peening for best result. This makes sure the weld bead remains ductile and tough. ALLOY BASE Ni,Si

SPECIAL FEATURES l Very good wetting property for thin sections and filling up cavities. l Carbon dissolving capacity is high. SPECIFICATION: AWS 5.15: E Ni­CI APPLICATIONS Reclamation of castings and machine parts, filling-in of blow holes in castings, joining cast iron to steel etc. PROPERTIES UTS : 29­32 kg/mm2 CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 Length (mm) 350 350 Current Range (Amp)

Reclamation Consumables

65-95 80-130

ESAB 802 KG
Economical Strength Welding of Cast Iron A nickel­iron alloy, low heat input electrode designed to weld all weldable cast irons. Weld metal is fully machinable with good strength that helps in the rectification of defects in heavy casting and for welding of cast iron to mild steel. Suitable for nodular cast iron repairs. ALLOY BASE Ni, Fe, Si SPECIAL FEATURES l Versatility in usage. l Good colour match.

SPECIFICATION: AWS 5.15: E NiFe­CI APPLICATIONS Repairing and joining of cast iron components and parts, repairing of engine heads, casings, impellers, rope drums, ingot moulds etc. Rectification and build-up of defective castings in cast iron foundry giving good colour matching and also for welding of cast iron to steel. PROPERTIES UTS : 38-40 kg/mm2 CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 50­90 80-125 110-165

TERROWELD CP
Welding Grey and Nodular Cast Iron at Low Heat A low heat input electrode for welding of cast iron components giving a very soft and highly ductile deposit with extreme crack resistance and easy machinability. It has a very soft, smooth and stable arc ensuring minimum dilution with base metal and leaves a thin easily detachable slag. ALLOY BASE Ni, Si, Fe SPECIAL FEATURES l Crackless joints in weldable cast iron grades. l Non-fluid slag removed by brushing only. APPLICATIONS Joining of cast iron to itself, surfacing of cast iron components, salvaging of casting defects as found

in cast iron gears and pulleys, water pump housing, cylinder blocks, lathe beds, sugar mill rolls, dies, etc. PROPERTIES UTS : 30­33 kg/mm2 WELDING PROCEDURE l When welding thick sections, preheating upto 150­ 200°C is desired. l Welding area should be cleaned of scales, grease, impurities, oil and dirt. l Welding should be done in stringer beads/skip welding/backstep welding. l Reinforcing studs should be used when the volume of weld metal required is more. l Light peening of the weld metal is advisable, when still hot, to minimize shrinkage stresses. (Contd...)

207

CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 60-80 90-110 110-160

TERROWELD CF
Low Heat Input Strength Joints A nickel­alloyed electrode for welding and repairing of cast irons, e.g. S.G.lron, malleable and grey iron castings etc. The electrode deposits a high strength weld metal combined with good toughness of the weld joint, thus making it suitable for joining cast iron to mild steel. ALLOY BASE Ni, Fe, Si, Mn SPECIAL FEATURES l Strength joints at low heat. l Less sensitive to contaminated iron. · Excellent weld bead appearance. TYPICAL APPLICATIONS Joining of cast iron components, welding of cast iron to steel, rectification and build-up of defective castings giving good colour matching. Repairing of complicated and cracksensitive castings involving hydrostatic pressure and dissimilar thickness, heavy sections and joints under restraint such as pumps, differential housing, cast iron dies etc.

Reclamation Consumables

PROPERTIES UTS : 36-39 kg/mm2 WELDING PROCEDURE l Clean the weld area of all scales, grease and dirt. l The smallest possible electrode diameter and the lowest possible current should be used to restrict the width of the HAZ. l Skip welding sequence may be used to limit the heating of the base metal. l Although preheating is not required in most cases, when welding thick sections and malleable irons, preheating to about 250­300OC is advisable to minimize the shrinkage stresses and cracking. CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 65-95 85-115 140-160

208

Steel and Dissimilar Joining Alloys
WELDING DISSIMILAR STEELS
Joining Stainless Steel to Low Alloy or Carbon Steel The most common and important instance of dissimilar metal joining is that of welding stainless steel to carbon­ manganese steel or to low alloy steel. The most common application is attachments or transitions. The welding is almost always carried out with over­ alloyed stainless consumables i.e. having higher alloy content than the base metal. Two different methods are employed for this type of welding. The entire weld groove can be filled up with the over-alloyed stainless steel or any nickel based consumable. Otherwise, the lower alloyed surface can be buttered with an over­ alloyed stainless weld metal and then the groove can be filled up with a consumable matching with the stainless side. The welding can usually be performed without preheating. However, if there is any recommendation for that particular grade of steel, then that has to be followed. WELDING MANGANESE STEELS Manganese steel typically contains 11-14% manganese and 1.0-1.4% carbon. Some other grades can have other minor alloying elements. This steel has an ability to workharden e.g. under high impact and/or high surface pressure. These steels have to be reconditioned by repairing cracks or breakages, rebuilding worn out portions and hardfacing to extend service life. Weldability of manganese steel is governed by the fact that it tends to become brittle when reheated and slow­ cooled. Consequently, the interpass temperature should not exceed 200°C. As a result, during welding of these steels, the following matters should be noted : l the heat input should be as low as possible l stringer beads should be used l simultaneous working with several components should be done, as far as practicable l the component can be cooled by putting it in cold water Welding manganese steel involves anyone of the fol­ lowing cases: l joining manganese steel to itself or to unalloyed, low alloy steel l rebuilding worn out surfaces For joining manganese steels and manganese steels to carbon steels, austenitic stainless consumables have to be used to obtain a tough and strong joint. Prior to surfacing also it is advisable to add a buffer layer of austenitic stainless consumables. On top of that regular 13% manganese type deposit is put as the surfacing layer. WELDING “DIFFICULT TO WELD STEELS” The following types of steel are regarded as ‘difficult to weld’ for their high hardenability : l high carbon steels l high strength steels l spring steels l tool steels l wear­resistant steels Steels of unknown composition are also treated as having limited weldability so that the weld does not fail in any respect. Welding theory says that all these steels can be welded with matching ferritic consumables with proper preheating and post-weld heat treatment (PWHT). But repair welding, by nature, does not always allow preheating or PWHT. Therefore, the safest way is to weld with austenitic stainless or nickel­based consumables. The risk of cracking due presence of hydrogen is neutralized by the greater solubility of hydrogen in austenite and also by the higher ductility of the weld metal. For welding steels of unknown composition, the best choice is a ferritic-austenitic duplex type of consumable. WELDING TOOL STEELS Tool steels have a higher carbon content along with chromium, nickel, molybdenum, vanadium and are generally heat-treated to achieve certain specific properties. The repair welding of tool steels without changing their inherent properties is very difficult. This calls for use of consumables producing a weld metal with matching composition, microstructure and properties. But practically, this is very difficult as it involves scaling change of dimension and time. The welding is simplified by using specific consumables developed for tool steels: Shock resistance, toughness, Straight chrome abrasion resistance martensitic deposit Hot strength, abrasion Fine carbides in resistance at high temperature martensitic matrix Edge retention at high High speed temperature, impact toughness steel deposit The welding is done by preheating the job to 200­500°C (as per the type of steel) and maintaining it during the course of the welding. The preheating and PWHT to be followed can be found in different international standards like SAE/AISI.

Reclamation Consumables
209

TERROWELD DMS
High Speed Touch Welding Electrode for X-ray Quality Auto­run Terroweld DMS is characterized by ‘Push­arc’ that speeds up the output even for unskilled welders. The low heat electrode is preferred to any similar electrode due to its very high speed of welding and ability to weld thin sheets without burn­through. Terroweld DMS is suitable for touch welding in all positions, so even unskilled welders can give X­ray quality welds. No slag cleaning is required by the welder since the nonsynthetic slag detaches itself from the bead automatically. ALLOY BASE Fe, Mn, Si SPECIAL FEATURES l Auto­run characteristic ­ low welder skill involved.

Self­lifting slag ensures no slag cleaning for the welder. · Runs on low OCV transformers. APPLICATIONS Joining thin sheets at high speed, welding boiler quality steels, ship plates, and general repair and maintenance operation of containers, air conditioning units, ducts, tanks, bus bodies, for great finish and shiny bead appearance. PROPERTIES UTS : 47-52 kg/mm2 Elongation : 24-28%
l

CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 50­110 70-140 100-190 150­210

Reclamation Consumables

ESAB 116
Low heat electrode for very high tensile strength joining A medium-to-heavy coated electrode, Esab 116 gives a hydrogen­controlled deposit for welding high­tensile low-alloy steels. The deposit has excellent resistance to creep and has a high corrosion resistance. It is used regularly for repairs of hot dies. SPECIAL FEATURES l Resists annealing l Stupendous weld strength l Weld deposit is insensitive to hot cracking TYPICAL APPLICATIONS Recommended for joining and repair of machine parts fabricated out of high tensile steels. It is also suitable for automotive parts, specific grades of armour plate

steel, and chemical plant parts where Ni­Cr­Mo steels are used. It is suitable for build­up and repair of forge dies. The maintenance of strength upto 538°C renders it usable on steam turbine rotors that operate upto this temperature. MECHANICAL PROPERTIES: UTS : 95 – 106 kg/mm2 Elongation : 15 - 18% CURRENT RANGE (AC 70, DC+/-):
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 450 450 450 Current Range (Amp) 60-90 100-140 130­180 170-230

OK 53.18
For welding galvanising baths Esab 53.18 is a special purpose electrode which gives a deposit that is almost pure iron that makes it the ab­ solute choice for welding galvanising baths. The low impurity content, especially silicon, ensures excellent resistance to molten zinc corrosion. The weld metal is fairly strong and ductile. The weld beads are smooth and shiny with easy slag detachabil­ ity. The electrode gives very low spatter for a pleasing welding experience. TYPICAL APPLICATIONS Special formulation for welding and repairing hot dip galvanising baths. Other applications include filling up

holes and building up worn out shafts and other ma­ chine parts that are not exposed to excessive wear. MECHANICAL PROPERTIES UTS : 44-48 Kg/mm2 Elongation (l = 4d) : 28-32% WELDING CURRENT: AC 50, DC+ CURRENT RANGE
Size (mm) 2.50 3.25 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 60-100 80­130 125-180 170-250

210

TERROWELD DBL
Super Ductile Joining and Buffering Terroweld DBL deposits a high strength low alloy weld metal recommended for building up and joining of low, medium carbon and low alloy steels. It is also suitable for giving buffer layers on medium and high carbon steels prior to hard surfacing. The weld deposit is extremely ductile and crack resistant. Produces excellent result in highly constrained heavy machinery joining. Low heat formulation suitable for joining thin section without risk of burn­through. ALLOY BASE Fe, Mn, Si, Ni SPECIAL FEATURES l Super­ductile weld. l Suitable for high speed welding. l Bonds easily with parent metal. APPLICATIONS Joining and build­up of medium tensile steels, joining dissimilar sections, restrained joints, giving buffer layers on pipes, flanges, pressure vessels, cross members, gun plates, steel castings, heavy machine components, etc.

Perfect in welding steels like free­cutting steels, where sulphur and other alloys are added. PROPERTIES UTS : 52­55 kg/mm2 Elongation : 28-32% CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 90-135 140-165 170-220

Reclamation Consumables

TERROWELD DLH
Vacuum Packed Electrode for Constrained Sections This low alloy high strength weld metal is recommended for building up and joining heavy sections of low, medium carbon and low alloy steels in critical components. The weld deposit is ductile and crack resistant. This process along with the special flux enables the electrode to be used directly in critical field condition without welding precautions as electrode redrying, preheating the workpiece, etc. The electrode needs no baking upto 8 hours after opening the VacPac. ALLOY BASE Fe, Mn, Ni SPECIAL FEATURE l No welding precautions are required. APPLICATIONS Joining & build-up of medium tensile steels, restrained joints, steel castings, heavy machine components, etc., dragline bucket and chains, dipper stick, repairing cranks and undercarriage, dozer blades repair, chassis of earthmoving equipment like dumper, shovel, dragline etc. and repairing pulleys of dragline.

PROPERTIES UTS : 54-59 kg/mm2 Elongation : 28-32% CURRENT RANGE : (AC 50, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 90­135 140-165 170-220

211

DUROCHROME
Low Heat Dissimilar Steel Strength Joining Esab Durochrome is an electrode for welding complex dissimilar alloys and high strength steels with low heat input giving sound joints, free from any cracks and fissures. The electrode is also suitable for depositing buffer layers prior to hard surfacing on high strength and high alloy steels. The deposit is corrosion resistant and resists high temperature oxidation. It provides excellent metal to metal frictional resistance. ALLOY BASE Fe, Cr, Ni, Mn SPECIAL FEATURES l Operates at low amperages on both AC & DC. l Smooth are, fine ripples and controlled easily detachable slag. l The duplex structure steel weld metal is extremely tolerant to dilution. APPLICATIONS Welding of high strength alloy steels, dissimilar joints, rebuilding of chemical agitator blades, shafts, rolling mill spindles, bucket lips, steel mill wobblers, coupling boxes, mill hammers, bar mill guides, sinter plant parts, etc.

Joining and surfacing of high carbon, low and high alloy steels, tool steels, spring steels, manganese steels, case hardening steels, etc. PROPERTIES UTS : 77-82 kg/mm2 Elongation : 30-35% CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 40-65 55­95 85-135 110-165

Reclamation Consumables

TERROWELD DS1
Crackfree Manganese Steel Joining and Buffering Terroweld DS1 provides a stainless steel deposit having high resistance to hot cracking with low heat input. It is ideally suited for joining manganese steel to carbon steel and for buffer layer deposition on manganese steel. Being able to withstand heavy impact, corrosion and moderate abrasion, this electrode can be used for build­up layers on high strength high alloy steel. ALLOY BASE Fe, Cr, Ni, Mn SPECIAL FEATURES l Weld metal is resistant to hot cracking. l Slag is easily detachable.

APPLICATIONS Joining and reinforcing of manganese steel components, joining of dissimilar steels, buffer layer prior to hard surfacing of bulldozer blades, crusher jaws, bucket teeth, sprockets etc. PROPERTIES UTS : 54-62 kg/mm2 Elongation : 38-42% CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 60-90 70-110 100-130 110­150

TERROWELD DS2
High Strength Dissimilar Joining Applications Terroweld DS2 is a low heat input electrode depositing super stainless weld metal recommended for joining of carbon steels and alloy steels to themselves or to other

high strength high alloy steels giving a high strength joint. It gives a good combination of impact, heat, and corrosion resistant properties. It can be used to join fatigued and dirty cast steel components. (Contd...)

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ALLOY BASE Fe, Cr, Ni, Mo SPECIAL FEATURES l Superior bonding with all steels. l Crack­less joint. l Very good strength and impact toughness. APPLICATIONS Joining high strength alloy steels, heat and scale re­ sistant steels. Suitable for stainless cladding on steels, furnace and combustion chamber parts, hydrogenation plants. Repair and surfacing of gears, spindles, worn out sprockets, valves, rolls, pinions, hot dies, reinforcing

of manganese steel components, salvaging of broken rolling mill spindles, hydel turbine blades, trash beams, etc. PROPERTIES UTS : 72-80 kg/mm2 Elongation : 29-34% CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 60-90 70-100 100-130 110-140

Reclamation Consumables

TERROWELD DS3
Strength Joining for Dissimilar and Unknown Steels Terroweld DS3 deposits a high ferrite stainless steel de­ posit suitable for joining, building up and buffering ap­ plications. The specially designed microstructure of the weld deposit ensures superior resistance to crack, cor­ rosion and oxidation. The electrode is suitable for join­ ing dissimilar, unknown and difficult to weld steels. It is suitable for welding thick sections with deep groove in all positions. Weld deposit is of excellent quality ensur­ ing fail­safe performance. ALLOY BASE Fe, Cr, Ni, Mn, Si SPECIAL FEATURES l Deposit gives high strength, combined with excellent resistance against impact, friction. l Heat and corrosion resistant surfacing.

l Smooth arc and fine ripples. APPLICATIONS Joining, surfacing and rebuilding shafts, spindle, gears, pinions, springs, bull gears and sprockets, pump, gear box casing, rolling stock couplings, universal coupling, chassis frames, shovel booms, wobblers, kiln tyres, hammer shafts etc. Also used as a buffer layer before hard surfacing of min­ ing and earth­moving machinery. PROPERTIES UTS : 80-86 kg/mm2 Elongation : 30-34%

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 70-100 100-130 110-140

TERROWELD DS4
Welding Stainless Steels to any Other Steel and Overlays Terroweld DS4 is a smooth running rapid flowing elec­ trode giving a deposit that is strong and ductile for very good resistance to impact. The weld metal is also suit­ able for stainless overlays, ‘butter layers’ as they are known, on carbon steels prior to joining with other stain­ less steels. It is also used for joining stainless steels to any other steel. ALLOY BASE Fe, Cr, Ni, Mn, Mo SPECIAL FEATURES l Ease of operation. l Easy slag peel off revealing shining bead. l Thick bead facilitating smooth surfacing.

APPLICATIONS Rebuilding of impellers, shafts valve faces and seats, and turbine blades to provide resistance to heat, abra­ sion, erosion and corrosion. Welding stainless steels to carbon steels, low alloy steels, cast steels and austenitic manganese steels and for depositing stainless tough overlays on cast steel and austenitic manganese steel parts. PROPERTIES UTS : 55-65 kg/mm2 Elongation : 28-34% CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 70-100 80-130 110-140

213

TERROWELD DS6
Single Electrode for Railway Points and Crossings Terroweld DS6 is a heavy-coated basic electrode for applications, which demand resistance to high abra­ sion coupled with heavy to moderate impact. It is a very smooth running electrode having very good slag de­ tachability and bead appearance. The weld deposit consists of fine austenite grains with about 5% carbide precipitated at the grain boundaries. ALLOY BASE Fe, Cr, Ni, Mn, Mo SPECIAL FEATURES l Beautiful bead appearance. l Exceptional slag detachability. l High recovery deposition. APPLICATIONS Suitable for welding and surfacing manganese steels where heavy impact loads accompanied by severe abrasion and friction is prevalent, such as in railway

Reclamation Consumables

points and crossings. This electrode obviates the need for separate electrodes for joining the points & cross­ ings and hardfacing. PROPERTIES UTS : 59-65 kg/mm2 Elongation : 18-22% Hardness : As deposited : 22-26 HRC Work hardened : 40-44 HRC WELDING PROCEDURE l Welding is recommended to be done by stringer beads. l All precautions, as necessary for welding manganese steel parts, should be taken. l Peening at hot condition has beneficial effect. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 Length (mm) 350 350 Current Range (Amp) 100-140 120-180

TERROWELD S1
Stainless Steel Electrode for Heat and Corrosion Terroweld S1 is an all­purpose stainless steel electrode having a high corrosion and heat resistance, which can be operated at very low heat input. It is specially rec­ ommended for repairing and joining extra low carbon grades of stainless steels, where a combination of cor­ rosion resistance, heat resistance and scaling resis­ tance is called for. ALLOY BASE Fe, Cr, Ni SPECIAL FEATURES l VacPac for ready use ­ without preheating within 8 hours. l Superior welding characteristics. l Finely rippled bead with minimum spatter. l All positions. APPLICATIONS Terroweld S1 is recommended for welding all austenitic

stainless steels of 18/8 and 19/9 types, particularly the ELC grades, and can be used for joining and repairing of mixers, valves, sterilizers etc., in dairy, chemical and distillery equipment. The electrode can also be used as a preventive overlay on steel. PROPERTIES UTS : 50-57 kg/mm2 Elongation : 38-44% WELDING PROCEDURE l The weld area should be cleaned of all dirt, grease and oil. l Stringer bead welds are preferable, maintaining a short arc. l Use smaller size of electrode wherever practicable. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 45-70 60-100 90-130 110-160

TERROWELD S2
Stainless Steel Electrode for Pitting Corrosion Terroweld 82 is a low heat input stainless steel elec­ trode having a high resistance to acid pitting. It is spe­ cially recommended for repairing and joining of extra low carbon and standard grades of stainless steels with

or without molybdenum, stainless clad steels and car­ bon steels. ALLOY BASE Fe, Cr, Ni, Mo SPECIAL FEATURES l VacPac for ready use ­ without preheating within 8 hours. (Contd...)

214

Suitable for all position welding. l Finely rippled bead with minimum spatter and easy detachability of slag. APPLICATIONS Terroweld S2 is recommended for corrosion resistance welds on 18/8 Mo stainless steel, especially 316 & 316L types. It is also suitable for protective overlay on 315, 318, 329 steels for medium hardness, for high corro­ sion resistance, for restrained joints and crack sensitive alloys. PROPERTIES UTS : 62-64 kg/mm2 Elongation : 34-39%
l

WELDING PROCEDURE l The weld area should be cleaned of all dirt, grease and oil. l Stringer beads are preferable, maintaining a short arc. l Smaller size of electrode should be used wherever practicable. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 45-70 60-100 90-130 110-160

Reclamation Consumables

TERROWELD S3
Stainless Steel Electrode for Oxidation Resistance Terroweld S3 is an all­purpose high alloy stainless steel electrode having high corrosion and heat resistance, which can be operated at low heat input. This electrode is specially recommended for repairing and joining of heat resistant stainless steel plates and pipes for pro­ tection against oxidation and corrosion. It is also suit­ able for joining dissimilar metals and overlays. ALLOY BASE Fe, Cr, Ni SPECIAL FEATURES l VacPac for ready use ­ without preheating within 8 hours. l Suitable for all position welding. l Finely rippled bead with minimum spatter and easy detachability of slag.

APPLICATIONS Terroweld S3 is recommended for welding all austen­ itic stainless steels for heat & oxidation resistance upto 1100°C in dairy, chemical & distillery equipment for ap­ plications like valves, heat exchangers etc. PROPERTIES UTS : 56-58 kg/mm2 Elongation : 30-35% WELDING PROCEDURE l The weld area should be cleaned of all dirt, grease and oil. l Stringer bead welds are preferable, maintaining a short arc. l Use smaller size of electrode wherever practicable. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 45-70 60-100 90-130 110-160

ESAB CSA
Cost Effective Means to Crack Resistant Welding The most crack­resistant electrode for welding steels of limited weldability, Esab CSA gives a tough weld metal that is designed to give superior crack resistance than what is available with normal 18-8-6 varieties. The elec­ trode has high current tolerance and maximum deposi­ tion rate. Extremely suitable for crackfree root-runs in 14% Mn steels. ALLOY BASE Fe, Cr, Ni, Mn SPECIAL FEATURES l Deposition efficiency: 190% (approx.)

Electrode gives high current tolerance and maxi­ mum deposition rate. l Most economic electrode for dissimilar steel joints. APPLICATIONS Welding and repairing manganese steels, cladding worn out parts in bulldozers, rail crossing, dredgers, contact layer etc. Joining austenitic manganese steel to carbon steel or hardenable steels without preheat and welding machine parts to excavating machine components. PROPERTIES UTS : 57-62 kg/mm2 Hardness : As deposited : 20-22 HRC Work hardened 45-49 HR (Contd...)
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215

WELDING PROCEDURE l 14% Mn steel should never be preheated for welding. l Heat input to the base metal should be kept minimum. l The weld bead may be peened with ball pen hammer just after welding. l Quenching has no adverse effect on welding and should be adopted whenever possible after slag removal and peening.

l

If required the Mn steel job may be submerged in water during welding.
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 100­150 150-200 200­250

CURRENT RANGE : (AC 70, DC+/-)

OK SELECTRODE 68.82
Versatile Electrode for Joining any Steel to any Steel OK Selectrode 68.82 deposits a high strength oxidation and corrosion resistant weld metal suitable for dissimilar steel joining and building­up applications. The weldmetal, being free from dilution effects and having high strength combined with good elongation, can successfully join thick section of any unknown steel and steels which are difficult to join. The high scaling temperature of weld metal makes the electrode usable for working at high temperatures. ALLOY BASE Fe, Cr, Ni, Mn SPECIAL FEATURES l Extremely smooth running performance. l ‘Fail­safe’ alloying.

Reclamation Consumables

Bonds with any steel. l Self­releasing slag. APPLICATIONS Joining unknown steels, steels of limited weldability, and dissimilar steel joining. Reclamation of shafts, universal coupling, gear teeth, pump casings, rolling mill spindles, buffer layers prior to hardfacing in mining and earthmoving equipment, coal pulverisers, pinions, crusher roller gears etc. PROPERTIES UTS : 79-86 kg/mm2 Elongation : 22-29%
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CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 50­80 75-110 100-140 130-160

OK 68.53
Classifications : EN 1600 E 25 9 4 N L R 3 2 Werkstoff Nr. (1.4410) OK 68.53 is a coated electrode for welding austenitic ferritic steels of Super Duplex types, e.g. SAF 2507 and Zeron 100. OK 68.53 has good welding characteristics in all positions and the slag is easily detachable. APPROVALS : VdTŰV WELDING CURRENT : DC+, AC OCV 60 V TYPICAL WIRE COMPOSITION (%) C Si Mn Cr Ni Mo N 0.03 0.6 0.7 25.5 10.0 4.0 0.25
YS UTS EL Charpy V

Mechanical Properties 700 MPa 850 MPa 30% +20, -40 50, 35 FN 35­50

Test temp OC Impact Values, J Ferrite content

CURRENT RANGE :
Size (mm) 2.50 3.25 4.00 Length (mm) 300 350 350 Current Range (Amp) 55­85 70-110 110-150

216

OK 69.33
A fully austenitic rutile - basic 20.25.4, 5 weld metal with better corrossion resistance to sulphuric acid than lower alloyed weld metals of AISI 316L and 317L type. Description and applications OK 69.33 is designed for welding of stainless steel with corresponding composition. This type of steel has better resistance to sulphuric acids than lower alloyed stainless steels. OK 69.33 is recommended for swed­ ish Standard Standard steel SS 2562, Avesta 254 SLX UHB 904L, Sandvik 2 RK 65, 2R N65. Welding current: DC+, AC > 65V Diameter Length Current Arc Volts mm mm Amps Approx 2.5 300 60-90 25 3.25 350 85-130 26 4.0 350 120-180 28 Deposition data at max welding current Diam. Length Kg weld mm mm metal per kg of electrodes 2.50 300 0.58 3.25 350 0.58 4.00 350 0.51 Redrying: 250OC 2h

Classification DIN 8556: E 20 25 5 L Cu R Typical weld metal composition% C Si Mn Cr Ni Mo Cu <0.030 0.5 1 20.5 25 5 1.5 Typical mechanical properties All weld metal specimens 0.2% proof stress 400 N/mm2 Tensile strength 575 N/mm2 Elongation 4xD 35% Butt weld test Test temp CVN impact values. O +20 C 80J O -140 C 45J Ferrite Number : 0 Approvals TUV eignungsgeprüft Kg weld metal per hour arc time 1.0 1.5 1.9 Burn off time per electrode secs 45 52 64 Weight of weld electrode gm 13 21 34

Reclamation Consumables

Number of electrodes per kg weld metal 80 41 30

ASTRÄ ZF
Super resistance to sulphuric acid corrosion Asträ ZF is a high performance electrode with excel­ lent corrosion resistance to acids than the standard AISI 316L or 317L types where the alloy content is lower. A rutile based electrode, Asträ ZF is characterized by smooth running and a selfpeeling slag. SPECIAL FEATURES: l Stunning resistance to sulphuric, phosphoric, acetic acids l Smooth arc, a ripple free bead and a slag that re­ moves itself TYPICAL APPLICATIONS The electrode is designed for welding stainless steels of corresponding composition viz. Carpenter 20, SS 2562, Avesta 254 SLX UHB 904L, Sandvik 2RK65, 2RN65, etc. The weld deposit is resistant to sulphuric, phosphoric, acetic, oxalic, formic and other acids like fatty acids. The electrode can be successfully applied in pipeline and storage applications handling the above chemicals.

CLASSIFICATION: AWS 5.4: E 385-16 CHEMICAL COMPOSITION
C <0.030 Mn Si Cr Ni Mo Cu 1.4-1.8 0.4-0.6 20.0-22.0 23.5-25.0 4.5-5.2 1.3-1.9

FERRITE: 0 MECHANICAL PROPERTIES UTS : 56-58 kg/mm2 Elongation (l=4d) : 33-35% WELDING CURRENT: DC+, AC 65 WELDING PARAMETERS AND PACKING DATA Size Length Current Net Wt. of Net Wt. of (mm) (mm) (Amps) Electrodes Electrodes in a in a Carton Case (Kg) (Kg) 2.50 350 90­110 2 10 3.15 350 120-140 2 10 4.00 350 150-185 2 10 5.00 350 170-250 2 10

217

Non-Ferrous Alloys
WELDING NON-FERROUS ALLOYS
NICKEL AND NICKEL ALLOYS Nickel and nickel based alloys are used in industrial applications for: l corrosion resistance l heat resistance and high temperature properties l cryogenic properties Preheating is not normally required unless there is a risk of porosity from moisture condensation. PWHT is not usually needed to restore corrosion resistance. Inconel type of deposit is used for obtaining high temperature, high strength joints designed to perform at over 200°C such as on creep resistant chrome­ molybdenum steels to stainless steels. These types are suitable when welding sections over 25 mm. For welding tool steels requiring toughness under repeated cyclic stress and oxidation resistance upto 1000°C, Hastelloy C type of deposit is regularly used. The drop in strength and hardness as the temperature goes up is very gradual. COPPER AND COPPER ALLOYS The main features of copper and its alloys; l corrosion resistance l electrical and thermal conductivity In terms of weldability, the alloys have quite different welding characteristics. Copper needs substantial preheat to counteract the high thermal conductivity. But alloys like cupro­nickel can be fusion welded without any preheat, as the thermal conductivity is similar to low carbon steel. Buttering technique should be used to join copper alloys to carbon/stainless steel. This is to take care of the copper migration to the HAZ and precipitation at the grain daries. The buttering, with a pure nickel electrode, can be applied on either the copper or the steel side. The groove has to be filled up a stainless or a bronze type of deposit. The preheating should be 300­500°C when buttering copper or bronze whereas the preheating temperature has to be chosen according to the base material if the buttering is done on the steel side. ALUMINIUM AND ALUMINIUM ALLOYS The characteristics of aluminium and its alloys that make them amenable to fabrication are enlisted below. These are: l light weight l good corrosion resistance The filler metals used for welding aluminium alloys are selected considering the following aspects: l weldability of the parent metal l minimum mechanical properties of the weld metal l corrosion resistance Nominally matching filler metals are often employed for non-heat-treatable alloys. However, for unalloyed or lowalloyed materials and heat­treatable alloys, non-matching fillers are used to prevent solidification cracking. COBALT ALLOYS Cobalt alloys are known for excellent wear resistance at high temperatures and the weld metal is used in cutting and shearing operations at temperatures exceeding 600°C. These deposits exhibit high shock resistance, high hardness at elevated temperatures and scaling resistance and can be used in stamping dies, trimming cutters, trimming punches, etc.

Reclamation Consumables
218

ESAB CN1 G
Excellent High Temperature and Corrosion Resistance Esab CN1 G is an electrode designed to deposit weld with excellent resistance to corrosion and oxidation. It provides superior strength at temperatures above 650°C. ALLOY BASE Ni, Cr, Fe, Mn, Mo SPECIAL FEATURES l Smooth and stable arc with low spatter loss. l Excellent resistance to acid corrosion. l Superior strength at higher temperatures.

APPLICATIONS ESAB CN1 G is ideally suited for joining Inconel, Incoloy, etc. and their combination with stainless steels. PROPERTIES UTS : 60-64kg/mm2 YS : 40-44 kg/mm2 Elongation : 30-40% CURRENT RANGE : (AC 70, DC+)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 80­120 100-160 140-190

Reclamation Consumables

ESAB CN182
High Temperature Resistance Ultimate Bonding Esab CN182 virtually bonds with everything like ferrous metals, stainless steels, nickel steels, chromium steels, cobalt­based alloys, carbides. It is perfectly suitable for re­buffering hardfaced layer and welding dissimilar al­ loys. It can be used for welding 5% and 9% nickel steels, Inconel, Incoloy, etc. The weld metal is tough and ductile and can withstand severe thermal fluctuations. ALLOY BASE Ni, Cr, Mn, Fe, Nb SPECIAL FEATURES l Withstands stresses generated by thermal cycles. l Tolerant to dilution and produces crack resistant welds/clads, even in massive sections. l Superior bonding properties.

APPLICATIONS Repair of rotary kiln tyres, heat treatment equipment such as trays, tongs, cryogenic equipment, and fabri­ cation of nickel steels for corrosion resistant tanks and containers, heat exchangers, furnace components and fittings, and low temperature applications. It is suitable for welding of nickel, inconel, monel, stain­ less steels, heat-resisting steels and difficult-to-weld steels. This electrode is perfect for joining dissimilar metals and alloys like carbon steels, stainless steels, nickel and nickel alloys to each other. PROPERTIES UTS : 60-64 kg/mm2 Elongation : 42-48% Impact (CVN) at -196°C : 45-55 J CURRENT RANGE : (AC 70, DC+)
Size (mm) 2.50 3.15 4.00 5.00 Length (mm) 350 350 350 350 Current Range (Amp) 60-100 80­120 100-160 140-190

ESAB MONEL
Corrosion Resistant Surfacing and Joining Monel Esab Monel is a nickel­copper electrode for welding mo­ nel and similar alloys to themselves and to steels and for corrosion resistant cladding. The electrode has very low heat input characteristics and deposits homogeneous welds of superior quality. ALLOY BASE Ni,Cu,Ti SPECIAL FEATURES l Weld metal is ductile and crack resistant.

Resistance to marine corrosion. l Deposits a weld with fine bead appearance and easy de­slagging properties. APPLICATIONS Ideally suited for welding monel and monel­plated steels and for repairing monel casting defects. Joining monel to carbon steels and for overlaying on steel to obtain su­ perior corrosion resistance. Regularly used in chemical, food, dairy, and pharmaceutical industries. PROPERTIES UTS : 48-54 kg/mm2 Elongation : 42-48% (Contd...)
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219

CURRENT RANGE : ( DC+)
Size (mm) 2.50 3.15 4.00 Length (mm) 350 350 350 Current Range (Amp) 40-70 60-90 90-125

OK SELECTRODE 92.35
Service in Elevated Temperature and Corrosive Media OK Selectrode 92.35 is a nickel based superalloy elec­ trode, which offers resistance to most common acids. The weld metal obtained is machinable and retains hardness even after prolonged heating at high temper­ atures. Tensile strength of the weld metal at 800°C is about ten times higher than mild steel which implies that resistance to deformation from static and cyclic loading is much superior. It has smooth and pleasing welding performance with low spatter and easy slag detachability. ALLOY BASE Ni, Cr, Mo, Fe, W SPECIAL FEATURES l Super hot strength. l Bonds with all ferrous and Ni­base alloys. l Super resistance to corrosion from oxidizing acids, mixed acids, chloride salts.

Reclamation Consumables

APPLICATIONS Repair and hardfacing of hot pressing tools, hot forg­ ing dies, hot shear blades, hot trimming dies, joining of Nimonic and Inconel alloys, valves, stirrers and pump components requiring wear, oxidation and corrosion re­ sistance. Also recommended for overlaying or joining dissimilar superalloys like Hastelloy, Inconel, etc., and for joining these alloys to mild, low alloyed and stainless steels. PROPERTIES UTS : 54-62 kg/mm2 Hardness : 25-30 HRC CURRENT RANGE : (AC 70, DC+)
Size (mm) 3.15 4.00 5.00 Length (mm) 350 350 350 Current Range (Amp) 110­130 160-190 190­230

OK SELECTRODE 93.60
DESCRIPTION OK Selectrode 93.60 electrode of Stellite Gr. 250 type which is cobalt­chromium­iron heat resistant alloy with excellent resistance to thermal shock, impact, hot cor­ rosion and oxidation and also abrasion at high tempera­ tures from flue gas, slags. The alloy has good sliding properties. The alloy resists galling and corrosion to splendid levels. SPECIAL FEATURES l Smooth and stable are with low spatter. l Slag is easily detachable. l Gives a machinable hard facing alloy. APPLICATIONS Har facing of parts subjected to wear at elevated tem­ perature and in corrosive environment, valves, vale

seats, hot forging tools, dies, hot shear blades. OKS 93.60 is suitable for hardfacing of components such as grates, trays, radient tube supports and parts in contact with molten slags and molten coppor. MECHANICAL PROPERTIES Hardness : 35-45 HRC Tensile Strength : 551 MPa Elongation :8 CURRENT RANGE : (AC 70, DC+)
Size (mm) 3.20 4.00 Length (mm) 350 350 Current Range (Amp) 70-110 110-160

220

OK SELECTRODE 93.62
Excellent Wear resistance upto 600OC The weld metal has excellent resistance to friction, abra­ sion, impact, corrosion & oxidation and abrasion at high temperature. The alloy resists spalling due to thermal cycling is exceptional. And is characterized by its spat­ terless smooth arc and easy slag detachability. WELDING CURRENT: DC+, AC TYPICAL APPLICATIONS Hardfacing of parts subject to wear at elevated temper­ atures, also in corrosive environment. Surfacing of hot rolls, kneading rolls, press screws, band screws, skid buttons, dies, valves, buner nozzles, drawing valves, seats, steam ends etc. WELDING PROCEDURE l Clean weld area for oil, grease and other impurities. l Preheat job wherever possible. l Hold electrode perpendicular to work piece and weld in stringer beads. l Interpass temperature should not exceed 300°C l Cooling should be slow.

PROPERTIES Hardness : at 20°C at 300OC at 600°C

: 42-49 HRC : 42-49 HRC : 30-35 HRC

CURRENT RANGE : (AC 70, DC+)
Size (mm) 3.20 4.00 Length (mm) 350 350 Current Range (Amp) 70-100 110-160

Reclamation Consumables

OK SELECTRODE 93.66
High Temperature Chemical Inertness OK Selectrode 93.66 deposits a highly crack resistant weld metal of Stellite Gr. 6 type. The electrode is char­ acterized by its spatterless smooth arc and easy slag detachability. The weld metal has excellent resistance to friction, abrasion, impact, corrosion and oxidation and abrasion at high temperature. These features make it suitable for combined wear conditions. The alloy resists spalling due to thermal cycling and has good sliding properties. ALLOY BASE Cr, Co, C, W SPECIAL FEATURES l Retains about 40 HRC hardness at 750°C. l Only solution to complex wear system. l Exceptional resistance to corrosion. APPLICATIONS Hardfacing of parts subject to wear at elevated temper­ atures and also in corrosive environment like hot forging tools, hot shear blades and dies, cutting edges, grab

tongs, hot punches, knives, chemical valve seats, steam ends, pump sleeves, wear pads, screw conveyors, etc. in chemical, petroleum and sugar industries and also in steel plants. WELDING PROCEDURE l Clean weld area for oil, grease and other impurities. l Preheat job wherever possible. l Hold electrode perpendicular to work piece and weld in stringer beads. l Maintain interpass temperature 300°C or lower. l Cooling should be slow. PROPERTIES Hardness : At 20°C As deposited : 39-42 HRC Work Hardened : 43-46 HRC At 750°C As deposited : 19-22 HRC Work Hardened : 38-43 HRC CURRENT RANGE : (AC 70, DC+)
Size (mm) 3.25 4.00 Length (mm) 350 350 Current Range (Amp) 70-100 110-160

221

BRONZOID 1
Excellent Welding of Copper Alloys Bronzoid 1 is an electrode that provides an alloy suit­ able for welding brass, bronze, deoxidized copper, cast iron, steels and dissimilar metals. It has easy slag detachability and produces homoge­ neous and sound weld metal free from porosity and cracks. Excellent colour match on bronze. ALLOY BASE Cu, Sn, P SPECIAL FEATURES l Smooth and stable arc with almost no spatter loss. l The deposit can be machined to a smooth finish with low coefficient of friction. l Resistance to marine and steam corrosion.

APPLICATIONS Welding and surfacing of copper brass and bronze, cracked engine jackets, cylinder heads, electrical fit­ tings, propeller blades, pump parts, bearing bushing, shaft, castings, stampings and valves. Filling cavities in copper alloy castings, joining copper and bronze to cast iron overlays and steel. PROPERTIES UTS : 28-36 kglmm2 Elongation : 18-26% CURRENT RANGE : ( DC+)
Size (mm) 3.15 4.00 5.00 Length (mm) 450 450 450 Current Range (Amp) 60-120 90-170 125-230

Reclamation Consumables
222

Cutting and Gouging Electrodes
CUTTING AND GOUGING
The cutting, gouging and piercing by means of shielded metal arc welding principles is a flexible and economic method of removing metal. The process does not re­ quire any compressed air, gas or any type of special electrode holder as standard equipment can be used. The coating on cutting and gouging electrodes develops a strong gas jet, which blows away the molten material. These electrodes are excellent for preparation prior to repair of cast iron. The jet drives out and burns away impurities and/or graphite on the surface and thus re­ duces the risk of cracking and porosity when welding later. Gouging of manganese steel can also be suitably done. For gouging normally AC or DC­ should be used, where­ as for cutting and piercing DC+ is recommended. The arc is struck holding the electrode at 90° to the work­ piece. Once the arc is ignited, the electrode has to be pointed in the appropriate direction at 5­1 0° to the job surface and pushed in the forward direction. A to­and­ fro motion has to be maintained to carryon with the cut­ ting or gouging action. For piercing, the arc has to be struck in a vertical position and the electrode pushed down to penetrate through the material. The electrode is manipulated with a sawing motion to enlarge the bore.

Reclamation Consumables
223

TERROCUT
Precision Cutting Electrode Specially designed electrode producing a highly forceful and concentrated arc, which can be efficiently used for cutting and piercing holes in carbon steels, cast irons and manganese steels. Terrocut does not heat up the material excessively due to ionizing additives in coating design. This results in lower heat affected zone. SPECIAL FEATURES l High cellulose roaring arc. l Low heat affected zone.

APPLICATIONS Cutting of mild steels, low carbon steels, manganese steels, cast iron, copper, manganese, aluminium, nickel and their alloys, casting risers, gates, dressing for filling up, etc. Absolutely suitable for burning rivets, disman­ tling work at site and for cutting out unwanted metal in castings. CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 300 350 350 Current Range (Amp) 160-250 220-300 260-350

Reclamation Consumables

OK SELECTRODE 21.03
Single Electrode for Cutting and Gouging Even Underwater OK Selectrode 21.03 has a specially developed coat­ ing which produces a strong gas jet that blows away the molten material so that the electrode is absolutely suitable for gouging, cutting, chamfering, piercing, drill­ ing holes. It can be used in all positions except in verti­ cal up. Grooves are even and smooth and subsequent welding can follow without further preparation since the volume of slag is almost nil. With this electrode, the cutting and gouging activity can be taken up without the necessity of any gas or special electrode holder. SPECIAL FEATURES l Roaring arc force. l Thinner coating than other gouging electrodes ­ better positional properties. l Excellent performance even under water. l Sharp and clean kerfs.

APPLICATIONS Cutting, chamfering, gouging, and piercing of steel, cast iron, copper and its alloys, aluminium and its al­ loys, manganese, stainless steel, zinc, nickel and its al­ loys. Used for beveling, for joint preparation, gouging of cracks and back gouging of root runs especially when welding of steel structures, storage tanks, etc. and for removal of unnecessary metal in castings. PROCEDURE l Strike arc perpendicular to work piece. l Tilt the electrode at 10­15° and push forward. l Move the electrode sequentially up and down to melt and remove metal. CURRENT RANGE : ( DC+/-)
Size (mm) 3.15 4.00 5.00 Length (mm) 300 350 350 Current Range (Amp) 160-180 220-270 240-320

224

Cobalarc
COBALARC
Cobalarc ­ the future of hardfacing. This range of tubular electrodes gives a host of advantages over conventional coated electrodes in respect of hardfacing applications owing to its unique features. l The prime weapons that provide the hardness in hardfacing deposits are the metallic and nonmetallic carbides. In coated electrodes, the carbides are formed at the time of welding. Carbides, preformed, cannot be used in these electrodes because the high hardness renders them difficult to produce. But, Cobalarc electrodes have the advantage that the preformed carbides are put inside a hollow mild steel tube. l In hardfacing controlling the heat input is important because greater dilution will lower the hardness of the deposit. In this respect, Cobalarc gives a major headway because only a thin walled tube has to be melted instead of a solid wire. So the heat requirement will be considerably less and automatically the heat input will really be low. l The low heat input also reduces the heat­affected zone in the base metal.
l

l

l

l

Cobalarc provides economy as the total loss involves only .butt end loss and very negligible slag loss. Moreover, the butt end does not contain any carbide inside ­ it is only the hollow tube that is lost, so the actual loss is even lower. The slag formation is very small in Cobalarc. So the welder can apply the next run without wasting any time for deslagging. This gives an immense advantage of speed and productivity. So in 1 hour of arcing, Cobalarc gives 2­2.5 times the weight of deposit than coated hardfacing electrodes. A near absence of slag does not mean that Cobalarc deposits are exposed to the atmosphere for oxidation. The outer coating contains ingredients that burn in the welding arc and generate copious amount of fumes, which provides the shielding to the weld pool. This outer coating has one more function. Since it contains non­hygroscopic stabilizers the mild steel tube is free from rusting giving these electrodes an indefinite shelf life. The rigid tube also protects the preformed carbides from degeneration over time.

Reclamation Consumables
225

COBALARC 1M
Preformed Carbides to Resist High Stress Abrasion Cobalarc 1 M is the ultimate in welding technology. It has autogenous fume shielding over preformed carbides in a tubular form, which gives the user genuine low heat input and infinite shelf life by dint of its nonhygroscopic coating. It deposits fine chromium carbides in tough austenitic matrix and gives better abrasion resistance on mild and low alloy steel bases where impact requirement is limited. This will ensure excellent wear resistance on 12-14% manganese steel components. SPOT COLOUR: YELLOW ALLOY BASE Fe, C, Cr, Si SPECIAL FEATURES l Exceptional resistance to severe abrasion and moderate impact. l Oxidation resistance at elevated temperatures. l Unmatched deposition rates ­ high integrity deposits. l Compared to solid cored electrodes, the current requirement is low so the dilution by parent metal is contained to a minimum.

Reclamation Consumables

Non­hygroscopic coating needs no storage precaution – infinite shelf life. APPLICATIONS I.D. fan blades, impeller casings, dredger bucket lips, crusher jaws, bulldozer cutting edges, muller tyres, sizing screens, pulveriser and crusher hammers, ball mill liner plates, scraper blades, crane grab shovel, dragline bucket lips, points and cutting edges, teeth augers, conveyor chains, rolling mill guides, agriculture implements. The electrode is suitable for 12-14% manganese steel parts and also for carbon steel parts when resistance to abrasion is required. Also for applications which call for oxidation resistance. PROPERTIES Hardness : 55-59 HRC
l

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 5.0 6.3 8.0 10.0 Length (mm) 400 400 450 450 Current Range (Amp) 90-130 120-140 140-170 180-200

COBALARC 9
Preformed Carbides to Resist Abrasion at High Temperatures Cobalarc 9 is the ultimate in welding technology. It has autogenous fume shielding over preformed carbides in a tubular form, which gives the user genuine low heat input and infinite shelf life by dint of its nonhygroscopic coating. The weld metal consists of complex high temperature carbides, with high­stress abrasion resistance withstanding moderate to heavy impact even at high temperature. The deposit is easily grindable, with good impact property. SPOT COLOUR: GREEN ALLOY BASE Fe, C, Cr, Si, Mo, Mn, V SPECIAL FEATURES l Exceptional resistance to severe abrasion and moderate to heavy impact at elevated temperature. l Unmatched deposition rates ­ high integrity deposits.

Compared to solid cored electrodes, the current requirement is low so the dilution by parent metal is contained to a minimum. l Non­hygroscopic coating needs no storage precaution – infinite shelf life. APPLICATIONS Coal burner nozzles, clinker conveyor chains, railway tampers, sizing screens, augers, agricultural implements, rolling mill guides, heat resistant steel castings, pump casings, I.D. fans, tie rods, pug mill and augers, brick press screws, etc. where high stress abrasion is the major factor of wear at high temperatures. PROPERTIES Hardness : 57-62 HRC
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CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 5.0 6.3 8.0 10.0 Length (mm) 400 400 450 450 Current Range (Amp) 90-130 120-140 140-170 180-200

226

COBALARC 4
Preformed Tungsten Carbides for High Pressure Abrasion Cobalarc 4 is the ultimate in welding technology. It has autogenous fume shielding over preformed carbides in a tubular form, which gives the user genuine low heat input and infinite shelf life by dint of its nonhygroscopic coating. The electrode deposits fine tungsten carbide embedded in a hard and tough martensitic-austenitic matrix, which is suitable for extreme abrasion with low to moderate impact. It resists all forms of abrasion and wear. Deposition efficiency is very high when compared with coated electrode. SPOT COLOUR: PINK ALLOY BASE Fe, W, C, Co SPECIAL FEATURES l Exceptional resistance to severe abrasion and moderate to heavy impact at low to medium temperatures.

Low spatter level. l Unmatched deposition rates ­ high integrity deposits. l Compared to solid cored electrodes, the current requirement is low so the dilution by parent metal is contained to a minimum. l Non­hygroscopic coating needs no storage precaution – infinite shelf life. APPLICATIONS Rock drill bits, oil well drills, churn drills, sand gravel chutes, coal cutter bits and picks, bulldozer end plates, grader end bits, feed screens, scraper for sand and refractory materials, fan and pump impellers, pug mill augers and knives, choppers, post hole auger teeth, feed screws, mixer blades/paddles etc. PROPERTIES Hardness : 57-63 HRC
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Reclamation Consumables

CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 5.0 6.3 Length (mm) 400 400 Current Range (Amp) 90-120 120-140

COBALARC MX
Preformed Stabilised Carbides for High Temperature Complex Wear Cobalarc MX is the ultimate in welding technology. It has autogenous fume shielding over preformed carbides in a tubular form, which gives the user genuine low heat input and infinite shelf life by dint of its nonhygroscopic coating. In this case, preformed carbides in the tube route have been adopted to derive supersaturated composite alloy with high volume fraction of extreme abrasion resistant alloys along with complex stabilized carbides. While the electrode is best to solve critical wear problems at high temperature, it also performs better than chrome­ carbide electrodes even at room temperature. The deposit is absolutely unparalleled in its resistance to fine particle abrasion. Oxidation and corrosion resistance upto 1200°C. SPOT COLOUR: BLUE ALLOY BASE Fe, C, Cr, Mo, Nb, V, W, Ti SPECIAL FEATURES l Exceptional resistance to severe fine and coarse particle abrasion at ambient to temperatures around 800°C.

Low spatter level. l Unmatched deposition rates ­ high integrity deposits. l Compared to solid cored electrodes, the current requirement is low so the dilution by parent metal is contained to a minimum. l Non­hygroscopic coating needs no storage precaution – infinite shelf life. APPLICATIONS Exhaust fans handling high temperature flue gases with ash, catalyst particles, ash ploughs, conveyer screws, sinter plant components, copper ladles and other non­ ferrous industry applications, zinc industry blast furnace bells, Paulworth chutes, etc. PROPERTIES Hardness : 66-70 HRC
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CURRENT RANGE : (AC 70, DC+/-)
Size (mm) 6.3 8.0 Length (mm) 400 450 Current Range (Amp) 120-140 130-170

227

Flux Cored Wires
OKTUBROD 14.17
All Position Self-Shielded Basic FluxCored Wire OK Tubrod 14.17 is a self-shielded flux cored wire for the single and multi­pass welding of mild and medium/ high tensile steels in all positions including vertical up and overhead. The deposit is suitable as a buffer under­ neath higher hardness deposits. It is ideally suited for on site welding and can run in or­ dinary MIG machines as well as constant current flux cored arc welding wire feeders. ALLOY BASE Fe, C, Mn SPECIAL FEATURES l No shielding gas is required. l Equally suitable for flat and drooping characteristic power sources. APPLICATIONS Field equipment maintenance and repair, joining of MS and carbon manganese steels and cast and forged steel components as well as site welding of general and structural steel work. Also suitable for buffering in difficult positions at high deposition rate prior to hardfacing. PROPERTIES UTS : 58-62 kg/mm2 Elongation : 22-27% CURRENT RANGE : (DC-)
Size (mm) 1.2 1.6 2.0 Welding position F.H.V.O F.H.V.O F.H.V.O Current (Amps) 100-280 110-350 220-400 Voltage (Volts) 24-26 22-28 25-29

Reclamation Consumables

OK TUB ROD 14.18
Flux-Cored Wire for On-Site Buffering and Build-up OK Tubrod 14.18 is a self-shielded flux cored wire for single and multi­pass welding of mild and medium ten­ sile steels not exceeding 51 kg/mm2 in the flat and hori­ zontal­vertical positions. It is capable of high deposition rates, which is ideal for welding on site where notch toughness requirements are not binding. ALLOY BASE Fe, C, Mn SPECIAL FEATURES l Self­shielded wire ­ does not require costly shielding gas. l Excellent ductility.

APPLICATIONS Field equipment maintenance and repair as well as site welding of general and structural steel work. It is suitable for build­up and buffering prior to hardfac­ ing with very high hardness alloys. PROPERTIES UTS : 54-62 kg/mm2 Elongation : 21-26% CURRENT RANGE : (DC+)
Size (mm) 2.4 Welding position F.H Current (Amps) 350-450 Voltage (Volts) 27-32

OKTUBRODUR 14.70
Carbide Rich Flux-Cored Wire for Super Abrasion Resistance OK Tubrodur 14.70 is a self-shielded flux-cored wire for resistance to extreme abrasive wear by fine grained gritty particles like earth, ore, clay, sand, etc. As it is rich in chromium­based carbides, the weld deposit also provides good resistance to corrosion. It also has the added benefit of excellent wear resistance at high tem­ peratures. The deposit should be made between two to three lay­ ers. ALLOY BASE Fe, C, Cr, Mo, V

SPECIAL FEATURES l Superior resistance to abrasion and corrosion. l Grinding finish only. l No need of shielding gas. APPLICATIONS It is used widely in hardfacing of bucket lips, auger points, scraper blades, and a multiplicity of mining com­ ponents and earthmoving machinery where exceptional abrasion resistance is necessary. PROPERTIES Hardness : 50-60 HRC (Contd...)

228

CURRENT RANGE :
Diameter (mm) 1.6 2.4/2.8 Welding position F.H F.H Polarity DCDC+ Current (Amps) 200-400 350-450 Voltage (Volts) 30-36 30-36

OKTUBRODUR 14.71
Flux-Cored Wire for Crack-Free Dissimilar Steel Welding OK Tubrodur 14.71 is a stainless steel self-shielded fluxcored wire for joining of dissimilar steels as well as joining and cladding of 14% manganese steel. The weld metal, which is austenitic in nature, is ideal for buffering applications on manganese steels and hardenable steels for better impact toughness. ALLOY BASE Fe, C, Cr, Mn, Ni SPECIAL FEATURES l Stainless steel wire ­ no risk of rusting.

Tremendous impact toughness. APPLICATIONS It is used widely for joining dissimilar steels, welding of buckets, tooth points, and buffering of earth­moving machine components beneath hardfaced layers and for joining manganese steel to other steels. PROPERTIES UTS : 65-72 kg/mm2 Elongation : 32-35% Hardness : 20-22 HRC
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Reclamation Consumables

CURRENT RANGE :
Diameter (mm) 2.4/2.8 Welding position F.H Current (Amps) 300-450 Voltage (Volts) 30-37

OK TUBRODUR 15.40
Flux-Cored Wire for Good Wear Resistance OK Tubrodur 15.40 is a gas shielded flux-cored wire which deposits weld metal rich in alloys which helps it give excellent performance for metal-to-metal wear and impact loading conditions. The weld metal is perfectly machinable with standard cutting tools. ALLOY BASE Fe, C, Cr, Mn, Si SPECIAL FEATURES l Impact resistance is exceptional. l Rutile based flux gives excellent running performance.

APPLICATIONS Used widely for cost effective surfacing of wheel runners, track links, wheels and rollers for conveyor belts, wheels for mine trucks, rolls and shafts. It can also be used for buffering in case of heavy compressive and pounding loading. PROPERTIES Hardness : 32-40 HRC CURRENT RANGE :
Diameter (mm) 1.6 2.4
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Welding position F.H F.H

Current (Amps) 150-300 300-400

Voltage (Volts) 29-35 30-37

OK TUBRODUR 15.41
Flux-Cored Wire for Excellent Metal - To - Metal Resistance This is a tubular self shielded flux cored wire with a basic type of flux which deposits a weld metal that is endowed with alloying elements for providing excellent resistance for metal­to­metal wear and good impact resistance. The weld metal is machinable. ALLOY BASE Fe, C, Mn, Cr, AI SPECIAL FEATURES l Resistance to impact loads. l Basic flux ensures better recovery of alloys.

Weld deposit is machinable with absolutely no difficulty. APPLICATIONS OK Tubrodur 15.41 wire is used for on-site rebuilding of worn out parts of carbon­manganese rails, point frogs, rollers, shafts, and also intermediate build­up for harder final deposit giving the entire hardfaced layer a considerable resistance to impact. PROPERTIES Hardness : 28-36 HRC CURRENT RANGE :
Diameter (mm) 1.6 2.4 Welding position F.H F.H Current (Amps) 150-300 280-460 Voltage (Volts) 29-35 30-37

229

OKTUBRODUR 15.52
Flux-Cored Wire Imparting Abrasion Resistance OK Tubrodur 15.52 is an open­arc/gas­shielded/self­ shielded flux-cored wire, which deposits a martensitic weld metal containing some grain boundary carbides. It works excellent for combined wear of low-pressure abrasion and impact. The weld metal can only be machined by grinding. This can also be used safely for multilayer build­ups. ALLOY BASE Fe, C, Cr, Mn, Mo, Si SPECIAL FEATURES l Flexibility of operation - can be used with or without shielding gas. l High hardness ensures resistance to abrasive wear.

APPLICATIONS It is used widely for cost effective surfacing of earthmoving equipment, agricultural implements and other material handling applications like augers, mixer blades and vessels, scraper blades, cement mill crushers, and quarrying components. It is specifically designed for hardfacing of feed screws and ring grooves on diesel motor pistons. PROPERTIES Hardness : 56-60 HRC CURRENT RANGE : (DC+)
Diameter (mm) 1.6 2.4 Welding position F.H F.H Current (Amps) 150-300 280-460 Voltage (Volts) 22-28 23-30

Reclamation Consumables

OK TUBRODUR 15.60
Tough and Work Hardening Flux-Cored Wire Deposit OK Tubrodur 15.60 is a self-shielded flux cored wire for producing austenitic work hardening deposit with very good combination of impact and wear resistance. The deposit is absolutely crack­free and can be used for hassle­free joining of restrained and heavy sections of manganese steel. It can also be utilized for extremely fast overlays and is specially suitable for heavy or big jobs on which lot of metal has to be deposited. The interpass temperature, while welding, should not exceed 200°C. ALLOY BASE Fe, C, Mn, Ni, Si

SPECIAL FEATURES Self­shielded ­ liberty from gas costs. l Extreme crack resistance from the austenitic type of deposit. l High deposition rate upto 5.5 kg/hour. APPLICATIONS Rebuilding 12-14% manganese steel, which is normally found in crusher jaws, swing hammers, and innumerable parts and components of earth moving, mining and quarrying equipment. PROPERTIES Hardness : As welded : 20-25 HRC Work hardened : 44-48 HRC
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CURRENT RANGE : (DC+)
Diameter (mm) 1.6 Welding position F.H Current (Amps) 150-300 Voltage (Volts) 22-28

OK TUBRODUR 15.73
Flux-Cored Wire for Can cast Roll Rebuilding OK Tubrodur 15.73 is a versatile hardfacing flux-cored wire producing a highly alloyed steel deposit, which is especially suitable for applications involving wear at elevated temperatures. This special alloy is resistant to fatigue and impact at those temperatures owing to its hot hardness properties. 1.6 and 2.4 mm wires are to be used with a shielding gas - either C02 or Ar + 20%C02 mixture. 3.0 and 4.0 mm wires are for the submerged arc process and should be used with OK Flux 10.61. Machinable with only cemented carbide tools before cooling below about 100°C. On cooling to room temperature the machinability is considerably poor and
230

reheating to 100°C does not improve the machinability significantly. ALLOY BASE Fe, C, Mn, Cr, Ni, Mo, Nb, V SPECIAL FEATURES l Roll reclamation ­ concast and other hot rolls. l Non­scaling and non­sticking characteristics. APPLICATIONS Hardfacing of different kinds of shafts, valve seats, concast rolls and any other part subjected to wear and corrosion at higher temperatures. PROPERTIES Hardness : 45-51 HRC (Contd...)

WELDING PROCEDURE FOR SUBMERGED ARC WELDING l OK Tubrodur 15.73 should be deposited on DC (+/-). Negative polarity gives a higher deposition rate and less fusion of the base material and is recommend­ ed when the minimum possible dilution of the weld metal is desired. l Except at the start, preheat is not required while hardfacing solid carbon steel shafts having diameter upto about 200 mm.

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When multi­pass welding is being done, the inter­ pass temperature should preferably not fall below 300°C. CURRENT RANGE : (DC+/-)
Diameter (mm) 1.6 2.4 3.0 4.0 Welding position F.H F.H F F Current (Amps) 150-300 280-460 300-450 400-600 Voltage (Volts) 24-30 24-32 25-33 30-36

OK TUBRODUR 15.80
Flux-Cored Wire for High Pressure Particle Abrasion A self-shielded flux-cored wire, OK Tubrodur 15.80, deposits a martensitic weld metal containing a high volume of patented light carbides. This wire has been developed for maximum resistance to abrasive wear under load arising out of fine and lumpy particles along with moderate impact. The deposit is normally crack­ free and maintains very good hot hardness. The weld metal can only be machined by grinding and for best results restrict to one or two layers. ALLOY BASE Fe, C, Cr, Mn, Ti, Mo

SPECIAL FEATURES l Special patented design for cement mill crushers. l Basic type flux gives inclusion free deposit. APPLICATIONS This continuous flux-cored wire is used for items sub­ jected to a high degree of abrasive wear by fine grained materials under pressure like augers, mixer blades, scraper blades and cement mill crushers as well as many earth moving and quarrying components. PROPERTIES Hardness : 56-60 HRC CURRENT RANGE : (DC+)
Diameter (mm) 1.6 Welding position F.H Current (Amps) 150-300 Voltage (Volts) 22-32

Reclamation Consumables

OK TUBRODUR 15.86
Cored Wire for All Wear Factors OKTubrodur 15.86 is a gas-shielded metal-cored wire that deposits an alloy weld metal which can provide ex­ cellent resistance to all wear factors and patterns. Thus it can be used for wide spectrum of surfacing applica­ tions. The wire gives maximum resistance to erosion, abrasion, high temperature, corrosion, impact and fric­ tion. The deposit is crack­free and perfectly machin­ able. ALLOY BASE Fe, C, Cr, W, Co, Ni, Si, Mn SPECIAL FEATURES l Only continuous welding solution to complex wear system.

l Gas shielding ensures a good and clean deposit. APPLICATIONS It can be used for regular hardfacing of parts subjected to complex and combined wear patterns at elevated temperatures and also in corrosive environments. Typi­ cal applications are hot forging tools, hot shear blades & dies, hot punches, valve seats, steam ends etc. PROPERTIES Hardness : At room temperature : 40-43 HRC At 750°C : 20-23 HRC

CURRENT RANGE : (DC+)
Diameter (mm) 1.2 Welding position F.H Current (Amps) 120-240 Voltage (Volts) 22-32

231

Gas Brazing Alloys
BRAZING
Brazing is a welding process, which produces coales­ cence of materials by heating them to a suitable tem­ perature and by using a filler metal having melting point above 450°C. The filler metal is distributed between closely fitted surfaces of the joint by capillary action. The placement of the filler metal affects the quality of the joint. For normal lap joints, the filler metal should be supplied from one end only and allowed to flow com­ pletely through the joint by capillary action. The correct fluxing material must be used. The place­ ment of the flux also affects the quality of the brazed joint. Paste flux is the most common from and is usually spread over the surfaces to be joined. It is also painted on the pre-placed brazing filler materials. For some of the brazing methods a special atmosphere is used instead of flux, which is selected based on the metals being joined. When atmospheres are used flux may not be required. The atmosphere is the product of the combustion of the flame. The neutral or reducing flame is usually used. A slightly oxidising flame may be used for certain other materials. The general guideline for selection of flames is given below: Base Metal Flame type Aluminiums Slightly reducing Brasses Slightly oxidising Bronzes Slightly oxidising Copper Neutral Cupro­nickel Reducing Inconel Slightly reducing Cast Iron Neutral Wrought Iron Neutral Monel Slightly reducing

Reclamation Consumables
232

RUPATAM 2
Brazing of Copper and Copper Alloys SPECIAL FEATURES l Strong clean ductile joints in copper and copper alloys without flux. l Flame should be slightly oxidizing on copper and neutral on alloys. APPLICATIONS Extensive employment of the alloy in electrical

engineering for joints in motor windings, wires and cables, braided conductor, system and other conductor assemblies where any risk of corrosion by flux must be avoided. FLUX No flux for brazing of copper. In other cases use Rupatam A. PROPERTIES Melting Range 638 - 694OC Available D/A - (mm) - 1.6, 2.5, 3.15

RUPATAM 14
Brazing of Brass, Bronze, Molybdenum and Silver SPECIAL FEATURES l Rupatam 14 is used for obtaining strong, clean, and high tensile brazed joints in brasses, bronzes. It also effectively joins silver and molybdenum. l It is not recommended for ferrous metals or alloys of high nickel content due to the possibility brittle phosphide formation. l Flame should be slightly oxidizing on Cu and neutral on Cu alloys.

The deposit obtained has a high tensile strength. APPLICATION Extensive employment of the alloy in electrical engineering for joints in motor windings, wires and cables, braided conductor and other conductor assemblies where any risk of corrosion by flux constituents must be avoided. FLUX No flux for brazing of Cu. In other cases use Rupatam A. PROPERTIES Melting Range : 643-802oC Electrical conductivity : 8% I.A.C.S. Available D/A - (mm) - 1.6, 2.5, 3.15
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Reclamation Consumables

RUPATAM 35
Brazing Joints having Non-uniform Clearances SPECIAL FEATURES l It can be used in operations requiring a slightly higher brazing temperature. l The alloy is a free-flowing one with melting range for ensuring a good joint for joints where clearances are not even uniform.

APPLICATION It is an alloy suitable for general purpose work on engineering metals with excellent capillary flow with better ductility for filling gaps. FLUX Rupatam A PROPERTIES Melting Range : 607-702°C Available D/A - (mm) - 1.6, 2.5, 3.15

RUPATAM 43
Single Brazing Alloy for a Range of Applications SPECIAL FEATURES l This alloy can be used in brazing operation requiring a low temperature giving a quick and complete penetration. l It produces neat joints of very high strength that need little or no finishing. l It is essentially for use on joints that are closely fitted.

APPLICATION Rupatam 43 can be used in brazing steel, copper, brass, gunmetal, tin bronzes, aluminium and magne­ sium bronzes, copper nickel alloys and nickel silver of all varieties. FLUX Rupatam A PROPERTIES Melting Range : 608-617°C Available D/A - (mm) - 1.6, 2.5, 3.15

233

RUPATAM 50
Brazing Tungsten Carbide Tips SPECIAL FEATURES l This alloy has a wide wetting range, hence the solid and the liquid portions do not separate. l Good corrosion resistance ­ brazing stainless steels. l Rupatam 50 is ideal for bridging gaps.

APPLICATION This alloy is ideally suited and used extensively for braz­ ing carbide tool tips to tool shanks as it wets the tip beau­ tifully. It is also suitable for brazing stainless steels. FLUX Rupatam A PROPERTIES Melting Range : 632-688OC Available D/A - (mm) - 1.6, 2.5, 3.15

RUPATAM 60
Reclamation Consumables
Brazing Alloy for Joints Requiring High Electrical Conductivity SPECIAL FEATURES l For brazing in applications needing high degree of electrical conductivity. l Good colour match on silver.

APPLICATION This alloy is ideally suited and used extensively for braz­ ing electrical components requiring high electrical con­ ductivity. FLUX : Rupatam A PROPERTIES Melting Range :690-735OC
Available D/A - (mm) - 1.6, 2.5, 3.15 brazing tubular and sheet metal joining of steel, copper, galvanized iron. Also used for fusion welding of brass and bronze. Use an oxidising flame. FLUX Brazotectic PROPERTIES Melting Point (approx.) : 875°C UTS : 42-48 kg/mm2 Available D/A - (mm) - 1.6, 2.5, 3.15 PROCEDURE l The surface should be cleaned and degreased. l The surface is to be pre-tinned using the pure matrix end. l A very large tip size to be used and the flame ad­ justed to neutral for heating the tinned area. l The carbide­bearing end is introduced into the flame and the alloy is allowed to melt and flow on to the substrate. The temperature of bonding is 750800°C. l The carbide deposition to be uniformly maintained by rotating the rod. l The work should be continued to heat, slightly ahead of the overlay. l Overheating is to be avoided. l Cooling should be slow and the flux residue has to be removed. CARBIDE MESH SIZES ­3.2 mm to +1.5 mm ­5.0 mm to +3.2 mm -6.0 mm to +5.0 mm -10.0 mm to +6.0 mm

ESAB SILICON BRONZE
Economic High Strength Brazing Alloy SPECIAL FEATURES l Economy brazing for ferrous metals, copper and copper alloys. l Exceptional joint strength. APPLICATION Esab Silicon Bronze is an alloy that is ideally suited for

ESAB RUF-KUT
Rugged overlay alloy with tungsten carbide particles for maximum abrasion resistance Esab Ruf­Kut deposits hard tungsten carbide in a tough but ductile nickel-silver matrix that results in maximum abrasion and impact resistance from media like sand, earth, gravel and other minerals. This gives rise to a superior cutting action. The carbides are angular and varied in size embed­ ded in the matrix, which resists extensive compressive stresses and impact loading. High tensile strength and shear strength provides shockabsorbing characteristics. Good tinning qualities. TYPICAL APPLICATIONS ‘Widely used in oil, earth moving, agriculture, dredg­ ing, brick and cement industries to overlay drills, ream­ ers, stabilizers, core bits, augers, mill hammers, plough shares, dredge bucket lips, crusher rolls, mixer blades and pipe forming shoes. TYPICAL PROPERTIES Carbide hardness : 1500 VHN Matrix hardness : 200 VHN
234

CRYSTALLOY 60
TIG filler for resistance to combined complex wear Crystalloy 60 is an alloy that exhibits excellent resis­ tance to friction, abrasion, impact, corrosion & oxidation and abrasion at high temperature. Resistance to spall­ ing due to thermal cycling is exceptional. The alloy has good sliding properties. Good resistance to abrasion, impact and oxidation, fric­ tion makes it suitable for combined wear. Conforms to AWS : RCo Cr A SPECIAL FEATURES l Retains 40 HRC hardness at 750°C l Only solution to complex wear system

APPLICATIONS Resurfacing and hardfacing of parts subjected to wear at elevated temperatures and in corrosive environment. Valves, valve seats, hot forging tools, hot shear blades & dies, hot punches, steam ends, pump sleeves, wear pads, screw conveyors, etc. in chemical, petroleum, sugar and steel plants. PROPERTIES Hardness As deposited Work Hardened At 20°C: 39-42 HRC 43-46 HRC At 750°C: 19-22HRC 38-43 HRC AVAILABLE DIA. (MM) 0.8, 1.2, 1.6, 2.4, 3.2

CRYSTALLOY 61

Reclamation Consumables

TIG filler for resistance to heat and corrosion Crystalloy 61 is an alloy that exhibits excellent resistance to impact, corrosion & oxidation and also abrasion at high temperature. The alloy has good sliding properties. The alloy resists galling and corrosion to splendid levels. Exceptional resistance to impact friction, and oxidation makes it suitable for combined wear. Conforms to AWS : R CoCr C SPECIAL FEATURES l Gives 25 HRC hardness at 750°C APPLICATIONS Valves, valve seats, hot forging tools, hot shear blades & dies, hot punches, steam ends, pump sleeves, wear pads, screw conveyors, cutting edges of knives for wood,

paper, plastic and carpets. Refacing and hardfacing of parts subjected to wear at elevated temperatures and in corrosive environment. PROPERTIES Hardness At 20°C: 52-57 HRC At 600°C: 41-46 HRC At 800°C: 32-37 HRC Typical chemical composition C 2.2 Cr 30.0 W 12.5 Fe 3.0 Co Rest AVAILABLE DIA. (MM) 1.6, 2.4, 3.2, 4.0 Surfacing hot rolls, kneading rolls, press screws, band saws, feeder screws, wood­working tools, valves, valve seats, hot forging tools, hot shear blades & dies, hot punches, steam ends, etc. PROPERTIES Hardness As deposited At 20°C: 44-49 HRC At 600°C: 36-41 HRC Typical chemical composition: C 1.4 Cr 28.0 W 8.5 Fe 3.0 Co Rest AVAILABLE DIA. (MM) 1.6, 2.4, 3.2, 4.0 monel alloy used in petroleum and ammonium sulphate industry. This alloy is also used by power plants and any plant that handles seawater. Conforms to AWS : ER Ni Cu 7 ALLOY BASE Ni,Cu,Ti (Contd...)

CRYSTALLOY 62
TIG filler for resistance to high temperature wear Crystalloy 62 is an alloy that exhibits excellent resis­ tance to friction, abrasion, impact, corrosion, & oxidation at high temperature. The alloy has good sliding proper­ ties giving rise to exceptional abrasion resistance. Good resistance to abrasion, impact and oxidation, fric­ tion makes it suitable for combined wear. Conforms to AWS : R Co Cr B SPECIAL FEATURES l Retains 40 HRC hardness at 600°C l Machinable by cemented carbide tools APPLICATIONS

CRYSTALLOY 80
Filler Wire for Corrosion Resistant Monel Coating Crystalloy 80 gives a ductile and crack resistant weld deposit that meets rigid requirements on corrosion resistance against seawater. It joins corrosion resistant

235

TIG Filler Wires
SPECIAL FEATURES l Welding of ASTM 8127 and 8164 can be done successfully. l It also welds DIN Werkstoff Nr. 2.4360. l Exceptional resistance to reducing and oxidizing acids. APPLICATIONS Seawater corrosion resistant overlay, joining monel metal. PROPERTIES UTS : 50-56 kg/mm2 Elongation : 42-48% CLASSIFICATION: AWS SFA 5.14: ER Ni - 1 C 0.15 max Mn 1.0 max Fe 1.0 max Si 0.75 max Cu 0.25 max Al 1.5 max Ti 2.0­3.5 Ni 93.0 min PROPERTIES: UTS : 46 - 53 kg/mm2 Elongation (l=4d) : 25 - 30% AVAILABLE SIZES (mm): 1.2, 1.6, 2.4, and 3.2 SPECIAL FEATURES l Superb corrosion and heat resistance. l Resistant to carbon pickup. l Can take care of thermal or any cyclical loads. APPLICATIONS High temperature joining and surfacing, chemical handling equipment surfacing, welding 9% nickel steels and other cryogenic or high impact steels. PROPERTIES UTS : 66-72 kg/mm2 Elongation : 42-46% Available D/A - (mm) - 1.2, 1.6, 2.5, 3.2 ALLOY BASE: Ni, Cu SPECIAL FEATURES l Resistance to marine corrosion. l Smooth welding properties. APPLICATIONS Chemical and sea water handling areas. PROPERTIES UTS : 33­38 kg/mm2 Elongation : 36-44% Available D/A - (mm) - 1.2, 1.6, 2.5, 3.2 Conforms to AWS: Cu Sm A. TYPICAL APPLICATIONS: Welding and surfacing of copper brass and bronze, cracked engine jackets, cylinder heads, electrical fittings, propeller blades, pump parts, bearing bushing, shaft, castings, stampings and valves. Also usable for filling cavities in copper alloy castings, joining copper and bronze to cast iron overlays and steel. SIZES AVAILABLE: 1.6, 2.4, 3.2, 4.0 mm

CRYSTALLOY 81
Filler wire for joining nickel Crystalloy 81 is used extensively for joining nickel and nickel alloys. The weld deposit other than being highly ductile is resistant to most common acids. SPECIAL FEATURES: l Corrosion resistance l Bonds with all ferrous and nickel­base metals APPLICATIONS: Joining nickel and nickel alloys, dissimilar joining of nickel with steels and copper as well as copper alloys. The solubility of nickel makes it perfectly suitable for joining copper and copper alloys with steels.

Reclamation Consumables
236

CRYSTALLOY 82
Filler Wire with Corrosion and Heat Resistance Crystalloy 82 is used to weld high alloyed heat resisting and corrosion resisting materials, 9% Ni steels and similar steel for cryogenic applications. It has also exceptional notch toughness values, and resists stress corrosion cracking. It never hardens or embrittles even when diluted with high carbon. Conforms to AWS : ER Ni Cr 3 ALLOY BASE : Ni, Cr, Mn

CRYSTALLOY 85
Filler Wire for Corrosion Resistance from Acids and Seawater Crystalloy 85 is a filler alloy for TIG welding which shows good resistance to corrosion against seawater, chlorides, acids and alkalis. It can be used for joining of 90-10 and 70-30 cupronickel. The alloy has smooth flow and good wetting properties with base metal. Conforms to AWS : ER Cu Ni

CRYSTALLOY 90

Crack free welding of brass, bronze, deoxidized copper A copper­tin alloy suitable for welding brass, bronze, deoxidised copper, cast iron, steels and dissimilar metals. It produces homogeneous and sound weld metal free from porosity and cracks. It gives an excellent colour match on bronze.

Hot Metal Spray Powders
POWDER WELDING
The powder welding process basically uses a simple oxy-acetylene torch where finely divided powder is fed into the flame from a hopper attached to the torch. The powder melts to give a dense coating and forms a strong bond with the base material by surface alloying and diffusion. Fluxing elements such as boron and silicon are necessary in the powders for good metallurgical bond. This process is typically used for deposits having thickness between 0.2­12 mm, in particular for smaller parts or repairs. The process is applicable only in iron­ base, nickel­base or copper­base material. Hot metal powder alloys are mostly nickel-based. Nickel when added with boron gives hardness due to formation of borides. The percentage of boron can be monitored to achieve a particular hardness range. Boron also brings down the melting point of nickel and helps the powder to fuse much below melting point of steel. For enhanced protection against wear and increased corrosion resistance, silicon along with other special alloys is added. Some cobalt­based powders are also available but are not as costeffective as nickel­based powders. Tungsten carbide is added to a nickel boride matrix to combat highpressure abrasion. The flow of powder and spreading on base metal depends primarily on two characteristics: Powder particle shape and size. The mesh size determines the acceptability of the powder to be used by hot metal spray process. Usual range is between 15-160 microns. The shape of powder is very important for the welder as it solely determines the ease of flow of the powder through the nozzle of hot spray gun. The powder shape is dependent on the method of manufacture of the powders. Gas atomized powder have spherical particles resulting in a smooth flow through the nozzle and higher deposition rate. Ground powders have irregular shape and the flow characteristics are poor. Advantages of powder spray: l Thin layer can be given with hardness upto 65 HRC (upto 0.15 mm thickness). l Coating is uniform; hardly any post­machining required. l No heat treatment is required. l Self-fluxing: no slag cleaning required. l For machine parts, life obtained is much higher. The limitations are: l Not economic for thicker build­up on big jobs. l Not applicable for aluminium, magnesium components. l For big jobs furnace preheating and melting is required.

Reclamation Consumables
237

CASTCOAT 20
Buffer for Coating Machinable Build-up Cast Irons on Steels CastCoat 20 extends the benefit of powder coating to cast irons. It has excellent machinability and can be used for original or worn out components. For higher hardness requirements, it can be used as buffer layer to be coated by harder alloy grades. This CastCoat technology saves castings from being scraped and abraded. The wettability and fluidity adds to the advantage of being used for brazing and joining. The inertness of the base alloy can be utilized with much success to counter corrosion and oxidation related problems in the industry. The powder can also be used as a superbly machinable build­up and buffer layer on steels for subsequent coating by harder powders or welded alloy deposits.

Reclamation Consumables

ALLOY BASE Ni, B, Si, Fe SPECIAL FEATURES l Machinable deposit. l Good resistance to corrosion and oxidation. l Allowable build­up: 20 mm. l Coverage for a 1 mm thick layer: 650 cm2/500 gm. APPLICATIONS This powder is used for casting defect repairs, brazing and joining cast iron components, building up funnels or moulds in the glass industry, cast iron cylinder heads, engine blocks, housings, manifolds, and vessels handling acetic acid. PROPERTIES Hardness : 20-22 HRC Melting Point : 1100°C Good resistance to friction, corrosion and impact. Allowable build­up: 10 mm. l Coverage for a 1 mm thick layer: 650 cm2/500 gm. APPLICATIONS This powder is used for making hard deposit on gears and splines, cams and crankshafts, bearing surfaces, plungers and neckrings, automobile parts, railroad wheel burns, glass moulds, valve gates, sprockets and pistons, gauges, machine components. PROPERTIES Hardness : As-welded : 40-44 HRC At 500°C : 36-38 HRC Melting Point : 1100°C
l l

MULT/WELD 40
Good Resistance to Impact and Corrosion MultiWeld 40 allows reclamation of steel components which otherwise would have gone to the scrap yard as no other powder alloy has the fluidity and build-up capacity along with optimum properties for service. It is the only powder with machinability along with wear resistance. The versatility and dependability of the alloy makes it an indispensable powder for all maintenance departments in different industries. ALLOY BASE Ni, B, Si, Fe SPECIAL FEATURES . l Machinable deposit.

BOROSTRENGTH 60
Enhanced Protection against Abrasion and Corrosion BoroStrength 60 offers enhanced protection against friction, abrasion and corrosion for all machine components. Additionally, SoroStrength takes polish and resists oxidation at elevated temperature. The characteristic to produce very thin overlays obviates the necessity of machining later. The low coefficient of friction ensures simultaneous protection of matching parts if it is used in any such application. ALLOY BASE Ni, B, C, Cr, Fe SPECIAL FEATURES l Nil wear for metal­to­metal friction.

Excellent resistance to acidic/alkaline corrosion and oxidation. l Non­machinable deposit ­ can only be ground by sili­ con carbide or diamond wheel. l Allowable build­up: 1.5 mm. l Coverage for a 1 mm thick layer: 470 cm2/500 gm. APPLICATIONS This spray powder is used for making hard deposits on components like cams and indexing heads, turbine blades, pump shafts, extruder screws, seal rings, rocker arms, fan blades and liners, timber cutting blades, bushings, brick dies, mandrels. PROPERTIES Hardness : As-welded : 60-62 HRC At 500°C : 50-52 HRC Melting Point : 1100°C
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TUNGSTRENGTH 70
Ultimate Abrasion Protection Technology A protective coating by TungStrength 70 can effectively enhance component life and reduce spares inventory holding. As it retains its hardness upto 450°C, it can solve regular abrasion problems faced by maintenance engineers. TungStrength 70 exhibits a slag free deposit and better surface coverage. The composite alloy sys­ tem based on tungsten carbide ensures better micro­ structural properties and ease of bonding with any fer­ rous and nickel based material. ALLOY BASE Ni, B, W, C, Cr, Si, Fe SPECIAL FEATURES l Optimum matrix-carbide ratio prevents distortion during spraying.

Economic repair in case of chronic abrasion related jobs. l Non­machinable deposit ­ can only be ground by sili­ con carbide or diamond wheel. · Allowable build­up: 1.2 mm. l Coverage for a 1 mm thick layer: 460 cm2/500 gm. APPLICATIONS TungStrength 70 provides a hard deposit for prolonged life on machine parts viz. shear blades, die frames, wire drawing rolls, pulleys & capstans, wear rings, crusher teeth, guide rolls, conveyors, chains, mixer blades and paddles. PROPERTIES Hardness : As-welded : 62-64 HRC Retained upto : 450OC Melting Point : 1100°C
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Reclamation Consumables

ESAB WEAR PLATES
ESAB wear plates are composite plates having a highly alloyed wear resistant surfacing on a low carbon steel base. These plates are manufactured by customized automatic hardfacingprocess resulting in a hard, tough and highly wear resistant surface. The mild steel base makes the plates amenable to easy forming, welding or bolting to the component surfaces. The superiority of the ESAB range of wear plates is a result of strict sci­ entific and metallurgical control of all the stages of the production process backed up by the technical know­ how of ESAB in welding consumables.

Advantages of using ESAB wear plates 1. Ease in fabrication of components viz. pipes, ducts, chutes, etc. 2. Ease of welding to carbon steel structures. 3. Available in cut shapes as per the drawing provided by the customer ­ No additional cutting operation in­ volved 4. High concentration of carbides - excellent resistance to wear factors like abrasion, friction, erosion, im­ pact, oxidation 5. Tough matrix ensures proper anchorage of the car­ bide particles 6. Very small heat - affected zone ensures minimum metallurgical degradation Alloy base c, Cr, Mn, Mb C, Mn, Cr, Mo, Ti C, Cr, Mn, Mo, Nb, V Hardness Applications (HRC) 55­58 Crusher parts, bucket lips, conveyor screws

Type

Item Description

Chrome - C

Complex carbides in a tough matrix for resistance to severe abrasion and moderate impact loads Dense micro carbides in a hard martensitic matrix resisting severe coarse and fine particles abrasion.

Micro - C

58-62

Mixer biades, scrapers, mill parts, pipes

Therm - C

High temperature carbides in an austenitic matrix to resist complex wear at elevated temperatures. Retains hardness upto 800OC.

62 - 65

Sinter plant parts, chutes, boiler flue gas ducts

239

Applications in Industry Sectors Power Wagon tipplers, excavators, chutes, primary and secondary crushers, coal pipes, bunkers, apron feeders, mill vane wheel segments, boiler flue gas ducts, ash pipelines, screw conveyors ID fan blades, chtes, coal pipes, crushers, earth moving equipment, Y­ducts, clinker chutes, cyclones Sinter screen decks, hot discharge chutes, downcomer pipes, burden liners, discharge chutes, vibratory feeders, rolling mill guides Chute liners, shovel buckets, dragline buckets, dumper bodies, dozer blades, crusher parts, apron feeders, conveyor systems,

Cement Steel Mining

Chemical Crushers, mixing blades, slurry pipes, blowers, deflector plates Sizes available Plate dimensions: Plates are available as per drawing and / or customers’ requirements. Thickness: The plates may be supplied in bent forms in accordance Base Layer (mm) Hardfacing Layer (mm) with the drawing. The minimum bending diameter is 300 6 4 mm for the hardfaced layer inside. For joining the plates, 8 4 countersunk holes can be provided for subsequent attachment. These features are optional and shall be 10 4 charged extra. 12 4 Otherwise, basic coated mild steel electrodes may be 16 4 used to weld the plates to the components Wear Strips/ 8 5 Wear pads. 10 5 Esab India also supplies wear strips / pads with all the same featuresw as those of wear plates for ease of 8 6 attachment. These are available in different sizes as per 10 6 requirement of he end ­ user. These strips / pads can 12 6 be used on earthmoving equipment and preparation of convering system in differnt industries. They give economical and fast repairs with very quick inter ­ changeabillty.

Reclamation Consumables

ESAB ETH 500 PLATES
A quenched & tempered (Q & T) through hardened abrasion resistant plate for sliding and gouging abrasion applications. Reducing Maintenance in a Tough Industry WHY ETH? Expected Life Time l Lesser & Shorter Stops l Economic Life Time l Wear Proficient Exceptinal Impact Resistance l High Deformation Resistance l High Wear Resistance l Dependable Function Even Wear l Less Unplanned Stops l Accurancy of the End Products l Dependable Function

Durability l Unwavering & Firm Properties l Easy access to ESAB Excellent precision l Precision of weight l Higher capacity l Less dead weight & transport Smooth & Even Surface l Inhibit irregular wear l Smooth & Even Surface l Reduced Sticking problems TYPICAL COMPOSITION C 0.29 P 0.015 Mn 0.30 Si 0.30 S 0.003 Ni 0.20 Cr 1.0 Mo 0.25 B 0.0010

240

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Hardness : 477-534 BHN Fabrication : The ETH Plates can be easily joined by using ESAB Terroweld DBL electrodes. Cutting : Both oxy - acetylene flame cutting and plasma ­ cutting processes can be employed to cut these plates to the requisite shapes and sizes. Drilling & Counter - Sinking Holes : By using re­ placeable carbide insert tools. Available Thickness : 6, 8, 10, 12, 14, 16, 20, 25 100 mm

APPLICATIONS l Dragline buckets, Loader Buckets, Dumper Bodies, Agricultural Equipments l Conveyors, Screw Conveyors, Mixers, Moulds l Side Wedges of Jaw Crusher, Screws Feeder Table of Crusher Lining l Chutes, Hoppers, Ducts l Rail Cars - Sidewalls & bottom plates are subjectd to same wear as Dumber bodies. l Feed Hoppers, Feeders, Grating, Protection Plates.

CONVERSION CHART
To Convert from To Mass Force Stress kg metric tonne N MPa kgf/mm2 bar Energy Velocity J mm/sec Ib ton kgf Ibf kgf/mm2 ksi psi Pa atm ft­Ib kg­m in/min m/hr Flow rate lit/min Length
Temperature

Multiply by 2.205 1.102 0.102 224.8 0.102 0.145 1421.57 1 x 105 0.987 0.7376 0.102 2.362 3.6 2.119 0.06 0.039

PROPERTIES OF COMMON METALS
All the given values are correct for these elements in their pure form

Reclamation Consumables

Name
Aluminium Boron Cadmium Chromium Cobalt Copper Iron Manganese Nickel Niobium Silicon Silver Tin Titanium Tungsten Vanadium Zinc

Symbol AI B Cd Cr Co Cu Fe Mn Ni Nb Si Ag Sn Ti W V Zn

Melting Point (OC) 658 2300 320 1510 1490 1083 1525 1220 1452 1950 1370 960 232 1850 3000 1710 418

Sp. Gravity 2.58 2.5 8.64 6.5 8.6 8.9 7.86 7.39 8.9 8.4 2.0-2.4 10.5 7.3 4.54 19.1 5.5 7.12

cu.ft/hr cu.m/hr in

mm
F = C x 1.8 + 32

°C = (F-32)/1.8

241

COMPARATIVE HARDNESS SCALES
This chart is given as an indicative guide
Vickers VHN 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 310 320 330 340 350 Brinell BHN 76.0 80.7 85.5 90.2 95.0 99.8 105 109 114 119 124 128 133 138 143 147 152 156 162 166 171 176 181 185 190 195 199 204 209 214 219 223 228 233 238 242 247 252 257 261 266 271 276 280 285 295 304 314 323 333 HRB 41.0 48.0 52.0 56.2 62.3 66.7 71.2 75.0 78.7 81.7 85.0 87.1 89.5 91.5 92.5 93.5 94.0 95.0 96.0 96.7 98.1 99.5 (101 ) (102) (104) (105) 20.3 21.3 22.2 23.1 24.0 24.8 25.6 26.4 27.1 27.8 28.5 29.2 29.8 31.0 32.2 33.3 34.4 35.5 Rockwell HRC Vickers VHN 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 720 740 760 780 800 820 840 860 880 900 920 940 Brinell BHN 342 352 361 371 380 390 399 409 418 428 437 447 (456) (466) (475) (485) (494) (504) (513) (523) (532) (542) (551 ) (561 ) (570) (580) (589) (599) (608) (618) Rockwell HRC 36.6 37.7 38.8 39.9 40.8 41.8 42.7 43.6 44.5 45.3 46.1 46.9 47.7 48.4 49.1 49.8 50.5 51.1 51.7 52.3 53.0 53.6 54.1 54.7 55.2 55.7 56.3 56.8 57.3 57.8 58.3 58.8 59.2 59.7 60.1 61.0 61.8

Reclamation Consumables

62.5 63.3

64.0 64.7 65.3 65.9 66.4 67.0 67.5 68.0

242

Metal Selection Guide
ESAB CONSUMABLES FOR DIFFERENT REPAIR WORK
Hard Facing Base Material
Mild steel OK Select rode 21.03 High strength steel
14%

Gouging

Joining

Build-up

Metal to Metal

Mineral Abrasion
Cobalarc 1 M OK Tubrodur 14.70 Cobalarc 1 M OK Tubrodur 14.70 Cobalarc 1 M OK Tubrodur 14.70 Cobalarc 1 M OK Tubrodur 14.70

Impact Abrasion
Cobalarc 9 OK Tubrodur 15.52

Terroweld DBL OK Tubrod 14.17 OK Selectrode 68.82 ESAB CSA OK Tubrodur 14.71 Terroweld S2 OK Tubrodur 14.71 OK Selectrode 92.58 OK Tubrodur 15.66 Bronzoid 1

OK Selectrode 83.40 OK Selectrode 68.82 Astra MN OK Tubrodur 15.60 ESAB CSA OK Tubrodur 14.71 OK Selectrode 92.58 OK Tubrodur 15.66 Bronzoid 1

OK Selectrode 83.40 OK Select rode 68.82 Astra MN OK Tubrodur 15.60 OK OK Tubrodur 68.82 OK Selectrode 92.58

Reclamation Consumables

OK Selectrode 21.03 OK Selectrode 21.03

Cobalarc 9 OK Tubrodur 15.52 Cobalarc 9 OK Tubrodur 15.52 Cobalarc 9 OK Tubrodur 15.52

Manga-

nese steel

Stainless steel

OK Selectrode 21.03

Cast

OK Selectrode 21.03 OK Selectrode 32.03

iron

Copper Alloys

Bronzoid 1

Aluminium (12% SI)

OK Selectrode 21.03

OK Selectrode 96.50

OK Selectrode 96.50

243

SELECTION OF HARD FACING CONSUMABLES
Low Resistance against Abrasion High

Low

30-40 HRC Terroweld DS6* Terroweld MN* OK Tubrodur 15.60* OK Selectrode 83.28 OK Selectrode 83.40 OK Tubrodur 15.40 OK Tubrodur 15.41

> 40 HRC Terroweld 65 OK Tubrodur 15.52 OK Selectrode 84.84 Cobalarc 4 OK Tubrodur 15.80

Reclamation Consumables

OK Selectrode 84.78 Astra HTB Esab 116 Ni OK Tubrodur 15.73 Terroweld SHR OK Selectrode 84.80 Cobalarc 1M OK Tubrodur 14.70

Heat and Corrosion Resistance

Esab 550 Terroweld DS4* Esab CSA* Terroweld DS1* OK Tubrodur 14.71* OK Selectrode 68.82 Terroweld EWR Cobalarc 9 Cobalarc MX

Ni-based* Esab CN182* Esab CN1G* OK Selectrode 92.35*

Co-based OK Selectrode 93.66 OK Tubrodur 15.86

High High
244

Impact Resistance

Low

ESAB CONSUMABLES FOR JOINING OF DISSIMILAR METALS
Material Mild Steel High Strength Mild Steel High Strength Steel OK Selectrode 68.82 OK Selectrode 68.82 Esab CSA Stainless Cr-Ni-Steel 14% Mn-Steel Ni-Cr-Alloys Inconel Type Esab CN182 Ni-Cr-Alloys Monel Type Esab Monel Bronzoid1 OK Selectrode 92.58 OK Tubrodur 15.66 Stainless Cr-Ni Steel Esab CSA OK Tubrodur 14.71 Esab CSA OK Tubrodur 14.71 Esab CN182 Esab Monel Bronzoid1 OK Selectrode 92.58 OK Tubrodur 15.66 14% Mn-Steel Astra MN OK Tubrodur 14.71 Esab CN182 Esab CN182 Bronzoid1 OK Selectrode 92.58 OK Tubrodur 15.66 Ni-Cr-Alloys Inconel Type Esab CN182 Esab CN182 Bronzoid1 OK Selectrode 92.58 OK Tubrodur 15.66 Ni-Cr-Alloys Monel Type Esab CN182 Bronzoid1 OK Selectrode 92.58 OK Tubrodur 15.66 Bronzes · Avoid high dilution. . Preheating may be used for copper alloys, high carbon magnetic steels and cast iron.
Do not preheat non­magnetic steels. For stainless material of known composition,

Bronzes

Cast Iron

Reclamation Consumables

Bronzoid1

Esab CN182

. .

Cast Iron

OK
Selectrode 92.58 OK Tubrodur 15.66

use similar grade of electrode for best corrosion resistance. If the composition is unknown use OK Selectrode 68.82 or Terroweld DS3.

245

METAL IDENTIFICATION CHART
Magnet File Surface Colour Dark grey Grinding sparks Long Yellow lines Soft Malt­grey cast iron colour Red feathery lines Cast iron Pre­heating Peening Slow cooling Magnetic Dark grey Long Yellowish­ white lines with starts Hard Shiny grey Yellowish­red coarse lines Bright silver­grey Yellowish­red coarse lines Reddish­yellow shiny Soft Non-Magnetic Shiny Very light No visible sparks Aluminium alloys Pre­heat coarse materials to 150­200°C Matt­grey cast iron colour Hard Yellowish­white lines and sparks 14% Mn steel Low interpass No visible sparks Austenitic stainless steel Copper alloys Pre­heat coarse materials to 200­300°C 13% Cr steel Can be pre­heated Low interpass High carbon steel Low alloy steel Pre­heat heavy sections to 150°C Metal type Low carbon Cast steel Welding tips

Reclamation Consumables
246

Arc Equipment

Product Catalogue 2009

Arc Equipment

Welding and Cutting Equipment

1

MMA Transformers

TRANSWELD 400
Welding Transformer for Shop and Site Application
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THH 630
Welding Transformer for Industrial and Fematic Welding
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Natural air cooled for increased safety of the transformer. Horizontal shunt core design ensures longer operational life of the shunt-core moving mechanism. Well-spaced coils for adequate airflow to the transformer ensures longer service life. Robust and compact construction to withstand rough handling at sites. Ideal for TIG welding with optional TIG attachments.
Transweld 400 415 / 2 Lines of 3, 50 80 50 - 400 300 H Natural Air 600 x 410 x 720 115

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Heavy-duty fan cooled welding transformers for MMA welding with basic, rutile and high recovery electrodes. Horizontal shunt core design ensures longer operational life of the shunt-core moving mechanism. Well-spaced coils for adequate airflow to the transformer ensures longer service life. Robust construction and rubber wheels for easy mobility.

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Arc Equipment

Technical Data Mains supply, V/Ph, Hz Open circuit voltage, VAC (Max) Welding current range, A Output at 60% duty cycle, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg

Ideal for TIG welding with optional TIG attachments.
THH 630 415 / 2 Lines of 3, 50 73 - 80 90 - 630 500 H Forced Air 820 x 675 x 1050 210

Technical Data Mains supply, V/Ph, Hz Open circuit voltage, VAC (Max) Welding current range, A Output at 60% duty cycle, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg

249

RS 400
The All Purpose Thyristorised MMA Welding Rectifier
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EasyWeld SSR 400 / 600
Fully Thyristorised Heavy Duty Thyristorised MMA Welding Rectifier
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Reliable and high performance tyristorised MMA welding rectifier for projects, construction and pipe welding. Built-in Hot Start facility for easy arc striking. Burns all types of electrodes including cellulosic. Suitable for long lead welding with any type of electrode. Robust construction with large rubber wheels - ideal for site applications. Remote Control to adjust welding current during welding. Ideal for TIG welding with optional TIG attachments.
RS 400 3 x 415 ± 10%, 50 90 10 - 400 H Forced Air 825 x 695 x 1070 195

Heavy-duty thyristorised rectifiers for shop and site use. Hex phase rectification ensures excellent welding output. Hot Start, prevention against electrode freezing and protection against HF interference. True vertical welding characteristics. Remote Control to adjust welding current during welding. Ideal for TIG welding with optional TIG attachments.
EasyWeld SSR 400 EasyWeld SSR 600

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Arc Equipment

Technical Data Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg

Technical Data Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg

3 x 415±10%, 50 3 x 415±10%, 50 100 10 - 400 400 H Forced Air 100 10 - 600 600 H Forced Air

675 x 350 x 690 675 x 455 x 850 130 155

250

LHJ 425 / 750
Heavy Duty MMA Welding Rectifiers for Welding and Gouging
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Origo Arc 150 / 200
Single Phase Portable Inverters for MMA Welding
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Heavy-duty MMA welding rectifiers for MMA welding with electrodes of any class and arc gouging (LHJ 750). Stepless adjustment of welding current by hand crank. Fan cooled for optimum cooling of the power source. Rugged construction - body made of powder-coated steel to suit all weather application. Large rubber wheels and handle - easy maneuverability. Suitable for Scratch TIG.
LHJ 425 3 x 415, 50 76 55 - 425 300 H Forced Air LHJ 750 3 x 415, 50 87 80 - 750 600 H Forced Air

Burns 2.5/3.15 mm electrodes of any class continuously. Practical and rugged design - convenient to use. Can be used with longer input supply cable - provides a larger area of operation. Suitable for Scratch TIG.
Origo Arc 150 Origo Arc 200 1 x 230±10%, 50 1 x 230±10%, 50 16 60 - 75 4 - 150 110 IP 23C S IEC 60974-1, EN50199 16 60 - 75

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Technical Data Mains supply, Ph x V, Hz Fuse (slow), A Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg

Arc Equipment

l

5 - 180 140 IP 23C S IEC 60974-1, EN50199

Technical Data Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg

380 x 180 x 300 380 x 180 x 300 6.9 8

780 x 950 x 870 780 x 950 x 870 185 225

251

Origo Arc 4001i A22 / A24
Heavy Duty Inverters for MMA Welding
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Caddy Arc 251i A32 / A34
Portable inverter power sources for MMA Welding
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Burns up to 6.3 mm electrodes of any class. Basic analog control Panel A22 and advanced control panel A24 with digital display and finer controls. Adjustable arc-force and hot start options available. Dust filter and laquered electronics - increased reliability. Suitable for Scratch TIG.
Technical Data Arc 4001i 3 x 400±10%, 50 20 91 16 - 400 20 - 400 4 - 400 320 Forced Air IP 23 S IEC/EN 60974 -1/-10 652 x 249 x 423 40 Mains supply, Ph x V, Hz

Burns up to 4.0 mm electrodes of any class continuously. Rugged design - impact resistant polymer design. Built-in PFC to eliminate harmonics, digital display, Arc Plus II regulator common in A32 / A34 control panel. Adjustable arc force, hot start and 2 job memories (A34). Handles 100m long mains cable. LiveTIG Start for smooth and safe operation in TIG.
Technical Data Mains supply, Caddy Arc 251i 3 x 400 V, 50 Hz 16 78 4 - 250 / 3 - 250 190 IP 23 S IEC 60974 -1 / -10 418 x 188 x 208 10.5

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Arc Equipment

Fuse (slow), A Open circuit voltage, VDC (Max) Welding current range, A MMA MIG / MAG TIG Output at 60% duty cycle, A Type of cooling Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg

Fuse (slow), A Open circuit voltage, VDC (Max) Welding current range, A (TIG/MMA) Output at 60% duty cycle, A Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg

252

Origo Arc 410c / 650c / 810c
Chopper Based DC Power Sources for MMAW / CAG / GTAW
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653 cvcc
Power Sources for MIG/MAG, SAW, MMA Welding and Arc Gouging
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Robust construction to handle tough working conditions. Built-in arc force, hot start and anti stick functions. Burns electrodes of any class including cellulosic. Stepless welding current control and optional remote. Mains voltage compensation - stable welding. Digital VA meter to display the welding parameters (optional for Origo Arc 410c).
OrigoArc 410c 3 x 400±10%, 50 25 56 20 - 400 310 Forced Air IP 23 S OrigoArc 650c OrigoArc 810c

Multi-process thyristorised welding power sources suitable for heavy duty welding applications. MIG/MAG welding of all metals with 0.6 - 2.4 mm MS/Al/FC wire and suitable wire feeder. Control PCBs are housed suitably to protect from dust and dirt and permit longer operational life. Optional pulsing option available. Wide choice of functionalities with wire feeders MIG 4HD, Dura Drive 4-30 and Dura Drive 4-48.

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Arc Equipment

Technical Data Mains supply,Ph x V, Hz Fuse (slow), A Open circuit voltage, VDC Welding current range, A Output at 60% duty cycle, A Type of cooling Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg

Technical Data Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Dimensions, l x w x h, mm Weight, Kg

653 cvcc 3 x 400±10%, 50 59 50 - 750 750 600 Forced Air 819 x 483 x 622 240

3 x 400±10%, 50 3 x 400±10%, 50 50 56 20 - 650 490 Forced Air IP 23 S 63 56 20 - 800 630 Forced Air IP 23 S

EN 60974 -1/-10 EN 60974 -1/-10 EN 60974 -1/-10 1310 x 800 x 780 1310 x 800 x 780 1310 x 800 x 780 157 223 245

Special CVCC variants of the above are available in the 400 / 500 / 650A segment.

253

EDW 350 / 400 / 500
Engine Driven Welder + Power Unit
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Diesel engine driven welding units for MMA welding and auxiliary power supply unit. MMA welding with any class of electrode including cellulosic with long lead. Remote control unit is provided as standard to adjust welding parameters, while welding in progress. Highly efficient and powerful engine to work under any climatic conditions. Needs minimum maintenance except regular wearparts.

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Technical Data Engine Make Model No. of cylinders Type of cooling Starter Battery capacity, Ah Governor Power at 1500 rpm, BHP Fuel Fuel tank volume, ltr Fuel consumption, ltr/hr Welding Output Open circuit voltage, VDC Welding current range, A Output at 60% duty cycle, A Electrode type Electrode size, mm Auxiliary Output 3Ph supply, kVA, V/Ph, Hz 1Ph supply, kVA, V/Ph, Hz Size Dimensions, l x w x h, mm Weight approximate, Kg Undercarriage with tow bar Noise Level DB at 1 m distance Compliance

EDW 350 Mahindra & Mahindra 3305GM 3 Water 12V Lucas 75 Mechanical 30 Diesel 75 3.2 90 10 - 350 300 All including cellulosic 4.0 / continuous 7.5, 415 / 3, 50 2.5, 230 / 1, 50 2600 x 1030 x 1800 900 2 wheels as standard 75 CPCB

EDW 400 Cummins S3.8G4 4 Water 12V Lucas 120 Mechanical 58 Diesel 80 4.5 90 10 - 400 400 All including cellulosic 5.0 / continuous 10, 415 / 3, 50 5, 230 / 1, 50 2900 x 1400 x 2010 1250 2 wheels as standard 75 CPCB

EDW 500 Cummins S3.8G4 4 Water 12V Lucas 120 Mechanical 58 Diesel 80 4.5 90 10-500 400 All including Cellulosic 5.0 / continuous 10, 415 / 3, 50 5, 230 / 1, 50 2900 x 1400 x 2010 1270 2 wheels as standard 75 CPCB

Arc Equipment
254

Power Compact 255
Compact MIG / MAG Welding Package
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Migmatic 250
Power Source for MIG / MAG Welding
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Compact MIG/MAG packages with enclosed wire feeder. Spot, stitch and continuous welding operations. Adjustable burn back control Ideal for thin sheet fabrication and automotive industry.

Heavy-duty design for high quality of welding. Digital V/A meters for display of welding parameters. Spot and stitch welding timer. Ideal for sheet metal and automotive industry.

Technical Data Power Source Mains supply, Ph x V, Hz

Migmatic 250 Migmatic 250 3 x 415, 50

Technical Data Power Source Mains supply, Ph x V, Hz

Power Compact 255

3 x 415, 50

Open circuit voltage, VDC (Max) / steps 16 - 34 / 10 Welding current range, A Output at 60% duty cycle, A Type of cooling Dimensions, l x w x h, mm Weight, Kg Wire Feeder Wire feed speed, m/min Wire diameter, mm / type Weight, Kg 30 - 250 250

Open circuit voltage, VDC (Max) / steps 16 - 37 / 10 Welding current range, A Output at 60% duty cycle, A No. of inductance outlets Spot / interval welding time, sec Type of cooling Dimensions, l x w x h, mm Weight, Kg Wire Feeder (Enclosed) Wire feed speed, m/min Wire diameter, mm / type 1.5 - 22 0.8 - 1.2 / MS 30 - 250 190 2 0.2 - 2 Forced Air 840 x 375 x 736 90

Arc Equipment

Forced Air 620 x 390 x 580 78 Migmatic 1.5 - 22 0.8 - 1.2 / MS 6

255

Smashweld 4000T
All Purpose Semi-Automatic Welding Equipment
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LAB 4000
Heavy Duty Semi-Automatic MIG / MAG Welding Equipment
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MIG/MAG welding on all metals including Al and Cu. Rubber wheels and gas cylinder base. Digital V/A Meter to display welding parameters. Variable inductance to minimize spatter.

MIG/MAG welding on all metals including Al and Cu. Rubber wheels and gas cylinder base. Digital V/A Meter to display welding parameters. Stepless adjustment of welding current. Variable inductance to minimize spatter.

Technical Data Power Source Mains supply, Ph x V, Hz

Smashweld 4000T Smashweld 4000T 3 x 415, 50

Technical Data Power Source Main supply, Ph x V, Hz

LAB 4000 LAB 4000 3 x 415, 50

Open circuit voltage, VDC (Max)/steps 18 - 45 / 20 Welding current range, A 20 - 400 270 Forced Air 530 x 980 x 850 78 Servo - III 1 - 22 0.6 - 1.2 / MS, Al, FC 11

Arc Equipment

Output at 60% duty cycle, A Type of cooling Dimensions, l x w x h, mm Weight, Kg Wire Feeder Wire feed speed, m/min Wire diameter, mm / type Weight, Kg

Open circuit voltage, VDC (Max)/steps 17 - 44 / stepless Welding current range, A Output at 60% duty cycle, A Type of cooling Dimensions, l x w x h, mm Weight, Kg Wire Feeder Wire feed speed, m/min Wire diameter, mm / type Weight, Kg 40 - 360 320 Forced Air 885 x 505 x 1065 153 Servo - III 1 - 22 0.6 - 1.2 / MS, Al, FC 11

256

Technical Data Power Source Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A

Auto K 400

Auto K 600

3 x 415±10%, 50 3 x 415±10%, 50 55 60 - 400 400 68 60 - 600 600 470 Stepless RCU-AUTO K 400 Forced Air

Output at 100% duty cycle, A 310 Adjustment of welding current Stepless Remote current regulator type Type of cooling Dimensions, l x w x h, mm Weight, Kg Wire Feeder Drive system Speed control RCU-AUTO K 400 Forced Air

675 x 350 x 690 617 x 455 x 850 122 Servo - I DC motor Stepless 160 Servo - II DC motor Stepless

Auto K 400 / 600
Thyristorised Power Sources for MIG / MAG Welding
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Wire feed mechanism Length, m (Standard) Length, m (Optional) Wire feed speed, m/min Wire diameter, mm / type Weight, Kg

Double roll quick Double roll quick changeover type changeover type 5 10 / 15 / 20 1.5 - 19 m/min 0.8 - 1.2 7 5 10 / 15 / 20 / 30 1.5 - 19 m/min 0.8 - 1.6 9

Heavy-duty thyritorised welding power sources for high quality manual or mechanized MIG/MAG welding output. Hex phase rectification gives almost ripple free welding output free from spatter. Stick-out control eliminates demand for operator’s skill. Fresh Tip Treatment (FTT) control eliminates formation of globules at the wire tip during weld stop condition. Fresh Arc Start (FAS) control instantaneously enhances the arc-striking rate for better arc striking. Self hold circuitry with crater control module. Pre-flow of shielding gas with burn-back control for optimum utilizations. An ideal choice for MIG/MAG welding application with enhanced productivity and quality.

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Arc Equipment

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257

Technical Data Power Source Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Output at 100% duty cycle, A Adjustment of welding current Type of cooling Dimensions, l x w x h, mm Weight, Kg Remote Current Regulator type Synergic Pendant Wire and gas combinations for operation in the synergic mode

Auto K 400 Synergic

Auto K 600 Synergic

3 x 415±10%, 50 55 60 - 400 400 310 Stepless Forced Air 930 x 480 x 800 115 RCU-AUTO K 400 Wire Fe SS Al Wire Dia 0.8 / 1.2 / 1.6 0.8 / 1.2 / 1.6 0.9 / 1.2 / 1.6 Gas CO2 Argon Mix Argon

3 x 415 50 Hz 64 60 - 600 600 470 Stepless Forced Air 675 x 455 x 850 180 RCU AUTO K 600

Auto K 400 Synergic
Thyristorised Power Sources with Synergic Feature for MIG / MAG
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Synergic feature coupled with the features of standard Auto K 400 to operate in manual / synergic mode. Software based auto selection of parameters using inputs of wire diameter, material and shielding gas. User settable non-volatile and editable job memories. Separate adjustment for crater. LCD display for welding parameters. Mounted on rubberized wheels for better mobility along with gas cylinder base.

No. of job memories (User-defined) Wire Feeder Drive system Speed control Wire feed mechanism

9 Servo - I DC motor Stepless

9 Servo - 11 DC motor Stepless 2-roll quick changeover type 4-roll drive optional 5 1.5 - 19 m/min 0.8 - 1.6 MS / AI / FC

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2-roll quick changeover type 4-roll drive optional

Arc Equipment

Length of interconnection, mtr Wire feed speed, m/min Wire diameter, mm Wire type Weight, Kg

5 1.5 - 19 m/min 0.8 - 1.2 MS / Al / FC 7

5 Kg

258

Technical Data Power Source Mains supply, Ph x V, Hz Welding current - Max, A Dimensions, l x w x h, mm Weight, Kg Wire Feeder Type Wire feed mechanism

SCR 400(S)

3 x 415 ± 10%, 50 400 710 x 435 x 760 149 Servo 2-roll quick changeover type 4-roll drive optional

Weight, Kg

7

SCR 400(S)
MIG / MAG Welding units for Shipyard
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Heavy-duty thyristorised power sources designed specially to meet the welding applications for shipyards. Wire feeder interconnection up to 50m possible Suitable for all types of wires - Solid/flux-cored Light weight and compact wire feeder for reaching all locations Standard 2-roll quick changeover mechanism or optional 4-roll drive Outstanding welding performance.

Arc Equipment

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259

MIG C3000i MA6 MIG 3001i/4001i
•Lower power rating •Higher rated current at 100% duty cycle •Higher OCV •Overload and single phase protection •Ammeter •Remote control option Technical Data Mains voltage V, Hz Fuse, slow A Mains cable, Ø mm2 Setting range A MIG / MAG MMA TIG 4-300 MIG C3000i 400, 3-50 / 60 16 4x2.5 16-300 16-400 4-400 300/29V 240/26V 200/24V 70-80 30 42. 50/60 625x410x420 - 43.5 - H IP 23C S IEC/EN 60974-1,-10 CoolMidi 1800 External 4-roll Feed 3004/Feed 4804 upto 1.6mm MA 23 / 24 U6 / U8 53.5 H IP 23 S IEC/EN 60974-1,-10 CoolMidi 1000 External 4-roll Feed 3004/Feed 4804 upto 2.4mm CoolMidi 1000 63.5 H IP 23 S 300/29,0 240/28,0 200/24,0 67 30 42, 50/60 652x249x423 714x249x693 400/34 250/26.5 250/26.5 91 60 42, 50/60 652x249x423 714x249x693 MIG 3001i 4-300, 50/60 16 4x2.5 16-300 MIG 4001i 400, 3-50/60 20 4x4 20-400

Permitted load MIG / MAG at 35% duty cycle A/V 60% duty cycle A/V 100% duty cycle A/V Open circuit voltage V Open circuit power W Control voltage V. Hz Dimensions l x w x h, mm with cooling unit l x w x h. mm Weight 38 33 with cooling unit kg Insulation class Enclosure class Application class Standards IEC/EN 60974-1,-10 Water colling unit Wire feeder Built-in 4-roll 0.8-25.0 m/min 0.6-1.2mm Panels MA6 MA 23 / 24 U6 / U8

Arc Equipment
260

Technical Data Power Source Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg

Mig 5000i

3 x 400±10%, 50 80 16 - 500 500 400 Forced Air IP 23C S IEC/EN 60974-1 IEC/EN 60974-10 625 x 394 x 476 625 x 394 x 776* 66 / 86*

Aristo Mig 5000i
Heavy-duty Multi-process Inverter Power Sources for MIG/MAG (Pulse / Synergic / Non-Pulse), MMA Welding and Arc Gouging
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Cooling Unit* Cooling power, W** Coolant Coolant quantity, ltr Maximum water flow, ltr/min 2500* 50% water and 50% glycol* 5.5* 2*

Inverter power source for applications demanding high level of performance. Robust construction, body made of aluminium to prevent corrosion and handle tough working environments. Both Cooling Fan and Pump function on demand, extremely low no-load power consumption. Communication system is based on CAN-bus for efficient control with minimization of cables. Dust filter to handle tough and dirty working environment and avoid grinding dust and metal particles inside the chassis of the power source. Suitable for both manual and mechanized applications with outstanding welding characteristics.

Arc Equipment

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* Applies to water cooled models Aristo Mig 5000iw only ** At 40 Deg C temperature difference and flow rate 1.5 ltr/min

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261

Technical Data Power Source Mains supply, Ph x V, Hz

Mig U4000i

Mig U5000i

3 x 400±10%, 50

3 x 400±10%, 50 80 16 - 500 / 4 - 500# 500 400 Forced Air IP 23 S

Open circuit voltage, VDC (Max) 80 Welding current range, A Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg Cooling Unit* Cooling power, W** Coolant 2500* 50% water and 50% glycol* 5.5* 2* 16 - 400 / 4 - 400# 320 250 Forced Air IP 23 S

IEC/EN 60974 -1 IEC/EN 60974 -1 IEC/EN 60974 -10 IEC/EN 60974 -10 625 x 394 x 476 625 x 394 x 776* 61 / 81* 625 x 394 x 476 625 x 394 x 776* 69 / 89*

2500* 50% water and 50% glycol* 5.5* 2*

Aristo Mig U4000i / U5000i
Heavy-duty Multi-process Inverter Power Sources for MIG/MAG (Pulse / Synergic / Non-Pulse), MMA Welding and Arc Gouging
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Coolant quantity, ltr Maximum water flow, ltr/min # Current range for TIG * **

Applies to water cooled models Aristo Mig 4000iw / 5000iw only At 40 Deg C temperature difference and flow rate 1.5 ltr/min

Inverter power source for applications demanding high level of performance. Robust construction, body made of aluminium to prevent corrosion and handle tough working environments. Both Cooling Fan and Pump function on demand, extremely low no-load power consumption. Communication system is based on CAN-bus for efficient control with minimization of cables. Dust filter to handle tough and dirty working environment and avoid grinding dust and metal particles inside the chassis of the power source. Suitable for both manual and mechanized applications with outstanding welding characteristics.

Arc Equipment
262

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Technical Data 2/4 Stroke Crater filling Creep start Gas pre/post flow Digital V/A meters Gas purge/wire inching Pre-programmed synergic lines Memory 3 set

Control Panel Control Panel MA23 MA24 X X X X X X X X X X X X X

Feed 3004 / 4804 MA23/MA24
Wire Feeders for Aristo Mig 4000i / 5000i
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Heavy-duty construction with 4-roll drive. All feed rollers are geared and grooved for maximum grip and positive force to facilitate better feeding. Digital V/A meter for displaying welding parameters. Remote control available optionally. Fully enclosed wire spool to protect the wire spool.
Feed 3004 1 x 42, 50 4-Roll Drive Feed 4804 3 x 400 ± 10%, 50 4-Roll Drive

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Technical Data Mains supply, Ph x V, Hz Drive system

Arc Equipment

Length of interconnection, m 1.7/5/10/15/25/35 1.7/5/10/15/25/35 Max. diameter of wire spool, mm Wire feed speed, m/min Wire type Wire diameter, mm Enclosure class Standards of compliance Dimensions, l x w x h, mm Weight, Kg 330 / 440* 0.8 - 25 MS / Al / FC 0.6 - 1.6 IP23 IEC/EN 60974 - 5/10 330 / 440* 0.8 - 25 MS / Al / FC 0.6 - 2.4 IP23 IEC/EN 60974 5/-10

690 x 285 x 420 690 x 285 x 420 17.5 22.5 5**

Coolant - max pressure, bar 5**
* **

Applies to water cooled models Aristo Feed 3004w / 4804w only, which are suitable for Aristo Mig 4000iw / 5000iw only With additional bobbin adapter

263

Technical Data 2/4 Stroke Crater filling Adjustable burn back time Creep start Hot start Inductance Gas pre/post flow Digital V/A meters Gas purge/wire inching Pre-programmed synergic lines Memory 10 set

Control Panel U6 X X X X X X X X X X X

Pendant U8# X X X X X X X X X X (>100)

Feed 3004 / 4804 U6 Feed 3004 / 4804 U8 + Aristo Pendant U8
Wire Feeders for Aristo Mig U4000i / U5000i
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Memory 255 set Pulse / synergic pulse Create synergic lines # X

X X X

Can also be used with Aristo Mig 4000i / 5000i without TIG functionalities

Heavy-duty construction with 4-roll drive. All feed rollers are geared and grooved for maximum grip and positive force to facilitate better feeding. Digital V/A meter for displaying welding parameters. Remote control available optionally. Fully enclosed wire spool to protect the wire spool.
Feed 3004 1 x 42, 50 4-Roll Drive 1.7/5/10/15/25/35 Feed 4804 3 x 400 ± 10%, 50 4-Roll Drive 1.7/5/10/15/25/35 330 / 440** 0.8 - 25 MS / Al / FC 0.6 - 2.4 IP23

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Arc Equipment

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Technical Data Mains supply, Ph x V, Hz Drive system Length of interconnection, m

Max. diameter of wire spool, mm 330 / 440** Wire feed speed, m/min Wire type Wire diameter, mm Enclosure class Standards of compliance Dimensions, l x w x h, mm Weight, Kg Coolant - max pressure, bar * ** 0.8 - 25 MS / Al / FC 0.6 - 1.6 IP23

IEC/EN 60974 -5/-10 IEC/EN 60974 -5/-10 690 x 275 x 420 15 5* 690 x 275 x 420 19 5*

Applies to water cooled models Aristo Feed 3004w/4804w only, which are suitable for Aristo Mig 4000iw/5000iw only. With additional bobbin adapter.

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Technical Data Type of cooling Wire diameter, mm Wire type Rating, A @ % duty cycle Length, m Weight, Kg

PSF 250 Air/Gas 0.6 - 1.0 MS/Al/FC

PSF 305 Air/Gas 0.8 - 1.2

PSF 405 Air/Gas 0.8 - 1.6

PSF 505 Air/Gas 1.0 - 2.4

MS/Al/FC MS/Al/FC MS/Al/FC

250@60% 315@60% 380@60% 475@60% 3/4.5 1.8/2.5 3/4.5 2.5/3.3 3/4.5 3.1/4.2 3/4.5 3.9/5.3

MIG Torches - Air / Water Cooled
PSF 250 / 305 / 405 / 505 3/4.5m Air Cooled PSF 410w / 510w 3/4.5m Water Cooled
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Technical Data Type of cooling Wire diameter, mm Wire type Rating, A @ % duty cycle Length, m Weight, Kg

PSF 410w Water 0.8 - 1.6 MS/Al/FC 400@100% 3/4.5 3.0/3.9

PSF 510w Water 1.0 - 2.4 MS/Al/FC 500@100% 3/4.5 3.3/4.0

Heavy-duty construction. Ergonomically designed handle. All torches come with EURO connection as standard. All torches come with 50° swan neck as standard. Straight neck and 60° swan neck available optionally. 360° swiveling facility. Wide range of wear parts e.g. liners, contact tips and gas nozzles available for welding in all positions.

Arc Equipment

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Conforms to IEC/EN 60974-7.

international

standard

265

EasyWeld SSR400-T / 400T-Pluse
Thyristorised Power Source for DC TIG and MMA
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Caddy Tig 1500i / 2200i TA33 / TA34
Single Phase Portable Inverters for DC TIG / Pulse TIG / MMA Welding
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Robust and compact construction. Outstanding welding characteristics in TIG / MMA. Hex-phase rectification gives almost ripple free output. Suitable for all positional welding. True vertical welding characteristics. Built-in HF for smooth start in TIG. Higher OCV for better arc striking. Heavy-duty design, suitable for manual well as mechanized TIG applications of any kind. Built-in hot start and anti-stick in MMA improves droplet separation from the electrode and improves weldability. Remote control for adjustment of welding current while welding in progress.
EasyWeld SSR 400-T 3 x 415±10%, 50 100 10 - 400 400 310 H Forced Air 675 x 350 x 690 155

Rugged design - impact resistant polymer design. Built-in PFC to counter harmonics, Arc Plus II regulator for smooth output, handles 100m long mains cable. TIG - Start by HF/Lift Arc, up/down slope, pre/post gas. TA33 - Auto set of parameters based on plate thickness TA34 - Manually set pulse parameters in TIG.
Caddy Tig 1500i 1 x 230 V, 50 Hz 16 Caddy Tig 2200i 1 x 230 V, 50 Hz 16 72 4 - 220 / 3 - 220 150 IP23 S

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Arc Equipment

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Technical Data Mains supply, Fuse (slow), A

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Open circuit voltage, VDC (Max) 72 Welding current range, A (TIG/MMA) Output at 60% duty cycle, A Enclosure class Application class Standards of compliance Dimensions, l x w x h, mm Weight, Kg 4 - 150 / 3 - 150 120 IP 23 S

Technical Data Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A Output at 60% duty cycle, A Output at 100% duty cycle, A Class of insulation Type of cooling Dimensions, l x w x h, mm Weight, Kg * 400T Pulse Comes with Pulsing unit.

IEC 60974 -1 / -10 IEC 60974 -1 / -10 488 x 188 x 208 9.2 488 x 188 x 208 9.4

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Technical Data Power Source Mains supply, Ph x V, Hz Open circuit voltage, VDC (Max) Welding current range, A (TIG) Welding current range, A (MMA) Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class

Tig 3001i (TA24) Tig 3000i 3 x 400±10%, 50 67 4 - 300 16 - 300 240 200 Forced Air IP 23C S 652 X 249 X 423 33 IEC/EN 60974 1/-3 IEC/EN 60974 -10 TA24 HF / Lift Arc 2/4 0 - 10 0 - 10

Origo Tig TA24
Inverter Power Sources for DC TIG / Pulse TIG / MMA • Inverter power sources for MMA, DC TIG (TA23) and also DC Pulse TIG (TA24) with excellent welding output. • Robust and compact construction. • Digital display of the welding parameters. • 2 job memories (TA24). • All positional welding. • Burns MMA electrodes of any class of size up to 5.0 mm. • Trolley, remote hand / foot control optional.

Dimensions, l x w x h, mm Weight, Kg Standards of compliance Control Panel TIG start mode 2/4 Stroke Slope up, sec Slope down, sec Gas pre-flow, sec Gas post-flow, sec Pulse/background current, A Pulse/background time, sec Cooling Unit Coolant type

Arc Equipment

0 - 5 5 - 25 4 - 300 0.01 - 2.5 CoolMidi 1800 50% water / 50% ethylene glycol 1700 4.2 4 710 x 385 x 208 19 IEC/EN 60974-2/10

Cooling power, W* Coolant volume, ltr Max flow, ltr/min Dimensions, l x w x h, mm Weight (empty), Kg Standards of compliance

* At 40 Deg C temperature difference and flow rate 1.5 ltr/min

267

Technical Data Power Source Mains supply, Ph x V, Hz

Tig 4000i (TA4) Tig 4000i 3 x 400±10%, 50

Tig 4000i (TA6) Tig 4000i 3 x 400±10%, 50 90 4 - 400 16 - 400 320 250 Forced Air IP 23 S 625 x 394 x 476 625 x 394 x 776* 59 / 79*

Open circuit voltage, VDC (Max) 90 Welding current range, A (TIG) Welding current range, A (MMA) Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class Dimensions, l x w x h, mm 4 - 400 16 - 400 320 250 Forced Air IP 23 S 625 x 394 x 476 625 x 394 x 776* 59 / 79*

Aristo Tig 4000i TA4 / TA6
Inverter Power Sources for DC TIG / Pulse TIG / MMA
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Weight, Kg Standards of compliance Cooling Unit* Coolant type

IEC/EN 60974 -1/-10 IEC/EN 60974 -1/-10

Heavy-duty power sources for MMA, DC TIG (TA4) and also DC Pulse TIG (TA6) with excellent welding output. Robust and compact construction. Dust filter to withstand tough working environment. 10 job memories (TA6). Welding thin sheets using pulse TIG (TA6). All positional welding with high efficiency and quality. Suitable for applications. manual and mechanized TIG

50% water /

50% water /

50% ethylene glycol 50% ethylene glycol Cooling power, W** Coolant volume, ltr Max flow, ltr/min Control Panel TIG start mode 2/4 Stroke Slope up, sec Slope down, sec Gas pre-flow, sec Gas post-flow, sec Pulse / background current, A Pulse / background time, sec * ** 2500 5.5 2 TA4 HF / Lift Arc 2/4 0-5 0 - 10 0 - 5 5 - 25 --2500 5.5 2 TA6 HF / Lift Arc 2/4 0-5 0 - 10 0 - 5 5 - 25 4 - 400 0.001 - 0.1

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Arc Equipment

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Burns MMA electrodes of any class of size up to 6.3 mm. Trolley, remote hand / foot control optional.

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268

Technical Data Mains supply, Ph/L x V, Hz Open circuit voltage, V (Max) Welding current range, A

Heliarc 252

Heliarc 352

2/3 x 400±10%, 50 2/3 x 400±10%, 50 79 5 - 320 79 3 - 380 350 Forced Air 823 x 463 x 635 214 HW-26 HW-18 3.8 / 7.6

Output at 40% duty cycle, A 250 Type of cooling Forced Air

Dimensions, l x w x h, mm 823 x 463 x 635 Weight, Kg TIG torch, air cooled TIG torch, water cooled 180 HW-26 HW-18

Torch length, HW-26/18, m 3.8 / 7.6

Heliarc 252 / 352 AC/DC
Thyristorised Power Sources for AC/DC TIG / DC Pulse TIG / MMA
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Foot switch, Torch control, Digital Meter Pulse control kit Slope control kit

TIG FC-5B EHD FC-5B EHD TIG TC-2B Optional Optional Optional TC-2B Standard Optional Optional Optional WC-8C

Heavy-duty power sources for MMA, AC/DC TIG and DC Pulse TIG. with high quality welding output. Robust construction and proven design. Square wave AC output gives superior welding with improved cleaning. AC wave balance control - allows adjustment from maximum cleaning to maximum penetration. Arc force control — fine-tunes the arc for stick welding from soft to a high penetration, digging arc. Complete solid-state design with no mechanical contactor, which eliminates output drift as well as lowers maintenance and promotes long life. Adjustable pre-flow and post-flow gas control - protects weld area and extends tungsten life. Protected against overhearing and overcurrent.

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Power factor correction kit Optional Cooling Unit WC-8C

Trolley with 2-cylinder rack TR-23A Truck Kit TR-23A Truck Kit

Arc Equipment

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269

Technical Data Power Source Mains supply, Ph x V, Hz

Tig 2200i AC/DC (TA33 AC/DC) Tig 2200i 1 x 230±10%, 50

Tig 2200i AC/DC (TA34 AC/DC) Tig 2200i 1 x 230±10%, 50 64 4 - 220 16 - 160 150 Forced Air IP 23 S 418 X 188 X 345 15

Open circuit voltage, VDC (Max) 64 Welding current range, A (TIG) Welding current range, A (MMA) Output at 60% duty cycle, A Type of cooling Enclosure class Application class Dimensions, l x w x h, mm 4 - 220 16 - 160 150 Forced Air IP 23 S 418 X 188 X 345 15

Caddy Tig 2200i AC/DC, TA33 / TA34 AC/DC
Inverter Power Sources for AC/DC TIG / DC Pulse TIG / MMA
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Weight, Kg Standards of compliance Control Panel TIG start mode 2/4 Stroke Slope up, sec Slope down, sec Gas pre-flow, sec Gas post-flow, sec Pulse frequency DC, sec Frequency AC, Hz AC balance, % Plate thickness, mm Cooling Unit Coolant type

IEC/EN 60974 -1/-3 IEC/EN 60974 -1/-3 IEC/EN 60974 -10 IEC/EN 60974 -10 TA33 HF / Lift Arc 2/4 0 - 10 0 - 10 Preset 0 - 10 ---1-5 CoolMini 50% water, 50% mono ethylene glycol 780 2.2 2 407 x 188 x 151 4.5 TA34 HF / Lift Arc 2/4 0 - 10 0 - 10 Preset 5 - 25 0.01 - 2.5 10 - 150 50 - 98 -CoolMini 50% water, 50% mono ethylene glycol 780 2.2 2 407 x 188 x 151 4.5

Portable power sources with wide functionalities. Digital display, 2 job memories. TA33 - parameters adjusted based on plate thickness. TA34 - manually adjust all parameters. Burns MMA electrodes of any class of size up to 4.0 mm. Trolley and remote control available optionally.

Arc Equipment

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Cooling power, W* Coolant volume, ltr Max flow, ltr/min Dimensions, l x w x h, mm Weight (empty), Kg Standards of compliance *

IEC/EN 60974 -2/-10 IEC/EN 60974 -2/10

At 40 Deg C temperature difference and flow rate 1.0 ltr/min

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Technical Data Mains supply, Ph x V, Hz Open circuit voltage, V (Max) Welding current range, A (TIG)

Tig 3000i AC/DC, TA24 AC/DC 3 x 400±10%, 50 64 4 - 300

Welding current range, A (MMA) 16 - 300 Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class Dimensions, l x w x h, mm Weight, Kg 240 200 Forced Air IP 23C S 652 X 412 X 423 42 IEC/EN 60974 -1 / -3 / -10 HF / Lift Arc 2/4 0 - 10 0 - 10 0 - 5 5 - 25 4 - 300 0.01 - 2.5 50 - 98

Origo Tig 3000i AC/DC, TA24 AC/ DC
Inverter Power Sources for AC/DC TIG / DC Pulse TIG / MMA
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Standards of compliance TIG start mode 2/4 Stroke Slope up, sec Slope down, sec Gas pre-flow, sec Gas post-flow, sec Pulse / background current, A Pulse / background time, sec AC balance, % AC frequency, Hz Electrode preheating Cooling Unit CoolMidi Coolant type Cooling power, W* Coolant volume, ltr Max flow, ltr/min Dimensions, l x w x h, mm Weight (empty), Kg Standards of compliance

Designed to weld any metal e.g. aluminium, copper, stainless steel and its alloys with high performance. Digital display, 2 job memories. QWave - High performance AC welding with low noise. Electrode preheating - excellent arc start and extended electrode life-time. Energy save made - cooling fan and pump on demand. Burns MMA electrodes of any class of size up to 5.0 mm. Trolley, remote hand / foot control optional.

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Arc Equipment

10 - 152 1 - 100 1800 50% water / 50% ethylene glycol 1700 4.2 4 710 x 385 x 208 19 IEC/EN 60974 -2 / -10

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* At 40 Deg C temperature difference and flow rate 1.5 ltr/min

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Technical Data Mains supply, Ph x V, Hz Open circuit voltage, V (Max) Welding current range, A (TIG) Welding current range, A (MMA) Output at 60% duty cycle, A Output at 100% duty cycle, A Type of cooling Enclosure class Application class Dimensions, l x w x h, mm Weight, Kg Standards of compliance

Tig 4300iw AC/DC, TA24 AC/DC 3 x 400±10%, 50 83 4 - 430 16 - 430 400 310 Forced Air IP 23 S 625 x 394 x 776 95 IEC/EN 60974-1/-2/-3/-10 HF / Lift Arc 2/4 0 - 10 0 - 10 0 - 5 5 - 25 4 - 430 0.01 - 2.5 50 - 98 10 - 152 1 - 100 Built-in 50% water / 50% mono ethylene glycol 2000 5.5 2

Origo Tig 4300iw AC/DC, TA24 AC/DC
Heavy-duty Inverter Power Sources for Manual / Mechanized TIG (AC/DC TIG / DC Pulse TIG) and MMA Welding
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TIG start mode 2/4 Stroke Slope up, sec Slope down, sec Gas pre-flow, sec Gas post-flow, sec Pulse / background current, A Pulse / background time, sec AC balance, % AC frequency, Hz Electrode preheating Cooling Unit Coolant type Cooling power, W* Coolant volume, ltr Max flow, ltr/min
*

Designed to weld any metal e.g. aluminium, magnesium, copper and its alloys, MS and SS with high performance. Robust construction, Digital display, 2 job memories. QWave - High performance AC welding with low noise. Electrode preheating - excellent arc start and extended electrode life-time. VRD - Voltage Reduction Device, safety feature in MMA. Energy save made - cooling fan and pump on demand. Burns MMA electrodes of any class of size up to 6.3 mm. Arc force, hot start, polarity switch for welding in MMA. Trolley and remote hand / foot control optional.

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Arc Equipment

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At 40 Deg C temperature difference and flow rate 1.0 ltr/min

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272

Technical Data

TXH 150 / TXH 150r / TXH 150V Air / Gas OKC 25 / 50 1.0 - 3.2 150 @ 35% 4/8
TXH 250w / TXH 250wr Water OKC 50 1.0 - 3.2 250 @ 60% 4/8 TXH 400wr TXH 400w / Water OKC 50 1.0 - 4.8 400 @ 35% 4/8

TXH 200 / TXH 200r / TXH 200V Air / Gas OKC 50 1.0 - 4.0 200 @ 35% 4/8
TXH 400w HD / Water OKC 50 1.0 - 4.8 430 @ 35% 4/8

Type of cooling Connection Size of TIG rod, mm Rating, A@% duty cycle Length, m
Technical Data Type of cooling

TIG Torches - Air / Water Cooled
TXH 150/200 4/8m Air Cooled TXH 250w/400w/400w HD 4/8m Water Cooled TXH 150r/200r 4/8m Air Cooled with Remote Functions TXH 250w/400w/400w HD 4/8m Water Cooled with Remote Functions TXH 150V/200V 4/8m Air Cooled for Scratch TIG
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Connection Size of TIG rod, mm Rating, A@% duty cycle Length, m

Rugged construction - trouble free operation with minimum maintenance. Ergonomically designed handle. Effective cooling system. All torches come with OKC connection as standard. TXH 150r/200r/250wr/400wr/400wr HD TIG torches available with remote control for CAN-bus based TIG machines i.e. for Caddy Tig 2200i AC/DC, Origo Tig 3000i, Origo Tig 3000i AC/ DC, Aristo Tig 4000i and Origo Tig 4300iw AC/DC. Gas valve mounted TIG torches TXH 150V/200V for scratch TIG using rectifiers. Wide range of wear parts e.g. collet, collet body, nozzle, and gas lens available for welding in all positions. All the TIG torches conform to international standard IEC/EN 60974-7.

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273

LPH 35 / 50 / 80 / 120
Rugged Power Sources for Air Plasma Cutting
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Faster and economical on Al, SS and CS below 20 mm. Cutting can be done from gauge thickness to thick plates. Very safe and convenient. No distortion even on sheets below 6 mm. Light weight torches make cutting effortless. Circle and profile cutting attachments available optionally.
LPH 35 3x415, 50 295 LPH 50 LPH 80 LPH 120 3x415, 50 3x415, 50 3x415, 50 320 -3.5 - 7 8/12* IP23 Forced Air 610x255 x515 52 680x325 x515 89 4.5 - 7 12/15* IP23 310 -4.5 - 7 25/35* IP23 310 -4.5 - 7 35/45* IP23

PowerCut 650 / 900 / 1300 / 1600
Inverter Power Sources for Air Plasma Cutting
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Inverter based power source, excellent cutting output. Robust and compact construction. Cuts thin sheets of gauge thickness to thick plates. Cutting packages with mechanized cutting torch also available for PC1300 and PC1600. Circle and profile cutting attachments available optionally.
PC-650 PC-900 PC-1300*** PC-1600*** 3x400, 50

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Technical Data Mains supply, PhxV, Hz OCV, VDC (Max)

Technical Data

Mains supply, PhxV, Hz 1x230*, 50 3x400, 50 3x400, 50 OCV, VDC (Max) 290 275

Arc Equipment

Output@% duty cycle, A Pressure, bar Cutting capacity, mm Enclosure class Type of cooling Dimensions, lxwxh, mm Weight, Kg Torch/length, m * Quality cut / sever capacity

278(typical) 278 90@60% 165/5.5 38/45** Forced Air 800x318 x419 42.7 AU PT-38 7.6/15.2

Output@% duty cycle, A 40@40% Air supply, ltr/min / bar Cutting capacity, mm Type of cooling 118/5.5 15.9/19** Forced Air

60@60% 70@100% 150/5.2 22/32** 165/5.5 32/38**

Forced Air Forced Air 760x390 760x390 x845 x845 131 167

Forced Air Forced Air 516x275 x409 39.5 800x318 x419 39

Dimensions, lxwxh, mm 483x318 x416 Weight, Kg Manual cutting torch Torch length, m 24

PT-30KK/4 PT-27/7.6 PT-27/7.6 PT-25/7.6

PT-31XLPC AU PT 38 AU PT 38 7.6/15.2 7.6/15.2 7.6/15.2

* Also available in 3 x 400V version ** Quality cut / sever capacity

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Technical Data Power Source Mains supply, Ph x V, Hz Open circuit voltage, VDC

CPRA 800(S)

CPRA 1200(S)

3 x 415, 50 22 - 55

3 x 415, 50 30 - 60 1000 Forced Air

Output at 100% duty cycle, A 800 Type of cooling Dimensions, l x w x h, mm Weight, Kg Forced Air

960 x 760 x 880 1000 x 800 x 900 325 LW SAW 375 Tractor LW

CPRA 800(S) / 1200(S)
Power Sources for SAW
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Welding Head SAW Tractor Wire (single) diameter range, mm Wire feed speed, m/min Welding current range, A Vertical adjustment, mm

2.4 - 5.0 / 6.3* 2.4 - 5.0 / 6.3* 0.3 - 18 200 - 1200 100 0.3 - 18 200 - 1200 100 180° 0.15 - 15 350

Rugged construction with sheet metal body, mounted on rubberized wheels. Heavy-duty construction, designed for continuous applications up to 1000 Amps. 4-step voltage control in coarse and fine mode. Mains voltage compensation ensures minimal fluctuation in arc voltage. Built-in protection against thermal overloading. Power and control units are housed separately for the easy of servicing.

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Swivel arrangement, degree 180° Speed range of tractor, m/min 0.15 - 15 Wheel center of tractor, mm Dimensions, l x w x h, mm * Standard / Optional 350

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1368x410x1145 1368x410x1145

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Arc Equipment

SAW Tractor LW - Tractor Mounted Welding Head
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Heavy-duty design ensures stable wire feeding and good welding output. Available in standard tractor mountable version and optional boom mountable version. Nozzle designed suitably for a no. of applications e.g. linear / fillet welding etc. User-friendly control panel with controls within easy reach of operator, for adjustment of parameters, while welding in progress. Creep feed start for non-explosive and smooth start of the welding.

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Welding Automation
Thyristorised SAW Power Sources - DC
LAF 635 / 1000 / 1000M / 1250 / 1250M / 1600 / 1600M
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Excellent welding characteristics throughout the entire current and voltage. Good arc stability at low as well as high voltages.
LAF 635 LAF 1000 LAF 1000M LAF1250M LAF 1250M LAF 1600M LAF 1600M

Mains supply, V/Hz Max output at 60% duly cycle, A Max output at 100% duty cycle, A Setting range, A/V, MIG/MAG Setting range, A/V, SAW Open circuit voltage, V No load power, W Efficiency at max current Power factor at max current Voltage, 3 ph 60 Hz, V Voltage, 3 ph 60 Hz, V

Endosure class, protection External dimensions, LxWxH, mm Weight, kg

400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 800/44 1000/44 1000/44 630/44 800/44 800/44 1250/44 1250/44 1600/44 1600/44 50/17-630/44 50/17-1000/45 50/17-1000/45 60/17-1250/44 60/17-1250/44 - 30/21-800/44 40/22-1000/45 40/22-1000/45 40/22-1250/44 40/22-1250/44 40/22-1600/46 40/22-1600/46 54 52 52 51 51 54 54 150 145 145 220 220 220 220 0.84 0.84 0.84 0.87 0.87 0.86 0.86 0.90 0.95 0.95 0.92 0.92 0.87 0.87 400/415 400/415/500 230/400/415/ 400/415/500 230/400/415/ 400/415/500 230/400/415/ 500 500 500 440 400/440/550 230/400/440/ 400/440/550 230/400/440/ 400/440/550 230/400/440/ 550 550 550 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 670x490x1090 646x552x1090 646x552x1090 774x598x1428 774x598x1428 774x598x1428 774x598x1428 260 330 330 490 490 585 585

Arc Equipment

Thyristorised SAW Power Sources - AC
TAF 800 / 1250
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A2/A6 Process Controller PEH
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Control boxes usable for SAW and GMAW together with A2/A6 automatic welding machines. Adaptable to LAF/TAF series of power sources, technical specifications as under. IP 23 355x210x164 42 (AC)/50-60 5.5 900

Heavy-duty thyristorised AC power sources with square wave output. Excellent arc ignition characteristics and good welding properties. Ideal for SAW.
TAF 800 TAF 1250 1250 400/281250/44 72 0.86 0.76 400/415/500 400/440/550 IP 23 74x598x1228 608 800 300/28800/44 71 0.86 0.75 400/415/500 400/440/550 IP 23 774x598x1228 495

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Enclosure class, protection External dimensions, LxWxH, mm Mains supply, V/Hz Weight, kg Max power consumption, VA

Max output at 100% doty cycle, A Setting range, A/V Open circuit voltage, V Efficiency at max current Power factor at max current Voltage, 1 ph 50 Hz, V Voltage, 1 ph 60 Hz, V Enclose class, protection External dimensions, LxWxH, mm Weight kg

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Orbital TIG Welding
A21 PRB/PRC/PRD 100/PRD 160/ POC 12-60, Aristo Mech Tig 4000iw The ESAB welding program for mechanised tube welding is based on the TIG welding method with a non-consumable tungsten electrode. To further improve weld quality and decrease costs, ESAB have developed microprocessor controlled power sources for orbital TIG welding, the Aristo MechTig 4000iw with control boxes Aristo MechControl 2 and 4.

A21 PRD 160 is a water-cooled flexible pipe-welding head for pipes with an outer diameter of 160 mm or more. It consists of an articulated carriage that travels around the pipe on a rack adapted to match the diameter of the pipe. To ensure maximum flexibility it is built in modular form.

A21 PRB welding head is compact and easy to use as a result of its unique pincer action, which reduces settingup times to a minimum. The welding head is positioned and secured around the tube with great accuracy in seconds. The PRB welding heads are available in three sizes for tubes with outer diameters of 17 to 170 mm.

A21 POC 12-60 is a welding head for tube-to-tube sheet TIG welding. It is a precision-built, robust and versatile welding head 12 to 60 (93) mm outer tube diameter. It has a very high centering accuracy and centering mandrels are available for inner tube diameters from 10 mm.

A21 PRC welding head has a weaving movement and arc voltage control, which produces higher productivity and better welding quality, particularly when welding thick-walled tubes.

Arc Equipment
Aristo MechTig 4000iw is designed to work together with the Aristo MechControl 2 and 4. This is a 400A heavy-duty inverter based power source having compact design with outstanding welding characteristics. Connection cables up to 8m provide a working range of 16m.

A21 PRD 100 welding head is designed for high precision, and quality. It is a TIG welding head for tubes with an outer diameter of 100 mm or higher. Due to compact design and low profile it requires only 73 mm clearance around the tube. This is water-cooled welding head usable up to 400A.

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It is a small, compact, motor-operated trolley designed for the mechanisation of GMAW, gas metal arc welding, in particular. The permanent magnet built-in magnet, which can be switched on/off, holds the tractor in the correct position on the work-piece. Travel speed, m/min Weldilng speed, m/min Control voltage, V, AC Max power consumption, W Intermittent welding range, cm Crater fill duration, s Weight, kg External dimensions, LxWxH, mm 2.5 0.15-1.5 36-42 25 1-99 0-9.9 8.5 400x340x370

Tractor Automats - Miggytrac
Miggytrac 1001 It is a compact motor powered tractor into which a standard ESAB welding torch can be attached. It is mounted on four driving wheels together with the magnet ensuring stable operation. The magnet holds the tractor in the correct position on the work-piece, even if it is bent or angled. Welding speed, m/min Control voltage, V, AC 0.15-1.2 36-46 20 7 266x257x267

Miggytrac 3000

Arc Equipment

Power, W Weight, kg External dimensions, LxWxH, mm

Miggytrac 3000 It is a small, compact, motor-powered tractor with four wheel drive, integrated wire feed and water-cooled welding torch, designed for horizontal MIG/MAG welding of plates and beams. The carriage follows the weld joint by one front and one rear guide and wheel. Travel speed, m/min Welding speed, m/min Control voltage, V, AC Max power consumption, Intermittent welding range, cm Crater fill duration, cm Weight, kg 2.5 0.15-1.5 36-46 W 80 1-99 0-9.9 17

Miggytrac 2000

Miggytrac 2000

External dimensions, LxWxH, mm 370x400-530x520

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Quick set-up and easy operation Programmable with five programs Calibrated setting values in mm, cm and sec Programmable “backfill” for crater filling

Tractor Automats - Railtrac
Railtrac F1000 Railtrac F1000, Flexi, for welding and thermal cutting.
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Welds and cuts in all positions on magnetic and nonmagnetic materials Quick assembly and easy operation Programmable with five programs Calibrated setting values in cm, mm and sec Programmable “backfill” for crater filling

Railtrac FW1000/FW1000 L Railtract FW1000, Flexi Weaver, for oscillated welding. The Railtrac FW 1000 can be delivered in a “FW1000 L” version if the welding process need to be done with a lower welding speed than with FW1000.
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Welds and outs in all positions on magnetic and non-magnetic materials Quick set-up and easy operation Programmable with five programs

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Railtrac FR1000 Railtrac FR1000, Flexi Return, for welding and outing with automatic return.
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Arc Equipment

Welds and cuts in all positions on magnetic and nonmagnetic materials Quick set-up and easy operation Programmable with five programs Calibrated setting values in mm, cm and sec Programmable “backfill” for crater filling

Railtrac BV1000 / BVR1000 Railtrac BV1000 and BVR1000 are two automatic units for mechanising the repair and hardfacing of rail pro?les smoothly and efficiently. The equipment can be assembled, and controlled quickly and easily by one person. Learning to use it is easy and extremely fast. Rail length, m Welding speed, m/min Weaving range, mm Weaving speed, mm/s Max power consumption, Control voltage, V, AC Crater fill duration, s Zero-line shift, mm Programmable edge length, cm Weight, kg 2 0.1-1.5 1-80 7-50 W 80 36-46 0-9.9 25 (+-12.5) 6-99 7

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Railtrac FWR1000 Railtract FWR1000, Flexi Weaver Return, for oscillated welding with automatic return.
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Welds in all positions on magnetic and non-magnetic materials

The track for all the above models of Railtrac are made of Aluminium and can be either extended or cut to get the required length.

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A2 Multitrac with A2/A6 Process Controller PEH The A2 Multitrac with the A2/A6 process controller PEH is available for both SAW and the GMAW. If the SAWversion is chosen, the A2 Multitrac is capable of working with single or twin wire.
Wire Ø, unall, solid Wire Ø, SS Wire Ø, AI Wire Ø, CW Wire feed, m/min Travel speed, m/min External dimensions, LxWxH, mm 1.6-4.0 1.6-4.0 1.6-4.0 0.2-9 0.1-1.7 870x400 x830 47 2x1.2-2.5 0.8-1.6 2x1.2-2.5 0.8-1.6 0.2-9 0.1-1.7 1.2-1.6 1.2-2.4 0.2-16 0.1-1.7 0.8-1.6 0.8-1.6 1.0-2.0 1.2-2.4 2.0-25 0.1-1.73

870x400 870x400 870x400 x830 47 x830 43 x830 43

Tractor Automats - Trippletrac / Multitrac / Mastertac
A2 Trippletrac It is a three-wheeled tractor carriage steers with the front wheel. It is used for internal circumferential welding of large cylindrical objects due to its clever design with a steering wheel. The tractor can be equipped with A2-A6 Process Controller PEH or A2 Welding Controller PEI. Max load at 100% duty cycle, A Wire feed max, m/min Travel speed, m/min External dimensions, LxWxH, mm Weight, excl wire and flux, kg 800 0.2-9.0 0.1-1.7 594x686x956 47

Weight, kg

Arc Equipment

A6 Mastertrac It is a heavy-duty self-propelled, fourwheel drive, automatic welding machine. The advanced electronic control provides high precision and the digital display enables all the welding parameters to be preset accurately. It can be used for SAW as well as for GMAW.
Max load at 100% ditu cycle, A Wirediameter, mm Wire lead, m/min Travel speed, m/min External dimensions, LxWxH, mm 1500 3.0-6.0 0.2-4.0 0.1-2.0 600 1.0-3.2 0.8-16.6 0.1-2.0 1500 2x1500

2x2.0-3.0 2x3.0-6.0 0.2-4.0 0.1-2.0 0.2-4.0 0.1-2.0

1410x750 1410x750 1410x750 1410x990 x850 x850 x850 x850

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Roller Beds
Esab offers a wide range of roller beds with capacity varying from 5 - 250 tons. The roller beds have mechanical adjustment for circular work-pieces and self-aligning roller beds, which automatically adapt o the roller bed diameter. These roller beds are designed to operate in combination with A2/A6 automatic welding equipment and Esab’s columns and booms.

Positioners
Esab offers a comprehensive range of positioners for automatic welding. These very versatile welding tools enable welding to be carried out in the optimum positions to benefit the quality of the work. The positioners can be integrated with A2/A6 automatic welding equipment.

Arc Equipment
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Friction Stir Welding
Legio Friction Stir Welder The LEGIO combines the latest technology with proven quality. The modular system makes it possible to assemble welding stations to suit the most varied Friction Stir Welding applications. The LEGIO system consists of five basic designs in a series of seven sizes, covering a welding depth of 1.2 mm (.045 in) to 60 mm (2.4 in). These basic types can be supplemented with different types of equipment to suit the most varied production needs and give maximum flexibility to any production line.

Friction Stir Welding
Super Stir Friction Stir Welder The SuperStir program includes a variety of machines developed from a standarized SuperStir base unit having working ranges of 0.5x1.5m (19.7x59in) up to 10x20m (33x66 ft) within the same concept. This includes customized models of various designs for specific customer requirements in different production areas. These different designs are used worldwide in R&D centers for joining of extrusions to panels, in production of pressure vessels as well as small parts for the automotive and electronic industries.

Arc Equipment
282

The versatile Legio family includes linear motion with single or dual (over /under) heads, with or without tables. Dual axis (x-y) model is available with or without table. Tables include a whole pattern for attaching fixtures. Legio includes ESAB HMI control specifically designed for the Friction Stir Welding. It is a closed loop welding control, with ability to control Z-axis either by pressure or by position. PC network connections and data transfer are available optionally.

Robotics for Arc Welding
Esab offers a wide range of automated welding solutions using a range of robots from ABB. Robotics can provide a cost-effective and modular solution for a variety of welding applications with increased productivity. The various advantages of using robotics are: Built on an Open Structure The robots are equipped with a wide range of universal communications interfaces, configurable from S4Cplus, the robot’s controller. They can be connected to a PC for servicing purposes or the factory data network using one or two Ethernet links. The robots controller contains the standard field-buses and serial-channels for interfaces with a wide range of power sources and distributed devices. Flexibility - Develop Custom Functionality Using the arc-welding software ArcWave the robots can be configured. For advanced and critical welding applications customized functionality can be configured using RAPID, the high level programming language from ABB. Pre-program Offline New programs can be created, programs can be stimulated or robots can be pre-programmed for a specific functionality. Position Anywhere - Portability The robots can be mounted on a wall or inverted from gantries, columns with booms and elevators for heavyduty welding, allowing for a wide variety of working range capabilities. Workpiece positioners with one or two axis can also be added to this to increasing the flexibility in positioning. High Level of Accuracy The software is designed to achieve high-level accuracy to maintain the quality in the welding applications.

Arc Equipment
283

Range of Robots
IRB 140 ABB’s fastest and smallest arm-based industrial robot. Highly flexible with slim wrist, 6-axis robot able to reach into narrow, small spaces. Easy-to-mount equipment. Robust and compact. The standard IRB 140 can be mounted at any angle without modification for optimum reach and efficiency. Load capacity: 5 kg; supplementary load is: 1.5 kg; reach: 0.81 meters.

IRB 2400L Slim yet robust arm-based, 6-axis robot. All the IRB 2400 industrial robots are ideal for arcwelding applications. Features unlimited axis 6. IRB 2400L load capacity is 7 kg; reach 1.8 meters. IRB 2400/10 load capacity is 10 kg; reach 1.5 meters. IRB 2400/16 load capacity; 16 kg; reach: 1.5 meters.

Arc Equipment

IRB 4400 Compact, versatile robot with medium to heavy handling capacity. The B-axis robot can handle loads up to 60 kg, or up to 45 kg at very high speeds. Reach: 1.96 meters.

IRB 1400 Robust, well-proven, 6 axis, arm-based industrial robot with a large installed base. Well-balanced arm construction, plus maintenance-free gearboxes and cabling, reducing noise levels and maintenance requirements. Load capacity: 5 kg; reach: 1.44 meters.

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Accessories

ARC WELDING ACCESSORIES
Quality for Welders Performance ARMOUR HEAD SCREEN
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from weld spatters. Electrode Holders - 600 For sale comfortable, life long welding. They are designed for use with intermittent welding currents up to 600 A. Suitable for manual Welding Electrodes 1.6 mm to 6.3 mm. The welding cable is connected to the electrode holder by a slip proof mechanical fastening arrangement. Welding Cable Single core tough rubber sheathed copper cable and aluminium cable are available in the following sizes made exclusively for long life performance by ESAB. 400 amps. Aluminium and copper (70 sq. mm & 50 sq. mm respectively.) 600 amps. Aluminium and copper (120 sq. mm & 70 sq. mm respectively.) Conforming to IS-9857

Ultra light weight (Lighter than fibre glass) Rugged, Flame retardant construction Extended Crown: For better protection of the head. Lift up arrangement for the lens Height Adjustment: The facility to adjust the helmet height with respect to the operator’s convenience provides operator ease. Ratchet headgear: Ensures the fitting to any head size without slightest hesitation or problem. 4 point contact adjustment: Ensures perfect fitting to any face size and eye level. Rigid lower lib provided deflects welding spatter from chest area. Quality standards confirms to IS : 1179 - 1967

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Arc Equipment

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ARMOUR HAND SCREEN
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Ultra light weight (Lighter than fibre glass) Rugged, Flame retardant construction. Quality standards confirms to IS : 1179 - 1967. Accommodates Standard 41/4”x 31/4” welding lens. Concealed handle provides safety to welder’s hand

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ARMOUR RANGE OF ELECTRODE HOLDERS
EHOP 400/600 & EHJK 400/600 Specially designed for heavyduty use where Safety, Ease of Use and Economy is highly appreciated. The fully insulated fibreglass reinforced moulded handles and Tip insulators are provided to make the product shock proof, and resistant to Heat, Oil and light impacts. The main conductor bodies are made from special copper, which ensures better contact, conductivity and long life. The products confirm to International safety standard CE and BS EN-609? 4-11 . ARMOUR RANGE OF EARTH CLAMP ECAL Robust in construction and a long working life is the key points of the new Earth Clamps from ESAB. The special copper conducting path and the spring action clamping device, which ensure the best contact and conduction path. Quality is the key factor of our products. They confirm to Quality Standard BS - 638.

HANDYOVEN
Portable Electrode Drying Oven
ESAB Electrode drying oven - Handyoven is designed to make it portable and is ideal for redrying medium quantity of electrodes. Most of the welding electrodes, particularly the low Hydrogen Iron powder type electrodes may absorb moisture from the atmosphere. If the moisture is excess than the recommended level consistent with the type of flux, they should be redried before use at 130°C-230°C to drive away and absorbed moisture from the flux coating.

Arc Equipment

Specification
Input Supply Input Current Input Power Temperature Range No. of trays Storage Space 230 V Single phase 50 Hz. 2.8 A (Approx.) 600 watts 50° C to 230° C 2 No. 8 Kg. of electrode

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CHOICE OF FUSION WELDING METHOD
When choosing welding methods, you need to pay attention to several factors: 1. Required weld quality. 2. Which welding method is fit for use with the material in question. 3. Which welding method may be used in view of accessibility and position of the weld. 4. Availability of welding consumables of proper quality for the proposed welding method. 5. Number of workpieces to be welded or estimated welded volume, e.g per year. 6. Available welding equipment, positioners, roller beds, swivel tables, hosting gears etc. 7. Possibility or intention to invest money in highly productive welding equipment. 8. Workstation: a workshop or a building site? These differ with regard to the possibilities to weld acceptably, taking into consideration the general environment (outdoors, indoors with or without draft), possibilities to rotate, lift, transport or otherwise move the workpiece. 9. The welding methods for which the available welders are trained. The methods for which the company is authorized. Training possibilities. 10. Choice of welding method which gives the lowest costs. Calculation of consumables consumption. 11. Estimate of the accuracy of the joint preparation which must match the welding method. 12. Please also compare table-key data for the most common fusion welding methods. MIG/MAG-welding or Semi-Auto atic welding m 1. Electrode 2. Electrode from spool, solid or alternatively flux cored wire 3. Gas nozzle 4. Contact tip 5. Gas shield diagram shows spray arc and short-arc, respectively

TIG-welding. 1. 2. 4. 5. 6. Gas shield Tungsten electrode 3. Gas nozzle Filter wire Metal drops Molten pool

Arc Equipment

Welding Methods
MMA-welding-manual Metal Arc Welding or Manual stick electrode welding. 1. 2. 3. 4. 5. Gas shield from the electrode coating Electrode coating Core Wire Metal drops Molten pool SAW-welding (submerged Arc Welding). 1. Electrode from spool 2. Flux 3. Molten pool. Diagram shows the electrode surrounded by flux and a cover of melted flux
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Arc Equipment

MMA Manual Metal Arc Welding

Manual Metal Arc welding, also called hand welding, is still the best known and most common method of welding. Manual Metal Arc welding is noted for: 1. Low investment cost. 2. Low cost of filler material in relation to kgs. weld deposit. 3. Filler material (stick electrodes) are easily available in a wide range of types and dimensions. 4. Less strict demands on edge preparation and purity of the parent material than by other welding methods. 5. The same equipment can be used for all non-alloyed, low alloyed and stainless welding construction steels. Also for cast iron, modular iron and weldable non-ferrous metals. 6. Short set-up times, good at piece fabrication. 7. Can be used in all positions. Also in narrow spaces with hard to get at welding points. 8. Often gives a more machineable weld deposit than Gas Metal Arc Welding. 9. Reasonable heat input to the parent material. This gives reasonable grain growth and thus a transformation zone less exposed to brittle fracture than other methods working with higher heat input. The efficient and economical use of the Manual Metal Arc welding method can be summed up in the following seven recommendations. 1. Weld in the horizontal position with high recovery stick electrodes whenever possible. This minimizes both weld time and energy consumption. The use of roller beds and positioners can often contribute to a shorter weld time by making horizontal welding possible. 2. Use sufficiently strong power sources to make possible the use of fast welding high recovery electrodes. 3. Save on electricity by using power sources with high efficiency and low no load rating. 4. Use welding transformers for heavy plates, framework and in other cases when DC welding will

interfere through magnetic arc blow. 5. Use a static welding converter (rectifier or inverter) for welding of heavy plates if the mains supply is weak. 6. Use gravity welding for mass production of long straight fillet welds. 7. Weld vertical down instead of up whenever possible. Equipment The equipment consists of power source, welding cable, electrode holder and return cable. Below is a survey of the characteristics of different power sources. Welding transformers They give alternating currency (AC) and are the least expensive power sources. They have a high efficiency 80-90% for the most commonly used transformers for welding. They are used for welding of unalloyed, lowalloyed stainless steels and cast iron but not for e.g aluminium. Certain electrodes have better welding characteristics on alternating current (AC) than on direct current (DC). Among these electrodes you find in particular the high recovery types, and notably the larger dimensions. Welding rectifiers In this case a rectifier has been added to the transformer, thus supplying DC. It costs approximately twice as much as a transformer of corresponding size. For modern rectifiers, the efficiency is 60-80%. For both rectifiers and transformers, the efficiency is lower, the lower the used current is. Vice-versa a higher utilization of the capacity of the power source gives a higher efficiency. The rectifier may be used for all weldable materials. Welding converters One electric motor (AC) is coupled to a generator (DC). Generally, a more expensive solution than a rectifier of corresponding size. The efficiency is 50-60%. Its range of use is the same as that of the rectifier.

Arc Equipment
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Engine driven generators These normally provide DC. They are more expensive than converters and as a rule heavier. The smaller types normally have 2-stroke petrol engines, whereas larger ones have diesels. In both cases the engine drives the DC generator. Welding inverters This is the most recent development within Manual Metal Arc welding. Inverters produce DC or AC/DC. The efficiency is high - 80-90%. The cost is somewhat higher than that of a conventional thyristor regulated rectifier. The Inverter’s main components are:
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For fillet welds with 4-5 mm effective throat thickness, the maximum weld speed is 0.5 m/min when using OK Femax high recovery electrodes. For gravity welding using 600-700 mm long electrodes, you can reach a speed of up to 60m/manhour when welding straight fillet joints. For gravity welding, AC is always used. The effective throat thickness may be varied by using different electrode dimensions. Range of application-Material types Manual Metal Arc welding is used for all unalloyed, low alloyed and stainless common structural steels according to Swedish Standard (SS) and other comparable steels. See also “Standards, Classification System and Codes” in the ESAB Welding handbook-Filler Materials. These steels comprise:
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A rectifier which turns the incoming 3-phase AC (sometimes only 1-phase AC) into DC. An inverter which changes this DC into HIGH FREQUENCY AC. A transformer which takes this current down to a lower voltage (20-50 V). A rectifier which transforms the AC into DC suitable for welding.

Common structural steel. Pressure vessel steel. Ship plate. Cast steel and machine steel.

Manual Metal Arc welding is also used for:
l l l l

The entire process is controlled by a control circuit. The inverter’s main features are low weight and volume. Since both efficiency and power factors are high, smaller mains cables and fuses may be used in comparison to conventional rectifiers.

Cast iron. Spherolitic cast iron. Malleable iron. Weldable non-ferrous metals.

Arc Equipment

Productivity-Welding Speed A modern high recovery electrode, such as OK Femax 38.95, 6.0 mm and an efficient power source, such as THH 630, can reach a weld deposit of 13 kgs/hour when welding horizontally. Maximum weld deposit for OK Femax 33.80, dia 6.0 mm, is about 8.5 kgs/hour.

Range of application-Plate thickness Metal Arc welding is used for plate thicknesses from about 2 mm to the thickest normally used.

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MIG/MAG Gas Metal Arc Welding
MAG WELDING

Gas metal arc welding with active gas For this method it is significant that DC is used, and that the electrode is a wire which is automatically fed to workpiece. The arc is surrounded by the shielding gas. The negative pole of the power source is connected to the workpiece. MAG welding takes place in a shielding gas zone consisting of Carbon Dioxide (C02) or a gas mixture consisting of 80% Ar!Jon and 20% Carbon Dioxide. The Argon/C02 mixture is costlier than pure C02’ But it gives a softer arc, smoother weld and less spatter. The mixture also contributes to a higher strength and ductility of the weld metal. The Argon/C02 mixture is therefore generally preferred for welding of thin plate and often for low alloyed steel. The electrodes are usually solid wires with diameters 0.6, 0.8, 1.0, 1.2 or 1.6 mm, usually on spools of 5-15 kgs, or flux cored wires with diameters 1.2, 1.4, 1.6, 2.0 or 2.4 mm on spools of 15 and 25 kgs. Short Arc welding means a low arc voltage giving a short arc. Practically all metal transfer through the arc is completed by short-circuiting globules. Spray Arc welding needs more than 200 A and 25 V. On the whole, the metal transfer is by free-flight globules being forcefully propelled through the arc. Short Arc welding is the best method for: l Thin plate. l Thin pipes. l Root runs in butt joints with edge preparation. With Short Arc welding you weld in all positions. Welding vertical down should be limited to thin plate. There is a risk of insufficient penetration which grows with a growing plate thickness. This is more apparent at vertical down than in other welding positions.

Spray Arc welding IS tne best method for plate thickness above 3 mm. Spray Arc welding is only used in horizontal and vertical butt position. Productivity-Welding speed The welding speed of MAG welding is measured in kgs of weld deposit per hour. When welding horizontal fillet weld in thick materials, MAG welding is slower than Manual Metal Arc welding using high efficiency stick electrodes. MAG welding is suitable for thin plates. You can also weld medium size plate, piece constructions and small to medium sized crossbar jobs with good economy. The advantages of MAG welding are: 1. No stoppages for change of stick electrodes (in comparison with Manual Metal Arc welding) 2. Less distortion due to shrinking in comparison with Manual Metal Arc welding. The advantages are: l less straightening work after welding l often simpler welding fixtures l possibly a better bead appearance 3. Smaller joint volumes when compared to Manual Metal Arc welding because of the thinner electrode. A 6.0 mm coated high recovery stick electrode may have an outside diameter of about 15 mm. 4. There is no de-slagging. A certain quantity of metal oxide is found as “slag isles” on the bead. The origin is a chemical reaction between Mn, Si and C02’ They should be removed, if strict rules apply to the surface of the weld. 5. There is no risk of hydrogen brittleness in quenching steels caused by moisture in a stick electrode coating. 6. The weld deposit quality may well be compared with what can be achieved with normal basic electrodes.

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Range of application - Materials - Plate thickness All unalloyed and low alloyed steels may be welded. Use Short Arc from about 0.8 to 3 mm and Spray Arc from about 3 mm plate thickness. MAG welding with flux cored wires is done with plate thicknesses from about 8 mm for longer beads and up to 10 mm for shorter (less than 0.5 m).

MIG WELDING
Gas Metal Arc welding with Inert (non-active) Gas In MIG welding, as in MAG welding, you work with Short Arc as well as Spray Arc. The most common gas is Argon, but mixtures of Argon and Helium are also used. When welding stainless steel, it is often difficult to achieve a good penetration. If some few per cents of Oxygen are added to the mixture, this disadvantage is overcome and the arc will be stabilized. Helium-Argon mixtures give a “hotter” weld than pure Argon. These mixtures are therefore often preferred for thick copper and aluminium materials. For aluminium welding of medium thickness, pure Argon is used. Welding positions are: Short Arc-all positions, Spray Arc-horizontal position. The radius of action is 3-16 m from the wire reel, depending on machine model. The equipment is the same as for MAG welding. The shielding gas Argon wth 2% C02 has given as good results as Helium with Argon, when welding heavy stainless plate. Since Argon witn 2% C02 is less expensive than Argon/Helium, the former gains in popularity for stainless. However, steels with extra low carbon content should not be welded with Argon/Helium. Instead, Argon+2% 02 is used.

Arc Equipment

In any case, the quality of the weld deposit is the best, provided parent material and the filler material are of good quality and the welding carried out professionally. Productivity - welding speed For materials which are welded by MIG, you seldom use as high welding current as for unalloyed or low alloyed steels. The maximum weld speed is therefore usually lower with MIG than with MAG welding. The MIG method in comparison with Manual Metal Arc welding is highly productive method for stainless steel, aluminium, copper, copper alloys, nickel and nickel alloys. Range of application - materials - plate thickness MIG is used for
l l l l

Stainless steels. Aluminium and aluminium alloys. Copper and copper alloys. Nickel and nickel alloys.

These materials are welded from about 1 mm thickness and up. Unalloyed steel is MIG welded in the same joint preperations as for Manual Metal Arc welding.

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TIG (GTAW) Tungsten Inert Gas Welding
TIG (GTAW WELDING)

TIG is a welding method where the electric arc is created between a non-melting electrode and the workpiece in an atmosphere of inert gas. That means that the gas does not take part in any chemical reaction during welding. The arc melts the parent metal and the welding consumable, if any. The molten pool, as well as the electrode, is protected from Oxygen and ‘Nitrogen in the air by the shielding gas. This gas is usually Argon, but Helium or mixtures of Helium and Argon are also used. TIG welding is done with DC or AC. DC negative pole is used for all metals which do not form oxides which are difficult to weld, like e.g aluminium and magnesium. They are instead welded with AC, the positive amplitude of which has a good breakdown effect of the oxide. The name of this method was taken from the first letters of Tungsten Inert Gas. Range of application The TIG process is noted for high weld quality, purity of weld material and an even surface. It is used where quality demands are high, e. g. within the nuclear and process industries, but also for difficult-to-weld materials such as titanium, monel, copper-nickel etc. The largest range of application is for stainless steels and light metals.

TIG is used both for manual and mechanized welding. For manual welding, the welding consumable is fed by hand, as for oxyacetylene welding. In equipment for mechanized welding, a feed unit is used for wire. The welding wire is on a spool and is automatically fed to the welding torch. TIG welding is used from 0.5 mm material thickness and up to 5-6 mm. For heavier material, TIG is often used for root beads in order to make sure of a perfect root pass. No other method equals TIG in this respect. Consecutive beads are made with more productive methods and filler materials such as Gas Metal Arc, Submerged Arc or Manual Metal Arc with high recovery electrodes. With plate thickness of less than 1 mm, you often use flange butt joints and edge joints. Butt joints are welded up to 3-4 mm thickness. Above that, you use, V- or Ujoints. Sometimes also x-joints. In this case the groove angle should be 60° and the unbevelled edge 1-1.5 mm. A general rule for selecting the welding current is: Aluminium 45 A, copper 70 A, steel 50 A per mm thickness. TIG is used in all positions. Productivity-Welding speed Manual TIG welding : about 30 cm/min : about 80 cm/min

Arc Equipment

Mechanized TIG welding

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Range of application - plate thickness - edge preparation Use I-joints for plate thickness about 2-12 mm. Use V oints or double V-joints above that. The joint must be j accurately cut. Gaps, if any, must not exceed 1 mm. In order to profit from the economical benefits of the method, the joint must be well planned and executed. It should be easy to weld with this method, all dimensions are to be exact. This will give an even weld without burning through or giving root defects. It should have a proper bottom section, consisting either of parent material, a backing bar or a handwelded root bead. Having this, the joint will withstand the deep penetration which is typical for Submerged Arc welding. Of course the joint must be clean. Impurities of water, oil, paint and rust will always mean a risk of pores being formed. Submerged Arc Welding requires in short a more expensive edge preperation than Manual Metal Arc. The difference in cost is, however, so small that there is no reason to try to save on the preparation work. A clean, well prepared joint permits higher welding speed. This amply compensates for the more expensive edge preparation.

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Common Faults in Arc Welding
Weld faults are in most cases hidden deep under the surface of the weld, and therefore difficult to detect. The most common and reliable methods of detection presently used are ultrasonic and X-ray tests. These methods permit quality control of the weld without changing or destroying it. You can expose most faults with respect to type, size and position. The X-ray test has also proven to be of great importance to the welder himself. It has been established that certain faults, which the welder perhaps makes more or less unconsciously, gradually disappear if he is shown X-ray pictures and informed of what they reveal. In other words, the X-ray picture is an excellent educational means. It makes the weld so to speak ‘’transparent” and shows it in full length. The welder can easily learn from the fault, since you can conclude how the fault arose from the nature and position them. In this way, the welder can steadily manage to eliminate possible shortcomings and improve his craftmanship. The most common faults are pinholes, slag inclusion, undercuts, root defects, incomplete penetration, and cracks. Above all, incomplete penetration, slag inclusion, undercuts and root defects can be linked to lack of skill and precision on behalf of the welder. Incomplete penetration that is incomplete fusion between weld and parent material, may easily occur at Gas Metal Arc welding if not done professionally. In most cases, the cause is a too short training period. The welder has been put into the production before theoretical and practical training have been carefully accomplished. A common cause of incomplete penetration with Gas Metal Arc welding is usually too low travel speed. This gives a molten pool too large for the arc to melt the joint walls. On the other hand, incomplete penetration is not rare when thick stick electrodes are used in Manual Metal Arc.

Incomplete penetration will occur if the welder strikes the arc against one of the fusion faces and lets the molten pool run down onto the other, cold face. It may also occur if too low current is used on very thick material. Then the heat supply will not be sufficient to melt the parent material. Slag inclusions On an X-ray picture, slag inclusions stand out as lines. The picture below shows a cross section of the weld. Here, the de-slagging has been incomplete between the beads. When the top bead was welded, pieces of slag from the previous bead were not melted. Instead, the top bead sealed them in. You will observe this on the X-ray picture as typical lines. The risk of creating this fault is greater if the underlaying bead is strongly convex. If, for some reason, a strongly convex bead is welded, it is recommended to grind off some of it. Then the risk of fault is eliminated.

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Please pay special attention to multi-bead welds! check carefully that there exist no sharp angles between the different beads. If so, it may be impossible to remove the slag or melt down slag deposits all the way to the bottom when laying the next bead. The pictures below shows a multi-bead weld which is incorrectly done. Narrow grooves have been created beween the beads. The same weld, but correctly done, is shown further on.

Undercut will always mean a weakening of the joint. Therefore please always weld so that undercut is avoided. If, in spite of all precautions, this cannot be achieved, then in most cases the undercut should be welded up. In undercut, it is common to find slag deposits remaining inside the weld. But the X-ray film will reveal slag inclusions. Root defects Root defects are simply caused by incomplete penetration. They appear on the X-ray film as sharp straight lines. In Manual Metal Arc welding, they may be caused by the use of an electrode of too large diameter. The electrode has been too thick to go down far enough. Root defects can also arise if the gap between joint edges is too small.

Undercut

Arc Equipment

Undercut may be caused by too high current, incorrect electrode movement, or welding electrode/gun/head angle. Under certain conditions they are disastrous. Through their form they can serve as dangerous indications of fracture specially so if the welded joint is exe posed to variations in pressure and elongation. In the case of V-joints, the welder should often check, by looking, if there is a root defect or not. If there is a defect, it must be removed through root gouging. If it is not

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removed, the defect is closed-in by the backweld. It will then be revealed by the X-ray or ultrasonic inspection. In Submerged Arc welding, the penetration in the joint is an important factor. When root defects appear, the penetration has been inefficient. If, in the case of double-sided welding, the beads have not met at the bottom, there could be several reasons such as:
l l l l l l

in connection with the gouging of the root before the back bead is welded. It should, however, also be noted that cracks may appear in the weld or the parent material which have nothing to do with the welding procedure. Examples of this are hot cracks or solidification cracks which run along in the middle of the weld. These are common at fillet welds, where a difficult tension situation is at hand. The reason for these cracks may be parent material. This could be difficult-to-weld steel, having too high contents of Carbon, Sulphur and possibly Phosphorus. These elements give certain segregation effects when the molten pool solidifies. Acid electrodes are especially sensitive to impurities. Rutile electrodes are less sensible and basic ones are practically nonsensitive. Unlimited weldable steels have maximum proportions of Carbon 0.20%, Sulphur 0.05% and Phosphorus 0.04%. If parent metals containing more of these are to be welded, basic electrodes should be used. Then you will avoid hot tears also by high proportions of these elements. The same advice is given also for the use of basic electrodes if you have to weld a material where the composition is unknown. Hot tear The most common cause of hot tear in Submerged Arc Welded joints is a pipe-formation combined with segregation of Carbon and Sulphur. The relation between width and depth of the weld reinforcement should be gre(:!.ter than 1. If this is insufficient, formation of pipes will occur. In such a case it is in reality a question of shrink holes and not crack formation as such. If crack formations are found in the parent material in close vicinity of the weld, these are definitely hardering cracks. The composition of the parent material has been such that the sections heated by the welding up to hardening temperature cracked during the subsequent cooling. The result is a hard and brittle zone close to the weld, giving cracks. This is a risk always at hand with hardenable parent materials if the cooling-off speed is not prolonged. Such a prolongation is to a certain extent achieved by using thicker electrodes. These give a greater heat input during the welding. But often this is not enough, for instance at welding of low alloyed steels, which also a relatively low Carbon contents are very disposed to hardening.

The joint had a too big unbevelled edge. Too small groove angle. Possibly both these causes together. Too low welding current. Too high or low welding speed. The two beads are not exactly facing each other.

Cracks In most cases, cracks are not directly dependant on the welder’s skill. But a weld can be done in such a way that formation of cracks is promoted. If there are faults in the weld, of course the risk of cracks is.greater due to tension or other influences than if the weld is completely homogeneous.

Arc Equipment

X-ray pictures often show that cracks emanate from slag inclusions, small root or other defects - especially with alloyed steels. Incorrect weld sequences and the tensions they cause may be of course also result in cracks. If welding jobs are well planned, the weld sequences should be decided by the construction department or works management and marked out on drawings. In this connection, attention should also be devoted to the tact welds. If you want to achieve a truly high-quality weld, you should remove the tacks as the welding proceeds. It sometimes happens that weak tack welds crack d.ue to influence of shrink-tensions. If you weld over such a cracked weld, you cannot be sure that it is molten and absorbed in the pool. The result might be a remaining crack in the finished weld. In cases where the workpiece is accessible for welding from both sides, you often tack weld at the back. The tacks are then removed

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pressure and the direction was oriented up through the middle of the molten pool. This is the last portion to become solidified. In Manual Metal Arc welding, porosity is commonly caused by Hydrogen from basic electrodes which were stored incorrectly. Porosity can also be caused by moisture, paint and other impurities on the fusion faces. Gas Metal Arc welding is even more sensitive when it comes to paint, oil and other impurities. Porosity may also be caused by a poor gas shield. The surrounding air is sucked into the molten pool and form CO (carbon monoxide). In Submerged Arc welding, the penetration is powerful. Porosity may occur if the plates are lamellated. During the penetration, the weld will absorb too much of the oxides present in this kind of defect. Submerged Arc welding requires the same cleanliness of the fusion faces as Gas Metal Arc welding. The parent material must then be preheated. Depending on the disposition to hardening of it, you chose a higher or lower preheating temperature or rather working temperature. If this temperature is correctly chosen, also steels disposed to hardening may get a soft transformation zone. Pinholes Pinholes may appear in different forms. Gases formed during the solidification of the molten pool do not escape. They are “stuck” and the solidification takes place around the gas bubles. One kind of pinhole is called surface porosity and may form a string along the weld - easily visible. In this case, the gas formation occured under heavy

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Industrial Gas Equipment

Gas Equipments

Process Description

Gas Equipments
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302

Gas Equipments

Gas Equipments

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Single Stage Regulators

Gas Equipments
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Gas Equipments

305

Double Stage Regulators

Gas Equipments
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Gas Equipments

307

High Pressure Regulators

Gas Equipments
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Gas Equipments

309

Pipe Line Regulators

Gas Equipments
310

Special Regulators

Gas Equipments
311

Cutting Blowpipes

Gas Equipments
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Gas Equipments

313

Welding & Heating Blowpipe

Gas Equipments
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Gas Equipments

315

Flashback Arrestors

Gas Equipments
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Gas Equipments

317

Small Cutting Machine

Gas Equipments
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Gas Equipments

319

Cutting Nozzles

Gas Equipments
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Gas Equipments

321

Welding Tips

Gas Equipments
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Gas Equipments

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Accessories

Gas Equipments
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Gas Equipments

325

326

Gas Equipments

PPF & Welding Accessories

Gas Equipments
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328

Gas Equipments

Gas Equipments

329

HELMETS, MASKS & SCREENS

Gas Equipments
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Gas Equipments

331

RESPIRATORY EQUIPMENT

Gas Equipments
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Gas Equipments

333

SPECTACLES, GOGGLES & VISORS

Gas Equipments
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Gas Equipments

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WELDING CURTAINS

Gas Equipments
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WELDING GLOVES

Gas Equipments
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SAFETY FOOTWEAR

Gas Equipments
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Gas Equipments

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WELDING CABLES

Gas Equipments
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ELECTRODE HOLDERS & CLAMPS

Gas Equipments
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World leaders in welding and cutting technology and systems.
ESAB operates at the forefront of welding and cutting technology. Over one hundred years of continuous improvement in products and processes enables us to meet the challenges of technological advnce in every sector in which ESAB operates. Quality and environment standards Quality, the environment and safety are three key areas of focus. ESAB is one of few international companies to have achieved the ISO 14001 and OHSAS 18001 standards in Environmental, Health & Safely Management Systems across all our global manufacturing facilities. At ESAB, quality is an ongoing process that is at the heart of all our production processes and facilities worldwide. Multinational manufacturing, local representation and an international network of independent distributors brings the benefits of ESAB quality and unrivalled expertise in materials and processes within reach of all our customers, wherever they are located.

ESAB Sales and Support Offices worldwide

* Includes manufacturing facilities of ESAB North Amercia. A wholly owned subsidiary of Anderson Group Inc.

Plot No. 13, 3rd Main Road Industrial Estate Ambatur, Chennai 600 058. email : info@esabindia.com www.esabindia.com

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