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KWT Special Stainless 3rd Edition PDF
KWT Special Stainless 3rd Edition PDF
TODAY
SMAW FCAW
Steel type Key notes for application
Brand name(1) AWS class. Brand name(1) AWS class.
317L Low carbon (0.04% max.) [P] NC-317L E317L-16 [P] DW-317L E317LT0-1/-4
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
[P] MG-S308 ER308 [P] TG-S308 ER308 [P] PF-S1 / [P] US-308 ER308
- - - - - -
[P] PF-S1M / [P] US-316 (Single pass) ER316
- - [P] TG-S316 ER316
[P] PF-S1 / [P] US-316 (Multi-pass) ER316
- - [P] TG-S316L ER316L - -
[P] TG-S316L ER316L [P] PF-S1M / [P] US-316L (Single pass) ER316L
[P] MG-S316LS ER316LSi
[P] TG-X316L R316LT1-5 [P] PF-S1 / [P] US-316L (Multi-pass) ER316L
- - - - - -
- - - - - -
[P] NO4051 -
- - - -
[P] TG-S310MF -
- - [P] TG-S317L ER317L [P] PF-S1 / [P] US-317L ER317L
[P] TG-S347 ER347
[P] MG-S347S ER347Si [P] PF-S1 / [P] US-347 ER347
[P] TG-X347 R347T1-5
[P] MG-S347LS ER347Si [P] TG-S347L ER347 - -
[P] MG-S347S ER347Si [P] TG-S347 ER347 - -
[P] MG-S347S ER347Si [P] TG-S347 ER347 [P] PF-S1 / [P] US-347 ER347
[P] MG-S347S ER347Si [P] TG-S347 ER347 - -
- - [P] TG-S310 ER310 - -
- - [P] TG-S329M - - -
[P] MG-S410 ER410 [P] TG-S410 ER410 [P] PF-S4M / [P] US-410 -
- - [P] TG-S410Cb - - -
- - - - - -
- - - - - -
[P] MG-S430M - - - - -
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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above, DW-308L is suited for flat and horizontal
position welding with both CO2 gas and 75-80%Ar
+ balanced CO2 mixed gas shielding. DW-308L
can be used in welding both 304L and 304 stain-
less steel.
DW-308L
1.6
Spatter generation (g/min)
1.2
0.8
Figure 3: Excellent self-peeling slag removability of DW-308L.
0.4
0.0
150 200 250
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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It has generally been believed that welding stain-
less steel in vertical and overhead positions was
more difficult than mild steel because molten
DW-308LP also represents a new generation of metal was more likely to drop. This difficulty was
stainless flux cored wires, but in a different way than assumed because of the differences in the physical
properties of stainless steel: it has a lower melting
DW-308L. As easy to use as a mild-steel flux cored
point (1400-1427C) than mild steel (1500-
wire, DW-308LP can easily be used in all positions 1527C), and less thermal conductivity (0.04 cal/
including vertical, horizontal, and overhead. cm/sec/C in the 0-100C range as opposed to 0.11
cal/cm/sec/C in the 0-100C range).
Basic characteristics of DW-308LP
However, DW-308LP has jumped over these hur-
As seen in the AWS classification designations dles to become a superior flux cored wire suitable
shown above, DW-308LP is suitable for welding for welding in all positions. Figure 2 shows an
in all positions, with both CO2 gas and 75-80%Ar application for DW-308LP: a curved, large-diame-
+ balanced CO2 mixed gas shielding. DW-308LP ter water pipe that, because of the inherent diffi-
can be used in welding both 304L and 304 stain- culty in positioning the work, requires all-position
less steel. welding. DW-308LP is suitable for welding fixed
pipes, storage tanks and rolling stock, which are all
What makes DW-308LP difficult to position during welding.
a new generation wire?
Overhead
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DW-316L is classified as AWS A5.22 E316LT0-1 ':VWDLQOHVVZLUH
PP
':VWDLQOHVVZLUH
PP
and E316LT0-4, suitable for welding both 316L
and 316 stainless steel in flat and horizontal posi-
tions. As for shielding, either CO2 gas or 75- 0,*VWDLQOHVVVROLGZLUH
80%Ar + balanced CO2 gas mixtures can be used. PP
&RYHUHGHOHFWURGH
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
Vertical-up position
35
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For 6-mm thick plate
30
Root fac e: 1 mm
Because of the superior corrosion resistibility, Root gap: 3 mm
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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DW-309L weld metal
DW-309L is designed so that its weld metal can (4) Buffer layers in welding 304 or 304L stainless
accommodate adverse effects caused by dilution steel to carbon or low-alloy steel.
by carbon or low-alloy base metals. The adverse Carbon or low-alloy
effects include martensite (a brittle structure) for- base metal E308 or E308L
mation and fully austenitic structure (non-ferrite- weld metal
7
PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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DW-309LP, the reader may refer to the descrip- Figure 2: A cross sectional view of a cargo tank and a variety
tions of the DW-309L classification. of welding joints in all positions.
304 or 304L
clad
Carbon steel
E308 or E308L
Carbon steel
weld metal
Figure 1: Cargo tanks of a chemical tanker. weld metal
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Photo courtesy of Hitachizosen Co., Ltd.
Part of the DW stainless steel series, DW-309MoL As DW-309MoL and DW-309MoLP weld metals
and DW-309MoLP are special flux-cored wires. contain sufficient amounts of ferrite, they can
They are indispensable filler metals for welding accommodate the detrimental effects caused by
dissimilar metal joints, such as in the buffer layer dilution by the carbon or low-alloy base metal.
of clad steels, and the underlayer for overlaying. These effects may include the formation of
Mo-bearing austenitic stainless steel (316L and martensite (brittle structure) and a fully austenitic
317L), duplex stainless steel, carbon steel, and structure (sensitive to hot cracking) in the weld
low-alloy steel usually constitute such dissimilar metal. Similar to mild-steel titanium-type flux-
metal joints and clad steels. For the overlaying cored wires, these wires offer excellent usability
substrates, carbon steel and low-alloy steel are with a stable arc, low spatter, self-peeling slag
used. The demand for cost effective clad steels in removal, regular bead shape, and glossy bead
particular, and thus for suitable filler metals, is appearance. Table 2 shows an example of a weld-
expected to increase due to the brisk business in ing procedure for 317L stainless clad steel.
the relevant industries.
Table 2: One-side welding of 317L stainless clad steel plate
DW-309MoL and DW-309MoLP are classified as with DW-309MoL and a FB-B3 backing
AWS A5.22 E309LMoT0-1/-4 and E309LMoT1- Pass Trade Size Welding Amp. Volt. Speed
1/-4 respectively. As the AWS classifications indi- No. designation (mm) position (A) (V) (cm/min)
cate, the former is suitable for flat and horizontal 1 DW-100 1.2 Flat 200 24 15
fillet welding, whereas the latter is suitable for 2 DW-100 1.2 Flat 280 30 25
positional welding; both wires use either CO2 gas 3 DW-309MoL 1.2 Flat 180 26 43
317L clad
Table 1: Typical chemical and mechanical properties of DW-
309MoL and DW-309MoLP deposited metals with CO2
shielding gas
12
Carbon steel
Trade designation DW-309MoL DW-309MoLP
C (%) 0.027 0.025
Si (%) 0.61 0.62 4 FB-B3
backing
Mn (%) 1.18 0.81
(a) Weld pass sequence
P (%) 0.019 0.020
S (%) 0.009 0.010
Ni (%) 12.60 12.44
Cr (%) 23.20 22.60
Mo (%) 2.37 2.21
(1) 28 25
FNW
0.2% PS (MPa) 540 540 (b) Cross section macrostructure
TS (MPa) 720 699
El (%) 30 30
9
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the ductility (elongation) of the weld metal is
10
PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
PRE (Table 1) or Pitting Resistance Equivalent is ride-involved applications. DW-329AP weld metal
used as the pitting index to evaluate the resistance features, as shown in Table 2, excellent resistance
to pitting corrosion. With a higher PRE value, the to pitting corrosion due to its elaborate chemistry
pitting corrosion resistance can be improved. The design.
WRC chemistry-phase diagram (Figure 3) is com-
monly used for estimating the ferrite number Table 2: Results of pitting corrosion testing of DW-329AP (1.2
related to the ferrite content of duplex stainless mm) weld metal with 80%Ar-20%CO2 shielding(1)
steel weld metals. Corrosion loss
Testing condition Judgement
(g/m2-hr)
20C-24hr 0.005 No pitting
25C-24hr 0.032 No pitting
1LHT 1L&1&X
70 Welding position 1G 3G
60 Specimen size (mm) 20T x 25W 20T x 25W
Absorbed energy (J)
Tensile
20
Appearance(1) Left below Right below
10
Judgement Acceptable Acceptable
0
-80 -60 -40 -20 0 20 Note (1) Appearance of specimens after testing by 2TR-180.
Test temperature ()
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
PREMIARC Engine
20-Year Track
MX-A430M is an Records for
Unsurpassed FCW Welding Auto-
for Cr Stainless motive Exhaust
Steel Welding Exhaust
manifold
Flexible
tube
Converter Center
pipe
Muffler Systems
The automotive industry worldwide has been pro- conventional ER430 wire to prevent incomplete
moting weight reduction of car bodies by using fusion as shown in Figure 2.
thinner, lighter materials to improve the fuel con-
sumption efficiency, and improving the fuel com-
bustion efficiency to reduce exhaust gases. In this
trend, automotive exhaust systems have seen inno-
vations in steel materials, and the increasing use of
17%Cr and 13%Cr ferritic stainless steel sheets
and pipes for exhaust manifolds, converters, and MX-A430M Conventional ER430 wire
mufflers. To respond to this trend, Kobe Steel Figure 2: MX-A430M weld metal sufficiently bridges the gaps
developed MX-A430M metal-type flux-cored wire avoiding incomplete fusion in the 3-layer lapping joint that
about 20 years ago. Since then this wire has earned consists of a 1.5-mm stainless, 1.0-mm carbon, and 1.5-mm
stainless steel assemblage with a root gap of 1.0 mm
a high reputation for the following advantages. between sheet metals (130A, 17V, 45cm/min., 80%Ar-
20%CO2).
1. HIGHER BURN-THROUGH RESISTANCE:
Automotive exhaust parts use sheet metals as thin 3. SUPERIOR CRACK RESISTANCE: The weld-
as 0.8-2.0 mm. MX-A430M (1.2 mm) offers ing joints of auto parts are inevitably contaminated
higher resistance to burn-through (excessive melt- with machine oil caused by press-forming. Oil can
through) as shown in Figure 1. This results from be a source of carbon, sulfur and hydrogen, caus-
proper penetration and a wider weld pool. ing cracks in the weld. MX-A430M offers superior
crack resistance, because of its finer microstructure
N o burn-through over conventional ER430 wire (Figure 3).
Welding speed (cm/min)
C onventional
E R4 3 0 wire
N o burn-through
MX-A 430M
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
7*;/ $:6$5/7
7*;/ $:6$5/7
7*;/ $:6$5/7
7*; $:6$57
The TG-X series of flux-cored stainless steel filler Stainless steel sheath
rods can eliminate gas purging for back shielding
the root pass weld in one-side TIG pipe welding, cut-
ting the costs for back shielding gases and gas
purging downtime including the setting time for gas
purging jigs. Process pipelines of Type 304, Type
Flux
316, Type 347 and dissimilar metals are typical
applications for TG-X308L, TG-X316L, TG-X347 and Figure 1: A cross sectional view of TG-X flux-cored filler rod.
TG-X309L, respectively.
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
How TG-X filler rods can cut costs for higher than that of solid filler rods. However, if
gas purging and back shielding you would calculate the total welding cost by mul-
tiplying the unit prices for each factor, you may
The use of a conventional solid filler rod needs notice that the TGX series can save a great deal in
back shielding with an inert gas: normally argon terms of total welding cost.
gas. Though the time and the amount of an inert
gas needed for purging the inside of the pipe vary Chemical and microscopic proper-
depending on the inside diameter and the length of ties of root pass welds
the pipe to be purged, they affect markedly the
total welding cost. Table 1 compares the uses of a Chemical compositions of the root pass welds are
usual solid filler rod and a TG-X filler rod on the shown in Table 2 for individual TG-X filler rods.
factors affecting the welding costs in root pass As shown in this table, every TG-X filler rod
welding on a pipe with an inside diameter of 305 exhibits low nitrogen in the bulk of root pass weld
mm. It is obvious that the use of a TG-X filler rod metal. Electron Probe Micro-Analysis (EPMA) of
can noticeably reduce labor (man-hour) by 23-74% the vicinity of the reverse surface area has verified
and the total argon gas consumption by 55-91% in that no microscopic condensation of nitrogen can
a comparison with typical solid filler rods. be observed. Still more, microstructure testing has
revealed that the distribution of ferrite precipita-
Table 1: A comparison between TG-X and solid filler rods on tion in the austenite matrix is uniform throughout
man-hour, argon gas consumption, filler rod consumption and the root pass weld. Low nitrogen content, together
power consumption in root pass welding of a pipe with the glossy bead appearance mentioned above,
Filler rod TG-X Solid is evidence of the effectiveness of the shielding
70 70 effect of the slag of TG-X filler rod.
Groove
preparation 1 1
3 2.5 Table 2: Typical properties of single-V groove one-sided root
Back shielding Without back
300 mm 6000 mm pass weld with TG-X filler rods
shielding for local for entire
length of pipe shielding shielding
Filler rod for TG-X308L TG-X316L TG-X309L TG-X347
Prepurging(1) Not required 5.2 min. 104 min. root pass(1) (2.2mm) (2.2mm) (2.2mm) (2.2mm)
Setting jigs Not required 10 min. Not req. Type of base metal 304, 316L, Mild steel / 321,
Welding(2) 35 min. 30 min. 30 min. and thickness 9 mm 9 mm 316, 20 mm
19 mm
Arc time rate 50% 50% 50%
Total man-hour 35 min. 45 min. 134 min. Welding position Flat Flat Flat Flat
Total power
0.405 kwh 0.358 kwh 0.358 kwh Cr 18.89 18.93 19.47 18.67
ferrite content of
consumption
Mo - 2.17 0.35 -
(1) The prepurging condition is per AWS D10.11-7X (Guide for Root
Pass Welding and Gas Purging). Nb - - - 0.44
(2) Shielding gas flow rate for welding: 15 liter/min
Welding condition: 110 Amp./13 Volt. Ti - - - 0.07
(3) Shielding gas flow rate for back shielding: 8 liter/min.
N 0.044 0.041 0.038 0.044
On the other hand, with a TG-X filler rod, because FS, FN 4.6-5.7 7.1-7.6 6.9-8.5 4.4-6.2
15
PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
Tips for using TG-X filler rods Change the welding mode
to crater treatment
The following are the specific techniques for root
Root pass welding direction
pass welding with a TG-X filler rod.
(2) PROPER KEYHOLE TECHNIQUE to help Maintain solid slag both on the crater and on the
the molten slag flow to the backside of the root: bead on the reverse side when re-starting an arc to
Welding direction Weld metal join a preceding bead. The re-arcing point should
be placed back from the edge of the crater by
0.5-1.0mm
approximately 10 mm as shown below.
Root
opening
Re-start the arc at
0.5-1.0mm the 10-mm backward point
from the crater edge
Cross-sectional solid slag
Keyhole Molten pool
Cross-sectional
Welding direction weld metal
(3) HIGHER FEEDING PITCH with careful wire
feeding than with a solid filler rod to ensure ade-
quate fusion of the rod and a sound penetration Re-start the arc
when solid slag remains
bead and to compensate a slightly lower deposition
efficiency of TG-X filler rods.
In 5G position welding, the termination of the suc-
(4) PROPER WELDING CURRENT to ensure ceeding bead onto the crater of the preceding bead
regular fusion and penetration: should be done in the uphill positions to control the
Plate thickness 3-5 mm 6-9 mm 10 mm min
molten slag and thereby to help create the keyhole:
Proper bead connecting point
Amperage 80-90 A 90-105 A 90-110 A in the uphill position
Preceding bead
Base metal
1
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
C Si Mn P S Ni Cr
&UHT &U0R6L1E
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
Table 2: Typical corrosion test results of NC-38L deposited Tips for better results with NC-38L
metal to evaluate the intergranular corrosion resistance
65% nitric acid test (Huey test) The choice of NC-38L can be the way to fulfill
As weld 0.00052 ipm
strict requirements for ferrite content, corrosion
650C x 2hr, AC 0.00069 ipm
resistance and mechanical properties. The choice
1050C x 30min, WQ 0.00047 ipm
of NC-38L can also be the way to get sound welds
in out-of-position welding by both AC and DCEP
Copper sulfate sulfuric acid test (Strauss test)
polarity. When you use NC-38L, however, the fol-
650C x 2hr, AC No defect lowing tips should be noted in order to get better
results.
(3) CONSISTENT MECHANICAL PROPER-
TIES (Table 3) of the weld metal due to properly (1) No preheating should be used when you weld
controlled chemical compositions: 304L and 304 type stainless steel. Rather, the
interpass temperature should be kept at 150C or
Table 3: Mechanical properties of NC-38L all-weld metal lower. This is to minimize the heat-affected zone,
vE at 0C
and thereby to minimize sensitization of the base
0.2%PS TS El.
(MPa) (MPa) (%) (J) metal that is caused by Cr-carbide precipitation at
Typical 410 580 48 78 the grain boundaries of the heat-affected zone.
AWS req. - 520 min. 35 min. -
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
C Si Mn P S Ni Cr Mo
Typical 0.023 0.57 1.56 0.025 0.003 12.17 18.68 2.20
AWS 0.04 0.90 0.5- 0.04 0.03 11.0- 17.0- 2.0-
req. max. max. 2.5 max. max. 14.0 20.0 3.0
19
PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
(2) EXCELLENT RESISTANCE AGAINST gen- Why NC-36L has lived so long
eral, intergranular, and pitting corrosion:
Since it was launched in the markets, NC-36L has
Because of the sophisticated design of its chemical seen its features refined and its markets expanded.
composition NC-36L weld metal features excellent Kobe Steel pursues continual quality control so as
resistibility against general, intergranular, and pit- to maintain the outstanding features of NC-36L
ting corrosion. Table 1 shows several corrosion produced in Japan and Thailand. This quality con-
test results of NC-36L deposited metal. trol is a key factor in the product's persistently high
reputation, particularly in such specialty fields as
Table 1: Corrosion test results of NC-36L deposited metal in the chemical, oil refinery, paper, and nuclear-
the as-welded (AW) and sensitizing treatment (SE) conditions power industries. In construction of the equipment
for these industries the quality control is one of the
Type of corrosion and test method Typical test results
most important keys to the success.
General corrosion by
Corrosion loss:
5% diluted sulfuric acid test
5 g/m2/h Tips for better results with NC-36L
(JIS G0591), AW
Intergranular corrosion by Corrosion rate: The choice of NC-36L can be the way to fulfill
65% nitric acid test 0.00138 ipm stricter requirements for ferrite content, corrosion
(ASTM A262-C), AW (inch per month)
resistibility, and mechanical properties. When you
Intergranular corrosion by Bending test after use NC-36L, however, the following tips should be
copper sulfate sulfuric acid test corrosion test: noted in order to get better welding results.
(ASTM A262-E), SE(1) No cracking
(1) SE: 650C2h followed by air cooling. (1) No preheating should be used when you weld
316L- and 316-type stainless steels. Rather the
(3) CONSISTENT MECHANICAL PROPER- interpass temperature should be kept at 150C or
TIES (Table 2) of the weld metal due to the elabo- lower. This is to minimize the heat-affected zone,
rately designed chemical composition: and thereby to minimize sensitization of the base
metal that is caused by Cr-carbide precipitation at
Table 2: Mechanical properties of NC-36L all-weld metal the grain boundaries of the heat-affect zone and
can cause weld decay or localized corrosion at the
0.2%PS TS El. vE at 0C
(MPa) (MPa) (%) (J)
areas adjacent to the grain boundaries in a corro-
Typical 420 580 45 83
sive environment.
AWS req. - 485 min. 30 min. -
(2) Use proper welding currents. This is to mini-
mize the electrode-burn caused by Joule's heat.
(4) POSITIONAL WELDING SUITABILITY in The electrode-burn adversely affects usability and
flat, horizontal, vertical, and overhead positions. mechanical properties of the weld metal.
20
PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
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PRODUCTS SPOTLIGHT KOBELCO WELDING TODAY
In fabricating pressure vessels for high-tempera- diluted weld metal, thereby ensuring the austenite
ture high-pressure hydrotreating, the inner surface + ferrite microstructure to prevent hot cracks in the
of the vessels is cladded by overlay welding with weld metal. Dilution is defined as the change in
stainless steel welding consumables. Most of the chemical composition of a deposited metal caused
inner surface is overlay welded by either sub- by the admixture of the base metal or underlayer
merged arc welding or electroslag welding. How- weld metal. It can be measured by the mass per-
ever, the inner surface at the butt joint area of the centage of the base metal or underlayer weld metal
shell is overlay welded by shielded metal arc weld- that was fused in the weld metal as shown in Fig-
ing as shown in Figure 2. ure 3 for groove welds and bead-on-plate welds.
Typical value of dilution for shielded metal arc
welding is believed to be 25-40%.
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Key points in
22
THE WORLDWIDE MANUFACTURER
JAPAN: THAILAND:
KOBE STEEL, LTD., Welding Business THAI-KOBE WELDING CO., LTD.
Marketing Dept., International Sales & Marketing Sec. Tel. (66) 2 636 8650 to 8652 Fax. (66) 2 636 8653
Tel. (81) 3 5739 6331 Fax. (81) 3 5739 6960
KOBE MIG WIRE (THAILAND) CO., LTD.
KOREA: Tel. (66) 2 324 0588 to 0591 Fax. (66) 2 324 0797
KOBE WELDING OF KOREA CO., LTD.
Tel. (82) 55 292 6886 Fax. (82) 55 292 7786 MALAYSIA:
KOBE WELDING (MALAYSIA) SDN. BHD.
KOBELCO WELDING MARKETING OF KOREA CO., LTD. Tel. (60) 4 3905792 Fax. (60) 4 3905827
Tel. (82) 51 329 8950 to 8952 Fax. (82) 51 329 8949
INDONESIA:
CHINA: P.T. INTAN PERTIWI INDUSTRI
KOBE WELDING OF SHANGHAI CO., LTD. (Technically Collaborated Company)
Tel. (86) 21 6191 7850 Fax. (86) 21 6191 7851 Tel. (62) 21 639 2608 Fax. (62) 21 649 6081
AMERICA
USA:
KOBELCO WELDING OF AMERICA INC.
Tel. (1) 281 240 5600 Fax. (1) 281 240 5625