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com

FLUX-CORED WIRES
FOR HIGH TEMPERATURE AND CREEP-RESISTANT STEELS
 www.boehler-welding.com

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BÖHLER WELDING
From the very beginning of welding technology, BÖHLER
WELDING has been one of the leading developers, man-
ufacturers and suppliers of welding consumables world-
wide. The brand BÖHLER WELDING offers the entire
range of consumables for joint welding.
Ever since 1926 customers and partners in more than
100 countries all over the world have put their trust in
our products and solutions. The technical knowledge
globally gained on site during these eight decades makes
BÖHLER WELDING the preferred partner of leading en-
terprises in the most demanding industrial sectors. Our ex-
perienced application consultants will be pleased to
develop together with you the technically and economi-
cally optimum solution for your individual requirements.
www.boehler-welding.com
It goes without saying that our extensive product range
is constantly aligned to the current industrial specifica-
tions. As one of the pioneers, we are already today
working in close cooperation with our customers and
partners on the innovative products and solutions of the
future.
If this brochure does not answer all your questions,
we are at your disposal and will be pleased to advise
you.
For more detailed information about the listed welding
consumables and/or our entire range, please refer to our
BÖHLER WELDING manual or visit us on the internet
at www.boehler-welding.com
 www.boehler-welding.com

Overview

Flux-cored wire for high temperature and creep-resistant steels

BÖHLER WELDING has a long tradition of manufacturing
welding consumables for thermal power stations. Whereas, due
to welding requirements, welding with stick electrodes and
GTAW welding was used in almost all cases in the past, the
GMAW method with flux-cored wires is now also becoming
more common in this segment. The economic benefits of flux-
cored wires compared to stick electrodes is a strong argument.
In boiler construction creep values are exceptionally important.
BÖHLER WELDING has gone to enormous lengths and started
creep tests for all the relevant qualities of flux-cored wire. For
some types more than half of the 30.000 hours necessary have
already been successfully completed. Creep resistant flux-cored
wires from BÖHLER WELDING therefore provide high quality
and proven reliability for economical joint welds.

The strict welding requirements that apply in boiler construction Our experienced technicians will assist you with any welding
can also be met completely with flux-cored wire. questions and will be happy to personally give detailed informa-
tion from the creep tests.
BÖHLER WELDING would like to offer its customers this
economic advantage and already has a wide range of flux-cored
wires for welding high temperature steels and creep resistant
steels in power station construction.

High temperature and

creep-resistant steels Flux-cored wire EN-ISO AWS Page
Alloy Material

0.5Mo P/T1 DMO Ti-FD T MoL P M 1 E81T1-A1M 8

1Cr 0.5Mo P/T11 DCMS Ti-FD (T CrMo1 P M 1) E81T1-B2M 8

2.25Cr 1Mo P/T22 CM 2 Ti-FD T ZCrMo2 P M 1 E91T1-B3M 8

9Cr 1Mo +VW P/T91 C 9 MV Ti-FD T 69 T1-1M-9C1MV E91T1-B9M 8

C 9 MV-MC * TS 69T15-1G-9C1MV EC90C-B9 8
P/T92 P 92 Ti-FD T ZCrWMo9VNb P M 1 E91T1-GM 8

18Cr 11Ni 304H, 321H E 308 H-FD T Z19 9 H R M (C) 3 E308HT0-4/-1 9

E 308 H PW-FD T Z19 9 H P M (C) 1 E308HT1-4/-1 9
* Metal-cored wire

Welding with BÖHLER DCMS Ti-FD … from BHDT, piping system for Borealis

4
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An economical alternative

For many applications welding with flux-cored wires has clear

benefits. Whereas these are above all economic benefits com-
pared to stick electrodes, flux-cored wires are outperforming
solid wires when it comes to technical quality.
The stable, wide arc, intensive penetration and very good
bead wetting create a very homogeneous weld profile with a
notch-free weld, and no lack of fusion.
Therefore, in power stations, where reliability is crucial, we
can recommend flux-cored wires as THE economical alternative
to stick electrodes.
The advantages of the flux-cored wire
over the stick electrode are obvious:
■ Significantly higher deposition rate
■ Easy to use, hence fewer welding faults
■ Continuous welding, no stopping and starting,
less rework necessary
■ Large parameter window
■ Very good positional welding characteristics
■ Low spatter formation

Economic comparison between a stick electrode and a flux-cored wire ...

... for a multi-layered V-weld 1 m long ... for a simple fillet weld, vertical-up,
welding time 1 minute.
Test situation:
V-weld joint
20 mm wall thickness – 60° opening angle
Root already welded
(flux-cored wire with ceramic backing)
PF position
Pure welding time in seconds,
relating to 1 m weld

Stick electrode Flux-cored wire

Ø 4 mm Ø 1.2 mm

Welding time for Welding time for

Layer structure Stick electrode Flux-cored wire
stick electrode [s] flux-cored wire [s]
Ø 3.2 mm electrode Ø 1.2 mm
1st filler pass 681 377 105 A v = 9 m/min, 190 A
Ø 1.2 mm
2nd filler pass 822 381 v = 10 m/min, 230 A
Ø 1.2 mm
3rd filler pass 973 400 Ø 4 mm electrode v = 9 m/min, 210 A
150 A
4th filler pass 1.058 All layers woven out
Ø 1.2 mm
Capping 1.530 451 v = 9 m/min, 210 A
5.064 s 1.609 s
Total
(1 h 24 min) (27 min) ➥ 2/3 time-saving

BÖHLER WELDING flux-cored wires for high temperature and creep-resistant steels 5
 www.boehler-welding.com

Advantages

User-friendly welding

Easy parameter setting: A large parameter window enables various

welding duties to be performed:
45
■ In the application:
40
❑ One wire diameter (1.2 mm)
35
❑ For virtually all wall thicknesses (> 3 mm)
30

Voltage (V)
❑ In the current range 125 to 280 A
25
❑ Suitable for root pass welds 20

15
■ Due to the easy torch handling: 10
BÖHLER C 9 MV Ti-FD

❑ The character of the arc (wide and intensive) 5

is very forgiving
0
5 10 15 20 25
❑ The penetration is reliable Wire feed (m/min)
❑ Always short-circuit-free and with little spatter
❑ The large parameter window enables well wetted, flat,
Flux-cored wires provide a much higher
dent-free (non-convex) welds to be produced over a deposition rate than stick electrodes:
large setting range, therefore reducing grinding 6
Theoretical deposition rate at 100 % duty cycle (kg/h)

5,5
Electrode, BÖHLER C 9 MV, Ø 3.2 x 350 mm
■ For positional welding: 5 Electrode, BÖHLER C 9 MV, Ø 4.0 x 350 mm
Flux-cored wire, BÖHLER C 9 MV Ti-FD, Ø 1.2 mm
❑ No parameter change necessary 4,5
Welding position: horizontal (PA)
4

Overall this results in: 3,5

■ High process reliability 3

■ Fewer repairs 2,5

2
■ Very good X-ray quality
1,5
■ Simple welder qualification and training
1

0,5
... and therefore reliable quality despite 0
0 100 150 200 250
lower fabrication costs! Amperage (A)

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Advantages

Welding comparison

A welding comparison between a flux-cored wire and a stick

electrode was carried out for the film „Welding with high tem-
perature and creep-resistant flux-cored wires in power station
construction“.

A pipe made of creep-resistant steel (P91) was welded with a

rutile flux-cored wire, BÖHLER C 9 MV Ti-FD. The pipe welding
took place in real welding conditions with preheating.

The comparison shows that the same welding task can be com-
pleted in a third of the time with a flux-cored wire. For a pipe
with a diameter of 40 cm and a wall thickness of 30 mm this is
an enormous time saving!

You can find the film on the internet at

www.boehler-welding.com/english/motion_pictures.htm

Ground section of a V-weld, 30 mm wall thickness,

base material P91, BÖHLER C 9 MV Ti-FD

Welding comparison between flux-cored wire and stick electrode

BÖHLER WELDING flux-cored wires for high temperature and creep-resistant steels 7
 www.boehler-welding.com

Flux-cored wires for high temperature and creep-resistant steels

BÖHLER Typical
Standard EN ISO analysis Mechanical properties Processing instructions
Standard AWS %

BÖHLER DMO Ti-FD C 0.04 a Redrying: 150°C / 24 h possible

T MoL P M 1 Si 0.25 Yield strength Re N/mm2: 510 (≥470) Shielding gas: Ar + 15-25% CO2
E81T1-A1M Mn 0.75 Tensile strength Rm N/mm2: 570 (≥550)
Mo 0.50 Elongation A5%: 23 (≥22) ø 1.2 mm:
Impact strength ISO-V KV J +20°C: 140 (≥47) Current [A] 150-330
Voltage [V] 23-35
*a annealed, 620°C / 1 h, furnace to 300°C, air
Shielding gas Ar + 18% CO2

BÖHLER DCMS Ti-FD C 0.06 a Redrying: 150°C / 24 h possible

(T CrMo1 P M 1) Si 0.22 Yield strength Re N/mm2: ≥470 Shielding gas: Ar + 15-25% CO2
E81T1-B2M Mn 0.75 Tensile strength Rm N/mm2: ≥550
Cr 1.20 Elongation A5%: ≥20 ø 1.2 mm:
Mo 0.47 Impact strength ISO-V KV J +20°C: ≥47 Current [A] 150-330
P <0.015 Voltage [V] 23-35
As <0.005 *a annealed, 690°C / 1 h
Sn <0.005 Shielding gas Ar + 18% CO2
Sb <0.005

BÖHLER CM 2 Ti-FD C 0.08 a Redrying: 150°C / 10 h possible

T CrMo2 P M 1 Si 0.25 Yield strength Re N/mm2: 600 (≥400) Shielding gas: Ar + 15-25% CO2
E91T1-B3M Mn 0.80 Tensile strength Rm N/mm2: 700 (≥500)
Cr 2.25 Elongation A5%: 19 (≥18) ø 1.2 mm:
Mo 1.10 Impact strength ISO-V KV J +20°C: 70 (≥47) Current [A] 150-330
P <0.015 Voltage [V] 23-35
As <0.005 *a annealed, 720°C / 2 h
Sn <0.005 Shielding gas Ar + 18% CO2
Sb <0.005

BÖHLER C 9 MV Ti-FD C 0.10 a Shielding gases: Ar + 15 - 25% CO2

T ZCrMo9VNb P M 1 Si 0.20 Yield strength Re N/mm2: 580 (≥565)
E91T1-B9M Mn 0.70 Tensile strength Rm N/mm2: 720 (690-830) ø 1.2 mm:
Cr 9.00 Elongation A5%: 17 (≥16) Current [A] 160-300
Ni 0.60 Impact strength ISO-V KV J +20°C: 47 (≥27) Voltage [V] 23-35
Mo 1.00
V 0.20 *a annealed, 760°C / 3 h, furnace to 300°C, air
Nb 0.04 Shielding gas Ar + 18% CO2
N 0.04

BÖHLER C 9 MV-MC C 0.10 a Shielding gas: Ar + 2.5% CO2

TS 69T15-1G-9C1MV Si 0.30 Yield strength Re N/mm2: 650 (≥520) or Ar + 15-20% CO2
E90C-B9 Mn 0.60 Tensile strength Rm N/mm2: 760 (≥620)
Cr 9.00 Elongation A5%: 18 (≥17) ø 1.2 mm:
Ni 0.70 Impact strength ISO-V KV J +20°C: 55 (≥47) Current [A] 150-290
Mo 1.00 Voltage [V] 18-30
V 0.20 *a annealed, 760°C / 3 h, furnace to 300°C, air
Nb 0.05 Shielding gas Ar + 2.5% CO2
N 0.04

BÖHLER P92 Ti-FD C 0.10 a Shielding gas: Ar + 15-25% CO2

T ZCrWMo9VNb P M 1 Si 0.20 Yield strength Re N/mm2: 620 (≥565)
E91T1-GM Mn 0.60 Tensile strength Rm N/mm2: 750 (690-830) ø 1.2 mm:
Cr 9.00 Elongation A5%: 17 (≥16) Current [A] 160-300
Ni 0.50 Impact strength ISO-V KV J +20°C: >47 Voltage [V] 23-35
Mo 0.50
W 1.50 *a annealed, 760°C / 4 h, furnace to 300°C, air
V 0.20 Shielding gas Ar + 18% CO2
Nb 0.04
N 0.04

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Flux-cored wires for high temperature and creep-resistant steels

BÖHLER Typical
Standard EN ISO analysis Mechanical properties Processing instructions
Standard AWS %

BÖHLER E308H-FD C 0.06 u Redrying: 150°C / 24 h possible

T Z19 9 H R M 3 Si 0.60 Yield strength Re N/mm2: 390 (≥350) Shielding gases: Ar + 15-25% CO2 or 100% CO2
E308HT0-4/1 Mn 1.20 Tensile strength Rm N/mm2: 585 (≥550)
Cr 19.40 Elongation A5%: 42 (≥35) ø 1.2 mm:
Ni 10.10 Impact strength ISO-V KV J +20°C: 80 (≥47) Current [A] 125-280
FN 3-8 Voltage [V] 20-34
*u untreated, as-welded
Shielding gas Ar + 18% CO2

BÖHLER E308H PW-FD C 0.05 u Redrying: 150°C / 24 h possible

T Z19 9 H P M(C) 1 Si 0.60 Yield strength Re N/mm2: 390 (≥350) Shielding gases: Ar + 15-25% CO2 or 100% CO2
E308HT1-4/1 Mn 1.20 Tensile strength Rm N/mm2: 585 (≥550)
Cr 19.40 Elongation A5%: 42 (≥30) ø 1.2 mm:
Ni 10.10 Impact strength ISO-V KV J +20°C: 90 (≥47) Current [A] 110-210
FN 3-8 Voltage [V] 20-31
*u untreated, as-welded
Shielding gas Ar + 18% CO2

Creep-tested quality!
We know how important certified quality is to our customers!
Of course we aim to offer the expected reliability for
BÖHLER WELDING flux-cored wires just as we do for all our
welding consumables. It was therefore clear to us from the very
start that we had to begin very extensive and protracted tests
to prove the creep strength with our high temperature
flux-cored wires.
A relatively long period of over 30.000 hours (about 3.5 years!)
is stipulated when running series of tests for creep values. In the
meantime, about two thirds of the series have been performed.
This long observation period is already delivering very informa-
tive test results which can be considered as highly positive. The
measurement points are all in the scattering range of the base
metal. The diagrams here show a section of the test series.
Our technicians will gladly discuss personally your exact
requirements and the details of these test series.
We have many years of experience welding high temperature
components, this enables us to extend to our customers our
knowledge and the underlying security that they can undertake
their welding not only rapidly but also with the highest
possible quality. Benefit from this experience and security, and
keep your costs low, with our flux-cored wires!

BÖHLER CM 2 Ti-FD BÖHLER C 9 MV Ti-FD

550°C 575°C
575°C 600°C
625°C
Stress (N/mm2)
Stress (N/mm2)

Base material Base material

Running specimens Running specimens
Broken specimen Broken specimen

Time (h) Time (h)

BÖHLER WELDING flux-cored wires for high temperature and creep-resistant steels 9
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Example application

BÖHLER DMO Ti-FD

Converter for voestalpine Stahl (HF Industriemontagen)

10
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Additional information

Other brochures about BÖHLER WELDING welding consumables are available in

several languages for selected industries and applications. You will receive more
information from the BÖHLER WELDING sales partners or on the internet at
www.boehler-welding.com/english/brochures.htm

The specifications in regard to the type and application of our products
are only for the user’s information. The data specified for the mechanical
properties always refer to the weld metal alone under observance of the
applicable standards. In the weld joint, the weld metal properties are influ-
enced, among other factors, by the parent metal, the welding position and
the welding parameters. A guarantee of suitability for a certain type of ap-
plication requires an explicit written agreement in each individual case.
Subject to modifications.
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 Published by BÖHLER WELDING

Böhler Schweißtechnik Austria GmbH

Böhler-Welding-St. 1
8605 Kapfenberg / AUSTRIA
+43 (0) 3862-301-0
+43 (0) 3862-301-95193
postmaster.bsga@bsga.at
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BSGA 04/2012 ENG1000

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