Export Product Hand Book

Contents
Sr. No. Description Page No.
1 Company Overview 2
2 Research and Development 3
3 Maintenance and Repair Welding 4
4 Metal Preparation 5
5 Aluminium 8
6 Cast Iron 12
7 Copper 19
8 Steels 24
9 Surfacing Alloy 36
10 Continuous Wire 61
11 Wear Plate 63
12 Thermal Spray Process 66
13 Technical Specification 72
01
Overview
EWAC Alloys Limited is pioneer in Our fully equipped repair shop at Taloja,
bringing in the concept of “Repair Mumbai is geared up to take turnkey
rather than Replace” critical and costly p ro j e c t s re l a t i n g t o p ro v i d i n g
components though our specially maintenance welding through arc and
developed welding products and gas welding and thermal spray process.
processes. We are retaining our market Our trained engineers and wide network
leadership in this field from last 5 of distributors across the country are
decades in India. available any time at your door steps to
The products and processes are provide consultancy in diagnosing
manufactured in the state-of-the-art customers’ problem of metal joining /
manufacturing facility located at breakdown / wear & suggest solutions
Ankleshwar, Gujarat. from our product range.
A team of qualified R&D engineers are
engaged in bringing new products and
processes helping industries to save
millions through repair and
maintenance welding technology.
Our range of products includes Special
Welding Electrodes, Gas Brazing Rods
and Fluxes, Atomised Metal Powder
Alloys, Flux-Cored Continuous Wires,
Polymer Compounds & Wear Resistant
Plates.
02
Research and Development
EWAC R & D center is equipped with Some of the in-house testing

state-of-the-art facilities and facilities include:
p ro f e s s i o n a l l y q u a l if i e d a n d
Scientific Diagnosis
experienced researchers. This Centre • Dry Sand Abrasion Tester

is recognized by Department of
• High Temperature Air Jet Erosion
Science and Industrial Research
(DSIR), Government of India. The Tester
center always engaged in • High Temperature Abrasive Wear
developing steady stream of new, Tester
innovative and value engineered
products. • Slurry Erosion Tester
• E l e c t ro c h e m i c a l C o r ro s i o n
R&D Center is equipped with
sophisticated equipment to carry out Analyser
wear, corrosion, metallurgical • Image Analyser
studies and failure analysis.
Exclusive test rigs have been • Vacuum Emission Spectrometer
developed to simulate service • Pilot plant for Wear Plate
conditions for ranking and product
development
recommendation.
03
Maintenance and Repair Welding
Why it is different? Low Heat Input

Production welding generally done under Laboratory and field tests on a wide variety
optimum conditions. The specifications are of arc welding electrodes conducted by the
set, the appropriate equipment is provided EWAC Research team have revealed that
for, the chemistry of base metals is known, various properties of the weld deposit can be
the parameters are readily controlled and / or modified or controlled by the use of lower or
controllable, and if necessary, prototypes higher amperage values in the specified
can be made and subjected to destructive range of welding currents. For simplicity, the
tests to confirm physical properties of the higher range is denoted as the “I” range; the
welds. In contrast, maintenance and repair lower range is denoted as the “II” range. The
welding presents wide disparities compared use of either range gives distinctly different
to production welding. Operating problems weld characteristics and the choice of range
involve a host of unknowns, restraints and should be determined by the circumstances
limitations. Welding alloys have to possess of the application.
special features to overcome the handicaps
of welding problems relating to pre and post The “I” range is used for:
heat, heat of application, base metal 1. All reasonable thick base metal sections,
distortion and dilution, cracking, bond fairly large parts and broad surfaces.
strength, solidification rates and weldability.
2. Thick overlays, multi-pass work, or work
Failure due to poor design and excessive that can be accomplished with a single
loads thick pass.
Maintenance welders have to contend with 3. Applications requiring rapid deposition
other factors – such as poor design of parts rates.
which failed in service, modification of parts
in the field (such as add-ons, reinforcements, 4. Weld protective coatings requiring the
etc.) and other equipment subjected to best combination of hardness and
stress by production demands which exceeds toughness.
the original requirements. The “II” range is used for:
Maintenance and Repair Welding 1. Thin sections, small parts and limited
Technology surface area.
Challenged by the differences in field 2. Single-pass overlays and for non-
welding conditions, the EWAC R&D team continuous or “staggered” cladding.
has developed special coatings for stick
electrodes and gas rods to overcome the 3. Parts of intricate design or shape (to
problems posed by limitations of available minimize warpage and distortion)
welding equipment, skill levels, in situ
4. Applications requiring optimum deposit
welding, heat input, unknown base metals,
microstructure, achieved through
contaminants etc. where required, additives
controlled carbide formation.
such as deoxidizers, degassifiers, nucleants
etc., have been incorporated into the 5. Situations where the only available
coating formulation to provide highest power source is of a limited input type.
weldability interms of slay removal fluidity,
bead shape, liquidus and temperatures etc.
04
Metal Preparation
In Maintenance and Repair Welding for every Industry
chamfering, cutting, gouging or piercing is often an
important aspect in the preparation of the workpiece.
Removing layers of corroded, worn, fatigued, porous or
cracked metal permits the perfect bonding of weld metal.
EWAC Alloys metal removing electrodes are faster and
easier to handle. With low heat input to base metals, the
dangers of stress and distortion are almost completely
eliminated. Any welder can cut, pierce, or chamfer any
metal with no special training, no special equipment,
compressed air or oxygen cylinders.
05
EWAC GougeTec AC/DC+
Gear box housing
An excellent electrode for gouging and beveling and removable

of weld defects for ferrous or non-ferrous metal
Typical Applications: Procedure:
Gouging cast iron & other metals, removal Insert EWAC GougeTec electrode into a
of old welds and rivets. conventional electrode holder. Use ac or dc
reverse polarity. Point electrode in direction
Outstanding Features: of travel, at an angle of not more than 30°
• No oxygen, other gas or special
with the plane of the work. Strike arc. Push
electrode holder.
electrode along the line of cut, quickly for a
• Exothermic coating that concentrates
shallow chamfer, more slowly, or with a
arc force.
• Further finishing not necessary. weaving motion for a deeper groove.
Utilizing the heat and force of the highly
Recommendation: concentrated arc, push the molten metal
Where chamfering, grooving or gouging is ahead and away. If deeper gouge is
necessary, without supplementary gases needed, repeat procedure.
and extensive equipment. For preparing
Recommended Amperages:
sections prior to welding, gouging out old
or defective weld metal, removing flash Size (mm) I - Range
and risers. Ideal to remove most unwanted 3.15 250-325
metal prior to final machining. Can be used
4.00 300-400
for ferrous or non-ferrous metals. A highly
heat resisting electrode whose special 5.00 350-450
exothermic coating concentrates the force
of the arc right at the point of application.
A finishing operation is rarely necessary.
06
EWAC Pierce AC/DC-
Pump casing
Special electrode for all position cutting and piercing of

all metals
Piercing, cutting stainless and cast iron, Marks or scribe line where cut is desired.
cleaning castings, removing flash and On DC machine, use straight polarity. No
risers. special holder or compressed air needed.
When applying EWAC Pierce electrode,
Outstanding Features:
use both the arc-blow, caused by the
• Versatile, cuts through any metal.
exothermic coating, plus pressure with the
• Exothermic coating with concentrate
hand. When arc is struck, push and pull,
arc.
holding electrode at a 45° angle and using
Recommendation: a sawing motion to cut. The closer the arc,
For highest speed, all position cutting and the faster, cleaner, cooler the cut. For
piercing of all metals using standard piercing holes, hold electrode vertically,
electric arc equipment. Also for and push in and out.
chamfering, gouging, cleaning out
defects, burning rivets, beveling metal
prior to welding. Ideal for cutting and Metal Thickness CutTrode Amperages
piercing mild carbon steel, stainless steels, Upto 25mm 3.15 150-350
cast iron, malleable iron, nickel and nickel 6.5mm to 37.5mm 4.00 165-375
alloys, aluminium, copper, bronze. No
12.5mm to 75mm 5.00 175-400
special skill, supplementary equipment or
oxygen tanks are required. Slow burn-off
rate leaves little residue, requiring
comparably less finishing. Electrode not
overheat, can withstand high amperage.
07
Aluminium
General Properties:
• Light weight - only one-third of the weight of steels of equal
volume; aluminium equipment are portable.
• Strong - several grades are even stronger than mild steel.
• Reflects light - accepts a “mirror” polish for high reflectivity.
• Conducts heat - used in radiators and other heat transfer
devices.
• Resists corrosion - thanks to its adherent oxide film.
• Conducts electricity - 60% effective compared to copper, yet
much lighter in weight.
• Easy to cast in complex shapes - automobile water pumps,
pistons, blocks and heads are examples.
• Non-toxic - so it is excellent for pots and pans.
• Easy to weld - by Arc, Gas, GTAW & GMAW.
• How to Identify:
1. Light in Weight
2. Non-Sparking
3. Silver in Colour
4. Chips do not burn
08
EWAC AL 521 DC+
Boat Fabrication
Special aluminium electrode for joining and maintenance

welding application
Engine blocks, housings, pumps, tanks, Clean weld area. Bevel thickness 3.2 mm or
moulds, pistons, fans, frames more to a 75º vee. For thick sections,
pre-heating up to 200ºC will produce
Outstanding Features: faster, flatter deposit at reduced
• Dense, porosity-free deposits. amperages. Use dc reverse polarity. Strike
• Excellent arc stability. arc by lightly drawing electrode on work
• Joining, overlaying and filling. piece or with copper starting block.
• No melting of base metal. Maintain a short arc with electrode almost
perpendicular. Back-whip craters. Chip
Recommendation: slag between passes. Allow to cool slowly.
High strength, versatile alloy ideal for
production as well as maintenance
Size (mm) I - Range II - Range
welding. Joints are three times stronger
than conventional aluminium electrodes. 3.15 120-140 90-110
This rapid-depositing alloy is particularly 4.00 140-160 105-130

recommended for heat-treated
Tensiles Strength: 240 MPa (34,000 psi)
aluminium, heavy castings, long joints, and
repairing cracks, filling holes and building
up missing sections. Rapid solidification of
weld metal facilitates horizontal and
vertical welding.
09
EWAC BR 590
Condenser Tube
An advanced torch brazing rod for high strength joining of

aluminium parts
Furniture, frames, appliances, radio Clean joint area. For best results, clearance
instruments, ducts. should be 0.07 mm to 0.15 mm. EWAC BR
590 Flux mixed with a small amount of
Outstanding Features: water or alcohol should be applied to rod
• High-strength fillets, tee, lap and flange and joint. It may also be applied dry by
joints. dipping the hot end of the rod into flux and
• Excellent colour match. transferring flux to the joint area. Keep
• Smooth, thin fillets. torch moving rapidly and flame cone 25
• No melting of base metal. mm to 75 mm from base metal. When flux
is molten, apply alloy to the joint. Cool
Recommendation: slowly. Remove flux residue by quenching
Provides exceptional thin-flowing while part is at 100°C.
properties for oxy-acetylene or oxy-
Size:
hydrogen applications on sheet, tubing,
Size (mm)
and cast forms of aluminium. For corner
joints where small fillets are required. 1.6
Aluminium furniture, window frames, 3.15

radio and aircraft instruments, extrusions, 0
Bonding Temperature: 570 C
and appliances. For light to heavy gauges.
10
Cast Iron
There are Four basic types of cast iron
Gray Cast Iron

Soft
Less brittle
Highly mechinable
Weldability: Good
Nodular Cast Iron

High strength
Resists shocks
Highly machinable
Weldability: Good
Malleable Cast Iron

Soft
Better Strength
Machinable
Weldability: Good
Chilled / White Cast Iron

Hard
Brittle
Abrasion resistant
Weldability: Difficult (Considered non-weldable)
11
EWAC CI 407 AC/DC+
Motor Casing
Innovative alloy with strong arc force and cleaning action for
contaminated cast irons
Contaminated cast irons, cast Iron defects, Clean weld area, drill holes at the starting
cast Iron furnace equipment sealing all- and end of crack on Cast Irons. Use EWAC
soaked cast Iron parts. GougeTec electrode for preparing U-
groove. Deposits offer spray type of metal
Outstanding Features: transfer. The welding alloy should be
• Nickel-free deposits. deposited on base metal with the electrode
• Spray type of metal transfer. tilted slightly in the direction of travel. Do
• High tolerance to impurities. not weave. Use short beads not exceeding
• Excellent colour match to gray cast iron. 30 mm, back whip crater. Remove slag by
chipping and brushing.
Recommendation:
Non-conductive coating prevents side
arcing; greatly aids welding in tight corners
and deep holes. Used as a buffer layer on 3.15 105 - 125 70 - 95
all cast irons. Exceptional performance on 4.00 130 - 150 95 - 120

contaminated surfaces. Deposits exhibit
Hardness: 40-50 HRc (3 layer)
colour match on cast irons.
12
EWAC CI 421AC/DC+
Gear Box Casing
Versatile electrode for welding of heavy sections and crack

sensitive applications
Machine bases, pumps and differential Clean weld area. Vee out cracks with
housings, cast iron dies EWAC GougeTec after drilling holes at the
ends of the cracks. Preheat is not required
Outstanding Features: in most cases except for critical parts to
• Excellent weldability. 250°C. Direct arc on deposited weld metal.
• For heavy cast iron sections. Lightly peen to relieve stress. Chip slag
• Machinable deposits. between passes. Use skip welding
• For joints subject to hydrostatic sequence in complicated assemblies.
pressure. Cover casting and allow to cool slowly.
Recommendation: Recommended Amperages:

For crack-sensitive applications such as Size (mm) I - Range II - Range
castings involving hydrostatic pressure, 3.15 110-120 85-100
joints under restraint, dissimilar
4.00 130-145 110-120
thicknesses and the general welding of
very heavy sections. Excellent for joining Tensiles Strength: 400 MPa (57,000 psi)
cast iron to steel. Circumferential pipe Hardness: 80-90 HRb (3 layer)
welds, especially heavy wall thicknesses,
can be made without danger of cracking.
Dense weld deposits are completely
machinable.
13
EWAC CI 422 AC/DC-
Engine Block
A high Ni electrode for repairing thin sections of gray cast iron

with good machinability
Engine blocks, cast iron gears and pulleys, Clean weld area to remove scale, grease
sliding tables for machine tools, cylinder and dirt. Drill holes at starting and end of
heads. cracks. Remove cracks with EWAC
GougeTec electrode. Preheat part to
Outstanding Features: around 2000C. Use a short to medium arc
• Superior crack resistivity. at minimum amperage. Use stringer bead,
• Welding of unknown grades of CI. follow skip / staggered technique. Peen to
• “Cold arc“coating offers minimum base relieve stresses. Skip weld to avoid
metal penetration and dilution. excessive local heat. Remove slag between
• Best for thin sections. passes. Use base layer of EWAC CI 407 on
• Superior for out-of-position welding. contaminated surfaces. Allow to cool
• Ideal for cladding. slowly.
Recommendation:
Welding of cast iron part with minimum
heat input. Superior for thin gray cast iron. 2.50 60-75 35-50
Excellent for building up missing sections, 3.15 90-110 55-80

cladding, filling holes, repairing broken 4.00 110-130 80-100
and cracked Cast Iron.
Tensile Strength: 350 MPa (50, 000 psi)
Hardness: 80-90 HRb (3 layer)
14
EWAC CI 423 AC/DC+
Mill Yoke
Electrode designed with innovative core wire offers good

weldability, high tensile strength, ductility and machinability
Machine tool bases, valve body, pumps, Clean weld area. Drill holes on the starting
gear boxes, gear teeth, couplings, piping, and end of cracks. Remove damaged metal
transmission housing etc. using EWAC GougeTec electrode. In most
cases part should be welded cold
Outstanding Features: (maximum inter-pass temp 600C). For
• Dense deposits with excellent complicated parts preheat to at least
machinability. 300 0 C. Using short arc at lowest
• High tensile strength and high ductility amperage, deposit stringer bead with skip
ensure maximum safety margin. welding. Chip slag with wire brush and
• Wide range of base metal (CI) peen each deposit.
compatibility.
• Special core wire and flux coating Recommended Amperages:
permits consistent, porosity free Size (mm) I - Range II - Range
welding. 2.50 90-100 70-80
• Excellent tolerance to impurities. 3.15 110-120 90-100
4.00 145-160 120-135

Recommendation:
Joining of cast iron and cast iron to steel of
Tensile Strength: 500 MPa (72,000 psi)
similar / dissimilar thicknesses. Repair
welding of high strength, heavy duty
ductile irons involving massive section and
for joints under restraints.
15
EWAC CI 424 AC/DC-
Nodular Iron Casting - Cylinder Head
For joining steel to Cast Iron & rebuilding of nodular and

alloyed cast irons
Nodular iron casting, housing, foundry Remove cracks with EWAC GougeTec
defects, pump casings, high strength electrode. Drill holes at the starting and
alloyed cast iron gear boxes, machine end of the cracks. Deposit weld metal
bases, cast iron die cladding and build up directly on job. Use skip welding on
etc. complicated sections. Maintain interpass
temperature of 1000C. Chip slag between
Outstanding Features: passes and peen deposits. Fill crater at end
• Ideal for joining cast iron to steel. of each pass. Cover the component and
• Deposits having high crack-resistivity allow slow cool.
due to Nodular deposits.
• Exceptional weldability on thick cross Recommended Amperages:
sections. Size (mm) I - Range II - Range
• Excellent machinability. 2.50 80-90 60-70
3.15 105-115 85-95

Recommendation:
4.00 130-140 110-120
For superior penetration on contaminated
5.00 155-170 125-145
surfaces of all ductile iron such as nodular
and malleable, as well as joining of gray
Tensile Strength: 400 MPa (58, 000 Psi)
cast iron to steel. Fully machinable deposit,
recommended for crack resistant joining,
overlaying, built up and filling porosity.
16
Terra CI 94 AC/DC-
Motor Casing
An excellent electrode for weld repair of cast iron

Repair of casting defects, machine build- Clean weld area. Drill holes at ends of
Up, foundry defects, pump body, motor cracks and vee out using EWAC GougeTec.
base, coupling. Preheat is not required in most cases except
critical parts to 250°C. Using minimum
current and maintaining short arc gap,
• Dense deposits with good bonding.
deposit stringer beads 25 to 75 mm long at
• Optimum machinability.
a time. Whip-back craters. Peen each bead
• Excellent operating characteristics.
after deposition. Remove slag between
passes.
Recommendation:
Weld repair of foundry defects such as
blow holes, shrinkage cavities, missing
sections etc. where a sound machinable Size (mm) Amperages
deposit is essential. Also, for rectification of 2.50 50-70

machining errors and build-up of worn-out 3.15 80-100
areas of cast iron parts.
4.00 100-120

17
Copper
General Properties:
• Excellent Thermal and Electrical conductivity
• Outstanding resistance to corrosion
• Extremely ductile
• Excellent metal to metal wear resistance
• Distinctive colour
Types of Copper & Copper Alloys:
Electrolytic Copper:
• Electrolytic Copper is 99.9% pure & contains 0.01 % to 0.08% oxygen
• Has excellent thermal & electrical conductivity
• Difficult to weld due to formation of Cuprous Oxide
Deoxidised Copper:
• Copper is 99.95% pure & free from oxygen
• Has excellent thermal & electrical conductivity
• Easy to weld
Brass:
• It’s a copper alloy where principal alloying element is Zinc
(up to 40%)
• Has excellent corrosion resistance
• Has good working properties
Bronze:
• It’s a copper alloy where principal alloying element is either Tin or
Aluminium (up to 10%)
• Has excellent corrosion resistance
• Excellent anti-frictional properties
18
EWAC CU 630 DC+
Contact Clamp - Electric Arc Furnace
Non-ferrous electrode for welding all grades of copper

Electrical bus bars, switch gear, Ensure the surfaces to be welded are free
transformers, generators, evaporator from oxides, corrosion and contamination.
shells, distillation columns, cooling pans, The high thermal conductivity of copper
heat exchanger, boilers, steam coils, high dissipates heat from the weld area rapidly,
pressure conduits. causing lack of fusion or porosity in the
Outstanding Features: welds. Therefore, preheating of large parts
• Compatible with many copper alloys to 400-600°C is recommended. Use DC
with excellent colour match. positive polarity for the electrode. Weld
• Deposits can be electro-plated with with short arc & weaving technique. Chip
nickel & chromium. slag between passes and wire brush
• Weld metal exhibits higher thermal & deposit. Peen welds in red - hot condition
electrical conductivities. to minimise residual stresses.
• Suitable for copper-cladding of ferrous Recommended Amperages:
materials & for joining copper to Size (mm) Amperage
steels.
3.15 80 - 130
• Excellent resistance to atmospheric &
marine corrosion. 4.00 130 - 170
Recommendation: Tensile Strength: 8 - 14 Kg/mm2

For arc welding applications requiring high
Conductivity: 80% IACS
purity copper deposits. Recommended for
welding of all copper grades (oxygen-free,
phosphorus deoxidised, refined, high
conductivity etc.)
19
EWAC Bronz 6028 AC/DC-
Impeller
High strength bronze electrode for welding of bronze, brass,

carbon steel & cast iron
Impellers, marine components, pump Clean weld area. Remove damaged metal
casing, castings, gear teeth, packing by chiseling. Bevel edges 90°. Preheat
glands and sleeves, dissimilar metals. heavy sections to 100°-250°C. Using short
arc at minimum amperage, deposit thin
stringer beads. Back-fill craters and chip
• Excellent weldability on ac/dc in all
slag between passes. Peening of deposits
positions.
re c o m m e n d e d . A i r- c o o l t o ro o m
• Dense, porosity-free deposits which are
fully machinable and colour matching to temperature.
bronze. Recommended Amperages:
• Wide usability for steel, cast iron, bronze
etc. in joining and overlaying
applications. 3.15 80-120 80-100
4.00 110-150 90-120

Recommendation:
A unique bronze alloy electrode offering Hardness: 75-85 HRb (3 layer)
exceptional weldability. The arc drive is
Tensile Strength: 35 Kg/mm2 (50, 000 psi)
strong and controlled providing superior
arc stability and easy handling features.
The deposits are easily machined to a
smooth surface with low coefficient of
friction. Deposits have good resistance to
salt water and steam corrosion.
20
EWAC BR 604
Tube to Tube Sheet Joining
Torch brazing rod for self-fluxing copper-to-copper joints

Electric motor repairs, armatures, air Clean the surface. Jigs or fixtures are
conditioning and refrigeration tubing. recommended for good fit and proper
clearance. Flux is not required for Cu-to-Cu
Outstanding Features: brazing. For brazing of copper based alloys
• Low melting brazing alloy.
(ie., brass or bronze). Use EWAC BR 604
• Strong, ductile, leak-proof joints.
flux. Heat the entire assembly evenly, until
• Silver-bearing; thin flowing.
copper turns dull red in colour or the flux, if
• Good corrosion resistance.
• Self fluxing for copper to copper used, liquefies. At this stage, melt off a
brazing. drop of alloy from the rod and flow it into
the joint. Repeat this, until the joint is
Recommendation: completed.
For production brazing of lap, flange and
‘T’ joints of copper, brass & bronze metals. Recommended Amperages:
The alloy displays good capillary properties, Size (mm)
to enable satisfactory flow & penetration 1.6
even in narrow corners or areas. The alloy is
3.15
‘self-fluxing’ for Cu-to-Cu joints. Use of
EWAC BR 604 flux is recommended for Bonding Temperature: 6400 C
brazing of copper alloys such as brass or
Tensile Strength: 35 Kg/mm2 (50,000 psi)
bronze. This alloy is not recommended for
brazing of ferrous or nickel alloys.
21
EWAC BR 650
Turbine Blades
High silver brazing alloy with excellent fluidity for

brazing narrow clearance joints
Instruments, high-speed tools, dies, Clean joint area. Paint EWAC BR 650 flux
carbide tipping, thin tubing, wire mesh, on the rod and on the joint. Heat broadly,
electrical contacts. using an excess acetylene flame, until flux
liquefies. Flow alloy completely through
Outstanding Features: the joint. Cool slowly and remove flux
• High degree of wettability. residues.
• Low melting. Recommended Amperages:
• Very high strength joints.
ROD Shim
• Extremely thin flowing.
1.6 25 x 0.075
• Especially for dissimilar combinations.
3.2 25 x 0.075
Recommendation: Bonding Temperature: 6000 C

An extremely versatile low melting alloy
Tensile Strength: 63 Kg/mm2 (90,000 psi)
with excellent wettability for thin flowing
applications on copper, nickel, carbon and
alloy steels, carbides and stainless steel.
Ideal for lap, T’ flange and square butt
joints of dissimilar metals. Excellent for
delicate parts, light gauge metals and heat
treated parts. Use with furnace, induction
equipment or oxy-acetylene torch.
22
Steels
Types of Steels
Low Carbon Steel
• Contain up to 0.3 % carbon
• Have very good ductility and weldability.
• Low strength
• Examples-Frames, Angles, Channels, Pipes etc.
Medium Carbon Steel
• Carbon content varies from 0.3% to 0.6%
• Have much good strength
• Have higher hardness than low carbon steels
• Have tendency to crack in the HAZ.
• Tendency to crack more with Hydrogen embrittlement if
Carbon equivalent more than 0.55%.
• Examples-Machine parts, Structures, Gears, Cast Steel components etc.
High Carbon Steel
• Contain more than 0.6 % carbon & less than 2%
• Can be heat treated & hardened.
• Have very high strength.
• Have poor weldability.
• Used in service where high hardness desired.
• Examples- Dies, Springs, Cutting tools etc.
Alloy Steel
• Low alloy steel: Contains alloying elements, less than 10%.
High alloy steel: Contains alloying elements more than 10%.
• Improved mechanical strength and toughness
• Increase or decrease propensity to hardening during
heat treatment
• Examples - Austenitic Manganese steel, Stainless Steel, Tool Steel,
Die Steel etc.
23
EWAC ST 206 LH AC/DC+
Support Roller Buildup
Moisture resistant electrode for welding low alloy and high

tensile steels
Crane jibs, frames, truck chassis, heavy Clean weld area. Maintain medium to
equipment maintenance. short arc length. Horizontal fillet welds can
be made using the contact technique.
Outstanding Features: Vertical joints should be welded from the
• Low hydrogen electrode with non- bottom up by weaving rapidly. Do not
hygroscopic coating. whip. Slag is easily removed by chipping.
• Suitable for cast steels containing
Sulphur. Recommended Amperages:
• High arc force purges out impurities. Size (mm) I - Range II - Range
• High tensile, ductility and crack
2.50 70-80 60-70
resistance. Anti-spalling under extreme
3.15 120-135 100-115
pressure.
• X-ray quality weld deposits. 4.00 150-165 135-150
5.00 185-200 165-185

Recommendation:
Tensile Strength: 560 MPa (81,000 psi)
For medium carbon steel, low alloy and
high tensile steel, ‘problem’ steel and
structural steel sections. Elements like
Sulphur, Phosphorous etc. which produce
porosity are purged from molten pool by
electrode arc action.
24
EWAC CPEM 021
Bucket
Electrode for high strength joining of low, medium carbon and

low alloy steel
Buckets, boom, stick, C frame & Clean weld area. Remove all fatigued or
undercarriage components of cracked metal. Bevel heavy sections 60°-
earthmoving equipment. 90° vee. Use short arc to deposit stringer
beads. Chip slag between passes. Peen
Outstanding Features: deposits in crack-sensitive applications.
• Low heat input. Prevent localised heat build-up by
• Compatibility with wide range of steels. staggered welding. When welding
• High ductility. Manganese steels, do not allow job
• Excellent crack resistivity. temperature to exceed 150°C.
Recommendation:
Size (mm) Amperages
For welding of similar and dissimilar
combinations of low-medium carbon 3.15 55-100
steels, low alloy steels, manganese steels, 4.00 85-140
etc. as encountered in construction and 5.00 135-185
mining industry.
25
EWAC ST 208 AC/DC+
Swing Gear
A high alloy electrode for welding dissimilar steel and

unknown steels
Chassis frames, gears, springs, tool steels, Clean weld area and ensure joint
dissimilar alloy steels joining. preparation. For certain high alloy steels,
preheat up to 1500C is recommended.
Outstanding Features: Hold a short arc. Run stringer beads.
• Very high tensile strength and ductility. Intermittent welding may be used specially
• Easy strike and re-strike. on high alloy steels. Cool each pass before
• “Cold arc” coating leading to low heat chipping slag. Maintain heat build-up max
input. 3000C.
• Superior for joining dissimilar steels.
• Outstanding resistance to shock &
impact.
• Easy Slag removal. 2.50 60-70 50-60
• High frictional wear resistance. 3.15 90-100 75-90
4.00 110-140 90-110

Recommendation:
5.00 160-180 150-160
For high strength welds & overlays on all
steels requiring best possible properties. Tensile Strength: 850 MPa (1,20,000 psi)
For leaf and coil springs, Vanadium -
Molybdenum spring steels, mild steel,
medium carbon steels and dissimilar steels.
26
EWAC ST 208 SPL AC/DC+
Shaft Keyway Crack
Weld metal with high toughness, high strength & ductility for
joining dissimilar steels
Joining dissimilar steels, dies, tools, Clean weld area. Bevel heavy sections. Tilt
springs, machinable build-up & overlay. electrode 100-150 in direction of travel.
Burn-off rate is rapid and uniform
Outstanding Features: permitting rapid advance with no
• Refined grain structure with improved “sticking” or “drifting”. Restrict weaving
strength and ductility. to 2-3 X electrode diameter. Peen to relieve
• Superior crack resistance. stresses. Slag releases easily. Restrict
• Spray type metal transfer. Preheat to 1500C max.
• Joining steels of unknown composition.
• Machinable built up and overlay.
Recommendation: 2.50 60-70 45-60

Frigid arc coating plus high alloy core 3.15 80-100 70-80
generates highly ionized arc for spray 4.00 120-145 100-120
transfer of weld metal. Addition of special
5.00 170-200 145-170
micro alloying elements produces refined
grain structure. Recommended for similar Tensile Strength: 850 MPa (1,20,000 psi)
and dissimilar steels. Suitable for joining
steels of different section thickness.
27
EWAC ST 208 S AC/DC+
Gear Teeth Buildup
Very low heat input electrode for joining, built-up of dissimilar

& difficult to weld steels
Typical Applications: coating plus high alloy core wire generates
Joining and buttering of thin, difficult-to- highly ionized arc for “spray type” transfer
weld Steels including cast steels, high of weld metal for welder comfort. Weld
carbon steels, high alloy steels, tool steels deposits with refined grain structure
and steels of unknown composition. e.g. ensures high strength, high toughness and
Bearing areas of shafts, edge build-up of ductility.
gears, keyways, bellows etc.
Procedure:
Outstanding Features: Clean weld area. Deposit with electrode
• Low dilution, lowest thermal stresses. tilted 100-150 in direction of travel. Burn-off
• Easy arc strike even at very low rate is rapid and uniform, permitting rapid
amperages. advance with no “sticking” or “drifting”.
• High strength and ductility of weld Weld with short arc length and minimal
deposit due to refined grain structure. weaving. Remove slag between passes.
• Superior crack resistance, even when
diluted with high Carbon Steels.
Recommendation: Size (mm) Amperages
A special Cr-Ni alloy giving high strength 1.6 25 - 35
joints with excellent resistance to cracking.
Low amperage enables welding of thin
Tensile Strength: 840 MPa (1,20,000 psi)
cross sections. Proprietary formulation of
flux coating permits low-heat input
welding in all positions. “Cool arc” flux
28
EWAC ST 202 HD AC/DC+
Kiln Tyre Buildup
Special coated electrode for joining and repair of heavy and

massive sections and dissimilar steels
Rotary kiln tyres, hear treatment Clean weld area, removing all fatigued and
equipment such as retorts, racks, trays, damaged metal. Bevel heavy section 900
tongs etc, Earthmoving equipment, vee. Pre-heating necessary only for crack-
cryogenic equipment, joining dissimilar sensitive base materials or massive parts.
combinations of steels. Deposit stinger or 2-x weaved beads using
short arc and minimum amperage,
Outstanding Features: backwhipping all craters. Chip slag
• Suitable for both joining and overlaying. between passes, wire brush and peen each
• Excellent resistance to corrosion, deposit. Cool slowly.
oxidation and thermal shock.
• Extraordinary weldability without Recommended Amperages:
electrode overheating. Size (mm) I - Range II - Range
• Strong tough welds. 2.50 90-125 80-90
3.15 130-170 110-130

Recommendation:
For all steels including heat-treatable types, 4.00 160-200 140-160
difficult-to-weld types and those with
unknown composition. Also for nickel Tensile Strength: 620 MPa (90,000 psi)
alloys and their dissimilar combinations.
A key characteristic is that deposits are able
to withstand stresses produced by thermal
cycling or by strains caused by weld
shrinkage in massive sections.
29
EWAC ST 210 AC/DC+
Coal burner bucket
Excellent electrode for joining wide range of SS and MS base

metal for oxidation and heat resistance applications
Valves, tanks, heat exchangers, heat Clean weld area. Tack at short intervals
treating boxes and baskets. when jigs are not available. Square butt
weld thickness upto 10 gauge. Heavier
Outstanding Features: sections should be bevelled 60°. Maintain
• Ideal for oxidation and heat resistance. short arc and deposit stringer beads. Avoid
• Ideal for joining of stainless steel of weaving. Deposit a number of light beads.
unknown composition. Use an intermittent welding sequence to
• Smooth, rapid, spatter-free deposition. prevent overheating. Remove slag. Use
electrode positive with DC machine.
Recommendation: Minimum open circuit voltage for AC :55 V.
Excellent weldability, no spatter, high
strength and elongation for 25/20 type
stainless steel and other unknown stainless
steels. Designed for applications requiring 2.50 60-70 40-50
a high degree of oxidation resistance and 3.15 85-100 55-75
high strength at temperatures up to 4.00 115-135 80-105
1000°C. Used also for welding stainless
steel to mild steel. Tensiles Strength: 660 MPa (95,000 psi)
30
EWAC ST 202 NT DC+
Skid of Walking Beam Furnace
Superior alloy for joining high alloy steels subjected to thermal

cycling and joining with low effects of HAZ
Typical Applications: joining where PWHT is 100% not possible.
Maintenance and repair of high alloy steels Can be recommended for welding high
subjected to cryogenic & thermal cycling, section thickness.
joining & repair of heavily constrained and
massive sections, draw bars & connecting Procedure:
h i t c h e s , t o n g s , f l a m e h a rd e n i n g Ensure welding surfaces are free from
equipment, heavy cross sections gears, contaminations. For steels with carbon
furnance parts, kiln tyres. equivalent to above 0.45% preheating
between 150°C to 300°C is necessary.
Outstanding Features: Operate at lowest possible current setting.
• Excellent crack resistance, unaffected by Weld with short arc and stringer beads
base metal dilution. avoid weaving, chip slag between passes &
• Suitable for both high temperature peen. Use stainless steel wire brush to
service / thermal cycling and sub-zero remove slag residues.
service. Recommended Amperages:
• Exceptional combination of tensile
properties and impact strength.
2.50 60-80 50-70
• Excellent oxidation resistance.
• No effects on heat treatment. 3.15 80-100 70-90
Recommendation: 4.00 110-130 90-110

For joining & overlaying of high alloys
subjected to thermal cycling or wide Tensile Strength: 620 MPa (90,000 psi)
temperature range. Recommended for
31
EWAC SLP 610
Bearing Housing
Paint-on solder paste for soldering of dissimilar metals except

Al and Mg
Instruments, gauges, tinning, radiator Clean joint area. Paint the alloy on all
repair, costume jewellery. surfaces to be joined by means of a brush
or spatula. If a wire is to be joined, it may be
Outstanding Features: dipped into the paste. With a torch keep
• Paint-on solder-flux paste. the flame at about 50 mm from the work
• All purpose - for use on all metals and constantly in motion until the clear flux
except aluminium and magnesium. flowing to the top starts to darken. In
furnace, 250° to 275°C is the best
• Easy to use -place and heat.
operating temperature. With solder iron,
apply directly or indirectly to the area.
Recommendation: Allow part to cool for solidification.
A newly formulated paint-on solder paste Remove flux with a damp cloth or rinsing in
combined with flux. Recommended for hot water.
soldering dissimilar metals other than
aluminium and magnesium. Ideal for Bonding Temperature: 1900 C
applications where preplacement of solder
Tensile Strength: 7,000 psi
is required for furnace and automatic
soldering. Low heat input, good fluidity
and joint strength. For torch, furnace or
solder iron.
32
EWAC BR 516
Pipe Joints
Flux coated brazing rod suitable for joining of dissimilar steel

to Cu alloy including Ni enhanced high strength bronzes
Typical Applications: Remove flux residues by washing with
Tubular chassis, frames, drills and cutters, water. Use EWAC BR 516 flux for
carbide tipping, piping, keys, composite supplementary requirements.
tools and dies, steel furniture.
Size:
Size (mm)
• Durable and flexible flux coating. 2.5
• No smoke, fumes; clear visibility of 3.15
molten pool.
• Superior wettability and bonding. Bonding Temperature: 8750C
• Excellent capillary action. Tensiles Strength: 700 MPa (1,00,000 psi)
• Thin flowing.
Procedure:
Clean and degrease joint areas. Bevel
heavy section. Preheat parts. Melt off drop
of flux from end of rod on beginning of
joint area. Continue heating until flux
liquefies. Deposit alloy drop by drop,
feeding into flame as required, making
sure each drop bonds properly. Air cool.
33
EWAC BR 545
GI Pipe Fittings
Flux coated brazing rod for joining all type of steel, stainless
steel, cu alloy, cast iron & galvanized steel
Exhaust manifold, metal frames, car Clean joint areas. Bevel heavy section.
bodies, piping, flanges, cast iron housing, Preheat casting and heavy plates to
copper base plumbing and galvanised
approximately 400°C. For GI use oxidising
sheets & tubes.
flame for pre-heating then with neutral
Outstanding Features: flame melt some flux from the end of the
• Durable and flexible flux coating. rod on the beginning of joint. Heat broadly
• Retains corrosion resistance properties till flux liquefies. Deposit alloy thereafter,
after brazing on galvanized surfaces. making sure each drop flows and bonds
• No smoke, fumes; clear visibility of properly. Air cool. Remove flux residues by
molten pool. washing with water. Use EWAC BR 545
• Superior wettability.
flux for supplementary requirement.
• Can be brazed directly on contaminated
surface. Size:
Size (mm)
Recommendation:
For joining all types of steels, stainless 3.15
steels, copper alloys, cast iron and 5.00
galvanised sheets. Outstanding wetting
action, especially for contaminated cast Bonding Temperature: 8500 C
i ro n . I d e a l f o r d i s s i m i l a r m e t a l Tensiles Strength: 450 MPa (65,000 psi)
combinations. Flux provides double action
cleansing / deoxidation without glare of
molten metal or fumes.
34
Surfacing
Alloys
Surfacing Alloys is a term used by EWAC to describe a
wear protective coating.
Previous terminology, such as “hardfacing, hard
surfacing or hard overlaying” stressed only one
characteristic of the welding material. Hardness is not
only the one factor that determines how well a material
will resist wear under different service environments.
Surfacing Alloys surpass the single concept of hardness
and use a system approach to the solution of wear
problems.
Primary Wear Factor:
• Friction or Adhesion
• Abrasion
• Impact
Secondary Wear factor:
• Erosion
• Corrosion
• Cavitation
• Heat
35
EWAC HF 001 AC/DC+
Bucket
An advanced electrode for applications subjected to abrasive

wear
Pulverisers, skids, cement grinder rings, Clean weld area. Use EWAC GougeTec to
mill hammers, bucket teeth, excavator remove contaminated, fatigued and
parts, screws, mixers scrapers. damaged metal. Preheat heavy sections to
about 200° - 250°C. Use stringer or
Outstanding Features: weaving technique holding a short to
• Dense and spatter-free deposit. medium arc. Long deposits may be made
• Resists high abrasion. without danger of cracking. Do not allow
• Rapid deposition. excessive heat build-up. Chip slag between
• All position. passes and allow to cool.
Recommendation:
For weld protective coating subject to Size (mm) I - Range II - Range
abrasive wear and moderate impact. For 3.15 95-100 85-95

use on steel, manganese steel and 4.00 125-150 90-115
malleable iron. Ideal for both new or worn
5.00 175-200 140-165
parts, especially for multi-pass build-ups.
All Position weldability. Hardness: 56-61 HRc
36
EWAC HF 002 AC/DC-
Stacker Reclaimer Bucket
A versatile electrode offers single layer hardness with superior

abrasion resistance
Jaw crusher plate, excavator bucket, lips, Clean weld area. Use EWAC GougeTec
teeth, fan blades, hammers, scrapper, electrode to remove fatigue or damaged
augers, pulveriser. metal. Preheat if necessary. Deposit the
alloy directly on base metal. Do not preheat
Outstanding Features: on 14%Mn steels. Deposit a buttering
• Excellent resistance to abrasion. layer of EWAC BU 102, inter pass
• Smooth bead appearance. temperature should be below 1500C. For
• High resistance to erosion. air hardenable steel and cast iron,
• Superior weldability with single layer buttering layer of EWAC ST 207 & EWAC
hardness. CI 422 should be deposited respectively.
Restrict deposits to maximum 2 layers.
Recommendation:
For steel parts requiring resistance to Recommended Amperages:
severe abrasive wear. Deposits polish in Size (mm) I - Range II - Range
service providing a very low co-efficient of 3.15 110-130 90-110

friction & erosion resistance. Very smooth 4.00 150-170 130-150
highly ionised spray transfer. All position
5.00 180-200 160-180
welding electrode.
37
EWAC HF 003 AC/DC+
Hydro Pulper Impeller
An unique electrode for applications subjected to abrasion,

erosion, corrosion combined with impact
Augers, screw conveyors, scrapers, Clean metal surfaces. Use EWAC
paddles, wear pads, impactor bar, pusher GougeTec electrode to remove damaged
shoes, impeller etc. metal. Preheat is recommended for alloy
steel and cast iron. Maintain medium arc
Outstanding Features: with electrode at an angle of 750 from
• Superior abrasion & moderate Impact horizontal in direction of travel.
resistance.
• Frigid arc coating with superior Recommended Amperages:
weldability. Size (mm) I - Range II - Range
• Smooth, ripple free beads. 3.15 100-120 80-100
• Excellent resistance to erosion. 4.00 145-160 120-135
5.00 180-200 160-180

Recommendation:
Applications where a combination of two Hardness: 55-61 HRc (3 layer)
or more wear factors like abrasion, erosion,
corrosion combined with moderate
impact. Deposits are ripple free and hence
offer high wear resistance.
38
EWAC HF 004 AC/DC-
Stacker Reclaimer Bucket
Very high abrasion resistant alloy with extra high deposition

rates
Reclaimer bucket, stacker bucket, dragline Remove all damaged and fatigued metal.
buckets, lips, tooth points, cutting edges, Maintain medium arc length and electrode
scraper blades, crushing hammers, vertical, deposit stringer or 1½ X weave
conveyor chains, mixer blades, sludge patterns, back fill craters. Single pass
pumps etc. overlay is normally recommended. If more
build up is required, use cushion layer of
Outstanding Features: EWAC BU 104 for steel, EWAC BU 102 for
• High resistance to wear from combined 14%manganese steels and EWAC CI 424
abrasion, pressure and moderate for cast iron. Use hard silicon carbide
impact. wheels for grinding.
• Easy handling, rapid deposition rate,
very thin slag. Recommended Amperages:
• Thick single pass deposits with extra Size (mm) I - Range II - Range
high yield. 3.15 150-170 100-120
4.00 210-250 160-200

Recommendation:
A unique electrode for anti-wear coatings 5.00 250-280 190-200
on carbon steels and austenitic manganese
steels. The weld deposits have very high Hardness: 62-68 HRc (2 layer)
content of hard constituents making
extremely resistant to intense abrasion
under pressure combined with moderate
impact.
39
EWAC HF 005 AC/DC-
Sinter Star Crusher
Weld metal with outstanding abrasive wear resistance even

at elevated temperature
Sinter star crusher, grate bars, clinker Remove all damaged & fatigued weld
conveyor chains, coke pusher shoes, metal and clean weld area. Maintain short
augers, billet conveyor guides, hot slag to medium arc length, deposit stringer or
conveyor, blast furnace hoppers, pug mill 1½ X weave patterns. Back whip crater. For
knives. high carbon steels, preheat up to 2500C.
Use EWAC BU 104 as a cushion alloy if
Outstanding Features: more build up is required. For austenitic
• Excellent resistance to abrasive wear at manganese steel do not allow temperature
elevated temperature. of parts to rise more than 1500C & use
• Easy handling with high deposition rate. EWAC BU 103 as a cushion layer. Slow cool
• Thick single pass deposits with extra after welding.
high yield.
• Very thin Slag. Recommended Amperages:
Recommendation: 3.15 150-170 120-140

An advance electrode for overlaying of 4.00 200-220 140-160
carbon steel and austenitic manganese
5.00 230-250 160-180
steels for applications subjected to
a b r a s i o n & e ro s i o n a t e l e v a t e d Hardness: 62-68 HRc (2 layer)
temperature. The deposit consists of high
percentage of special constituents which
retain abrasion resistance up to 6500C.
40
EWAC HF 006 AC/DC+
Tool Die
Special electrode to develop tools for cutting and piercing of

all metals
Composite high-speed-steel dies, tools, Clean weld area. Preheat larger and
trimming dies, shears, punches. complicated sections 200°C - 450°C. On
dc, use reverse polarity. Strike arc on scrap
Outstanding Features: steel and carry over to weld area. Deposit
• Heat treatable deposits. 50 - 75 mm at a time, avoiding
• High speed steel overlays. overheating. Chip slag between beads,
• Excellent cutting, shaving and piercing and peen to minimize stresses. Post heat
qualities. large and complicated sections. Use EWAC
ST 208 SPL as a cushion, layer.
Recommendation: Recommended Amperages:
Provides maximum hardness of edges at
high temperatures. For use where cutting,
shaving, or piercing qualities are required. 2.50 75 - 90 50 - 65
Excellent for knife edges, and machine tool 3.15 105 - 120 80 - 95
parts subject to heavy frictional wear. Ideal
4.00 130 - 140 110 - 120
for building composite blanking or
punching dies.
Hardness: 57 - 63 HRc (3 layer)
41
EWAC CP HFD 010
Forging Die
Repair and build-up of drop forging tools and damaged

profiles
Drop forging dies, punches, inserts. Clean weld area. Remove all cracked or
fatigued metal with EWAC GougeTec. Pre-
Outstanding Features: heat job to 400°-450°C and maintain
• Superior deformation resistance at high throughout welding. Deposit with short
temperatures. gap, keeping electrode perpendicular to
• Excellent compatibility with die block welding direction. Peening of deposits is
steels. essential. Chip slag between passes. After
• Machinable with tungsten carbide tool. completing deposition, air-cool the job to
• All position weldability. 200°C to develop uniform hardness. Then
transfer to a furnace at 550°C-600°C and
Recommendation: temper for 12-16 hours. Remove into still
Joining and build-up on all drop forging air and cool.
tools. Repair of worn out or damaged Recommended Amperages:
profiles. Salvage scrapped undersized die-
Size (mm) Range
blocks by total re-build with weld metal.
3.15 90 - 130
Overlaying of complicated profiles
requiring combination of high hardness 4.00 120 - 160
and toughness combined with good 5.00 150 - 160
machinability such as gear pinion teeth.
42
EWAC CPBF 024 AC/DC+
Caster Roll
Heat treatable alloy with good resistance to impact and

compressive load upto 5000C
Blast furnace bells (seat area), rolling mill Clean weld area. Remove old fatigued or
rolls, shear knives, cable sheaves / pulleys, damaged metal. Pre-heat heavy sections to
winches, crushing hammers, dredge 150°-200°C. Using short arc and electrode
cylinders. tilted at 10° in travel direction, deposit
stringer beads. Back-whip craters and chip
Outstanding Features: slag between passes. Allow to cool slowly.
• Hard, tough, crack-free machinable Large overlays can be stress-relieved by
deposit. holding at 500°C for 6-8 hours, followed
• Balanced abrasion / impact / friction by slow cooling.
wear resistance.
• Heat - treatable.
• Abrasion resistance upto 5000C. Size (mm) I - Range II - Range
• Deposit machinable by carbide tools. 3.15 110 - 150 90 - 130
4.00 160 - 180 140 - 160

Recommendation:
5.00 180 - 200 160 - 180
For multi-layer overlay on all types of plain
carbon steels and ferritic / martensitic low Hardness:
and medium alloy steels. For “on-site” At 300C 48 - 52 HRc (3 layer)
work including all position welding. At 4000C 42 HRc (3 layer)
43
TriboTuf 6517 AC/DC+
Crusher Hammer
A Unique Titanium Carbide Alloy System for Wear-facing

against severe Impact & Abrasion
Clinker breaker hammers, blow bars, roller Remove all damaged and fatigued metal
press rolls, cane knives, shovel buckets, and clean the weld area. Maintain short to
shredders, augers, scraper blades, tamping medium arc length. Use stringer beads to
tools etc. deposit.
Outstanding Features: Recommended Amperages:

• Finely dispersed titanium carbides in
Size (mm) I - Range
martensitic matrix.
• Crack-free multilayer deposit. 3.15 70-100
• Consistency in hardness irrespective of 4.00 100-130

number of layers. 5.00 120-160
• High resistance to impact, pressure &
abrasion. Hardness: 52-60 HRc
• Ideal for thick, multi-pass, protective
coatings.
Recommendation:
Unique Martensitic Ti-C alloy designed for
surfacing of carbon steel and manganese
steel components, subjected to high
impact combined with severe pressure and
abrasion in service conditions.
44
CP ET 071 AC/DC+
ID Fan
Unique tubular electrode with high abrasion resistance property

Coal burner nozzle, tips, crusher hammers, Clean weld area. Remove fatigued & worn
ID fans, grizzly bars, crusher housing, metal. Pre-heat if required. Fine stress-relief
scraper blades, bucket teeth & lips. checks are expected in the weld deposit.
Use 40% overlap between adjacent passes
Outstanding Features: when hardfacing entire area. Avoid
• Specially designed for highest excessive heating of the base material.
deposition rate and high metal recovery. Grind weld deposit for smooth surface
• Primary chromium carbides in hard finish.
martensitic matrix. Recommended Amperages:
• Excellent resistance to abrasion & mild
Size (mm) I - Range
impact.
• Moisture resistant coating. 6.00 100 - 130
8.00 150 - 200

Recommendation:
Ideal for severe erosive / abrasive wear
resistance upto 250°C. The weld
microstructure shows fine carbides
uniformly distributed throughout the
matrix. Required hardness & wear
resistance can be achieved in single layer
deposit.
45
PyroCarb 077 AC/DC-
Crowbar Hardfacing
An electrode for high temperature abrasion & erosion

Sinter star breakers, tip casting, coke Remove all damaged and fatigued weld
pusher shoes, billet conveyer guide, hot metal and clean weld area. Maintaining
slag, conveyers, augers and clinker short to medium arc length, deposit
grinders. stringer and weaved beads. For medium
carbon steels, preheat upto 250°C. Use
EutecTrode 2B as cushion alloy if more
• Refractory carbides of Cr, Mo, Nb, W,
build-up is required.
Vin Fe-Cr-C eutectic matrix.
• Excellent resistance to wear upto 6500C. Recommended Amperages:
• Easy handling with rapid deposition
rate.
3.15 150 - 170 100 - 140
Recommendation: 4.00 190 - 250 140 - 160

An advanced electrode for overlaying of
Hardness: 60 - 68 HRc (2 layer)
carbon steels & low alloy steels for
applications involving abrasion and erosion
at elevated temperatures. The weld
deposit contains high percentage of
refractory carbides, enabling abrasion at
elevated temperature.
46
NanoCarb 110 AC/DC-
Scew Edges
Scientifically engineered electrode based on Nano Technology, that

exhibits extraordinary wear resistance given at elevated temperatures

Grizzly bars, exhaust fans, mixer blades, Remove all damged and fatigued weld
furnace chutes, scrappers, sinter crusher metal with Chamfertrode and clean
bars, sinter plant fans, screw conveyers and
weld area. Maintain short to medium arc
many other equipment from severe
length and hold a near vertical electrode
abrasion and erosion at elevated
temperatures. angle. Deposit stringer or 1.5 X weave
beads. Back whip crater. For high carbon
Outstanding Features: steels, preheat to 250 - 3000C maintain
• High single pass hardness. inter pass temperature to 1500C show
• Exceptional abrasion & erosion cool after welding. Smooth and ripple -
resistance.
free deposit with micro-fissure stress
• Elevated temperature applications.
relieving cracks.
• Ultra - hard coatings with good
toughness. Recommended Amperages:
• Multi - layer deposits achievable. Size (mm) I - Range
• High deposition rate with high metal 4.00 130 - 170
recovery.
Hardness: 67 - 71 HRc
47
EWAC BU 101 AC/DC+
Mill Pinions
Anti-spalling weld deposit with excellent cushioning, good

impact resistance & high compressive strength
For built-up prior to hard facing for mill Clean weld area. Use EWAC GougeTec
pinions, slide ways, hammers, wobblers, electrode to remove fatigued or damaged
excavators, sprockets, rollers, shaft and metal. Preheat heavy section to about
gear teeth. 1500C. Use stringer or weaving technique
with a short to medium arc holding
Outstanding Features: electrode at an angle of 600 to the
• Deposits have high compressive horizontal. Do not allow excessive heat
strength. build-up. Chip slag between passes. Allow
• An alloy for protective coating on all to cool slowly.
ferrous metals.
• High toughness and resistance to
deformation. Size (mm) I - Range II - Range
• Rapid deposition in all positions. 4.00 130-140 110-125
5.00 160-175 135-150

Recommendation:
An alloy for protective coating to resist Hardness: 25-35 HRc (3 layer)
severe impact on ferrous parts subject to
heavy shock loading and pounding in
service. Frigid Arc coating permits rapid
weld metal deposition in all welding
positions. Superior for field welding.
48
EWAC BU 102 AC/DC+
Crusher Hammers
A versatile electrode with excellent resistance to impact with

work hardening capability
Crusher hammer, wobblers, frogs, Clean weld area. Use EWAC GougeTec
sprockets, bucket teeth, wear parts, shovel electrode to remove damaged metal. Do
track pads, under carriage components, not preheat manganese steels. Maintain a
scraper blades. short to medium arc length. On Mn steel
keep bead length 75-100 mm at a time.
Outstanding Features: Inter-pass temperature should be
• Tough overlay on manganese steel and maintained below 1500C by following
alloy steel. back-step technique. Skip welding is
• For severe impact, shock and recommended on large parts. Peening
hammering applications. while hot reduces residual stresses. Cool
• Frigid arc coating for lowest possible slowly.
amperage.
• Work hardens in service. Recommended Amperages:
Recommendation: 3.15 120-140 100-120
A ferrous base electrode with additions of 4.00 160-190 130-140
Ni, Mn & other elements to improve
5.00 180-200 160-190
welding properties. Use on alloy steel as a
cushion layer before hardfacing. Hardness: As deposited, 80-90 HRb (3 layer)
Work hardened, 35-45 HRc
49
EWAC BU 103 AC/DC+
Crusher
An advance work hardenable alloy with superior anti-impact

property coupled with pressure and abrasion
Track rollers, hydraulic turbines, crusher Clean weld area. Remove worn and
hammers, overhead gantry tracks, drive fatigued metal. Use of EWAC GougeTec
sprocket wheels, conveyor rolls, crossings recommended. For medium carbon steels
and points, cushion layer applications prior preheat upto 300°C, depending on carbon
to final hardfacing. content and section thickness. Do not
preheat austenitic manganese steels and
interpass temperature should not exceed
• High ‘as-deposited’ hardness.
150°C during welding. Using short arc and
• Work-hardens rapidly in service.
electrode tilted 10° in direction of travel,
• Excellent crack resistance by absorption
deposit stringer beads. Remove slag
of internal stresses.
between passes and peen deposits.
• Excellent ac/dc weldability and handling
features. Recommended Amperages:
Recommendation: Size (mm) I - Range II - Range
A new high chrome-manganese alloy 3.15 130 - 160 100 - 130
electrode for wear protection of carbon 4.00 150 - 180 120 - 150
steels, alloy steels, etc. Also, ideal as
cushion layer. The weld metal displays high Hardness:
‘as-deposited’ hardness which increases As deposited, 15-25 HRc (3 layer)
Work hardened, 35-45 HRc (3 layer)
further on work-hardening. The deposits
are machinable with normal cutting tools.
50
EWAC BU 104 AC/DC+
Gear Teeth
A High alloy electrode for anti-wear protective coating & high

strength joining
For joining: under carriage parts, Clean weld area. Deposit stringer beads or
sprockets, ripper shanks. use 2X weave pattern. Back whip to fill up
For Build-up: Gear teeth, Impactors, craters and remove slag between passes.
sprockets, trencher teeth, bucket teeth, Peen deposits where maximum crack
hammers, augers, under carriage
resistivity is required. Cool naturally. On
components, scrapper blades, crusher
14% Mn steel, use skip welding or back
jaws.
step technique to prevent heating above
Outstanding Features: 1500C.
• Excellent resistance to impact and Recommended Amperages:
scoring.
• High work hardening rates.
• Excellent operating characteristics with 2.50 100-140 75-100
fast deposition rate. 3.15 140-170 90-130
• Excellent crack resistance.
4.00 180-250 120-160
Recommendation: 5.00 210-260 160-190

A high alloyed electrode for similar & dis- Hardness: As deposited, 80-90 HRb
similar joining, cladding and applications
Work harden, 25-34 HRc (3 layer)
subjected to compressive service.
Outstanding weldability with extra high Tensile Strength: 610 MPa (88,000 psi)
deposition rate. Weld metal is completely
machinable with tungsten carbide tools.
51
EWAC BU 105 AC/DC+
Screw
Cobalt base alloy with excellent wear resistance at elevated

temperatures
Drill collars, chemical valve seats, pump Clean weld area. Remove fatigued or
sleeves, wear pads, screw conveyors. damaged metal with EWAC GougeTec.
Remove all sharp corners and projections.
Outstanding Features: Grind all surfaces to remove oxides and
• Exceptional resistance to corrosion. other contaminants. Preheat if necessary
• Good all-round resistance to abrasion. for low carbon, air hardenable steels and
• Dense deposit with excellent bead cast iron. For cast iron and air hardenable
formation. steels deposit a buttering layer of EWAC CI
• Super resistance to heat giving high hot 422 and EWAC ST 202 HD respectively.
hardenss values. Then, deposit the cobalt alloy. For low
carbon steel the alloy can be deposited
Recommendation: directly.
Cobalt alloy electrodes for producing
excellent wear resistant overlays on carbon
Size (mm) I - Range
and alloy steels. Excellent results obtained
even when high temperature service 3.15 70 - 100
conditions prevail. Specifically provides 4.00 100 - 150
ease of deposition and freedom from 5.00 130 - 190
porosity, cracking and other faults
common in products of this type. Hardness: 35 - 45 HRc (3 layer)
52
EWAC BU 107 AC/DC+
Die
Cobalt base alloy with superior wear properties for critical

surfacing and repair applications at high temperatures
Hydraulic turbine parts, hot cutting tools, Clean weld area. Remove all fatigued
chemical and high pressure steam valves, and cracked metal and previous overlays.
hot forming rolls and dies, augers, exhaust Preheat generally not required but
valves. beneficial when welding heavy sections
Outstanding Features: or crack-sensitive base metals. Maintain
• Cobalt based alloy having high short gap and deposit stringer beads.
resistance to corrosion, impact, friction, Back-whip craters. Remove slag
abrasion and erosion. between passes. For out-of-position,
• Superior resistance to thermal shock & hold shorter arc and weave moderately.
oxidation. Recommended Amperages:
• Outstanding weldability with excellent
deposit crack-resistivity.
• Easily machinable & work hardnable. 3.15 90 - 100 70 - 90
4.00 120 - 140 90 - 120

Recommendation:
5.00 150 - 170 120 - 150
For all steels, including the heat-treatable
types. Also for overlay applications on Hardness: 25 - 35 HRc (3 layer)
cobalt alloys and special purpose steels.
53
EWAC BU 108 AC/DC+
Feed Screw
Cobalt alloy based electrode with excellent resistance to heat,

impact and abrasion
Hot pressing dies, shear blades, hot cutting Clean weld area. Remove fatigues or
blades, hot hardness dies. damaged metal with EWAC GaugeTec.
Remove all sharp corners and projections.
Outstanding Features: Grind all surfaces to remove oxides and
• Exceptional resistance to heat with high other contaminants. Preheat if necessary
hot hardness. for low carbon, air hardenable steels and
• Good all-round resistance to impact and cast iron. For cast iron and air hardenable
abrasion. steels deposit a buttering layer of EWAC CI
• Dense deposit with excellent bead 422 and EWAC ST 202 HD respectively.
formation. Then deposit the cobalt alloy. For low
carbon steel the alloy can be deposited
Recommendation: directly.
Cobalt alloy electrodes for producing Recommended Amperages:
excellent wear resistant overlays on carbon
Size (mm) Amperage
and alloy steels. Excellent results obtained
even when high temperature service 3.15 70 - 100
conditions prevail. Provides ease of 4.00 100 - 150
deposition and freedom from porosity,
5.00 130 - 190
cracking and other faults common in
products of this type. Recommended for Hardness: 40 - 50 HRc (3 layer)
handling equipment for hot steel, dies etc.
54
Superfuse 123
Scrubber Fan Impeller
A wear resistant hard surfacing ‘paint-on-paste’ for high wear’

applications
Product Description: Procedure:
Product consists of a “paint-on-paste” Clean the base metal thoroughly from
formulated by suspending chrome boride residues of oil, dust, grease & oxides.
particles in an aqueous base for easy Grinding is preferred. Apply the paste on
application. Upon fusion with a substrate, the cleaned surface to a thickness of 1.0-
1.5 mm. Ensure the applied paste is
it forms ultra hard chromium boride
uniformly spread on the job surface. Allow
crystals with superior anti-wear properties.
the applied paste to fully dried in air
Typical Applications: (Normally 1/2 to 1 hour). Fusion of the
ID fan blades, scrappers, screw conveyors, coating can be done by FuseTrode or Oxy
FK pump screws, air separator guide, Acetylene process. Use FuseTrode for
sinter fans, PA fans etc. fusion. Use DC source with electrode
negative. Fuse by weaving the electrode.
Outstanding Features: Allow the fused deposit to cool in still air.
• Excellent abrasion & erosion resistance. Oxy-Acetylene Process is recommended if
base metal thickness is less than 5 mm. Use
• Easy to apply.
carburizing flame. As the bonding
Recommendation: proceeds, move the flame along at a rate
Coating is recommended on low carbon sufficient to keep the ‘sweating’ ahead of
steel components, medium carbon, low the flame. Width of the path depends on
alloy steel & stainless steel. Not the surface area & base metal thickness.
recommended for non ferrous metals & Coverage: 300 cc/kg of paste
cast iron. (Avg. coating thickness = 1.5mm)
55
EWAC BR 585
Solenoid Valve Piston
Flux coated brazing alloy for built up & overlay application on

all ferrous and non-ferrous alloys
Gear teeth, shafts, bearing seat, pistons Clean and degrease joint areas. Pre-heat
sprockets, pump bodies, impellers, wear parts. Deposit initial tinning layer of the
pads, guides. alloy. Melt off drop of flux from end of rod
to the beginning of joint area. Continue
Outstanding Features: heating until flux liquefies. Deposits alloy
• Dense deposits with low coefficient of drop by drop, feeding into flame as
friction. required, making sure that each drop
• Excellent corrosion resistance. bonds properly. Air cool. Remove flux
• Highly machinable. residues by washing with water. Use EWAC
• Excellent control on multi-pass build-ups. BR 585 flux for supplementary
• Deposits work harden in service. requirements. Additionally the deposits
• Deposits are flame machinable. can be flame machined using oxy-
acetylene flame.
Recommendation:
Size:
For build-up and overlay applications on all
Size (mm)
ferrous and non-ferrous alloys except
white metals. Superior brazeability and 3.15
control. Ideal for building up broken or 5.00

worn gear teeth, worn bearing areas, valve
seats and pistons. Bonding Temperature: 8750 C
Tensiles Strength: 600MPa (87,000 psi)
56
EWAC SLP 603
Bath Shower Mixer
A solder alloy with excellent corrosion resistance suitable for SS,

brass, bronze, Ni alloys and carbon steels parts
Tanks, sinks, stainless pipes, instruments, Clean joint area. Apply EWAC SLP 603 Flux.
solar heaters etc. Heat indirectly by oxyacetylene, blow-
torch, soldering iron, etc. until flux
Outstanding Features: liquefies. Apply alloy until it flows through
• Retains high gloss.
the joint. Remove flux residues.
• Rapid solidification.
• Stronger than lead/tin solders. Size: (Spool)
• Non-toxic free from cadmium, lead, Size (mm)
zinc, antimony.
1.6
Recommendation: 3.15
High strength silver-bearing solder-type 0
Bonding Temperature: 225 C
alloy. For all type of stainless steel and
Note: Also available in paste form as
dissimilar metal joining, especially SS to
copper, brass and bronze. Deposits do not EWAC SLP 603 PA
turn black as conventional solders.
Excellent ductility with good impact
resistance. Electrical applications requiring
higher conductivity and brightness,
corrosion resistant deposits. Can be readily
plated.
57
EWAC Drill Shield 008
Drill Bit
Composite gas brazing filler rod with hard carbides embedded

in tough matrix
Drill bits, stabiliser, fishing tool, masonry Clean & degrease the surface to be coated.
drill, rotary cutting tool. Use extended portion of carbide free rod
for tinning. Adjust oxyacetylene torch to
Outstanding Features: neutral flame. Using very large Nozzle tip
• Excellent resistance to high abrasion with broad flame. Heat tinned surface to
coupled with pressure. re-melting temperature, then direct flame
• Tough copper alloy matrix withstands on to rod to deposit matrix and carbides.
shock loading. Avoid overheating. Remove flux residues.
• Low temperature deposition retains
hardness, sharpness and angularity of Available Size:
carbides.
Carbide Mesh Size (mm) Coating Flux Colour
• Optimum abrasion resistance and
-3.2 + 1.5 Pink
cutting action.
-5.0 + 3.2 Yellow
Recommendation: -6.0 + 5.0 Blue
Ideal for deposition of carbides uniformly
-10.0 + 6.0 Green
on Ferrous and Non-Ferrous metals.
Mining grade carbides ensures consistent Hardness: Matrix - 200 BHN,
quality & retention of cutting edges. Carbides - 1200 Hv (min)
Improved brazeability permits bonding
well below the critical temperature of
ferrous metals, especially advantageous
for repairing carbide tipped drills.
58
Continuous
Wires
OPEN ARC FCAW (Flux Cored Arc Welding)
• In this process, arc is struck between the continuous flux cored

wire and the base metal. The shielding is provided to the weld
deposit by the gas evolved due to combustion and
decomposition of flux contained within the wire with or
without auxilliary shielding gases.
59
Properties
EWAC S-602 EWAC S-603 EWAC O-606 EWAC O-510 EWAC O-512 EWAC O-517 EWAC O-521 EWAC O-52B EWAC O-540 EWAC O-564 EWAC O-570 EWAC O-630
(Typical)
Hardness 37-42 HRc 47-53 HRc 52-60 HRc 90 HRb 58-64 HRc 52-58 HRc 90 HRb 25-35 HRc 18 - 28 HRc 85 - 90 HRb 52-60 HRc 62-68 HRc
(welded) (welded)
35 - 45 HRc 25 - 35 HRc
(service) (service)
Tensile
Strength N/A N/A N/A 50 kg / mm2 N/A N/A 63 kg / mm2 N/A N/A 55 kg / mm2 N/A N/A
Abrasion
Resistance C C A C A A C B B c A A
Impact
Resistance B C B B c A B B A A B C
75
Abrasion +
EWAC Flux Cored Wire
Impact C C B C B A C B B B B B
Machina-
bility A B N/A A N/A N/A B A B A N/A N/A
Suitability
for Joining N/A N/A N/A A N/A N/A A C C A N/A N/A
Multi Pass
Build up A A C A C A A A A A C C
60
Base Low & Low & Low & Low Carbon Low & Low & Mn Steels, Low & Low & Low & Low & Low &
metal Medium Medium Medium Steels & Medium Medium Dissimilar Medium Medium Medium Medium Medium
Compa- Carbon & Carbon & Carbon & Low Alloy Carbon & Carbon & Steels, Carbon Carbon & Carbon & Carbon & Carbon &
tability Alloy Steels, Alloy Steels, Alloy Steels, Steels Alloy Steels, Alloy Steels, Low or High Steels Alloy Steels, Alloy Steels, Alloy Steels, Alloy Steels,
Mn Steels, Mn Steels, Mn Steels Mn Steels, Mn Steels Alloy Steels Mn Steels Mn Steels & Mn Steels Mn Steels
Ni Alloys Ni Alloys Ni Alloys Dissimilar steels
Out Outstanding Outstanding Excellent Good TS & High High High TS, Resists Excellent for High Excellent Single layer
Standing Resistance to Wear to Abrasion Crack Temperature Temperature Impact & plastic high Impact Resistance Resistance to Hardness &
Features Metal to Metal to Resistance Resistance abrasion & abrasion & Crack deformation, & Abrasion to Pressure Grinding highest
Metal Wear Metal Wear Erosion Impact Resistance Metal to areas & Impact abrasion & Abrasion
Corrosion under Resistance Resistance Corrosion Metal wear Moderate Resistance
Resistance temperature upto 650oc upto 400oc Resistance Impact
Typical Concast Pinch Roll & Scrapper Ball mill Sinter Pump Bucket Pinion, Crusher Crusher Excavator tee Augers,
Applica- Rolls, Steel steel Mill Blades, trunion & Handling Impellers, Repair, Trackpads, Hammers, Bars, Crusher ths, Dredger Press Screws,
Scrapper Blades,
tion mill Rolls Roll Wear Crusher Heavy Equipment, Crusher
Idlers etc Stacker Blow bars, Jaws, Drive buckets, Mixer Bladed,
wear Protection Hammers, Equipment Hot Slag Hammers, Wheel, Track Rollers Sprocket, Scrapper Bars Scrappers
protection Pug mill Maintenance conveyor’s Pug mill Screws Guide Rolls Roll mill Crusher etc.
Screws Crane Jibs etc. Tie-Tamping Tools Guides
A - Excellent | B - Good | C - Fair
Wear Plate
A ready-to-use wear plate fabricated from carbon
steel plate with single or multi-layer fashion welded
coating.
Unique Features:
• Manufactured using 3 axis robot welding technique and
controlled ‘cool’ welding process.
• Overlay with a dense, extremely tough and consistent
microstructure.
• Cladding with low dilution, uniform hardness and exceptional
wear properties.
• Stress-relief cracks perpendicular to the welding direction,
which does not propagate to the base metal.
61
EWAC TenaPlate 518
Ore handling liner plates
Unique composite wear plate for heavy impact combined with

pressure and abrasion
Typical Applications: Wear plate dimension:
Secondary crusher discharge chutes, Base plate dimension : 1500 x 3000 x 10 mm
crusher bodyliners, material handling Cladding thickness : 10 mm
impact zone liners, flapper gates, impactor Cladded area : 1220 x 2740 mm
liners, deflector plates, etc. Weld bead pattern : Straight
Outstanding Features: Hardness:

• Superior resistance to severe impact & 50 - 60 HRc (First layer)
abrasion.
45 - 55 HRc (Second layer)
• Uniform microstructure throughout
the coating.
Note:
• Low dilution with uniform hardness.
• Tough matrix with finely dispersed In addition to standard plates, the plate can
carbides. be cut to any specific size as per the
• Outstanding wear properties up to requirement and supplied.
400 °c.
Microstructure:
Uniform distribution of fine carbides in
tough eutectic matrix. Such unique
microstructure offers excellent impact
combined with abrasion resistance.
62
EWAC Wear Plates
A ready-to-use wear plate fabricated from Carbon Steel plate

with single or multi-layer fusion welded coating.
EDP - 550 EDP - 650 EDP - 750 EDP - 950
Earth moving bucket Transer Chute Blade Liner for Fan impeller BLT Chute
Typical Application: Typical Application: Typical Application: Typical Application:

Liners / Components Liners / Components Liners / Components B LT d i s t r i b u t i o n
which are subjected which are subjected which are subjected chutes / MTA plates,
to Abrasion / Impact to severe Abrasion to high Abrasion / Hot gas ventilators,
(Screens in Steel (Screens in steel Impact. hot gas ducts / pipes.
Industry) industry / Fan casting
/ VRM liners etc).
Description: Description: Description: Description:

Cr-C System for Cr-B-C System for Cr-Nb-C System for Complex carbide
good abrasion and high abrasion and severe abrasion and system for severe
moderate impact low impact medium impact abrasion and erosion
applications upto applications upto applications upto applications upto
2500C 2500C 4500C 6500C
Hardness: Hardness: Hardness: Hardness:

54-58 HRc 58-62 HRc 58-64 HRc 58-64 HRc
Wear Plate Dimension:

a) Base Plate Dimension: 1220 x 2740mm
b) Base Plate Thickness: 5mm and above
c) Cladding Thickness: 3mm and above
Unique Features:
• Manufactured using 3 axis robot welding technique and controlled ‘cool’ welding process.
• Overlay with a dense, extremely tough and consistent microstructure.
• Cladding with low dilution, uniform hardness and exceptional wear properties.
• Stress-relief cracks perpendicular to the welding direction, which does not propagate
to the base metal.
Note: In addition to the standard plate, specific shape & size of the pate can be cut,
bend and fabricated as per requirement.
63
Thermal
Spray Process
Microflow Process :
The EWAC TriboJet process is designed to
protectively coat a variety of metals, by means of
an oxyacetylene powder delivery system. Purpose
designed alloys of the Microflow range are flame
sprayed onto the workpiece surface to bond by
diffusion with the base metal. Combining the
advanced Microflow technology with the new
EWAC TriboJet delivery system makes it possible
to carry out even the most ambitious preventive
and repair maintenance programmes, with many
applications in virtually all industrial sectors.
64
EWAC 001 P
Trash Plate
Nickel - base alloy with excellent wear properties

Typical Applications: Recommendation:
Cams, screws, ceramic die cutters, fan Combined with its low coefficient of
blades, patterns, dies tools. friction, EWAC 001 P is ideal for
applications involving metal-to-metal
Outstanding Features: contact. Deposits can be ground with great
• Retains high hardness at elevated precision, to a smooth, highly polished
temperatures. finish. EWAC 001 P wets out easily on
• Resists galling, scoring and seizing. steels, stainless steels, cast iron, nickel and
• Excellent weldability. nickel alloys. Recommended uses include
• Exceptionally dense, smooth finish. all applications where frictional and
• Non-magnetic. abrasive wear are severe. Thin overlays are
recommended. Deposits are not heat-
treatable.
65
EWAC 002 P
Sand Mixer Blade
Tungsten carbide reinforced Nickel - base alloy with

exceptional resistance to abrasion and erosion
Gonveyor chains, mixer paddles, muller EWAC 002 P is tungsten carbide bearing
ploughs, die frames, screws, tyre chains, alloy providing superior weldability on flat
sand slinger cups, mechanical seals. and contoured surfaces and providing
coatings with combined hardness of nickel
Outstanding Features: based matrix and carbide particles.
• Unequalled abrasion resistance. Coatings are exceptionally wear resistant
• Excellent edge retention. against abrasive media (such as sand,
gravel, cement etc.), thermal cycling, heat
• Outstanding weldability.
scaling and corrosion. EWAC 002 P coating
• Resistance to oxidation. exhibit superb edge buildup characteristics
• Resists “Softening Effects” of high especially where retention of a “cutting
temp, or thermal cycling. edge” is critical to the performance of the
part or tool. Recommended on steels,
stainless steels, cast iron & nickel alloys.
66
EWAC 003 P
Gear
Ni - B - Si system offers combination of wear, toughness,

hardness and machinability
Shafts, gears, gauges, tools, valve pumps, EWAC 003P is designed to produce
feed rolls, moulds, splines, rear axle tubes. deposits for wide range of service
conditions. Coatings combine substantial
Outstanding Features: hardness with overall toughness to resists
• Superior toughness. most combinations of friction, abrasion
• Unlimited build-up capability. and impact. This alloy can be used either as
• Good weldability. thin overlay or for multiple pass
• Excellent machinability with carbide applications on steels, SS, nickel alloys and
tools. c a s t i r o n . E WA C 0 0 3 P i s a l s o
• Low coefficient of friction. recommended where parts may be
subjected to corrosion from steam, sea
water and / or other chemical agents.
67
EWAC 004 P
Flange
Nickel - base alloy ideal for filling, sealing, cladding & joining
cast iron to steel
Engine blocks, exhaust manifolds, blow EWAC 004 P has universal use on cast iron.
holes, differential housings, gears, pulleys, Its outstanding wettability on cast iron
cladding cast iron, glass moulds. makes it ideal for filling, sealing, cladding &
joining cast iron to steel. Deposits are
Outstanding Features: smooth, dense and machinable. Excellent
• Very good machinability. ductility and capacity to absorb stress
• High resistance to impact. makes it perfect for thin buildups or as a
• High ductility. cushion for heavier buildups. Deposits will
• High tensile strength. resist heat scaling, impact and corrosion.
Hardness: 80 - 100 HRb
68
EWAC 005 P
Rail Track Repair
Nickel - base alloy for faster deposition for joining, cladding

and sealing
Gears, shafts, patterns, clutches, E WA C 0 0 5 P d e p o s i t s a re e a s i l y
templates, keyways. machinable. The deposits offer excellent
corrosion resistance to most common
Outstanding Features: corrosive elements; withstand heat scaling
• Excellent corrosion resistance. and provide very good impact resistance.
• Perfect cushion for “one-pass” harder Superior toughness makes EWAC 005P, an
overlays. excellent choice as a “cushion” over which
• Ideal for joining, cladding or sealing. a harder alloy can be deposited for surface
• Excellent all-round toughness. wear resistance. Recommended for use on
steels, stainless steels and nickel alloys.
Hardness: 80 - 100 HRb
69
Technical &
Specification
Data
70
General Application Data
Controlling Heat Input of heat into the parent metal. The

amperage is lower, the voltage is less,
The design of the joint has a distinct
and therefore the watt input is reduced.
bearing upon the amount of heat
necessary to effect a bond. The A 3.2 mm electrode with high nickel
illustrations show various types of content for cold welding of cast iron,
joints. Each requires a slightly different can be used on castings only four mm
treatment to obtain maximum results. thick and with an arc of only 1.6 mm
instead of the conventional 3.2 mm arc
Less heat is required for open chamfer
gap.
joints, fillets and coatings. More heat is
needed when the filler alloy has to A 3.2 mm EutecTrode® designed for 1.6
flow by capillary attraction through mm thick stainless steel can be operated
square butt of lap joints. with a gap of only few tenths of microns.
New types of XuperLIFE electrodes can
The flux plays a most important part in
be operated as contact electrodes which
the low heat input metal joining
reduces the heat input still more.
process. A special alloy is needed for
each metal and a special flux for each 3.2 mm EutecTrode for cast iron Xyron®
alloy. 2-24®, can be operated at sixty amps
instead of a hundred amps which is
The flux has many specific duties to
required by conventional electrodes.
perform. It dissolves surface oxides,
prevents formation of oxides during
heating on the base metal and filler
alloy and reduces surface tension. It
may contain metallic elements which CARBURISING
alloy with the base metal, and it may
have to retard cooling. Basically, there
are two different techniques used NEUTRAL
when applying these alloys - bead

forming, and thin flowing. Bead OXIDIZING
forming uses the lowest heat and is
used to fill a veeorto build up a section.
Fig. 1
Thin flowing alloys are for close fitting
joints. A slightly higher heat is needed A 1.6mm size of Steel Tectic will operate
to thin flow the alloy. as low as thirty Xuper 680S amps. This
The principles of low heat input metal low heat input improves working
joining have been equally successful conditions, improves weldability, and
when applied to metallicarc welding. prevents deep fusion with its danger of
distortion, warpage and over-heating of
The weld is obtained with lower the parent metal are minimized.
current values. The result is a reduction
71
Fig. 1 shows the three types of flame Furnace and induction heating are
used with an oxy-acetylene torch. economical methods for production
Carburizing has the lowest heat and operations. Thin flowing alloys may be
an oxidizing flame the highest heat. pre-placed in the form of a ring, brushed
with the correct Eutector Flux and the
Study figures 2-7 fully to understand
joint completed in a furnace without
the relationship between the type of
further handling.
torch flame and the angle at which it is
used. Correct manipulation of the oxygen and
acetylene controls will produce the type
When light metals such as aluminium
of flame recommended for each
are joined, the lowest heat is required
operation. Excess acetylene, sometimes
and the torch is adjusted to
called a carburizing flame, produces the
carburizing.
lowest heat, a neutral flame comes next
The corresponding Eutector® Flux is and is most often used. The hottest
always used with each alloy. flame of all is excess oxygen, called an
oxidising flame.
The Eutec-TinWeld® alloys are Fig. 2 - The amount of heat transferred

combinations of alloy in powder to the base metal depends upon the
form mixed with specially distance the torch is held from the
compounded fluxes. They can be metal. Generally the lower the melting
painted onto the joint area and will point of the alloy the greater the
replace rings orshims. distance the torch is held from the
metal.
Temperatures shown in most cases in
this product spectrum represent the
solidus of the alloy.
72
Fig. 3 - The first illustration shows a globule of deposited alloy. The heat has been
insufficient to flow it out. The second shows the alloy flowed out and alloying to the
base metal. The third illustration shows the base metal melted when too great a heat
was used.
EWAC BEAD FORMING ALLOYS
Fig. 4 - One of the most important differences between Low Heat input joining and
fusion welding is the angle at which the torch is held. A low angle keeps the base metal
at a bonding temperature but does not overheat it. The higher the melting point of the
alloy the closer the flame cone is held to the parent metal.
Fig. 5 - Keep the flame in constant motion to spread
the heat evenly. Do not concentrate the flame upon
one spot or over heating will result.
It is important to preheat the base metal surrounding
the joint area. If the immediate vicinity only is heated,
when thicker sections are involved, the preheat may
not be uniform throughout the section.
Fig. 6 - This chart shows how the flame cone is manipulated. The part is broadly heat
with wide circles. The circles become smaller as the bonding temperature is reached
and the movement of the torch is slowed down.
73
Fig. 7 - When applying the alloy the zigzag
motion of the torch should be continued or if
a circular motion is used, the circles should be
small. The heavy black dots indicate where
the rod has been dipped into the molten
puddle. Each bead is flowed ahead before
another is applied. The rod is raised slightly
after each deposit to permit the flame to heat
the metal ahead of the deposit.
Fig. 8 - A rough surface is preferable to a

polished surface for joining operations.
Best results will be obtained upon
chemically clean surfaces and roughening
will improve joint efficiency.
Fig. 9 - Most of EWAC thin flowing alloys possess

Bead the great advantage of being both bead forming
Forming
and thin flowing. This permits the same rod to be
used for thin flowing through a joint, and providing
a build-up upon the outside. The thin flowing
operation is done first and, because of the higher
Thin heat necessary to thin flow the alloy, the joint will
Flowing
not fail when the buildup is made with the bead
forming technique.
Fig. 10-Operations are speeded up when a number of parts can be joined in a furnace.
The parts are positioned in a jig and rings of alloy are pre-placed. Flux is applied and
one heating operation is sufficient for large number of parts.
74
Graph of Theoretical Volumes of Weld Metal for
Varying Preparations Against Plate Thickness
A one metre long weld on a 50mm plate needs 800 CC of weld metal with double ‘V’.
Preparation and 1450 CC of weld metal with a 600 single Vee. In case the weld metal is
steel, the weight of weld metal required will be 5.95 kg and 11.65 kg respectively.
For non ferrous metals, Volume has to be multiplied by appropriate density to get the
weight.
75
Useful Welding Data
Melting Point Temperature Temperature Expressed as

of Metals Conversion Chat Degrees Celsius
Metal or Alloy Melting Point, 0C °C °F 0 0

1000 F C
1800
Aluminum, pure......................................... 659 950
1700 425 219
Brass and Bronze ........................................ 870-900 900
1600
Copper....................................................... 1083 850 1050 566
1500
Iron, Cast & Malleable ................................ 1250 800
750 1400 1090 588
Lead, Pure .................................................. 327.5
Magnesium ................................................ 651 700 1300
650 1200
1125 607
Monel ........................................................ 1310
600 1100
Nickel......................................................... 1452 1130 610
76
550 1000
Silver, Pure.................................................. 960.5
500 1400 760
Steel, Hi-Carbon 900
450
(040% to 0.70% Carbon) .......................... 1400 800
400 1600 871
Steel, Medium Carbon 700
350
(0.15% to 0.40% Carbon) ......................... 1450 600 200 1093
300
Steel, Low Carbon (less than 0.15%) .......... 1500 250 500
Stainless Steel, 18% Chromium, 200 400
8% Nickel .................................................. 1425 150 300
Titanium..................................................... 1800 100 200

50 100
Tungsten .................................................... 3370
0
Zinc, Cast or Rolled .................................... 419 0
- 50
Tensile Strength Fractional Inches GAS Pressures
(Wire Diameters)
Pounds / Square Inch converted to The metric equivalent Pounds / Square inch converted
Kilograms Force / Square Millimeter expressed in Millimetre to Atmospheres
Inch
psi kgf / mm2 Fraction Millimetre psi bars
30,000 21.1 3 / 64 1.2 8-10 .50 - .63
33,000 23.2 1 / 16 1.6 4-5 .24 - .31
34,000 24.0 5 / 64 2.0 11-13 .72 - .83
35,000 24.6 3 / 32 2.4
50,000 35.2 1/8 3.2
53,000 37.2 5 / 32 4.0
77
55,000 38.6 3 / 16 4.8
60,000 42.2 1/4 6.4
62,000 43.6
65,000 45.7
70,000 50.0
80,000 56.0
85,000 60.0 ROD DIAMETER
90,000 63.3
(mm)
95,000 66.8
100,000 70.3
110,000 77.3 5 4 3.15
120,000 84.3
Hardness Scale Conversion Chart
Sr. Brineli 3000kg Sr. Rockwell Brineli 3000kg
Rockwell Vickers Load 10mm
Vickers
C B Load 10mm C B
No. A Carbide DPH No. A Carbide DPH
1 70 86.5 - - 31 40 70.5 - 371 393
2 69 86.0 - 1004 32 39 70.0 - 362 383
3 68 85.5 780 942 33 38 69.5 - 353 373
4 67 85.0 745 894 34 37 69.0 - 344 363
5 66 84.5 - 854 35 36 68.5 - 336 353
6 65 84.0 739 820 36 35 68.0 – 327 343
7 64 83.5 722 789 37 34 67.5 – 319 334
8 63 83.0 705 763 38 33 67.0 - 311 325
9 62 82.5 683 739 39 32 66.5 - 297 317
10 61 81.5 670 716 40 31 66.0 - 294 309
41 30 65.5 - 286 301
11 60 81.0 654 695
42 29 65.0 - 279 293
12 59 80.5 615 675
43 28 64.5 - 271 285
13 58 80.0 599 655
44 27 64.0 - 264 278
14 57 79.5 595 636
78
45 26 63.5 - 258 271
15 56 79.0 577 617
46 25 63.0 - 253 264
16 55 78.5 560 598
47 24 62.5 100 247 257
17 54 78.0 543 580
48 23 62.0 - 243 251
18 53 77.5 525 562
49 22 61.5 99 237 246
19 52 77.0 512 545
50 21 61.0 98 231 241
20 51 76.5 496 528 51 20 60.5 97 226 236
21 50 76.0 481 513 52 18 - 96 219 230
22 49 75.5 469 498 53 16 - 95 212 222
23 48 74.5 455 485 54 - - 93 203 213
24 47 74.0 443 471 55 - - 92 194 204
25 46 73.5 432 458 56 - - 90 187 196
26 45 73.0 421 446 57 - - 89 179 188
27 44 72.5 409 435 58 - - 87 171 180
28 43 72.0 400 424 59 - - 85 165 173
29 42 71.5 388 413 60 - - 83 158 166
30 41 71.0 381 403 61 - - 81 152 160
Important Grades of Carbon and Alloy Constructional Steels
Pertaining to DIN (German) Standards
Annealed Heat Treatment Ruling Mechanical Properties
Composition Hardness Section
DIN Grade OQ WQ T Dia YS TS EL
BHN 0 0 0
C Mn Cr Others (max) C C C (mm) Kg / mm2 Kg / mm2 %
1 2 3 4 5 6 7 8 9 10 11 12 13 14
17222 50 Cr V4 .47 / .55 .80 / .1.1 .90 / 1.2 V.07 / .12 235 830 / 860 - 280 / 340 Hardened 160 170 / 230 5
Spring and
Steels tempered
strips
Properties
Vary
according
to thickness
79
58 Cr V4 .55 / .62 .80 / 1.1 .90 / 1.2 V.07 / .12 235 830 / 860 - 280 / 340 - do - 180 190 / 240 4
1654 42 Cr V6 .38 / .46 .50 / .80 1.4 / 1.7 V.07 / .12

Drawn
steels for
cold
processed
screws
and bolts
17210 16 Mn .14 / .19 .80 / 1.1 - - 207 860 / 870 - 170 / 210 Core Zone 60 80 / 110 10
Case Cr5 of 30mm
hardening dia blank
steels hardened
sample bar
20Mn Cr5 .17 / .22 1.1 / 1.4 1.0 / 1.3 - 217 860 / 870 - 170 / 210 - do - 70 100 / 130 8
15 Cr Ni6 .12 / .17 .40 / .60 1.4 / 1.4 Ni 217 820 / 830 - 170 / 210 - do - 65 90 / 120 9
Pertaining to DIN (German) Standards
Annealed Heat Treatment Ruling Mechanical Properties
Composition Hardness Section
DIN Grade OQ WQ T Dia YS TS EL
BHN 0 0 0
C Mn Cr Others (max) C C C (mm) Kg / mm2 Kg / mm2 %
1 2 3 4 5 6 7 8 9 10 11 12 13 14
17200 CK 45 .42 / .50 .50 / .80 - - 206 830 / 860 820 / 850 530 / 670 Up to 16 48 75 / 90 14
Heat 17 to 40 40 65 / 80 16
treatable 41 to 100 36 60 / 72 18
Steels
40 Mn 4 .36 / .44 .80 / 1.1 - Si .25/.50 217 830 / 860 820 / 850 530 / 670 Up to 16 65 90 / 105 12
17 to 40 55 80 / 95 14
41 to 100 45 70 / 85 15
34 Cr 4 .30 / .37 .50 / .80 .90 / 1.2 - 217 830 / 850 820 / 840 530 / 670 Up to 16 80 100 / 120 11
17 to 40 65 90 / 105 12
41 to 100 55 80 / 95 14
25 Cr Mo4 .22 / .29 .50 / .80 .90 / 1.2 Mo 217 840 / 860 830 / 850 530 / 670 Up to 16 65 90 / 105 12
.15/.25 17 to 40 55 80 / 95 14
41 to 100 42 65 / 80 16
80
Note: P & S each = 0.35 max. For all grades Si = .15 / .35 except 40 Mn 4, where it is given | OQ = Oil Quenced | WQ = Water Quenched | T = Tempered.
Signs and Abbreviations

< Not more than Reduced by 2 for 100mm and over A total of Se, Zr, Mo, and Pb not to exceed 1% > Not less than
AC - Normalised (air cooled)
HT - Hardened and tempered
R - Hot Rolled
CR - Cold Rolled
CD - Cold Drawn
OH - Oil Hardened
AH - Air Hardened
Basic Steel Types (AISI and SAE grades) Open Hearth and Electric Steel Bars
AISI Corresponding Chemical Composition - Percent

Number SAE Number C Mn P. Max. S Si Ni Cr Mo
C1030 1030 0.28 / 0.34 0.60 / 0.90 0.040 0.050 - - - -
C1035 1035 0.32 / 0.38 0.60 / 0.90 0.040 0.050 - - - -
C1040 1040 0.37 / 0.44 0.60 / 0.90 0.040 0.050 - - - -
C1037 1037 0.32 / 0.39 1.35 / 1.65 0.040 0.08 / 0.13 - - - -
C1140 1140 0.37 / 0.44 0.70 / 1.00 0.040 0.08 / 0.13 - - - -
4027 4027 0.25 / 0.30 0.70 / 0.90 0.040 0.040 0.20 / 0.35 - - 0.20 / 0.30
81
4037 4037 0.35 / 0.40 0.70 / 0.90 0.040 0.040 0.20 / 0.35 - - 0.20 / 0.30
4140 4140 0.38 / 0.43 0.75 / 1.00 0.040 0.040 0.20 / 0.35 - 0.80 / 1.10 0.15 / 0.25
4320 4320 0.17 / 0.22 0.45 / 0.65 0.040 0.040 0.20 / 0.35 1.65 / 2.00 0.40 / 0.60 0.20 / 0.30
E4340 E4340 0.38 / 0.43 0.65 / 0.85 0.025 0.025 0.20 / 0.35 1.65 / 2.00 0.70 / 0.90 0.20 / 0.30
5140 5140 0.38 / 0.43 0.70 / 0.90 0.040 0.040 0.20 / 0.35 - 0.70 / 0.90 -
5150 5150 0.48 / 0.53 0.70 / 0.90 0.040 0.040 0.20 / 0.35 - 0.70 / 0.90 -
E52100 52100 0.95 / 1.10 0.25 / 0.45 0.025 0.025 0.20 / 0.35 - 1.30 / 1.60 -
8620 8620 0.18 / 0.23 0.70 / 0.90 0.040 0.040 0.20 / 0.35 0.40 / 0.70 0.40 / 0.60 0.15 / 0.25
8640 8640 0.38 / 0.43 0.75 / 1.00 0.040 0.040 0.20 / 0.35 0.40 / 0.70 0.40 / 0.60 0.15 / 0.25
8822 8822 0.20 / 0.25 0.75 / 1.00 0.040 0.040 0.20 / 0.35 0.40 / 0.70 0.40 / 0.60 0.30 / 0.40
9840 9840 0.38 / 0.43 0.70 / 0.90 0.040 0.040 0.20 / 0.35 0.85 / 1.15 0.70 / 0.90 0.20 / 0.30
1. Grades shown in the above list with prefix letter ‘E’ are generally manufactured by the basic electric furnace
process. All others are normally manufactured by the basic open hearth process but may be manufactured by the
basic electric furnace process with adjustments in phosphorous and sulphur.
2. The phosphorous and sulphur limitations for each process are as follows:
Basic electric furnace - 0.025 maximum per cent
Basic open hearth - 0.040 maximum per cent
Acid electric furnace - 0.050 maximum per cent
Acid open hearth - 0.050 maximum per cent
82
3. Minimum silicon limit for acid open hearth or acid electric furnace alloy steel is 0.15 percent.
4. Small quantities of certain elements which are not specified or required are present in alloy steels. These elements
are considered as incidental and may be present to the following maximum amounts : Copper 0.35 per cent; Nickel
0.25 per cent; Chromium 0.20 per cent and Molybdenum 0.06 percent.
5. Where minimum and maximum sulphur content is shown it is indicative of resulphurized steels.
6. The chemical ranges and limits shown are subject to the check analysis tolerances.
EN-Series-British Standard Schedule 970 - 1955
Chemical Composition - Percent Physical Properties Conditions or
E. N. No. 2 Limiting Size
C Mn Ni Cr Mo Others T/S Kg/mm e% Izod Joules
1 2 3 4 5 6 7 8 9 10 11
1A .07 / .15 .80 / 1.20 – – – – 50 10 – 15 mm and less
S .2 / .3 45 14 – Over 15 to 35mm
P < .07 40 14 – Over 35 to 65mm
Si < .10 35 14 – Over 65 to 100mm
– 35 26 – 100mm other finishes
8 .35 / .45 .60 / 1.0 – – – S&P < .6 55 20 – 150mm
Si .05 / .35
8 .35 / .45 .60 / 1.0 – – – S&P < 0.6 R 70 20 55 10 to 20mm
70 20 28 Over 10 to 20mm
83
R
Si .05 / .35 R 70 20 20 Over 20 to 65mm
Q 65 22 35 Over 65mm
9 .50 / .60 .50 / .80 – – – S&P < 0.6 70 18 – Normailised 100mm
R 70 18 – Hand T 50mm
Si .05 / .35 S 80 18 – Hand T 30mm
T 85 15 – Hand T 30mm
80/100 12 – Cold drawn 50mm max.
15 .30 / .40 1.3 / 1.7 – – – S&P < 0.5 Q 65 22 35 Hand T 100mm
Q 65 22 48 Hand T 100mm
Si .10 / .35 R 70 20 40 Hand T 65mm
S 80 20 40 Hand T 20mm
16 .30 / .40 1.3 / 1.8 – – .20/.35 S&P < 0.5 R 70 22 55 Hand T 150mm
S 80 20 55 Hand T 100mm
Si .10 / .35 T 55 18 55 Hand T 65mm
U 95 17 48 Hand T 30mm
V 100 16 48 Hand T 100mm
1 2 3 4 5 6 7 8 9 10 11
18 .35 / .45 .60 / .95 – .85 / 1.15 – S&P < .05 R 70 22 55 Hand T 100mm
Si .10/.35 S 80 20 55 Hand T 65mm
T 85 18 55 Hand T 30mm
19 .35 / .45 .50 / .80 – .90 / 1.50 .2 / .4 S&P < .05 R 70 22 55 Hand T 150mm
Si .10/.35 S 80 20 55 Hand T 100mm
T 85 18 55 Hand T 65mm
U 95 17 48 Hand T 65mm
V 100 16 48 Hand T 30mm
W 110 15 40 Hand T 30mm
Y 125 10 15 Hand T 25mm
24 .35 / .45 .45 / .70 1.3 / 1.8 .90 / 1.4 .2 / .35 S&P < .05
Si .10/.35 S 80 20 55 Hand T 150mm
T 85 18 55 Hand T 150mm
84
U 95 15 48 Hand T 100mm
V 100 16 48 Hand T 65mm
W 100 15 40 Hand T 30mm
X 120 14 35 Hand T 30mm
Y 125 14 30 Hand T 30mm
Z 155 8 11 Hand T 30mm
31 .9 / 1.2/ .3 / .75 / – 1 / 1.6 – S&P < .05 Brinell not exceeding 229
Si .10/.35 in the softened state.
36 <0.15 / .45 .3 / .60 3 / 3.75 .6 / 1.10 – S&P < .05 85 15 48 H and T to be given on
Si .10/.35 30 mmdia. test bar
36B .12 / .18 .3 / .6 3 / 3.75 .6 / 1.1 – S&P < .05 100 13 40 As above
Si .10/.35
40B < .2 / .3 .4 / .65 .4 2.90 / 3.5 .4 / .7/ - R 70 22 55 150mm
- S 80 20 55 150mm
1 2 3 4 5 6 7 8 9 10 11
– T 85 18 55 150mm
– U 95 17 48 150mm
41A < .25 / .3 .65 / .40 1.4 / 1.8 .1 / .25 AI .90/1.30 R 70 20 55 H and T 150mm
S&P .05 S 80 19 55 H and T 100mm
Si .10 / 45 T 85 17 48 H and T 65mm
41B < .35 / .45 .65 / .40 1.4 / 1.8 .1 / .25 AI .90/1.30 R 70 20 55 H and T 150mm
S&P .05 S 80 19 55 H and T 100mm
Si .10 / 45 T 85 17 48 H and T 65mm
45 < .50 / .60 .7 / 1.0 – – – S&P < .05 Mechanical properties are not part of the
Si 1.5/2 contractual obligations of this specification
47 .45 / .55 .5 / .8 – .8 / 1.2 – S&P < .05
85
Si < .50
V < .15 ------ do ------
48 .45 / .55 .5 / .8 – 1 – S&P < .05
Si < .1/.5 ------ do ------
52 < .4 / .5 .3 / .6 < .50 7.5 / 9.5 – S&P .04 - - Hardened and
Si < 3/3.75 Brinell 255 / 293 tempered
351 < .20 .6 / 1.0 .6 / 1.0 .4 / .8 < .10 S&P < .05 70 18 40 -
Si < .35
352 < .20 .50 / 1.0 .85 / 1.25 .6 / 1.0 < .10 S&P < .05 80 15 28 -
Si < .35
353 < .20 .50 / 1.0 1.0 / 1.5 .75 / 1.25 .08 / 15 S&P < .05 100 12 28 -
Si < .35
354 < .20 .50 / 1.0 1.5 / 2.0 .75 / 1.25 .10/.20 S&P < .05 120 12 28 -
Si < .35
Stainless and Heat Resisting Steels
AISI Chemical Composition Ranges and Limits - Percent

Number C Si, max. Mn Cr Mo Ni Others
201 < 0.15 0.75 5.50 - 7.50 16.00 - 18.00 – 3.50 - 5.50 N < 0.25
302 < 0.15 0.75 < 2.00 17.00 - 19.00 – 8.00 - 10.00 –
304 < 0.08 0.75 < 2.00 18.00 - 20.00 – 8.00 - 12.00 –
304L < 0.03 0.75 < 2.00 18.00 - 20.00 – 8.00 - 12.00 –
310 < 0.25 0.75 < 2.00 24.00 - 26.00 – 19.00 - 22.00 –
316 < 0.08 0.75 < 2.00 16.00 - 18.00 2.00 - 3.00 10.00 - 14.00 –
86
316L < 0.03 0.75 < 2.00 16.00 - 18.00 2.00 - 3.00 10.00 - 14.00 –
316Ti < 0.08 0.75 < 2.00 16.00 - 18.00 2.00 - 3.00 10.00 - 14.00 Ti < 5 x C
321 < 0.08 0.75 < 2.00 17.00 - 19.00 – 9.00 - 12.00 Ti < 5 x C
347 < 0.08 0.75 < 2.00 17.00 - 19.00 – 9.00 - 13.00 Cb + Ta < 10 x C
410 < 0.15 1.00 < 1.00 11.50 - 13.50 – – –
420 < 0.15 1.00 < 1.00 12.00 - 14.00 – – –
430 < 0.12 1.00 < 1.00 14.00 - 18.00 – – –
431 < 0.20 1.00 < 1.00 15.00 - 17.00 – 1.25 - 2.50 –
501 < 0.10 1.00 < 1.00 4.00 - 6.00 0.40 - 0.65 – –
Index
Sr. Product Page No.

No.
1. Metal Preparation 5
2. EWAC GougeTc 6
3. EWAC Pierce 7
4. Aluminium 8
5. EWAC AL 521 9
6. EWAC BR 590 10
7. Cast Iron 11
8. EWAC CI 407 12
9. EWAC CI 421 13
10. EWAC CI 422 14
11. EWAC CI 423 15
12. EWAC CI 424 16
13. Terra CI 94 17
14. Copper 18
15. EWAC CU 630 19
16. EWAC Bronz 6028 20
17. EWAC BR 604 21
18. EWAC BR 650 22
19. Steels 23
20. EWAC ST 206 LH 24
21. EWAC CPEM 021 25
22. EWAC ST 208 26
23. EWAC ST 208 SPL 27
24. EWAC ST 208 S 28
25. EWAC ST 2002 HD 29
26. EWAC ST 210 30
27. EWAC ST 202 NT 31
28. EWAC SLP 610 32
29. EWAC BR 516 33
30. EWAC BR 545 34
31. Surfacing Alloy 35

32. EWAC HF 001 36
33. EWAC HF 002 37
34. EWAC HF 003 38
87
Sr. Product Page No.
No.
35. EWAC HF 004 39
36. EWAC HF 005 40
37. EWAC HF 006 41
38. EWAC CP HFD 010 42
39. EWAC CPBF 024 43
40. TriboTuf 6517 44
41. CP ET 071 45
42. Pyrocarb 077 46
43. NanoCarb 110 47
44. EWAC BU 101 48
45. EWAC BU 102 49
46. EWAC BU 103 50
47. EWAC BU 104 51
48. EWAC BU 105 52
49. EWAC BU 107 53
50. EWAC BU 108 54
51. Superfuse 123 55
52. EWAC BR 585 56
53. EWAC Drill Shield 008 57
54. EWAC SLP 603 58
55. Continuous Wire 59
56. EWAC S-602; EWAC S-603; EWAC O-606; EWAC O-510; EWAC O-512; EWAC O-517; 60
EWAC O-521; EWAC O-52B; EWAC O-540; EWAC O-564; EWAC O-570; EWAC O-630
57. Wear Plate 61

58. EWAC TenaPlate 518 62
59. EDP 550; EDP 650; EDP 750; EDP 950 63
60. Thermal Spray Process 64
61. EWAC 001 P 65
62. EWAC 002 P 66
63. EWAC 003 P 67
64. EWAC 004 P 68
65. EWAC 005 P 69
66. Technical Specification 70
67. Index 87
88
Notes
89
90
EWAC / 01 / 18 / BM /Rev. 4/ EWAC reserves the rights to alter specifications without prior notice.
EWAC Alloys Limited

L&T Business Park, Tower - B, TC - II, 5th Floor, L&T Gate No. 5,
Powai Campus, Saki Vihar Road, Powai, Mumbai - 400 072, INDIA.
Tel: + 91 22 6705 9854 / 74 | Fax: +91 22 6705 9876
E-mail: care@ewacalloys.com | URL : www.ewacalloys.com
CIN: U74999MH1962PLC012315

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Contents

Sr. No. Description Page No.

2 Research and Development 3

3 Maintenance and Repair Welding 4

12 Thermal Spray Process 66

EWAC R & D center is equipped with Some of the in-house testing

experienced researchers. This Centre • Dry Sand Abrasion Tester

Why it is different? Low Heat Input

Gear box housing

An excellent electrode for gouging and beveling and removable

Special electrode for all position cutting and piercing of

Special aluminium electrode for joining and maintenance

This rapid-depositing alloy is particularly 4.00 140-160 105-130

An advanced torch brazing rod for high strength joining of

Aluminium furniture, window frames, 3.15

Gray Cast Iron

Nodular Cast Iron

Malleable Cast Iron

Chilled / White Cast Iron

all cast irons. Exceptional performance on 4.00 130 - 150 95 - 120

Gear Box Casing

Versatile electrode for welding of heavy sections and crack

Recommendation: Recommended Amperages:

A high Ni electrode for repairing thin sections of gray cast iron

Excellent for building up missing sections, 3.15 90-110 55-80

Electrode designed with innovative core wire offers good

4.00 145-160 120-135

Nodular Iron Casting - Cylinder Head

For joining steel to Cast Iron & rebuilding of nodular and

3.15 105-115 85-95

An excellent electrode for weld repair of cast iron

deposit is essential. Also, for rectification of 2.50 50-70

Tensiles Strength: 410 MPa (59,000 psi)

Contact Clamp - Electric Arc Furnace

Non-ferrous electrode for welding all grades of copper

Recommendation: Tensile Strength: 8 - 14 Kg/mm2

High strength bronze electrode for welding of bronze, brass,

4.00 110-150 90-120

Tube to Tube Sheet Joining

Torch brazing rod for self-fluxing copper-to-copper joints

High silver brazing alloy with excellent fluidity for

Recommendation: Bonding Temperature: 6000 C

Support Roller Buildup

Moisture resistant electrode for welding low alloy and high

5.00 185-200 165-185

Electrode for high strength joining of low, medium carbon and

A high alloy electrode for welding dissimilar steel and

• High frictional wear resistance. 3.15 90-100 75-90

4.00 110-140 90-110

Shaft Keyway Crack

Recommendation: 2.50 60-70 45-60

Gear Teeth Buildup

Very low heat input electrode for joining, built-up of dissimilar

Kiln Tyre Buildup

Special coated electrode for joining and repair of heavy and

3.15 130-170 110-130

Coal burner bucket

Excellent electrode for joining wide range of SS and MS base

Skid of Walking Beam Furnace

Superior alloy for joining high alloy steels subjected to thermal

Recommendation: 4.00 110-130 90-110

Paint-on solder paste for soldering of dissimilar metals except

Flux coated brazing rod suitable for joining of dissimilar steel

An advanced electrode for applications subjected to abrasive