Professional Documents
Culture Documents
A STUDY ON WELDING
PRODUCTIVITY AND ECONOMY
FOR SMAW & FCAW PROCESSES
By
P M GANESAN
Enrolment No. 020233
Prof. S K AGRAWAL
Metallurgical Engineering Department, M.S. University of Baroda
Vadodara, Gujarat
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Certificate
Kolkata.
Dissertation Guide
(Prof.S K Agrawal)
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Acknowledgement
(PM Ganesan)
Date: 28-Jun-05 Roll No 020233
Place : Jamnagar
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Contents
Abstract
Introduction
Concept of productivity, economy and decision making
Technical efficiency and economic efficiency
Decision making and forward planning
Objective of this experiment
a. Background for conducting this Experiment
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m. Arc voltage
n. Travel speed
o. Shielding gas flow
p. Deposition rate and efficiency
q. Advantages of FCAW
r. Limitations of FCAW
7. Comparison of SMAW and FCAW processes
8. Experimental Work
a. Test data for SMAW:
b. Test data for FCAW:
c. Test Data OF SMAW Process with E6010 + E7018
d. Test data for FCAW Process E6010 + E71 T1 with 75%
Argon+25% Co2
e. Weld metal recovery data taken from actual tests
f. Final data and case study report based on summary of all tests
conducted
9. Conclusion of Case study
10.References
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1.0Abstract:
Every welding process possess its own advantages and limitations and selected
after careful analysis and study of variables related to the process /product
form and application criteria. Factors governing the selection of welding
process includes the type of the product to be welded, material, joint
geometry, field and service conditions, productivity expectations, capital cost,
availability of resources, quality requirements, net cost savings etc.
Currently in India, shielded metal arc welding is the major welding process
dominates the welding industry and plays a key role compared to other
welding processes. To achieve the higher productivity and cost savings, it is
necessary to adopt suitable welding process, which can be superior to SMAW
and can be justified fully in terms of productivity, quality and cost.
Comparative production studies were conducted to establish the facts and to
arrive conclusion.
This concept will be applicable for pipe spools welding in a fabrication shop for
welding groove and fillet weld joints in out of position. Process will be applied
for large bore spools welding i.e. for Pipe diameter equivalent or greater than
168 mm OD and wall thickness of 7.11 mm and above. For study purpose only
two welding processes were taken into account i.e. SMAW and FCAW. Since
carbon steel pipe spools fabrication is 85% of the total scope, selection of the
high productive and cost economic welding process plays a vital role.
2.0Introduction:
This experiment was conducted to find the facts of productivity and cost
economy of two welding processes viz. SMAW and FCAW when compared to
each other. Other welding processes were not taken into account in this study
after careful evaluation and analysis of their advantages and disadvantages
with respect to specific application i.e. welding of large bore pipe spools of
medium to heavy wall thick in out of position.
The organization has given directive to increase the productivity and quality by
using FCAW with the same input that costs for SMAW or even decrease the
input costs proportionately for achieving higher technical and economical
efficiencies. These experiments were conducted for decision making and
forward planning.
Economy is consisting those aspects of economics and its tools of analysis that
are relevant to an engineer’s decision making and forward planning process. It
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largely uses the profit economic theory and considers only that particular
environment of decision-making.
Issues in economics that are related to decision making and forward planning
are what to produce, how to produce and problems of efficiency and continual
improvement.
Forward planning is deciding the future course of action of the company which
includes formulating future plans/policies with respect to production, pricing,
profit and so on.
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The prime objective of conducting this experiment was to select the most
productive, qualitative and cost competitive welding process for the said
application.
Before we select the above two welding processes for comparison in this
paper, it is necessary to describe the back ground for not taking the other
welding processes into account.
5.0Background for conducting this Experiment
Earlier the fabrication shop has selected and applied the following welding
processes for executing the first stage pipe spools fabrication scope:
Gas Tungsten arc welding (GTAW) process for Pipe diameter of 2” and
below, and for root pass welding
Shielded metal arc welding (SMAW) process was applied to a limited
extent for large bore pipe spools fabrication
Gas metal arc welding (GMAW) process was applied for welding pipe
diameters from 3” and above and for pipe wall thickness of 7.11 mm
and above.
Flux cored arc welding (FCAW) process was applied to weld the O” lets
(Branches) of heavy wall thickness and normally in flat position
welding.
Submerged arc welding (SAW) process for welding pipe wall thickness
above 12.7 mm and for pipe diameter of 8” and above in flat position.
Machine welding of GMAW and SAW for welding butt joints of pipe
spools where the job can be rotated.
Shielding gas selected for GTAW is pure Argon and 75%
Argon+25%Co2 gas mixture for GMAW and FCAW.
5.1Summary of observations after completion of the first stage
fabrication scope
In large bore diameter pipe spools, highest weld repair % was
observed in welds made by using GMAW process due to wind blow.
Porosity was the major defect observed in welds.
Highest productivity was achieved respectively in SAW, FCAW and
GMAW processes and excellent quality were achieved in weld joints,
made by using machine-welding processes.
However lot of material handling work was involved and man-hours
were spent in facilitating the machine welding due to its
disadvantage of welding in flat position only. Also this was leading
to complete the pipe spool assembly at two stages i.e. preliminary
fit up stage to facilitate the job rotation for machine welding and
final fit up stage for completing the whole assembly for
semiautomatic welding.
40 Ton inventory of E71T-1 FCAW wire was available due to scope
reduction in work and less application than planned.
Difficulties in training welders in GMAW and SAW processes and
maintaining them.
Difficulties of welding pipe spool joints at remote locations where
the shielding gas outlet was not provided and rolling of the shop
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6.0Experiment summary
For carbon steel (A 106 GR.B OR Equivalent) Pipe spools welding, E6010 is
used for root pass application and rest passes by E7018 for conditions where
back chipping is not possible. We want to use E71T-1 and E7018 in our Studies
for comparison. Gas shielded FCAW will be used for the studies due to its
various advantages over self shielded. Since the pipe spool joints will be
welded normally in out of position, studies were conducted to simulate the
same i.e. in 5G positions. Considering the various pipe diameters and
thickness involved in welding, it is decided to use the common minimum pipe
diameter and thickness aiming the minimum deposition rates that can be
achieved by using these welding processes. Shielding gas selection for FCAW
will be either Co2 or 75%Argon+ 25% Co2 mixture. We have conducted trials
by using both for calculating the cost difference.
7.0Overview of Welding
What is Welding?
Welding is a joining process in which metals are heated, melted and mixed to
produce a joint with properties similar to those of the materials being joined.
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The Weld
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Fast-Fill is required when a large amount of weld metal is needed to fill the
joint especially in flat position. A heavy weld bead can only be laid down in
minimum arc time with a high deposition rate. However, Fast-Fill becomes a
minor consideration when the volume of weld metal to be deposited is less.
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Fast-Follow suggests that the molten metal follows the arc at rapid travel
speed, giving continuous, well-shaped beads, without "skips" or islands. This
trait is especially desirable on relatively small single-pass welds, such as those
used in joining sheet metal. Depends upon the joint, a welding process may
fall under two or more categories.
Penetration varies with the joint. With some joints, penetration must be deep
to provide adequate mixing of the weld and base metal and with others it must
be limited to prevent burn through or cracking.
Figure – 2
Any joint may need predominantly any
one of the above requirements, but Fast fill
other requirements shall also be
fulfilled in terms of the previously
mentioned four factors. To determine
the appropriate welding process,
efforts focused on the requirements of
the weld joint. A joint that requires, or
can be welded by, just one arc welding
process is rare. In fact, the majority of
joints usually are characterized
by a combination of these
requirements to varying degrees.
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Weld Specifications. Consider the welding process, which should provide and
meet the weld properties specified by the code governing the work. In our
case ASME B31.3 is the design and construction code applicable.
Operator Skill. Operators may develop skill with one process more rapidly
than another. Training the welders/welding operators in a new process is an
additional cost factor and maintaining them in the employment roll, till the
completion of job especially when more demands are there for welders in the
market. The welding process should be user friendly for training the welders,
i.e. FCAW in our case.
Base-Metal Conditions. Rust, oil, fit-up of the joint, weld ability of the steel,
and other conditions must be considered. These factors could limit the usefulness
of a particular process.
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Arc Visibility.
The completed checklist should contain every factor known to affect the
economics of the operation. Some may be specific to the weld job or weld
shop. Other items might include:
Human prejudice should not enter the selection process; otherwise objectivity
is lost - when all other things are equal, the guiding criterion should be overall
cost.
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Figure-5,
Personnel Step 4 - Review of the Application
Protection by Manufacturer. This may seem
redundant, but the talents of
experts should be utilized. Thus,
the checklist to be used is tailored
by the user to suit individual
situation.
Normally we strive to get the best possible price on welding equipment and
consumables, considering the minimum features required for carrying out the
welding process. Although this is an admirable goal, we may be overlooking
the big picture which says that rather than aim for a savings based on a one-
time purchase price, look for ways to get productivity savings. By reducing
overall welding costs, the productivity savings that are realized multiply year
after year. Productivity savings will allow a company to keep saving even when
the price of equipment, consumables or welding accessories goes up.
Outlined below are the steps to reduce welding costs and realize productivity
savings in the cost of doing business:
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In many shops, the operator has to go to a tool room or supply area for a new
contact tip, coil of wire or other welding accessory. This takes valuable time
away from the welding cell and slows down overall productivity. To improve
the operating efficiency and minimize wasted time, companies should stock at
least a limited supply of all necessary items near the welding station - this
includes shielding gas, flux, wire and other welding accessories. Another
helpful productivity enhancing tip is to switch to larger spools of wire such as
from 25 lb. spools to 44 or 60 lb. spools to even larger packages of 1,000 lb.
reels or 1,000 lb. drums. A simple switch like this means less changeover time,
which adds up over the weeks, months and years.
Leaks in the gas delivery system can also create a potential loss of money. By
looking at the amount of consumables purchased each year and then examining the
total gas purchased, a company can determine if there is a significant loss. If there
is a loss suspected, one of the easiest ways to check for leaks is to shut off the gas
delivery system over the weekend. Check the level before end of the shift and then
again on to determine before starting if gas was used while the system was in shut
down mode.
How many times each piece is handled in the shop may be an eye-opener to
reducing wasted time. To measure such an intangible as this, operators are
asked to put a soapstone mark on the piece each time it is touched - some
companies are surprised to find out how many times a part is picked up,
transported and laid down in the manufacturing process. In the case of one
company, moving the welding shop closer to the heat treatment station
eliminated four extra times that the part was handled. Basically, handling a
part, as few times as possible and creating a more efficient production line or
work cell will reduce overall costs.
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One of the "cardinal sins" that almost every shop does is over weld. This
means that if the drawing calls for a 1/4" fillet weld, most shops will put down
a 5/16" weld. The reasons? Either they don't have a fillet gauge and are not
exactly sure of the size of the weld they are producing or they put in some
extra to "cover" themselves and make sure there is enough weld metal in
place.
But, over welding leads to tremendous consumable waste. Let's look again at
our example. For a 1/4" fillet weld, the typical operator will use .129 lbs. per
foot of weld metal. The 5/16" weld requires .201 lbs. per foot of weld metal - a
56 percent increase in weld volume compared to what is really needed. Plus,
we must take into account the additional labor necessary to put down a larger
weld. Not only is the company paying for extra, wasted consumable material, a
weld with more weld metal is more likely to have distortion because of the
added heat input. It is recommended that every operator be given a fillet
gauge to accurately produce the weld specified - and nothing more. In
addition, changes in wire diameter may be used to eliminate over welding.
We need to look for ways to create more efficiency in the welding process. This
includes examining such things as wire diameter, wire feed speed, voltage,
travel speed, gas type, transfer mode, etc. For instance, if the shop is
currently welding with a short arc process and a 75/25 blend of shielding gas,
it may be more effective to switch to a different gas and a spray mode of
transfer. Or, a change in process may be warranted based on the condition of
the part. If there is oxide on the part, it may be easier to change to a process
that will overcome contamination problems rather than try to clean each part
before welding. Our shop was using the GMAW- Short arc and later switched
over to FCAW – Gas shielded to achieve spray transfer.
Just this simple change in procedure can save quite a bit in weld metal. On a
3/4" thick piece, a double bevel will use 1.45 lbs. per foot of weld metal while
a single bevel will use 1.95 lbs. per foot.
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changing the design of the box to cut out lifting slots, it eliminated the need
for welding the handles - saving time and money. In another instance, rather
than making a part with an open corner, the design was changed to
accommodate a closed corner, which meant 1/3 less metal required to fill the
corner.
Also, the company was further able to redesign the part so that it was more
efficient
If robots are not justified, a company might determine that fixturing or hard
automation could be used to increase efficiency or quality. One company
incorporated fixturing and clamps to hold down a tank while the seam was
being welded. In another case, an automotive manufacturer decided that
automation was necessary because of the amount of parts and intricate angles
and welding positions.
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The core of the covered electrode consists of either a solid metal rod of drawn
or cast material. The core rod conducts the electric current to the arc and
provides filler metal for the joint. The primary functions of the electrode
covering are to provide arc stability and to shield the molten metal from the
atmosphere with gases created as the coating decomposes from the heat of
the arc.
The shielding employed, along with other ingredients in the covering and the
core wire, largely controls the mechanical properties, chemical composition,
and metallurgical structure of the weld metal, as well as the arc characteristics
of the electrode. The composition of the electrode covering varies according to
the type of electrode.
8.2Principles of operation
Shielded metal arc welding is by far the most widely used of the various arc-
welding process. It employs the heat of the arc to melt the base metal and the
tip of a consumable covered electrode. The electrode and the work are part of
an electric circuit. This circuit begins with the electric power source and
includes the welding cables, an electrode holder, a work-piece connection, the
work piece (weldment), and an arc-welding electrode. One of the two cables
from the power source is attached to the work. The other is attached to the
electrode holder.
Welding commences when an electric arc is struck between the tip of the
electrode and the work. The intense heat of the arc melts the tip of the
electrode and the surface of the work close to the arc. Tiny globules of molten
metal rapidly form on the tip of the electrode, then transfer through the arc
stream into the molten weld pool. In this manner, filler metal is deposited as
the electrode is progressively consumed. The arc is moved over the work at an
appropriate arc length and travel speed, melting and fusing a portion of the
base metal and continuously adding filler metal. Since the arc is one of the
hottest of the commercial sources of heat [temperatures above 9000 degrees
F(5000 degrees C) have been measured at its center], melting of the base
metal takes place almost instantaneously upon arc initiation. If welds are made
in either the flat or the horizontal position, metal transfer is induced by the
force of gravity, gas expansion, electric and electromagnetic forces, and
surface tension. For welds in other positions, gravity works against the other
forces.
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The process requires sufficient electric current to melt both the electrode and a
proper amount of base metal. It also requires an appropriate gap between the
tip of the electrode and the base metal or the molten weld pool. These
requirements are necessary to set the stage for coalescence. The sizes and
types of electrodes for shielded metal arc welding define the arc voltage
requirements (within the overall range of 16 to 40 V) and the amperage
requirements (within the overall range of 20 to 550 A). The current may be
either alternating or direct, depending upon the electrode being used, but the
power source must be able to control the level of current within a reasonable
range in order to respond to the complex variables of the welding process
itself.
8.3Covered Electrodes
In addition to establishing the arc and supplying filler metal for the weld
deposit, the electrode introduces other materials into or around the arc, or
both. Depending upon the type of electrode being used, the covering performs
one or more of the following functions:
Functions 1 and 4 prevent the pickup of oxygen and nitrogen from the air by
the molten filler metal in the arc stream and by the weld metal as it solidifies
and cools.
Either the extrusion or the dipping process applies the covering on shielded
metal arc electrodes. Extrusion is much more widely used. The dipping process
is used primarily for cast and some fabricated core rods. In either case, the
covering contains most of the shielding, scavenging, and deoxidizing materials.
Most SMAW electrodes have a solid metal core. Some are made with a
fabricated or composite core consisting of metal powders encased in a metallic
sheath. In this latter case, the purpose of some or even all of the metal
powders is to produce an alloy weld deposit.
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To increase the deposition rate, the coverings of some carbon and low alloy
steel electrodes contain iron powder. The iron powder is another source of
metal available for deposition, in addition to that obtained from the core of the
electrode. The presence of iron powder in the covering also makes more
efficient use of the arc energy. Metal powders other than iron are frequently
used to alter the mechanical properties of the weld metal.
The thick coverings on electrodes with relatively large amounts of iron powder
increase the depth of the crucible at the tip of the electrode. This deep crucible
helps to contain the heat of the arc and permits the use of the drag technique
(described in the next paragraph) to maintain a constant arc length. When iron
or other metal powders are added in relatively large amounts, the deposition
rate and welding speed usually increase.
Iron powder electrodes with thick coverings reduce the level of skill needed to
weld. The tip of the electrode can be dragged along the surface of the work
while maintaining a welding arc. For this reason, heavy iron powder electrodes
frequently are called drag electrodes. Deposition rates are high, but, because
slag solidification is slow, these electrodes are not suitable for out-of-position
use.
Arc Shielding
The arc shielding action is essentially the same for all electrodes, but the
specific method of shielding and the volume of slag produced vary from type to
type. The bulk of the covering materials on some electrodes are converted to
gas by the heat of the arc, and only a small amount of slag is produced. This
type of electrode depends largely upon a gaseous shield to prevent
atmospheric contamination. Weld metal from such electrodes can be identified
by the incomplete or light layer of slag, which covers the bead.
For electrodes at the other extreme, the bulk of the covering is converted to
slag by the heat of the arc, and only a small volume of shielding gas is
produced. The tiny globules of metal being transferred across the arc are
entirely coated with a thin film of molten slag. This molten slag floats to the
surface of the weld puddle because it is lighter than the metal. The slag
solidifies after the weld metal has solidified. The heavy slag deposits that
completely cover the weld beads identify Welds made with these electrodes.
Between these extremes are a wide variety of electrode types, each with a
different combination of gas and slag shielding.
Variations in the amount of slag and gas shielding also influence the welding
characteristics of covered electrodes. Electrodes, which produce a heavy slag,
can carry high amperage and provide high deposition rates, making them ideal
for heavy weldments in the flat position. Electrodes, which produce a light slag
layer, are used with lower amperage and provide lower deposition rates. These
electrodes produce a smaller weld pool and are suitable for making welds in all
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Shielded metal arc welding is one of the most widely used processes,
particularly for short welds in production, maintenance and repair work, and
for field construction. The following are advantages of this process:
(2) The filler metal, and the means of protecting it and the weld metal from
harmful oxidation during welding, are provided by the covered electrode.
(4) The process is less sensitive to wind and draft than gas shielded arc-
welding processes.
(6) The process is suitable for most of the commonly used metals and alloys.
SMAW electrodes are available to weld carbon and low alloy steels, stainless
steels, cast irons, copper, and nickel and their alloys, and for some aluminum
applications. Low melting metals, such as lead, tin, and zinc, and their alloys,
are not welded with SMAW because the intense heat of the arc is too high for
them. SMAW is not suitable for reactive metals such as titanium, zirconium,
tantalum, and columbium because the shielding provided is inadequate to
prevent oxygen contamination of the weld.
Operator duty cycle and overall deposition rates for covered electrodes are
usually less than provided with a continuous electrode process such as FCAW
(Flux Cored Arc Welding). This is because electrodes can be consumed only to
some certain minimum length. When that length has been reached, the welder
must discard the unconsumed electrode stub and insert a new electrode into
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the holder. In addition, slag usually must be removed at starts and stops and
before depositing a weld bead next to or onto a previously deposited bead.
Flux cored arc welding (FCAW) is an arc welding process that uses an
arc between a continuous filler metal electrode and the weld pool. The process
is used with shielding from a flux contained within the tubular electrode, with
or without additional shielding from an externally supplied gas, and without the
application of pressure.
The feature that distinguishes the FCAW process from other arc welding
processes is the enclosure of fluxing ingredients within a continuously fed
electrode. The remarkable operating characteristics of the process and the
resulting weld properties are attributable to this electrode development.
FCAW offers two major process variations that differ in their method of
shielding the arc and weld pool from atmospheric contamination (oxygen and
nitrogen). One type, self-shielded FCAW, protects the molten metal through
the decomposition and vaporization of the flux core by the heat of the arc. The
other type, gas shielded FCAW, makes use of a protective gas flow in addition
to the flux core action. With both methods, the electrode core material
provides a substantial slag covering to protect the solidifying weld metal.
9.1Principal features
Principal applications
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The type of FCAW used depends on the type of electrodes available, the
mechanical property requirements of the welded joints, and the joint designs
and fit-up. Generally, the self-shielded method can often be used for
applications that are normally done by shielded metal arc welding. The gas-
shielded method can be used for some applications that are welded by the gas
metal arc welding process. The advantages and disadvantages of the FCAW
process must be compared to those of other processes when it is evaluated for
a specific application.
Semiautomatic equipment
The basic equipment for self-shielded and gas shielded flux cored arc
welding is similar. The major difference is the provision for supplying and
metering gas to the arc of the gas shielded electrode. The recommended
power source is the dc constant-voltage type, similar to sources used for gas
metal arc welding. The power supply should be capable of operating at the
maximum current required for the specific application. Most semiautomatic
applications use less than 500 A. The voltage control should be capable of
adjustments in increments of one volt or less. Constant-current (dc) power
sources of adequate capacity with appropriate controls and wore feeders are
also used, but these applications are rare.
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Shielding gases
Carbon Dioxide
Carbon dioxide (CO2) is the most widely used shielding gas for flux cored arc
welding. Two advantages of this gas are its low cost and deep weld
penetration. Although it usually gives a globular metal transfer, some flux
formulations produce a spray-like metal transfer in CO 2.
2CO2 2CO + O2
In addition, molten iron reacts with CO2, producing iron oxide and
carbon monoxide in a reversible reaction:
Fe + CO2 FeO + CO
2CO 2C + O2
The effect of CO2 shielding on the carbon content of mild and low alloy
steel weld metal is unique. Depending upon the original carbon contents of the
base metal and the electrode, the CO 2 atmosphere can behave as either a
carburizing or de-carburizing medium. Whether the carbon content of the weld
metal will be increased decreased depends upon the carbon present in the
electrode and the base metal. If the carbon content of the weld metal is below
approximately 0.05 percent, the molten weld pool will tend to pick up carbon
from the CO2 shielding atmosphere. On the other hand, if the carbon content
of the weld metal is greater than approximately 0.10 percent, the molten weld
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pool may lose carbon. The loss of carbon is attributed to the formation of
carbon monoxide (CO), because of the oxidizing characteristics of CO 2
shielding gas at high temperatures.
When this reaction occurs, the carbon monoxide can be trapped in the
weld metal as porosity. This tendency is minimized by providing an adequate
level of deoxidizing elements in the core of the electrode. Oxygen will react
with the deoxidizing elements rather than the carbon in the steel. That
reaction results in formation of solid oxide compounds that float to the surface
of the molten weld pool, where they form part of the slag covering.
Gas Mixtures
Gas mixtures used in flux cored arc welding may combine the separate
advantages of two or more gases. The higher the percentage of inert gas in
mixtures with CO2 or oxygen, the higher will be the transfer efficiencies of the
de-oxidizers contained in the core. Argon is capable of protecting the molten
weld pool at all welding temperatures. Its presence in sufficient quantities in a
shielding gas mixture results in less oxidation than occurs with 100 percent
CO2 shielding.
The use of shielding gas mixtures with high percentages of inert gas for
electrodes designed for CO2 shielding my cause an excessive buildup of
manganese, silicon, and other deoxidizing elements in the weld metal. Such
higher alloy content of the weld metal will change its mechanical properties.
Therefore, electrode manufacturers should be consulted for the mechanical
properties of weld metal obtained with specific shielding gas mixtures. If data
are not available, tests should be made to determine the mechanical
properties for the particular application.
Most steels that are weldable with the SMAW, GMAW, or SAW processes
are readily welded using the FCAW process. Examples of these steels include
the following:
1) Mild steel, structural, and pressure vessel grades, such as ASTM A36,
A515, and A516
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Electrodes
Flux cored arc welding process owes much of its versatility to the wide
variety of ingredients that can be included in the core of a tubular electrode.
The electrode usually consists of a low carbon steel or alloy steel sheath
surrounding a core of fluxing and alloying materials. The composition of the
flux core will vary according to the electrode classification and the particular
manufacturer of the electrode.
Most flux-cored electrodes are made by passing steel strip though rolls
that form in into a U-shaped cross section. The formed strip is filled with a
measured amount of granular core material (alloys and flux). Closing rolls that
round it and tightly compress the core material then closes the filled shape.
The round tube is next pulled through drawing dies or rolls that reduce its
diameter and further compress the core. The electrode is drawn to final size,
and then wound on spools or in coils. Other methods of manufacture are also
used.
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4) Produce a slag cover to protect the solidifying weld metal from the air,
and to control the shape and appearance of the bead in the different welding
positions for which the electrode is suited.
5) Stabilize the arc by 0providing a smooth electrical path to reduce
spatter and facilitate the deposition of uniformly smooth, properly size beads.
EXXT-1.
Electrodes of the T-1 group are designated for CO2 shielding gas by this
specification and are used with DCEP. However, gas mixtures of argon and CO 2
are also used to improve usability, especially for out-of-position applications.
Decreasing amounts of CO2 in the argon-CO2 mixture will increase manganese
and silicon in the deposit and may improve the impact properties. The
electrodes are designed for single – or multiple – pass welding. A spray
transfer, low spatter loss, flat to slightly convex bead configuration, and a
moderate volume of slag, which completely covers the weld bead, characterize
the T-1 electrodes.
PROCESS CONTROL
Welding current
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Arc voltage
Arc voltage and arc length are closely related. The voltage shown on
the meter of the welding power supply is the sum of the voltage drops
throughout the welding circuit.
The arc voltage can affect the appearance, soundness, and properties
of welds made with flux-cored electrodes. Too high an arc voltage (too long an
arc) can result in excessive spatter and wide, irregularly shaped weld beads.
With self-shielded electrodes, too high an arc voltage will result in excessive
nitrogen pickup. With mild steel electrodes, this may cause porosity. With
stainless steel electrodes, it will reduce the ferrite content of the weld metal,
and this in turn may result in cracking. Too low an arc voltage (too short an
arc) will result in narrow convex beads with excessive spatter and reduced
penetration.
Travel speed
For gas shielded electrodes, the gas flow rate is a variable affecting
weld quality. Inadequate flow will result in poor shielding of the molten pool,
resulting in weld porosity and oxidation. Excessive gas flow can result in
turbulence and mixing with air. The effect on the weld quality will be the same
as inadequate flow. Either extreme will increase weld metal impurities. Correct
gas flow will depend on the type and the diameter of the gun nozzle, distance
of the nozzle from the work, and air movements in the immediate region of the
welding operation.
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Advantages of FCAW
Flux cored arc welding has many advantages over the manual SMAW
process. It also provides certain advantages over the SAW and GMAW
processes. In many applications, the FCAW process provides high-quality weld
metal at lower cost with less effort on the part of the welder than SMAW. It is
more forgiving than GMAW, and is more flexible and adaptable than SAW.
These advantages can be listed as follows:
Limitations of FCAW
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S No FCAW SMAW
12 Short circuiting mode of metal transfer Very good side wall lack of fusion
is not accepted for medium and heavy
wall thickness due to cold lap and lack
of fusion.
15 For the gas-shielded version, breezes The process is less sensitive to wind
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and drafts may affect the external and draft than gas shielded arc-
shield, but less than GMAW. Except in welding processes
very high winds this is not a problem
with self-shielded FCAW.
16 FCAW is presently limited to welding The process is suitable for most of
ferrous metals and nickel base alloys. the commonly used metals and
alloys
17 Shielding gas is required for the Auxiliary gas shielding or granular
FCAW-GS. For FCAW-SS no shielding flux is not required
gas is required. But poor weld finish
and extensive slag cleaning, spatter
generation are the limitations with
FCAW-SS.
18 FCAW electrode wire is more SMAW electrode costs less compared
expensive on a weight basis than solid to FCAW. But stub loss, less
electrode wires, except for some high deposition efficiency and less
alloy steels deposition rate are the
disadvantages.
19 Deposition rate of Gas shielded FCAW Deposition rate is less than FCAW.
is higher than self shielded FCAW,
SMAW and GMAW.
20 Deposition efficiency of FCAW-GS is Deposition efficiency is lower. It is
higher than SMAW but less than found 69% in our studies.
GMAW.
21 More smoke and fumes are generated Smoke generation is less than FCAW-
during welding compared to GMAW, GS and FCAW-SS.
SAW and SMAW. More smoke is
generated in self shielded FCAW than
FCAW-GS.
22 Equipment is more complex than that Equipment maintenance is less than
for SMAW, so more maintenance is FCAW.
required
23 Excellent bead appearance and no Bead appearance is not much good
cosmetic grinding are required for compared to FCAW-GS and cosmetic
FCAW-GS. grinding is required.
24 Shallow penetration and flat bead Convex bead appearance
11.0Experiment details:
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Sheet 1
Test Data OF SMAW Process with E6010 + E7018
Pass details AWS Diamet Voltag Amper Trav Tot Arc Cleanin No. Of Weig Total
Class er of e e el al tim g time electro ht weight
electrod spee tim e de per of used
e d e used elect electrod
rode e
in in in in min in in gram
mm min min gram
per .
min.
Root E6010 2.5 23 - 26 45 - 60 60 8 5.5 2.5 9.5 15 142.5
Hot pass E7018 2.5 22 - 24 75 - 85 100 7 5 2 5 25 125
Fill up – 1 E7018 3.15 20 - 24 90 - 70 15 10 3 6 41 246
100
Fill up – 2 E7018 4 20 - 24 120 - 35 21 14 7 8 60 480
130
Fill up – 3 E7018 3.15 20 - 24 90 - 85 12 6 3 4.5 41 184.5
100
Final – 1 E7018 3.15 20 - 24 90 - 75 12 6 3 4.5 41 184.5
100
Final – 2 E7018 3.15 20 - 24 90 - 75 12 6 3 4.5 41 184.5
100
Final – 3 E7018 3.15 20 - 24 90 - 75 12 6 3 4.5 41 184.5
100
Total Time 91 53 24
Sheet 2
Test Data for FCAW Process E6010 + E71 T-1 with CO2 gas
Pass details AWS Diamet Voltag Amper Trav Tot Arc Cleanin No. Of We Total
Class er of e e el al time g time electro igh weight
electro spee tim de used t of used
de d e per electrod
ele e
ctr
ode
In In In In min In In gram
mm min min gra
per m.
min.
Root E6010 2.5 23 - 45 - 60 55 6 5.5 1 9.5 15 142.5
26
Pass details AWS Diamete Voltag Amper Total Arc Clearin Flow Wire Tra Wire
Class r of filler e e time time g time rate of speed vel weight
wire gas spe per meter
ed
In In In min In LPM In mm In In gram
min min per min. mm
per
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min
.
Hot pass E71 T-1 1.2mm 23 - 130 - 8.5 4 1.5 12 to 5.46 112 6.95
24 150 15 .5
Fill up – 1 E71 T-1 1.2mm 24 - 150 - 10.5 6 1.5 11 to 5.9 81. 6.95
25 160 14 82
Fill up – 2 E71 T-1 1.2mm 24 - 140 - 10 6.15 1.5 12 to 5.9 81. 6.95
25 150 15 82
Fill up – 3 E71 T-1 1.2mm 25 - 140 - 6.25 3.25 1 12 to 5.9 180 6.95
26 150 14
Fill up – 4 E71 T-1 1.2mm 25 - 140 - 6.6 3.75 1 12 to 5.9 180 6.95
26 150 14
Final – 1 E71 T-1 1.2mm 25 - 140 - 9.85 5.35 1.5 10 to 5.9 120 6.95
26 160 12
Final – 2 E71 T-1 1.2mm 25 - 140 - 8.3 4.5 1 10 to 5.9 120 6.95
26 160 12
Total Time 60 33 9
Sheet 3
Test data for FCAW Process E6010 + E71 T-1 with 75% Argon+25% Co2
Pass details AWS Diamet Volta Ampe Trav Tot Arc Cleani No. Of We Total
Class er of ge re el al time ng electro igh weight
electro spee tim time de used t of used
de d e pe electrod
r e
ele
ctr
od
e
In In In min In min In In gram
mm min gr
per am
min. .
Root E601 2.5 23 - 45 - 62 8 5.5 3 9.5 15 142.5
0 26 60
Pass details AWS Diamete Voltag Amper Total Arc Clearin Flow Wire Tra Wire
Class r of filler e e time time g time rate of speed vel weight
wire gas spe per meter
ed
In LPM In mm In In gram
per min. m
m
per
mi
n.
Hot pass E71 1.2mm 29 175 9 4 1 24 5.6 11 6.95
T-1 0
Fill up – 1 E71 1.2mm 31 180 10 5 1 24 5.6 10 6.95
T-1 0
Fill up – 2 E71 1.2mm 31 180 6 5 0.5 24 5.6 13 6.95
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T-1 0
Fill up – 3 E71 1.2mm 31 180 8 4 0.5 24 5.6 13 6.95
T-1 0
Final – 1 E71 1.2mm 31 180 6 4 0.5 24 5.6 13 6.95
T-1 0
Final – 2 E71 1.2mm 31 180 6 4 0.5 24 5.6 13 6.95
T-1 0
Total Time 45 26 4
WELD METAL RECOVERY DATA – TAKEN FROM ACTUAL TESTS
FCAW FCAW
Serial
Details SMAW Remarks
No. (75%Ar +
(100 % CO2)
25% CO2)
6.00
1 Pipe dia. inch 6.00 inch 6.00 inch
18.25
2 Pipe thickness mm. 18.25 mm 18.25 mm.
Pipe weight 19.130
3 before root kg 19.200 kg 19.020 kg Weighted physically
Weight of Taken from sheet 1 & it
142.5
4 electrode used 142.5 gram 142.5grm is taken by physically
gram
for root weighting the electrode
All the end rods of
Stub loss for electrode which is
5 30 gram 30 gram 30 gram
6010 thrown cumulatively
weighed for root pass
Pipe weight 19.200 Weighted physically
6 after root Kg. 19.270 kg 19.090 kg
Taken from sheet 1 & it
is taken by physically
weighting the
Weight of
electrode, In case of
electrode/filler 1.589
7 1.341 kg 1.011 kg filler wire it is
wire used for kg.
calculated by equation:
fill up & final
Arc time x Wire
speed x Weight of
wire per meter.
All the end rods of
electrode which is
Stub loss for
8 0.210 kg ----------- ----------- thrown cumulatively
7018
weighed for fill up &
final pass
Material use for
welding Weight of electrode
9 1.379 kg 1.341kg 1.011 kg
excluding stub used of 7018 - stub
loss loss of 7018
Weighted physically
Pipe weight
10 after welding 20.15 kg 20.360 kg 19.990 kg
11 Weld metal 0.95 kg 1.09 kg 0.9 kg Weight of pipe after
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welding - weight of
pipe after root
welding
deposited in
7018/ E71 T-1
Weight of electrode
used for fill up &
Material loss in
12 0.429 kg 0.251 kg 0.111 kg final pass - weld
7018 / E71 T-1
metal deposited in
7018/E71 T-1
(Weld metal
Percentage of
deposited / Actual
13 Weld metal 68.89% 81.28% 89.02%
material used for
recovery
welding)*100
Formula used for calculation of numerical values in above tables with respect
to serial number reference:
4 = Cost of Electrode/Kg of weld metal deposit = one kg weld metal deposited
x cost of electrode per kg / weld metal recovery
5 = Cost of Shielding gas/Kg of weld metal deposit = one kg weld metal
deposited x cost of gas per kg / weld metal recovery
6 = Deposition rate Per Hour = Deposition rate in kg x weld metal recovery x
60 / minute
B = power cost of welding = cost per kWh x volt x ampere / 1000 x deposition
rate per hour
C = Power Cost for Mother Oven for re drying low hydrogen electrodes/kg of
electrode = 6 hour (cycle time) X rating in kilo watt per hour x cost per kWh /
over capacity
D = Power Cost for Holding Oven (BIG)/kg of electrode = 24 hour x rating kilo
watt per hour x cost per kWh / oven capacity
H = Labor and over head cost = Labor and over head cost per hour /
deposition rate per hour x operator factor
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