SMAW

Welding
1
2
3
 Flux Electrode
Gas
Electrode
Slag shield
metal

Penetration
Base metal Bead Molten
puddle

4
• electric energy provided
by a power source

• arc temperature (> 5000

C) melts
• base metal
• wire core and
• coating on the electrode
• gaseous shield from
burning of ingredients in the flux

• slag forms on top of the

weld puddle as weld cools 5
 Principles of SMAW

• welding machine supplies electric

current to electrode wire
• electric current travels through
ionised gas between the end of
electrode wire and base metal
• As the electric current flows through this
ionised gas
• Forms an electric arc
6
• electric arc produces heat
• that heats the base metal to its melting
temperature
• flux covering on the electrode wire melts
• a shielding gas created
• protects base metal,
• arc,
• Electrode
• weld
• from the atmosphere
7
• flux cools- solidifies - forms
a protective slag
• over the weld bead
• electrode wire melts -
becomes filler metal to the
weld

8
 Factors to be considered

1.Heat
2.Electrode
3.Electrode angle
4.Arc length
5.Speed of travel
9
 Heat
Q= I x V
S
 amount of heat produced proportional to amperage
 Amperage limited by the diameter of the electrode
 How much heat required?

 Thickness of the  Excessive heat  Insufficient heat

metal  Electrode easier to
 Electrode  Hard to start
start
diameter  Excessive penetration  Reduced
 Type of joint (burn through) penetration
 Electrode type  Excessive bead width  Narrow bead
 Weld position  Excessive spatter  Coarse
 Electrode overheating ripples

10
 Electrodes
Wire and flux coating

 consumable electrode
 different metals
Carbon steels
Low alloy steels
Corrosion resisting steels
Cast irons
Aluminum and alloys
Copper and alloys
Nickel and alloys
Hard surfacing 11
 Rimmed core wire for steel

 Outer portion soft- easy

to draw wire
 Interior- oxygen, CO, C
 Wire drawing it persists

 Killed- Si , Al
 Oxygen is fixed as oxides

12
 Electrode Flux
 Flux purpose:
 clean the surfaces of the joint chemically
 prevent atmospheric oxidation of rod
 reduce impurities by floating as slag

13
 Flux ingredients

1.Ingredients to form gas to protect

from atmosphere
2.Fluxing agents
3.Arc initiators and stabilizers
4.Deoxidizers
5.Fillers and metallic additions
6.Binders and flux strength
improvers 14
 Electrode Size

Thicker base metal- larger dia

(electrode dia not more than
thickness of BM)

out of position welding smaller

diameter
root passes in V-joints, smaller
larger diameter for the filler passes


15
 Electrode Storage

 kept in original container until

used
stored in a heated cabinet that
maintains them at a constant
temperature
storage of low hydrogen
electrodes very critical

16
 American Welding Society (AWS)
Classification System

distinguishes
tensile
strength
weld position
coating and
current
polarity
17
 Welding Currents
 Not all electrodes are designed to work with all power
sources

Common SMAW power sources

Alternating Current (AC)
Direct Current straight
polarity (DCSP) or (DCEN)
Direct Current Reverse
polarity (DCRP) or (DCEP)
18
 Arc Length

 distance between tip of electrode to weld puddle

 approximately equal to the diameter of the electrode

 Excessive length
 Excessive spatter
 Reduced penetration
 Poor quality weld

 Insufficient length
 Electrode sticks
 Narrow weld
 Poor quality weld

19
 Speed

Too slow
excessive width
excessive penetration
Too fast
narrower width
elongated ripple pattern
shallow penetration

Recommended
width 2-3 times diameter of
electrode,
uniform ripple pattern, full
20
penetration.
SMAW Joints

21
 Square Groove < 3 mm

 3mm thick with a single pass on one side, with no root

opening.
 Electrode manipulation should only be used to prevent
burn through

22
 Square Groove 3-6 mm

 3-6 mm thick
 single pass on one side or single pass on both sides
 root opening to achieve adequate penetration
 Electrode manipulation will reduce penetration

23
 > 6 mm
Single V Groove Weld
 > 6 mm thick requires joint preparation
 root face provided

 Depends on diameter of the electrode
 Several passes

24
Weld Defects

25
 Common SMAW Defects

Under Cutting Porosity

Hot Cracks
Slag Inclusions

 Hot cracks
 Caused by excessive contraction  Undercutting
of the metal as it cools.  improper welding
 Excessive bead size parameters; particularly the
travel speed and arc voltage.
 May also be found at the root of
the weld.  Porosity
 Slag inclusions  Atmospheric contamination
 Long arc or excess gas in the weld
 Incomplete removal of slag on pool.
multipass welds.
26
 SMAW Weld Defects-cont.

Incomplete fusion

Microcracks Toe cracks

Underbead cracks

 Toe Cracks
 Excessive heat and rapid cooling.
 Underbead cracks
 Excessive hydrogen in weld pool
 Microcracks
 Caused by stresses as weld cools.
 Incomplete fusion
 Incorrect welding parameters or welding techniques.

27
 Arc Welding Safety

1. Recognize that arc welding produces a lot of heat.

2. Use equipment according to manufacturers
recommendations.
3. Insure fire extinguishers are available
4. Provide a first aid kit
5. Use water filled containers to receive hot metal from
cutting operations.
6. Practice good housekeeping
7. Use appropriate PPE

28
 Arc Welding Safety-cont.

7. Insure all wiring is correctly installed and

maintained.
8. Remove or shield all combustible materials in work
area.
9. Do not use gloves or clothing which contain
flammable substances
10. Protect others from arc flash.
11. Protect equipment from hot sparks.
12. Use a fume collector.
13. Never work in damp or wet area.
14. Shutoff power source before making repairs or
adjustments, including changing electrode.
15. Don’t overload the welding cables or use cables with
damaged insulation.

29
 Low H2 Electrodes

 AWS A4.3 describes methods of measuring

diffusible H2
 Diffusible hydrogen designator is specified
 H16 (not more than 16 mL/100 gm of WM)
 H8 (not more than 8 mL/100 gm of WM)
 H4 (not more than 4 mL/100 gm of WM)
 H2(not more than 2 mL/100 gm of WM)
 Ex: A moisture resistant low hydrogen
electrode E7018-H4R
 Electrodes which can resist moisture pick up for extended time period is
designated as R in electrode classification

30
 AWS specifications

 A5.1(Carbon Steel)
 A 5.2 Carbon and Low Alloy Steel Rods for Oxyfuel Gas
Welding
 A 5.3 Aluminum and Aluminum Alloy Electrodes for SMAW
 A 5.4 Stainless Steel Electrodes for SMAW
 A 5.5 ( Low Alloy Steel)
 A 5.7 Copper and Copper Alloy Bare Welding Rods and
Electrodes
 A 5.8 Filler Metal for Brazing and Braze Welding
 A 5.11 Nickel and Nickel Alloy SMAW
 A 5.13 Surfacing Electrodes SMAW
 A 5.15 Welding Electrodes and Rods for Cast Iron

31
 Storage

 AWS A5.1(Carbon Steel)

 AWS A 5.5 ( Low Alloy Steel)
 Electrodes AWS A 5.1
 to be baked for 260°C to 430°C for 2
hours, if electrode is exposed for more
than 4 hours
 AWS A 5.5
 to be baked for 370°C to 430°C for 1
hour, if electrode is exposed for more
than 4 hours 32
C-Mn steels <60 ksi steels- E6010
Lower carbon (0.06-0.15%)C
HSLA steels Nb, V, Ti strengthened
 (used for cross country pipe lines)- E6010

33
 Pipe line construction

 Pipe line construction- No Low H2 electrodes

 Cellulosic preferred
 Poor penetration ability
 Large volume of viscous slag
(hampers downhill welding technique)
 Greater difficulty in overhead welding

For steels with rel high C

Root pass small
Hot-pass technique (welding continuously to maintain
preheating effect)

34
Q&T steel (ASTM A514
A517)
(50-150 ksi) (used for pen stock, earth
moving equipment, pressure vessels, bridges, ships,
mining equipment)

HY-100 E11018H2R

35
 HTLA
(Heat treatable Low alloy steels
similar to Q&T rel. high C 0.3-0.5%)

AISI 4340
No AWS designation
Electrodes (Military
specification)
AMS-6456 (4340) or 6457A
(4130) (C-0.3 % and no Ni)

36
 Cr Mo steels (C <0.15%)

Electrodes- low H2 (E-80XX

– E90XX)
Same composition as BM
Normally PWHT (600-750C)

37
 SS

 Ferritic SS: 11 – 30% Cr, low-C, low-N

 Martensitic SS: 11-17% Cr, 0.1 to 1% C

 Austenitic SS: 15 - 25% Cr, 8 – 20% Ni,

often also Mo, Ti, Nb, low-C

 Duplex SS (50A + 50F): 22 – 28% Cr,

4 – 7% Ni, 3 – 4% Mo, 0.14 – 0.30% N, low-
C

 Precipitation Hardening SS: 15 – 19% Cr,

3 – 8% Ni, additions of Cu, Ti, Al, Mo
 Stainless steels

 A 5.4 Stainless Steel Electrodes for SMAW

 Martensitic SS Types (410) (0.15C, 11.5-13.5 Cr , Mn 1.0 Si 1.0)
 only electrodes E410, E420 and E410Ni Mo listed in
AWS 5.4
 Lack toughness in AW condition (PWHT)
 E308 or E309 could be considered for toughness

 Ferritic SS Type 430 (0.12C, 16-18Cr Mn 1.0 Si 1.0)

 Only E430 is listed in AWS 5.4

39
 Austenitic SS

 E308, 309, 347, 316, 316L, 317

(not 321)
 If back gouging is not possible- root
pass No SMAW
 Only TIG

40
 Hot cracking ……

Popular remedy in austenitic SS

welds:

Depositing weld metal with 3 – 8%

ferrite

Origin of ferrite: Formed on

solidification and retained on
rapid cooling

Desirable microstructure achieved

through consumable
optimization,

use ofSchaeffler diagram

42
 Ppt hardened SS

 Martensitic (17-4 PH (3.5 Cu, 0.25

Nb))
 similar composition electrode A5.4
E630 (17-4 PH)
 When strength not a criterion, 309
used

43
 Duplex SS

Similar or enriched in Ni or
N2

44
45
Cladding

46
 SMAW- Aluminum wrought alloys- HT

SMAW of Al alloys-
small shops- non-critical applications- repair work
Not recommended for critical applications
Coating Active flux
Should be completed removed or else corrosion
With time- coating picks up moisture
deteriorates
Dry 70-90 C
DCEP
Factors: Moisture, cleanliness, preheating (for thicker), proper slag
removal

47
 2000- limited weldability with arc Welding processes with
flux
 6000 (6061, 6063) readily weldable with arc Welding
processes with flux
 6000 containing Zn (0.25%) such as 6009, 6010
limited weldablity with arc Welding processes with
flux
 7000- arc Welding processes with flux not
recommended (Zn ~4-7%)

48
 Al Casting Non HT group
designations
 Non-HT
 Almost same as wrought
 Except for 300 series Si with added Cu, Mg or both
360 (10 Si+0.5 Mg) general- purpose die cast alloy
380- (8.5 Si+ 3.5 Cu)
(for both the alloys Arc+flux processes not recommended)
 Al Casting Non-HT group
designations

Pure Al- 100

Copper – 200 (Limited weldability with Arc+flux
processes)
Si 400 (Readily weldable with Arc+flux processes)
Mg 500 (Arc+flux processes not recommended)
Zn700 (negligible Mg for ppt hardening)
(Limited weldability with Arc+flux processes)

eutectic

12
50
 HT castings

 No or low Cu castings readily or limited weldability with

Arc+flux processes

51
Mg alloys
 Mg alloys

 Processes using flux – do not provide adequate oxidation

protection for weld pool and BM

53
 Cu based alloys
 Coppers min 99.3% (O2 free, ETP, P-deoxidized)
 COPPER-ZINC ALLOYS (BRASSES) up to 20-30%
 COPPER-TIN ALLOYS (PHOSPHOR BRONZES) 10%-0.2% P
 COPPER-ALUMINUM ALLOYS (ALUMINUM BRONZES) 10%
 COPPER-SILICON ALLOYS (SILICON BRONZES) 3%
 COPPER-NICKEL ALLOYS 30%
 COPPER-ZINC-NICKEL ALLOYS (NICKEL SILVERS) 27% Zn 18%
Ni
 High Copper alloys ( up to 5% alloying)- Be Coppers, Cd Coppers, Cr Copper

54
Cu based alloys

55
56
 SMA Welding

 Coppers min 99.3% (O2 free, ETP, P-deoxidized)-

generally NR
 BRASSES generally Not Recommended Zn evaporation
problem
 If required with care

 Bronzes –Recommended

 PHOSPHOR BRONZES Fair Tin increases the hot-crack

susceptibility, Phosphorus beneficial as deoxidizer
 ALUMINUM BRONZES good
 SILICON BRONZES Fair Silicon beneficial effect on the weldability
because of its deoxidizing and fluxing actions

 COPPER-NICKEL ALLOYS Excellent esp 70-30

 Cu-Be Cu-Cd alloys- toxic fumes during welding
57
 AWS A5.6 Specification for Covered
Copper and Copper Alloy Arc Welding Electrodes

58
 SMAW limitations- Cu alloys

 porosity
 low weld strength
 due to oxygen content of the base metal
 oxygen absorption during welding
 more severe in joining coppers by SMAW than by the gas-
shielded processes
 Result in lower mechanical properties
 greatly limit the usefulness of weldments produced using
SMAW
 Additionally, electrical conductivity suffers greatly

59
 Brasses


 can be welded using SMAW
 electrodes ECuSi, ECuSn-A, ECuSn-C,ECuAl-A2, ECuAl-B
 Relatively large welding grooves required for good joint
penetration and
 to avoid the entrapment of slag
 Welding typically done using a backing strip of copper or
brass

60
 Brasses

 SMAW of low-zinc brasses

 Phosphor bronze electrodes
 such as ECu-Sn-A and ECuSn-C
 Preheating 200 to 260 °C
 narrow, shallow stringer beads
 SMAW of high-zinc brasses
 aluminum bronze (ECuAl-A2) electrodes
 Preheat and interpass 260 to 370 °C
 arc directly on the molten weld pool rather than BM
 advanced slowly to minimize zinc volatilization and
fuming

61
 phosphor bronzes

 limited welding Tin increases the hot-crack susceptibility

 ECuSn-A and ECu-Sn-C
 DCEP
 Preheating 150 to 200 °C
 interpass temperature must not exceed the preheat
temperature
 because of the hot shortness of these alloys
 extremely important in thicker sections
 Stringer beads with rapid travel speed
 first two passes are made with a weaving technique
 Hot peening
 Post weld heat treated to 480 °C

62
 Aluminum bronzes
Aluminum bronzes

 Low
 readily welded
Al(<7%- hotwrought
short) and cast forms
 High
 fluxing
Alaction removes the
7-10%-readily aluminum
welded oxides
wrought and cast forms
 Duplex
70 to 90° V-groove joint
structure
 fluxing
 backingaction
strip of the same
removes thecomposition as BM
aluminum oxides
 70
 weld
to metal excellent
90° V-groove hot strength and ductility
joint
Deposition
 backing technique
strip andcomposition
of the same bead thickness not critical,
as BM
 Aluminum bronze electrodes ECuAl-A2 and ECuAl-B for
 weld metal excellent hot strength and ductility
C61300 and
Deposition C61400 and bead thickness not critical,
technique
 Aluminum
 Preheating bronze
of thickelectrodes
sections needed 200and
ECuAl-A2 °interpass
ECuAl-B for
temperature
C61300 not exceeding 200 °C
and C61400
 Preheating of thick sections needed 200 °interpass
temperature not exceeding 200 °C

63
 alloys containing 7% Al need not be heat
treated
 Al > 7% are usually welded with
electrodes that contain more aluminum
than do ECuAl-A2 and ECuAl-B.

 ECuAl-C, ECuAl-D, and ECuAl-E

 (Al levels-12.5, 13.5, and 14.5%)
 best known as surfacing electrodes
 thick sections preheating up to 620 °C
 fan cooling to avoid cracking
 annealing at 620 °C (1150 °F) , followed
by fan cooling for stress relief

64
 silicon bronzes

 ECuAl-A2 or ECuSi electrodes

 Welding temperatures easily attained
 due to the low thermal conductivity of silicon bronzes
 preheat , interpass temperatures not to exceed 95 °C
 to prevent hot-short cracking
 up to 4 mm square grooves
 Thicker single-V-or double-V-groove of 60°

 Weld properties lower than those of GTAwelds

 may not meet code or design requirements for strength
 Peening reduces residual stress, minimizes distortion

65
 copper-nickel alloys

 wrought and cast forms can be welded using SMAW

 Weldability similar to low-carbon steels
 because the thermal conductivity similar to steel
 ECuNi for C70600 and C71500 with DCEP
 special care needed to ensure complete slag removal
before complete solidification of the weld metal
 SMAW preferred in some applications
 where access to the joint is limited as in the butt welding
of copper-nickel pipe

66
Ti alloys No SMAW

67
 Ni based alloys

• Commercially Pure Nickel

• Solid-Solution Alloys
• Precipitation-Hardenable Alloys
• Dispersion-Strengthened Alloys (ThO2)
• Ni-Ti Shape Memory Alloys

68
69
 Pure Nickel - Alloy 200
• Food processing equipment
• Caustic handling equipment
• Chemical Shipping drums
• Electrical & electronic parts
• Susceptible to graphitization at
grain boundaries at elevated
temperatures
 Solid Solution
Nickel - Copper (400, R-405)
• Resistance to Sea Water, chlorination
• Naval Application, Chlorination Plants, Water meter
parts, pump shafts, feed water heaters

Nickel-Chromium (600, 601, 690, 214, 230, G-30, RS-

330)
• Corrosion Resistance at Elevated Temp
• Furnace muffles, heat treating equipment, nuclear
steam tubing, heat exchangers, aircraft engine
components
Nickel-Iron-Chromium (800, 800HT, 825, 20Cb3, N-155,
556)
• High Temp Strength, Resistance to Oxidation
• Heat exchangers, carborizing fixtures, pickling tank
heaters, spent nuclear fuel element recovery,
hydrofluoric acid production

72
 Solid Solution

Nickel-Molybdenum (B, B-2, N, W)

• Low temp corrosion resistance, some acids
• Cryogenic Service

Nickel-Chromium-Molybdenum
(C-22, C-276, G, S, X, 622, 625, 686)
• Corrosion resistance at room temp

Cobalt-Chromium-Nickel-Tungsten
(L-605, 188, S-816, 54Co-26Cr)
• Sensitive to Copper contamination
 Precipitation-Hardenable
Alloys
Gamma Prime Precipitate
Nickel-Copper Alloys (K-500)
• Resistant to Sea Water, Chlorine
• Pump shafts, impellers, oil well drill collars,
electronic components, springs
•Sensitive to strain age cracking

Nickel-Chromium (713C, X-750, U-500, R-41, Waspalloy)

• Al-Ti-Nb strengthening
• Good high temp oxidation
• Gas turbine components

Nickel-Iron-Chromium (901, X-750)

• Forging applications
• generally not welded
Relative Weldability of PPt Alloys

AWS Welding Handbook

76
 Ni-based alloys- SMAW Electrode
composition similar BM
 minimum metal thickness about 1.3 mm
 ENi-1
 wrought and cast forms of nickel and nickel alloys to
themselves and to steel
 ENiCu
 nickel-copper alloys to themselves
 to surface steel with a nickel-copper alloy
 to weld clad side of a nickel-copper-clad steel
 to weld nickel-copper alloys to steel
 ECuNi
 nickel-copper, copper-nickel,
 overlaying steel
 buttering layer of ENi-1 before a copper-nickel layer

77
 ENiCrMo-3
 widely used because its high nickel content allows good
dissimilar weldability
 High molybdenum content matches or exceeds the pitting
resistance of the base alloys being welded
 wide range of pitting and crevice corrosion-resistant
alloys including alloy 625
 alloy 825, alloy 20, alloy G, and alloy G-3
 Used to weld to many HSLA steels
 ENiCrMo-4
 for SO2 environments in flue gas desulfurization (FGD)

78
 Nickel-chromium-iron electrodes
 ENiCrFe-2 and ENiCrFe-3
 Similar or dissimilar metal joints involving carbon steel,
stainless steel, nickel, and nickel-base alloys
 ENi-Cr-Fe-7
 690 to itself, to alloy 600
 690 to steel or to overlay certain grades of steel in nuclear
boiler and pressure water reactor applications

79
 ENi-Cr-Co-Mo-1 join nickel-chromium iron alloys
 for services 790 °C (1450 °F) to 1150 °C
 in oxidizing atmospheres
 ENiMo-1
 nickel-molybdenum alloys to themselves
 To other nickel-, cobalt-, and iron-base metals

 moisture-proof containers in a dry storage area prior to

their use
 If exposed to excessive moisture
 Rebake at 260 °C for 2 h or at 315 °C for 1h

80
 Tool steels
 SMAW most widely used
 flexibility
 accessibility
 simple and portable equipment
 variety of weld metal compositions based on readily
available covered electrodes

81
82
Cast irons

83
84
SMAW most widely used AWS A5.15-90
Nickel-base electrodes widely used

85
 Nickel-base electrodes widely used to weld cast irons
 Nickel, unlike iron, does not form carbides
 has a low solubility for carbon
 As the weld metal solidifies and cools,
 carbon is rejected from solution as graphite.
 This increases the volume of the weld metal, reducing
shrinkage stresses and reducing the likelihood of cracking
 · PREDOMINANTLY NICKEL
 · 50NI-50FE
 · NICKEL-IRON-MANGANESE
 · NICKEL COPPER

86
 Copper-base electrodes
 mainly used for surfacing iron castings on bearing
surfaces to improve corrosion and wear resistance, or
 for joining cast irons to dissimilar metals.
 base metal cleanliness when welding cast iron is very
important, especially prior to using copper-base
electrodes
 Copper-base electrodes classified in AWS A5.6-84

87
88
 AWS A5.6

 Phosphor-Bronze Electrodes
 ECuSn-A and ECuSn-C
 flow sluggishly
 require preheat and interpass temperatures of at least 205
°C baked at 120 to 150 °C

 Aluminum-bronze electrodes
 ECuAl-2
 ECuMnNiAl
 used for the repair of cast irons where a higher
 tensile strength is needed than that provided by the
ECuAl-A2, ECuSn-A, or ECuSn-C


89
Hardfacing

90
Hard facing

91

 Valve guides and  seats
 Seal rings, shafts
 Valve bodies, screw  segments
 Various types of  sleeves
 Marine, Automotive  & Diesel Engine
Valves
 Extruder screws
 Pump shafts,  sleeves

92
 AUTOMOTIVE
 trucks, automobiles, highway construction and
agricultural vehicles, cam actuators and shafts –
 Exhaust  manifolds - Pumps - Mufflers - Brakes -
Clutches -Cones - Synchronizers - Valve heads and stems
- Inlet and exhaust seats - Eccentrics - Eccentric shafts -
Rods - Rockers

93
I. Hardness- hot hardness, hot forging dies,
coal gasification / liquation equipment
II. Abrasion resistance
low stress- sand sliding down chute- scratch wear
High stress- ore fragmentation-grinding;; extrusion screws;
cutting shears;
high stress+impact – earth moving- gouging

94
95
96
97
98
III. Impact resistance- rails, hammers in large impact
mills; rock or ore crushing or pulverizing; wheels in
mine cars to transport ores from underground to
treatment plants

99
100
101
102
103
IV. Heat resistance- oxidation, high temp str retention,
thermal fatigue- continuous casting rolls in steel
mills, engine valves

V. Erosion, erosion-corrosion-
liquid droplet (cavitation), slurries; knives in food
processing; pumps handling corrosiove fluids; seating
surfaces of disesel engine valves; fluid control valves;
Air bubbles explode (collapse)- stellite
Fretting- rubbing (oxidative wear to abrasive wear)

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 Hammer mill pulverizers

 crush minerals, glass, chemicals, cement, metals, and paper.
 Ring mill pulverizers
 reduce aluminum, minerals, coal, and recyclables.
 Double roll crusher pulverizers
 reduce minerals and rock type materials.
 Shredder pulverizers
 cut metal, tires, plastic, medical waste, and paper
 Impactor pulverizers
 to break concrete, asphalt, and aluminum and
other construction material types

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VI. Metal-to metal contact wear – galling, control
valves –even few thousands of thou not tolerable;
unlubricated parts; (stellite by PTA, laves in Ni based)

 Adhesive- oxidative, metallic, galling

 Bearings- low stress oxidative- no
bonding
 High stress- valve and seat- metallic-
bonding
 Galling- valve and seat- debris
clearance increases

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 Co based Fillers
(broadly 2 types)

1. Carbide based
 5 types low C (0.2% to high 2.5%)
 low W (4% to 12%)
 Cr up to 30% and Mo some times
Carbides
(Co,W)6C to Co0.66 W0.34)C
 17% M7C3 carbides in 28Cr+4W+1.1C+Co

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 Co based

2. Laves based - may contain up to ~50% laves phase

HCP close packed intermetallic
Helps in resisting metal-to-metal contact wear
(carbides wear out mating surfaces)
1000-1200 VHN
Tribaloy T 800
Co+28Mo+17Cr+3Si

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 Ni based

 3 groups
 Boride contg- Ni+Cr+B+Si+C (B 1.5 to 3.5% with Cr 0 to
15%))
 Predominantly Chromium borides- 1800 VHN- very high
abrasion resistance, low impact + NiB also
 Carbide contg- not so popular
 Laves contg- Ni+32M0+15Cr+3Si

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 Fe based

 Tonnage base- extensive use

 Routine applications
 Earth moving applications
 Classification based on microstructure rather than
chemical composition
 Pearlitic, austenitic, martensitic, high alloy cast iron etc

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 High C+Cr- abrasion+oxidation
 Austenitic- (13%Mn+Cr- railway track work, hammers,
roll crushers)

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 W carbides

 In steel tubes
 For max abrasion resitance- oil well rock drill bits

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 applications

 M-to-m- high stress- stellite

 M-to-m- low stress-low alloy steel
 M-to-m- corrosion+ or oxidation Co or Ni
 Partcle impingement- high alloy cast irons
 Abrasion –low stress-carbides
 Cavitation- Co based
 Heavy impact-Mn austenitic
 Heavy imp+corr+oxid- Co-based
 Galling-Co- (laves)
 Gouging-Mn Austenitic
 High temp creep- Co or Ni carbide based

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 Carbide hardness

 SiC 3200
 W2C 3000
 Cr23C2 2700
 WC 2400
 Cr&C3 2100
 Cr23C6 1650
 Fe3C 1300

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 Alloy selection

 Criteria- BM, process, application

 Metallurgical aspects- high C- preheat
 Age hardenable
 COT differences
 Size of component
 Thermal spray- thin coatings, no dilution
 Welding- thicker+ good bond strength

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 Low alloy steel
 Chromium, Molybdenum and Manganese (total alloy
content of 6 to 12%)
 moderate in price and machinable,
 offer higher impact resistance
 but only moderate improvement over base metal abrasion
resistance.

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 higher iron base alloys
 (alloy content of 12 to 25% of Chromium and
Molybdenum, with Manganese and Silicon)
 Alloys with High Carbon content essentially cast irons.

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 Austenitic Manganese Steel

 impact resistant
 develop higher hardness and abrasion resistance through
mechanical deformation or work hardening,
 usually in operation:
 must avoid overheating which tends to embrittle the
overlay
 Alloy content can reach almost 40%.

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 high Carbon and higher alloy content (25 to
50%) alloys

 More expensive
 Chromium and Molybdenum
 form massive carbides.
 Hardness

 high that the deposit is non machinable

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 Cobalt base alloys with high proportions of Chromium
and Tungsten
 most versatile alloys,
 capable of resisting abrasion, corrosion, heat, oxidation,
impact and wear.
 Nickel base Hardfacing alloys
 selected for heat and corrosion resistance when metal to
metal contact wear is present

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 Tungsten Carbide (WC) particles
embedded
 matrix
 Iron, Steel, Bronze, Nickel or Cobalt
 highest abrasion resistance when impact
is low or moderate
 hard tungsten carbide particles
 deposited from a funnel, right on the molten pool, to be
embedded there, avoiding their passage into the high
temperature of the process (flame or arc) which might affect
them negatively

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 Hardfacing

 AWS A5.13 solid wire SMAW

 Except for tungsten carbide electrodes, the surfacing

 electrodes covered by this specification are classified
according to the chemical composition of the undiluted
weld metal

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 Stellite SMAW Welding
Electrodes

 Deloro Stellite

 2.6 mm
 3.2 mm
 4.0 mm
 5.0 mm
 6.4 mm

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 AWS A5.13 E CoCr-A
 produces a cobalt base weld metal, resistant to metal-to-
metal wear or erosion at service temperatures up to
900ºC.
 Weld metal is highly resistant to the most aggressive
chemicals

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Stellite SMAW Welding
Electrodes

129
NICKEL HARDFACING ALLOYS

130
 Fe Based

 AWS A5.13: E Fe 5 B

 produces a crack-free wear resistant tool steel deposit

 particularly suitable for applications involving severe
metal-to-metal wear
 AWS A5.13: E FeMn-B

 ideally suitable under conditions of heavy impact and

gouging with moderate abrasion and friction.
 Applications rolling, sliding and metal-to-metal wear
 used for joining 14Mn steels in low stress conditions

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 A5.21 composite surfacing rods and electrodes
 (Metal cored and flux cored composite (tubular)
surfacing electrodes and rods are classified on
the basis of the chemical composition of the
deposited weld metal.
 Tubular tungsten carbide bare rods are
classified on the basis of the mesh range.
quantity and composition of the tungsten
carbide granules.)

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135
 Aluminum wrought alloys- Non HT

Readily arc-flux weldable

Limited arc-flux weldable

Popular GTAW filler

Thanks

137
TYPICAL OXYGEN AND NITROGEN LEVELS OBTAINED IN
WELD METAL FROM SELECTED ARC WELDING
PROCESSES

138
139
carbon-steel-core wire and are classified as
ESt
These steel electrodes are specifically designed
for the welding of cast iron,

are different from ordinary mild steel electrodes

welds deposited by these electrodes

are not readily machinable,
it is almost impossible to prevent the formation of
hard weld metal with low ductility

140
 E7016 and E7018 sometimes used to weld cast irons
 For cosmetic repair in nonstructural applications where
machining is not necessary and cracking is not a major
concern
 These electrodes are classified in ANSI/AWS A5.1

 Stainless steel electrodes not used for welding cast irons

 due to the formation of chromium carbides during the
welding operation, resulting in a crack-prone brittle
microstructure

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