8. Consumables

download 8. Consumables

of 24

Transcript of 8. Consumables

  • 7/29/2019 8. Consumables

    1/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    TWICSWIP 3.1WIS 5

    WELDING INSPECTION

    CONSUMABLESIDENTIFICATION AND

    CONTROL

  • 7/29/2019 8. Consumables

    2/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    All those things used up in the production of a weld

    Though generally, we refer to those elementsthat are used in a specific welding process i.e:

    Electrodes, Wires, Fluxes and Gases

    Welding consumables

  • 7/29/2019 8. Consumables

    3/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Courtesy of ESAB AB

    Consumable types

    welding gases (MIG/MAG, FCAW, TIG)

    coveredelectrodes

    MIG/MAGsolid wire

    cored wire

    TIG/PAW rods

    SAW strips

    weldingfluxes(SAW)

    SAWsolid wire

  • 7/29/2019 8. Consumables

    4/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Positional capabilities

    Flux coating type

    Toughness 47 Joules

    Electrode

    Tensile & yield strength

    Any light alloying composition

    Electrical parameters & efficiency

    Low hydrogen content achievable

    E 46 31Ni B

    Strength

    Toughness

    Coating Shown on all electrodes

    BS EN 499 electrode designation

  • 7/29/2019 8. Consumables

    5/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Strength Toughness Coating Shown on all electrodes

    BS 639 electrode designation

    Positional capabilities

    Flux coating type

    Toughness 28 & 47 Joules

    Electrode

    Tensile & yield strength

    Electrical capability

    Low hydrogen content achievable

    E 51 33 B

    Electrode efficiency

  • 7/29/2019 8. Consumables

    6/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Electrode

    Tensile strength(PSI x 1000)

    Positional capabilities

    Flux coating &electrical characteristics

    E8018

    AWS A5.1 electrode designation

  • 7/29/2019 8. Consumables

    7/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    AWS A5.4 electrode designation

    Specification number

    Electrode

    Weld metal chemical composition

    Welding current type

    AWS A5.4 E 308L-16

  • 7/29/2019 8. Consumables

    8/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    MAG filler materialWire designation acc. BS EN 440:

    EN 440 - G 46 3 M G3Si1

    Standard number

    Weld deposit produced

    by gas shielded metalarc welding

    Tensile properties

    Impact properties

    Type of shielding gas

    Type of wire electrode

    EN 440 G463MG3Si1

  • 7/29/2019 8. Consumables

    9/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    MAG filler material

    Wire designation acc. AWS A-5.18:

    Minimum UTS of weld metal (ksi)

    Chemical composition of the solidwire or of the weld metal in caseof composite electrodes

    AWS A-5.18 ER 70 S-6

    Standard number

    Designate an electrode/rod(ER) or only an electrode (E)

    Solid (S) or composite (C) wire

    AWS A-5.18 ER70S-6

  • 7/29/2019 8. Consumables

    10/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    SAW filler materialWire/flux combination designation acc. BS EN 756:

    EN 756 - S 46 3 AB S2

    Standard number

    Wire electrode and/or

    wire/flux combination

    Tensile properties

    Impact properties

    Type of welding flux

    Chemical composition of

    wire electrode

    EN 756 S463ABS2

  • 7/29/2019 8. Consumables

    11/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    SAW filler materialWire/flux combination designation acc. AWS A-5.17:

    Minimum UTS ofweld metal (10 ksi)

    Temperature forimpact test

    Standard number

    SAW welding fluxHeat treatmentconditions

    Chemical composition

    of wire electrode

    AWS A-5.17 F 6 A 2-EM12KAWS A-5.17 F6A2EM12K

  • 7/29/2019 8. Consumables

    12/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Covered electrode packages

    Plastic foil sealed cardboard box

    rutile electrodes

    general purpose basic electrodes

    Tin can

    cellulosic electrodes

    Vacuum sealed pack

    extra low hydrogen electrodes

    Courtesy of Lincoln Electric

    Cou

    rtesy

    ofLincolnE

    l

    ectric

  • 7/29/2019 8. Consumables

    13/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Type of coverings

    Cellulosic covering:

    Rutile covering:

    flour and wood pulp are common constituents

    very high in hydrogen

    does not require backing or drying (excessiveheat will damage electrode covering!)

    are based on titanium oxide

    can be dried NOT BAKED!!!

    needs a reasonable proportion of combinedwater to keep the covering intact

    if moisture is driven off, the binding of the fluxwill suffer

  • 7/29/2019 8. Consumables

    14/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Type of coverings

    Basic covering:

    contain calcium compounds like calcium fluorideand calcium carbonate

    a.k.a. lime-coated electrodes

    basic refers to the chemical behaviour of the flux

    have the lowest level of hydrogen (less than 5ml/100 g of weld metal

    needs backing to perform correctly

    baking at approximately 350C for 2,5 hours (see

    also manufacturer recommendations!)after baking, maintain at minimum 120C to avoid

    moisture pick-up

    cannot be rebaked indefinitely!

  • 7/29/2019 8. Consumables

    15/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Moisture pick-up

    Moisture pick-up as a function of: temperaturehumidity

  • 7/29/2019 8. Consumables

    16/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Covered electrode treatment

    Baking oven

    Heated quivers

    only for maintainingof electrodes afterbaking

    need temperaturecontrol

    requires calibration

  • 7/29/2019 8. Consumables

    17/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Covered electrode treatment

    Cellulosic electrodes

    Rutile electrodes

    Use straight from

    the box - Nobaking/drying!

    If necessary, dry

    up to 120C- Nobaking!

    Vacuum packedbasic electrodes

    Use straight from thepack within 4 hours -No rebaking!

  • 7/29/2019 8. Consumables

    18/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Covered electrode treatment

    After baking, maintainin oven at 150C

    Basic electrodes Baking in oven 2,5hours at 350C!

    Use fromquivers at 75C

    If not used within4 hours, return tooven and rebake!

    Weld

    Limited numberof rebakes!

  • 7/29/2019 8. Consumables

    19/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Other filler material treatment

    Welding flux:

    might be fused or agglomerated

    supplied in bags

    Fused fluxes are normally not hygroscopic butparticles can hold surface moisture so only drying

    Agglomerated fluxes contain chemically bondedwater. Similar treatment as basic electrodes

    If flux is too fine it will pack and not feed properly.

    It cannot be recycled indefinitely

    must be kept warm and dry

    handling and stacking requires careCourtesy of Lincoln Electric

  • 7/29/2019 8. Consumables

    20/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Other filler material treatment

    Welding wires:

    supplied on wire/plastic spools or coils

    plastic spool wire spool coil

    random or line winding

    Courtesy of Lincoln ElectricCourtesy of Lincoln Electric Courtesy of Lincoln Electric

  • 7/29/2019 8. Consumables

    21/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Other filler material treatment

    Welding wires:

    carbon and low alloy wires are copper coated

    wires must be kept clean and free from oil and dust

    flux cored wires does not require baking or drying

    stainless steel wires are not coated

    Courtesy of Lincoln Electric Courtesy of ESAB AB

  • 7/29/2019 8. Consumables

    22/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Other filler material treatment

    Welding rods:

    supplied in cardboard/plastic tubes

    must be kept clean and free from oil and dust

    might require degreasing

    Courtesy of Lincoln Electric

  • 7/29/2019 8. Consumables

    23/24

    Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

    Gases

    supplied in cylinders

    for large quantities,storage tanks

    colour coded to minimise wronguse

    subject to regulations concerned

    handling, quantities andpositioning of storage areas

  • 7/29/2019 8. Consumables

    24/24

    C i ht 2004 TWI Ltd World Centre for Materials Joining Technology

    Quality assurance

    filler material must be stored in an area withcontrolled temperature and humidity

    poor handling and incorrect stacking maydamage coatings, rendering the electrodes

    unusablethere should be an issue and return policy forwelding consumables (system procedure)

    control systems for electrode treatment must be

    checked and calibrated; those operations must berecorded

    filler material suppliers must be approved beforepurchasing any material