Filler Metal

BASIC

WELDING FILLER METALTECHNOLOGY

A Correspondence Course

LESSON VI

CARBON AND

LOW ALLOY STEELFILLER METALS

FOR THE GMAW, GTAW ANDSAW WELDING PROCESSES

ESAB ESAB Welding &

Cutting Products

©COPYRIGHT 2000 ESAB WELDING & CUTTING PROD

Lesson 1 The Basics of Arc

Welding

Lesson 2 Common Electric

Arc Welding Processes

Lesson 3 Covered Electrodes

for Welding Mild Steels


for Welding Low Alloy Steels

Lesson 5 Welding Filler Metals for Stainless Steels

Lesson 6 Carbon & Low Alloy Steel Filler Metals - GMAW,GTAW,SAW

Lesson 7 Flux Cored Arc

Electrodes Carbon Low Alloy Steels

Lesson 8 Hardsurfacing

Electrodes

Lesson 9 Estimating &

Comparing Weld Metal Costs

Lesson 10 Reliability of Welding

Filler Metals

of 1Lesson 6 - Carbon & Low Alloy Steel Filler Metals for the GMAW, GTAW and SAW Welding Pr...

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Section Nr. Section Title Page

© COPYRIGHT 2000 THE ESAB GROU

LESSON VI

TABLE OF CONTENTSLESSON VI

CARBON & LOW ALLOY STEEL FILLERMETALS FOR THE GMAW, GTAW, AND SAW

WELDING PROCESSES

6.1 Introduction ............................................................................................. 1

6.2 Manufacturing ......................................................................................... 2

6.3 Wire Selection for Gas Shielded Arc Welding ........................................ 3

6.4 AWS Specification A5.18-93

Carbon Steel Filler Metals for Gas Shielded Arc Welding ....................... 6

6.5 Individual Filler Metal Characteristics ..................................................... 8

6.5.1 ER70S-2 ................................................................................................. 8

6.5.2 ER70S-3 ................................................................................................. 8

6.5.3 ER70S-4 ................................................................................................. 8

6.5.4 ER70S-5 ................................................................................................. 8

6.5.6 ER70S-6 ................................................................................................. 8

6.5.6 ER70S-7 ................................................................................................. 9

6.5.7 ER70S-G ................................................................................................ 9

6.6 ESAB Bare Solid Carbon Steel Wires .................................................... 9

6.6.1 SPOOLARC 65 ....................................................................................... 9

6.6.2 SPOOLARC 29S .................................................................................... 10

6.6.3 SPOOLARC 85 ....................................................................................... 10

6.6.4 SPOOLARC 86 ...................................................................................... 11

6.6.5 SPOOLARC 87HP .................................................................................. 11

6.7 AWS Specification AWS A5.28-96

Low Alloy Steel Filler Metals for Gas Shielded Arc Welding ................... 12

6.7.1 The Chromium-Molybdenum Types........................................................ 12

6.7.2 The Nickel Alloy Types ............................................................................ 13


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Page 1 of 1Lesson 6 - Carbon & Low Alloy Steel Filler Metals for the GMAW, GTAW and SAW Welding Pr...




LESSON VI

6.7.3 The Manganese-Molybdenum Types ........................................................ 14

6.7.4 SPOOLARC 83 ....................................................................................... 15

6.7.5 SPOOLARC Hi-84 .................................................................................. 15

6.7.6 All Other Low Alloy Types ......................................................................... 16

6.7.7 SPOOLARC 95 and 120 ......................................................................... 17

6.8 Wires and Fluxes for Submerged Arc Welding of Carbon Steels ........... 18

6.8.1 Equipment............................................................................................... 18

6.8.2 Welding Filler Metals .............................................................................. 19

6.8.3 Fluxes for Carbon Steel Electrodes ........................................................ 19


Carbon Steel Electrodes and Fluxes for Submerged Arc Welding ......... 21

6.10 ESAB Wires and Fluxes for Carbon Steel Submerged Arc Welding ...... 23

6.10.1 SPOOLARC 81 ....................................................................................... 23

6.10.2 SPOOLARC 29S .................................................................................... 23

6.10.3 SPOOLARC 80 ....................................................................................... 24

6.10.4 UNIONMELT 231 .................................................................................... 24

6.10.5 UNIONMELT 429 .................................................................................... 25

6.10.6 UNIONMELT 282 .................................................................................... 25

6.10.7 UNIONMELT 50 ...................................................................................... 26

6.10.8 UNIONMELT 80 ...................................................................................... 26

6.11 Electrodes and Fluxes for Submerged Arc Welding of the

Low Alloy Steels ...................................................................................... 27

6.11.1 Electrodes and Fluxes for Welding the Alloys......................................... 27


Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding ...... 28

6.12.1 Composition Requirements for Solid Low Alloy Electrodes .................... 29

6.13 Spoolarc Low Alloy Wires for Submerged Arc Welding .......................... 31

TABLE OF CONTENTSLESSON VI - Con't.


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LESSON VI

6.13.1 Manganese-Molybdenum Wires .............................................................. 31

6.13.2 Chromium-Molybdenum Wires ................................................................. 31

6.13.3 Nickel Wire .............................................................................................. 31

6.13.4 High Strength Wires................................................................................. 31

6.13.5 Special Purpose Wires ............................................................................ 31

6.14 Unionmelt Fluxes for Welding Low Alloy Steels ...................................... 32

6.14.1 Unionmelt 429......................................................................................... 32

6.14.2 Unionmelt 439......................................................................................... 32

6.14.3 Unionmelt 656......................................................................................... 32

6.15 Alloy Shield Composite Electrodes for Submerged Arc

Welding of the Low Alloy Steels .............................................................. 32

6.15.1 Alloy Shield B1S ..................................................................................... 32

6.15.2 Alloy Shield B2S ..................................................................................... 33

6.15.3 Alloy Shield B3S ..................................................................................... 34

6.15.4 Alloy Shield Ni1S .................................................................................... 34

6.15.5 Alloy Shield Ni2S .................................................................................... 35

6.15.6 Alloy Shield M2S..................................................................................... 35

6.15.7 Alloy Shield M3S..................................................................................... 36

6.15.8 Alloy Shield WS ...................................................................................... 36

6.15.9 Alloy Shield F2S ..................................................................................... 37

6.15.10 Alloy Shield 420SB ................................................................................. 37

Appendix A Glossary of Terms ................................................................................... 39

TABLE OF CONTENTSLESSON VI - Con't.


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®COPYRIGHT 2000 THE ESAB GROU

LESSON VI

CARBON AND LOW ALLOY STEEL FILLERMETALS FOR THE GMAW, GTAW AND SAW

WELDING PROCESSES

6.1 INTRODUCTION

6.1.0.1 During the early part of the 20th century, some welding was done using bare steel

wires or rods. The weld quality was poor because of the oxides and nitrides found in the weld

metal. Even after the advent of the extruded coated electrode in 1927, automated welding

using bare wires (or lightly coated wires) continued to be used, despite the poor qualities of

the welds, because this method allowed more rapid deposition of the weld metal. Critical

welds, however, were made with coated electrodes.

6.1.0.2 The advantages of using an inert gas to shield the arc were known during the 20’s

and 30’s, but the inert gases, such as helium and argon, were too expensive to produce.

6.1.0.3 In 1935, submerged arc welding (then known as submerged melt welding) was

introduced and provided a method of producing quality welds at greater welding speeds than

were obtainable with coated electrodes.

6.1.0.4 During World War II, the aircraft industry needed a reliable process for welding

magnesium engine parts and as a result, gas tungsten arc welding (GTAW), using a bare filler

wire and a helium gas shield, was developed.

6.1.0.5 Economical methods of producing the inert gases were ultimately developed,

leading to the use of solid wire with a helium or argon gas shield in the 1940’s. This process

became known as metal inert gas (MIG) welding.

6.1.0.6 In the early 1950’s, it was realized that a more economical shielding gas, such as

carbon dioxide, could be used if the wire chemistry was adjusted to neutralize the oxidizing

effect of this gas. Since carbon dioxide (CO2) is not an inert gas, the name MIG welding

actually did not apply to this process since CO2 is a reactive gas. As a result, the American

Welding Society has standardized on the term GMAW (Gas Metal Arc Welding) to include the

inert gases, active gases, and gas mixtures as covered in Lesson II. In Europe, the term MIG

(Metal Inert Gas) welding still applies to the process if an inert gas or mixtures of inert and

active gases are used, and the term MAG (Metal Active Gas) is used if straight CO2 is em-

ployed as the shielding gas.


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LESSON VI

6.1.0.7 Although carbon steel, low alloy steels, stainless steels, magnesium, copper, copper

alloys, titanium and other metals may be welded by one or all of the processes described

above, this Lesson will be confined to the filler metals for welding mild or carbon steels, and

low alloy high strength steels with the GMAW and GTAW processes.

6.2 MANUFACTURING

6.2.0.1 The manufacture of solid welding wires for GMAW or GTAW differs from the manu-

facture of coated or flux cored electrodes in that the deoxidizers and alloying elements that

contribute to the purity and mechanical properties of the weld metal, must be included in the

wire chemistry rather than in the flux. Therefore, the raw material must be ordered from the

supplier to exact specifications. When received, a sample from both ends of each coil of the

hot rolled rod is analyzed by the manufacturer to ensure that the “hot rod”, as it is called, meets

these specifications.

6.2.0.2 The hot rod is cleaned to remove mill scale or rust and drawn to an intermediate

diameter. At this stage, the wire has “work hardened” which necessitates that it be annealed

before it is copper plated, drawn down to final size, spooled and packaged.

6.2.0.3 Close quality checks must be made throughout the manufacturing process to insure

that the end product is a smooth finished, uniform diameter wire, that will feed easily through

the end user’s wire feeding equipment and welding gun. The wire is copper plated and/or

otherwise coated to retard oxidation or rusting of the wire, to decrease contact tip wear, and to

assure good electrical conductivity. The plating or coating must not flake off or leave a residue

that will clog the wire feed cable or the welding gun. If copper coated, the layer of copper must

be kept to a low level to minimize copper welding fumes and flaking.


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6.3 WIRE SELECTION FOR GAS SHIELDED ARC WELDING

6.3.0.1 When selecting the wire or filler metal for either the GMAW or GTAW process,

several things must be considered.

1. Mechanical Properties - The wire chosen must produce weld metal having approxi-

mately the same mechanical properties as the base metal whether it is carbon steel or

low alloy high tensile steel.

2. Shielding Gas - In Lesson II, we learned that the shielding gases used in GTAW of

carbon steel are pure argon or argon helium mixtures. In GMAW, shielding gases may

be pure CO2, or mixtures of argon, helium, CO2 and oxygen. The gas mixtures contain-

ing oxygen or CO2 will exhibit oxidizing characteristics which, if they combine with

carbon, will form carbon monoxide gas porosity in the weld metal.

a. The most common shielding gases used for welding mild and low alloy steels may

be classified in terms of their oxidizing effect as shown in Figure 1.

b. Each of the following variables should be considered when selecting the proper gas

for a specific job:

• MATERIAL TYPES • WELD METAL MECHANICAL

- Carbon, Stainless, Aluminum, etc. PROPERTIES

• MATERIAL CONDITION • JOB REQUIREMENT

- Rusty, Oily, Primed, etc. - Fit-Up

• TYPES OF METAL TRANSFER - Penetration

- Short Circuit, Spray, Pulse, etc. - Spatter Levels

OXIDATION POTENTIAL OF COMMONLY USED SHIELDING GASES

FIGURE 1

Pure Argon or 98% Argon 75% ArgonArgon - Helium 2% O2 25% CO2 Pure CO2

Mixtures

Process GTAW GMAW GMAW GMAW

Degree of Non- Slightly More MostOxidation Oxidizing Oxidizing Oxidizing Oxidizing


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LESSON VI

3. Wire Chemistry - In order to provide specific characteristics, it may be necessary to

have a filler metal that matches the base plate chemistry. The most common examples

are requirements to weld 1-1/4 Cr - 1/2 Mo steel with ER80S-B2(L) or 2-1/4 Cr - 1 Mo

steel with ER90S-B3(L) providing matching high temperature strength and scaling

resistance.

a. To minimize the oxidizing effect of the various shielding gases, elements that are

called deoxidizers are included in the wire in varying amounts. These deoxidizers,

usually silicon and manganese, and to a lesser extent titanium, aluminum, and zirco-

nium, will combine with the oxygen in preference to reacting with the carbon and will

form very small amounts of harmless glass-like slag islands on the weld surface.

b. In the case of GTAW of steels where inert gases such as argon or argon-helium

mixtures are used, there will be little or no loss of the deoxidizers.

c. In GMAW, where shielding gases of different mixtures are used and welds of the

highest quality are required, the filler wire must be selected to allow for the degree of

oxidation of the shielding gas. When welding carbon or low alloy steels with a 98%

argon - 2% oxygen mixture, wires containing low amounts of manganese and silicon

may be used. If welding carbon or low alloy steels with a 75% argon - 25% CO2 shield-

ing gas, wires with a higher amount of deoxidizers may be necessary to maintain the

proper manganese and silicon content in the weld metal. When welding with straight

CO2 as a shielding gas, wires with an even greater amount of deoxidizers may be

necessary.

4. Base Metal - The type of steel in the base metal will influence the type of wire selected.

Rimmed steel (see Lesson I), which involve the least oxidation during manufacture, will

require that the filler wire contain a higher level of deoxidizers than semi-killed steel that

is partially deoxidized. Killed steels that are fully deoxidized when manufactured may

be welded with wires with a lower deoxidizer content.

5. Rust and Mill Scale - which are actually iron oxide (FeO) are a further source of oxy-

gen that is detrimental to the weld metal unless a wire containing sufficient deoxidizers

is selected. Cold rolled steel, that is devoid of mill scale and is reasonably rust free,

may be welded with a wire having lower amounts of silicon and manganese. Hot rolled

steel, that is characterized by having some amount of mill scale on the surface, requires

a wire containing greater amounts of deoxidizers to produce sound welds.


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LESSON VI

6. Bead Geometry - Bead geometry (or bead shape) is influenced by both the amount ofdeoxidizers in the wire and by the specific selection of shielding gas. Increasing the

silicon and manganese content of the wire will produce flatter beads and better side

wall fusion (wetability) because the puddle is more fluid. See Figure 2.

a. The choice of shielding gas like-

wise influences bead shape. CO2

produces more spatter and a higher

crown or more convex bead.

Argon-CO2 and argon-O2 gas mixtures

provide smoother metal transfer, less

spatter, and better bead appearance.

7. Welding Current - When welding athigh current for greater weld metal deposition, the weld puddle becomes larger, mean-

ing that more of the base metal has been melted and will stay molten for a longer pe-

riod, allowing more time for oxidation and resultant porosity to take place. Also, high

currents produce a greater amount of heat in the arc area and will cause greater

amounts of an oxidizing shielding gas to be dissociated, thereby releasing more oxy-

gen in the area of the molten pool. For these reasons, a wire with higher levels of

deoxidizing elements should be selected for high current operation.

6.3.0.2 To summarize, the above 7 factors must be properly considered in order to produce

top quality welds. The economics of your decision should never compromise the need to

deposit the highest weld metal integrity possible. The result of your decision will only lead to

most cost effective choice of welding materials. The following are economic considerations:

1. The cost of the wire increases with the percentage of deoxidizers and alloying elements

such as silicon, manganese, chromium, molybdenum, nickel, etc. in the welding wire.

2. The cost of pure carbon dioxide is approximately one-fourth that of argon and

argon-CO2 or argon-O2 mixtures.

3. The deposition efficiency of solid wires is very high, but it varies with the shielding gas

and welding current being used. Figure 3 shows the average efficiency when using the

more common shielding gases. The differences in efficiency are due to spatter loss,

and are proportional to the amount of argon in the gas mixture. CO2 produces more

weld spatter and therefore a lower deposition efficiency.

SILICON-MANGANESE EFFECT ON BEAD SHAPEFigure 2

LOW SILICON-MANGANESECONTENT

HIGH SILICON-MANGANESECONTENT


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LESSON VI

4. The deposition rate of solid wires is very high when compared to that of coated elec-

trodes, but is somewhat lower than the deposition rate of flux cored electrodes.

6.4 AWS SPECIFICATION A5.18-93

6.4.0.1 This AWS specification is entitled Specification for Carbon Steel Filler Metals forGas Shielded Arc Welding. It covers bare carbon steel solid wires for use with the GMAW

and GTAW processes. It differs from the AWS specifications in the previous lessons in that it

classifies the chemical composition of the wire rather than that of the weld metal. It does,

however, classify the mechanical properties of the weld metal in the as-welded condition using

the gas metal arc welding process.

6.4.0.2 The chemical composition requirements are based on the chemical analysis of the

as-manufactured wire or filler metal and include the elements in the coating or copper plating

applied by the manufacturer.

6.4.0.3 The letter-number designations

in this specification are shown in Figure 4.

For example, ER70S-3 indicates an

electrode or welding rod (ER) that will

produce weld metal of a minimum 70,000

psi tensile strength (70); is a solid bare

wire or welding rod (S); of a specific

chemical composition (3) as shown in

Figure 5. For a complete chemical

composition of these wires, see AWS A5.18-93.

ELECTRODE OR WELDING RODMIN. TENSILE STRENGTH X 1000 psi

E R X X S - X

CHEMICAL COMPOSITIONBARE SOLID ELECTRODE OR ROD

LETTER - NUMBER DESIGNATIONSCARBON AND LOW ALLOY STEEL WIRES

FIGURE 4

DEPOSITION EFFICIENCIES - GAS METAL ARC WELDINGCARBON AND LOW ALLOY STEEL WIRES

FIGURE 3

Shielding Gas Efficiency Range Average Efficiency

Pure CO2 88% - 95% 93%

75% Ar - 94% - 98% 96%25% CO2

98% Ar - 2% O2 97% - 98.5% 98%


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LESSON VI

MAJOR ALLOYING ELEMENTS - % BY WEIGHT

AWS CLASS CARBON MANGANESE SILICON TITANIUM ZIRCONIUM ALUMINUM

ER70S-2 0.07 0.90 - 1.40 0.40 - 0.70 0.05 - 0.15 0.02 - 0.12 0.05 - 0.15

ER70S-3 0.06 - 0.15 0.90 - 1.40 0.45 - 0.70 — — —

ER70S-4 0.07 - 0.15 1.00 - 1.50 0.65 - 0.85 — — —

ER70S-5 0.07 - 0.19 0.90 - 1.40 0.30 - 0.60 — — 0.50 - 0.90

ER70S-6 0.07 - 0.15 1.40 - 1.85 0.80 - 1.15 — — —

ER70S-7 0.07 - 0.15 1.50 - 2.00 0.50 - 0.80 — — —

ER70S-G NO CHEMICAL REQUIREMENTS

CHEMICAL COMPOSITION - CARBON STEEL BARE WIRESFIGURE 5

6.4.0.5 Tensile strength requirements of the weld metal produced by the filler metals in this

classification are shown in Figure 6.

Tensile Yield

Shielding Strength Strength ElongationAWS Class Gas PSI PSI in 2" - % Min.

ER70S-2ER70S-3ER70S-4

ER70S-5 CO2 72,000 60,000 22ER70S-6ER70S-7

ER70S-G * 72,000 60,000 22* As agreed upon between supplier and purchaser

WELD METAL TENSILE REQUIREMENTS

FIGURE 6

}Minimum

AWS Class Impact Properties

ER70S-2 20 ft-lb @ -20° FER70S-3 20 ft-lb @ 0° F

ER70S-4 Not RequiredER70S-5 Not RequiredER70S-6 20 ft-lb @ -20° F

ER70S-7 20 ft-lb @ -20° FER70S-G As agreed between

supplier & purchaser

WELD METAL IMPACT PROPERTIES

FIGURE 7

6.4.0.6 Although Figure 6 shows CO2 as the shielding gas, the specification does not

restrict the use of argon-CO2 or

argon-mixtures. It states that a filler metal

classified with CO2 will also meet

specification requirements when used with

the above gas mixtures.

6.4.0.7 Impact properties, according to

the Charpy V-notch test as listed in the

specification, are shown in Figure 7.


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LESSON VI

6.5 INDIVIDUAL FILLER METAL CHARACTERISTICS

6.5.1 ER70S-2 - This classification covers filler metals that contain small amounts of

titanium, zirconium, and aluminum, in addition to the normal deoxidizing elements of manga-

nese and silicon. These wires are commonly referred to as “triple deoxidized wires”. They will

produce sound welds in all types of carbon or mild steels. They are especially suited for

welding carbon steels that are rusty or have mill scale on the surface. Weld integrity will vary

with the amount of oxides on the surface of the steel. They may be used with CO2, argon-CO2,

or argon-O2 shielding gas mixtures. They work well in the short-circuiting mode for

out-of-position welding.

6.5.2 ER-70S-3 - Filler metals of this classification contain a relatively low percentage of

deoxidizing elements; however, they are one of the most widely used GMAW wires. They

produce welds of fair quality when used to weld rimmed steels (steels with high oxygen con-

tent) using argon-O2 or argon-CO2 as a shielding gas. The use of straight CO2 is not recom-

mended when welding rimmed steels. Sound welds may be made when welding semi-killed

(low oxygen) and killed (fully deoxidized) steels using argon-O2, argon-CO2, or straight CO2.

6.5.2.1 Wires of this classification may be used for out-of-position welding in the

short-circuiting transfer mode using argon-CO2 or CO2 shielding gas.

6.5.2.2 When CO2 shielding gas is used, high welding currents should be avoided because

welds produced may not meet the minimum tensile and yield strengths of this specification.

6.5.3 ER70S-4 - Containing slightly higher silicon and manganese contents than the

ER70S-3 type, these filler metals will produce weld metal of higher tensile strength. Primarily

used for CO2 shielding gas applications where a higher degree of deoxidization is necessary.

6.5.4 ER70S-5 - The filler metals in this classification contain aluminum as well as silicon

and manganese as deoxidizers. The addition of aluminum allows these wires to be used at

higher welding currents with CO2 as the shielding gas. Not used for out-of-position

short-circuiting type transfer because of high puddle fluidity. Can be used for welding rusty or

dirty steels with a slight loss of weld quality.

6.5.5 ER70S-6 - Wires in this classification contain the highest combination of deoxidiz-

ers in the form of silicon and manganese. This allows them to be used for welding all types of

carbon steel, even rimmed steels, using CO2 as a shielding gas. They produce smooth, well

shaped beads, and are particularly well suited for welding sheet metal. This filler metal is also

useable for out-of-position welding with short-circuiting transfer. Moderately rusted or scaled


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LESSON VI

steels may be welded successfully with this wire. The weld quality depends on the degree of

surface impurities. This wire may be used for high current, high deposition welding using

argon mixed with 5-10% oxygen or carbon dioxide.

6.5.6 ER70S-7 - This wire is similar to the ER70S-3 classification, but it has a higher

manganese content which provides better wetting action and bead appearance. The tensile

and yield strengths are slightly higher, and welding speed may be increased compared to the

ER70S-3 type. This filler metal is usually recommended for use with argon-O2 shielding gas

mixtures, although argon-CO2 and straight CO2 may be used. The weld metal will be slightly

harder than that of the ER70S-3 types, but not as hard as an ER70S-6 deposit.

6.5.7 ER70S-G - This classification may be applied to solid filler metals that do not fall

into any of the preceding classes. It has no specific chemical composition or shielding gas

requirements, but must meet all other requirements of the AWS A5.18-93 specification.

6.6 ESAB BARE SOLID CARBON STEEL WIRES

6.6.1 Spoolarc 65 (AWS Class ER70S-2) - Spoolarc 65 is a cut length electrode avail-

able for a variety of tig and oxy-fuel gas welding applications. In addition to the standard

deoxidizers, ER70S-2 also contains additional cleaners such as aluminum, titanium, and

zirconium. This electrode is often used on out-of-position welding of pipe joints. The ends of

the 36" electrode can be flag tagged for identification purposes.

A. Typical Chemical Analysis of the Wire

Carbon 0.08% Phosphorus 0.011%

Manganese 1.00% Sulfur 0.009%

Silicon 0.40%B. Typical Mechanical Properties of the Weld Metal

As Welded Stress Relieved*

Yield Point, psi 67,500 62,500

Tensile Strength, psi 77,500 72,500

% Elongation (2") 31 33

% Reduction of Area 73 78

Charpy V-Notch Impacts

ft.-lbs. @-20°F 170 160

* 8 hrs. at 1150°F


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LESSON VI

6.6.2 Spoolarc 29S (AWS Class ER70S-3) - Spoolarc 29S is a copper coated wire for

general purpose welding with the gas-metal arc process. It contains sufficient deoxidizers to

produce sound welds on killed and semi-killed steels and adequate welds on rimmed steels.

Carbon dioxide or argon-CO2 shielding gas mixtures may be used. The smaller diameters (up

to .045") are especially useful for welding light gauge mild steel in all positions. Among the

many applications for which Spoolarc 29S may be used are farm equipment, metal furniture,

iron work, trailers, truck bodies, metal fixtures, light vessels, and hoppers.




Silicon 0.27%

B. Typical Mechanical Properties of the Weld Metal Using CO2 Shielding Gas

Yield Point, psi 60,100

Tensile Strength, psi 75,000

% Elongation (2") 32

Charpy V-Notch Impacts 95 ft.-lbs. @0°F

6.6.3 Spoolarc 85 (AWS Class ER70S-4) - Spoolarc 85 is a copper plated gas-metal

arc welding wire. This wire contains more manganese and silicon for greater deoxidation than

ER70S-3 wire. The additional levels of deoxidizers provides more improved rust and mill

scale tolerance, while improving bead cosmetics.




Silicon 0.39% Copper 0.16%






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LESSON VI

6.6.4 Spoolarc 86 (AWS Class ER70S-6) - Spoolarc 86 is a copper plated gas-metal

arc welding wire. Containing a high level of deoxidizers, it produces sound welds in all carbon

steels using CO2 shielding gas, argon/CO2 and argon/O2 mixtures. The arc is quiet and very

stable. High speed, high deposition welds can be made with argon-oxygen gas mixtures.

Ideal for welding sheet metal where smooth weld beads with good wetting action are desir-

able. It may be used to weld carbon steels that have a moderate amount of rust or mill scale.

Spoolarc 86 can also be used for out-of-position welding with the short-circuit transfer method,

making it ideal for pipe welding. Other applications are for bridges, building construction,

boiler and pressure vessels, storage tanks, auto parts, and construction equipment.




Silicon 0.57%





Charpy V-Notch Impacts 31 ft.-lbs. @-20°F

6.6.5 Spoolarc 87HP (AWS Class ER70S-7) - Spoolarc 87HP is a high manganese

carbon steel wire. It features an optimized manganese to silicon ratio to produce excellent

appearing welds over a wide range of welding parameters. It also produces excellent weld

metal mechanical properties and welds over moderate amounts of rust and scale.




Silicon 0.65%

B. Typical Mechanical Properties of the Weld Metal Using 75% Ar/25% CO2






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LESSON VI


6.7.0.1 This specification is entitled Specification for Low Alloy Steel Filler Metal for GasShielded Arc Welding. It covers the solid bare wires for welding those steels commonly re-

ferred to as the chromium-molybdenum (chrome-molys), manganese-molybdenum

(manganese-molys), nickel alloy and other low alloy steels. The wires referred to in this lesson

are for use with the gas-metal arc welding process and also may be used as filler metals for

the GTAW process.

6.7.0.2 The letter-number designations have the same significance as those used in the

carbon steel specification shown in Figure 4. Using ER80S-B2 as an example, the letters ER

indicate that it is an electrode or a welding rod; will produce weld metal of 80,000 psi tensile

strength (80); is a solid bare wire (S) of a specific chemical composition (B2) as described in

Figure 8.Major Alloying Elements - % By Weight

AWS Class Carbon Chromium Molybdenum

ER80S-B2L *0.05 1.20 - 1.50 0.40 - 0.65

ER80S-B2 0.07 - 0.12 1.20 - 1.50 0.40 - 0.65

ER80S-B3L 0.05 2.30 - 2.70 0.90 - 1.20

ER80S-B3 0.07 - 0.12 2.30 - 2.70 0.90 - 1.20

* Single figure denotes maximum

CHEMICAL COMPOSITION CHROMIUM-MOLYBDENUM SOLID BARE WIRES

FIGURE 8

6.7.1 The Chromium-Molybdenum Types (Cr-Mo) - The letter “B” designates a Cr-Mo

wire to be used for welding the Cr-Mo pressure vessel steels, and the number that follows desig-

nates the chemical composition of the filler metal. If the last number is followed by an “L”, it

indicates that the wire has a low carbon content.

6.7.1.1 Figure 8 shows only the major chemical composition requirements for these filler

metals. For complete requirements, see AWS A5.28-96 Filler Metal Specification.

6.7.1.2 Figure 9 shows the mechanical property requirements for the Cr-Mo weld metal.

6.7.1.3 Filler metals of the preceding classifications are used to weld the 1/2 Cr-1/2 Mo, 1

Cr-1/2 Mo, 1-1/4 Cr-1/2 Mo, and 2-1/4 Cr-1 Mo steels that are used in welding high tempera-

ture piping and pressure vessels. They provide a degree of corrosion resistance and are

used for welding dissimilar grades of Cr-Mo steels and carbon steels.


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®COPYRIGHT 2000 THE ESAB GROUP, INC

LESSON VI

6.7.1.4 These filler metals may be used with all GMAW metal transfer modes. The AWS

mechanical properties and impact properties are established using argon plus 1-5% oxygen

as a shielding gas. Straight CO2 and argon-CO2 mixtures may be used. These mixtures will

produce welds with deeper penetration, although impact properties will be somewhat lower.

6.7.1.5 Welding low alloy high strength steels with the GMAW process requires that pre-

heat, interpass, and post-weld temperatures be closely controlled to prevent cracking. The low

carbon filler metals designated by the letter “L” will provide greater resistance to cracking, and

are more suitable when post-weld heat treatment is not practical or possible.

6.7.2 The Nickel Alloy Types (Ni) - The letters

“Ni” designate that the filler metal is a nickel alloy

wire for welding the nickel alloy steels. The number

following the letters designates the chemical

composition of the wire. Figure 10 shows only the

amount of nickel required in the wire under this

specification. For complete chemical

requirements, see AWS A5.28-96 Filler Metal

Specification.

6.7.2.2 Figure 11 shows the mechanical property requirements for nickel alloy weld metals.

Tensile YieldStrength Strength Elongation Impact

AWS Class psi psi in 2", % Properties

ER80S-B2 80,000 68,000 19 Not Required

ER80S-B2L 80,000 68,000 19 Not Required

ER90S-B3 90,000 78,000 17 Not Required

ER90S-B3L 90,000 78,000 17 Not Required

All values are mininums

MECHANICAL PROPERTIES OF Cr - Mo WELD METAL

FIGURE 9

NickelAWS Class % by WeightER80S-Ni1 0.80 - 1.10

ER80S-Ni2 2.00 - 2.75

ER80S-Ni3 3.00 - 3.75

NICKEL REQUIREMENTS

NICKEL ALLOY SOLID BARE WIRESFIGURE 10


AWS Class psi psi in 2", Min. Properties

ER80S-Ni1 20 ft-lb @ -50°F

ER80S-Ni2 80,000 68,000 24 20 ft-lb @ -80°F

ER90S-Ni3 20 ft-lb @ -100°F

All values are mininums

MECHANICAL PROPERTIES OF NICKEL ALLOY WELD METALS

FIGURE 11

}


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LESSON VI

6.7.2.3 Nickel alloy wires are used for welding the nickel alloy steels that are employed in

applications requiring 80,000 psi tensile strength and good toughness at low temperatures.

The ER80S-Ni1 wire deposits weld metal containing a nominal 1% nickel, similar to an

E8018C3 coated electrode. The ER80S-Ni2 deposits weld metal containing a nominal 2-1/

2% nickel, similar to an E8018C1 coated electrode and the ER80S-Ni3 deposits weld metal

containing a nominal 3-1/2% nickel, similar to an E8018C2 coated electrode.

6.7.2.4 The weld metal deposit will have a chemical composition similar to the chemical

composition of the wire when argon-O2 shielding gas is used. If CO2 is used as a shielding

gas, the deoxidizing elements, such as manganese and silicon, will be considerably reduced

in the weld metal. The recommended shielding gas is argon plus 1.0 to 5.0% oxygen. Weld-

ing the nickel alloy steels usually requires that the weldment be preheated before welding, and

the interpass temperature controlled. It may also be necessary to subject the weldment to post

weld heat treatment, depending on the alloy and thickness of the material.

6.7.3 The Manganese-Molybdenum Types ”Mn-Mo” - The suffix letter “D” designates

a manganese-molybdenum wire to be used for welding the manganese-molybdenum steels.

The number that follows designates the chemical composition of the wire.

6.7.3.1 There is only one manganese-moly wire in this classification. It is designated asER80S-D2 and was formerly classified as E70S-1B in AWS Specification A5.18-89 (since

updated to A5.18-93).

A. Chemical Composition Requirements for ER80S-D2 Bare Solid Wire

Carbon 0.07-0.12% Nickel 0.15% max.

Manganese 1.60-2.10% Copper 0.50% max.

Silicon 0.50-0.80% Phosphorus0.025% max.

Molybdenum 0.40-0.60% Sulfur 0.025% max.

B. Mechanical Property Requirements ER80S-D2 Weld Metal

Yield Strength, psi 60,000





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LESSON VI

6.7.3.2 This wire is suitable for welding a large variety of low alloy and carbon steels. It is

excellent for out-of-position work and contains molybdenum for increased strength. Argon-O2

and argon-CO2 gas mixtures are recommended for maximum mechanical properties, but

welds made with CO2 shielding gas will still deliver mechanical properties within the specifica-

tion limits due to the high level of manganese and silicon in the wire. The high level of deoxi-

dizers allows this wire to be used over moderate amounts of rust and mill scale.

6.7.4 Spoolarc 83 (AWS Class ER80S-D2) - Spoolarc 83 is a small diameter copper

coated solid wire for gas metal arc welding. Because of the additional alloys, manganese,

and molybdenum, the deposit is adequate for high strength low alloy steels. In addition, the

higher levels of deoxidizers provide improved rust and mill scale tolerance, as well as

out-of-position capabilities. This wire is most commonly used on pressure vessel and gas

transmission line applications.




Silicon 0.27% Molybdenum 0.38%

B. Typical Mechanical Properties of the Weld MetalUsing CO2 Shielding Gas




% Reduction of Area 66.8


6.7.5 Spoolarc Hi-84 (AWS Class ER80S-D2) - Spoolarc Hi-84 is a 1/2% Mo wire that

has been microalloyed to produce exceptional impact toughness at temperatures as low as

-50°F. The weld metal deposit produces a high strength weld with good tolerance of rust and

mill scale.


Carbon 0.11% Nickel 0.15%

Manganese 1.90% Chromium 0.08%

Silicon 0.60% Ti and Zr 0.017%

Molybdenum 0.50%


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®COPYRIGHT 2000 THE ESAB GROUP, INC

LESSON VI

B. Typical Mechanical Properties of the Weld MetalUsing 98% Ar/2% O2

Shielding Gas





51 ft.-lbs. @-50°F6.7.6 All Other Low Alloy Types

6.7.6.1 Solid wires for welding the low alloy high tensile steels that do not fit into the com-

mon Cr-Mo, Ni alloys and Mn-Mo types, fall into the “all other” category. They produce welds

with very high strength and very good notch toughness. These alloys are designated by the

numbers “1”, “2”, or "G" as shown in Figure 12.

6.7.6.2 Only the major alloying elements for these wires are shown above. For complete

chemical composition requirements, see AWS Filler Metal Specification A5.28-96.

Major Alloying Elements - % By WeightAWS Class Carbon Manganese Nickel Chromium MolybdenumER100S-1 0.08* 1.25 - 1.80 1.40 - 2.10 0.30 0.25 - 0.55ER100S-2 0.12 1.25 - 1.80 0.80 - 1.25 0.30 0.20 - 0.55ER110S-1 0.09 1.40 - 1.80 1.90 - 2.60 0.50 0.25 - 0.55ER120S-1 0.10 1.40 - 1.80 2.00 - 2.80 0.60 0.30 - 0.65ERXXS-G As agreed between supplier and purchaser

*Single values are maximums.

CHEMICAL COMPOSITION - OTHER LOW ALLOYS - SOLID BARE WIREFIGURE 12


AWS Class psi psi in 2", Min. Properties

ER100S-1 100,000 88,000 - 102,000 16

ER100S-2 100,000 88,000 - 102,000 16

ER110S-1 110,000 95,000 - 107,000 15

ER120S-1 120,000 105,000 - 122,000 14

ERXXS-G * As agreed between supplier and purchaser

* Ultimate tensile strength must meet value placed after "ER"WELD METAL MECHANICAL PROPERTIES REQUIREMENTS - OTHER LOW ALLOYS

FIGURE 13

} 50 ft-lb @ -60°F

6.7.6.3 The mechanical requirements for the weld metal deposited in this classification are

shown in Figure 13.


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LESSON VI

6.7.6.4 The wires in this category were originally developed for the high strength steels in

military applications. Today, they are used in structural and other applications requiring tensile

strengths in excess of 100,000 psi and toughness at low temperatures. Common types of

steels welded with these wires are the T-1, HY-80, HY-100, NAXtra100 and others.

6.7.7 Spoolarc 95 and 120 (AWS Class ER100S-1 and ER120S-1) - Spoolarc 95 and

120 are Military grade high strength wires designed for welding HY-80 and HY-100 steels.

Both wires produce excellent mechanical properties and low temperature toughness. They

can be used for nonmilitary applications requiring high strength and low temperature tough-

ness.

A. Typical Chemical Analysis of the WireSpoolarc 95 Spoolarc 120

Carbon 0.07% 0.07%

Manganese 1.40% 1.30%

Silicon 0.35% 0.35%

Molybdenum 0.35% 0.45%

Chromium 0.20% 0.40%

Nickel 1.80% 2.60%

B. Typical Mechanical Properties of the Weld Metal Using 98% Ar/2% O2 Shielding Gas

Spoolarc 95 Spoolarc 120

Yield Strength, psi 95,000 112,000




ft.-lbs. @-0°F 93 100

ft.-lbs. @-60°F 65 75

The suffix letter “G” applies to solid wire electrodes and welding rods that do not fall into any of

the other classes in this specification. They must have at least one of the following: 0.50%

nickel, 0.30% chromium, or 0.20% molybdenum. They must pass the radiographic soundness

test for porosity or inclusions, and also the weld metal tensile tests that are spelled out in detail

in this specification.


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LESSON VI

6.8 WIRES AND FLUXES FOR SUBMERGED ARC

WELDING OF CARBON STEELS

6.8.0.1 In submerged arc welding (SAW), the weld metal quality, mechanical properties and

bead shape are the result of the electrode* (or wire) and flux combination used in a particular

application. Unlike coated electrodes, where the core wire and flux coating are inseparable,

various fluxes may be used with a given wire to produce the desired results. The weld area is

shielded by this blanket of flux. When molten, the flux forms a protective layer above the molten

weld metal that not only provides for specific mechanical properties, but also gives the bead

some shape.

Note - * The American Welding Society has standardized on the term “electrode” when referring to the wires used inSAW since these wires always carry the welding current. In this Lesson, the terms wire and electrode will be usedinterchangeably and will have the same meaning.

6.8.0.2 The advantages for using SAW are numerous. They include:

a. High rates of travel.

b. High deposition rates.

c. Superior weld metal integrity.

d. Reduce edge preparations.

e. Improved operator comfort and safety.

6.8.1 Equipment - The SAW process can utilize either an AC or DC power supply. DC is

most often chosen because it provides the following advantages:

a. Good control over bead shape and penetration.

b. Best arc starting characteristics on either electrode positive (+) or

electrode negative (-).

c. DCEN offers 10-15% higher deposition rates than AC.

d. DCEP offers better bead shape control and deeper penetration.

e. Lowest cost to purchase.

6.8.1.1 AC, on the other hand, provides features as well. They include:

a. Reduced arc blow (especially when amperage exceeds 800 amps or when

welding on heavy sections).

b. Increased flexibility when used in combination with multiple wires (DC-AC,

AC-AC, or AC-AC-AC).


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LESSON VI

6.8.2 Welding Filler Metals - A continuous bare electrode is fed into a blanket of granular

flux that covers the weld joint. Once current is applied to the electrode, usually ranging in size

from 1/16" to 1/4" diameter, an arc is established and the base metal, the electrode, and the

flux melt to form a molten puddle. The solid electrode is usually copper coated, except for

certain nuclear applications, to minimize contact tip wear and assure good current transfer to

the wire. The molten flux flows to the surface to form a slag while the metallic components

create a weld.

6.8.2.1 Since high currents are usually applied to the electrode, extremely high deposition

rates are possible with SAW. The current and voltage ranges reflected in Figure 14 will pro-

vide information on the deposition capability of SAW.

Deposition Rate*Wire Diameter Current Ranges Volts lbs./hr.

1/16" (1.6 mm) 150 - 500 19 - 27 5-17 (2.27- 7.71 Kg)

5/64" (2.0 mm) 200 - 600 20 - 28 6-22 (2.72- 9.98 Kg)

3/32" (2.4 mm) 250 - 700 22 - 30 8-24 (3.63-10.89 Kg)

1/8" (3.2 mm) 300 - 900 23 - 32 8-28 (3.63-12.70 Kg)

5/32" (4.0 mm) 400 - 1000 25 - 34 9-30 (4.08-13.61 Kg)

3/16" (4.8 mm) 500 - 1100 27 - 36 12-34 (5.44-15.42 Kg)

7/32" (5.6 mm) 600 - 1200 30 - 37 20-44 (9.07-19.96 Kg)

1/4" (6.4 mm) 700 - 1600 30 - 38 18-56 (8.16-25.40 Kg)

OPERATING RANGES AND DEPOSITION RATES(DCEP - ESO AVERAGE 8 X WIRE DIAMETER)

FIGURE 14

6.8.2.2 Composite submerged electrodes, as described in Lesson II, are not normally used

for welding carbon steel. They are, however, used in welding low alloy high strength materials.

Current and voltage ranges will differ, along with their respective deposition rates. These

electrodes will be discussed late in this lesson.

6.8.3 Fluxes for Carbon Steel Electrodes - The granular powder, referred to as “flux”,

under which the welding takes place, shields the molten puddle from the atmosphere, cleans

the weld metal, and influences the mechanical properties and shape of the weld bead. The flux

also acts as a barrier preventing the heat from escaping, permitting the desired depth of

penetration (this can vary with current and polarity). Fluxes differ as a result of the method

used to manufacture them.


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LESSON VI

6.8.3.1 Fluxes are classified as either “bonded” or “fused” based on the manufacturing

methods. When manufacturing a bonded flux, fine particles of various ingredients are dry

mixed and bonded together with a sodium silicate or other similar compound. The wet

bonded mix is pelletized and baked at relatively low temperatures. The pellets are then broken

into smaller pieces and screened into proper sizes and packaged for shipment.

6.8.3.2 The advantages of “bonded” fluxes are that additional deoxidizers and alloying

elements can be added. Secondly, this type of flux generally has a lower consumption rate.

The major disadvantage of a bonded flux is their inherent moisture pick-up, especially when

opened, bags are allowed to remain exposed to the atmosphere.

6.8.3.3 “Fused” fluxes are manufactured under different conditions. The raw materials are

mixed together and then melted at very high temperatures in a furnace. The molten mixture is

cooled either by pouring it onto a chill table and allowed to cool, or shooting the molten mixture

with a stream of water. The glass-like material is crushed, then screened to a particular par-

ticle size and packaged for shipment.

6.8.3.4 “Fused” fluxes offer several advantages to the user, including much less moisture

pick-up than bonded fluxes. Secondly, the user has better control of weld metal properties

after recycling used flux. The major disadvantage with fused fluxes is the inability to add

additional deoxidizers and alloys during manufacturing.

6.8.3.5 Fluxes are also described as “active” or “neutral”, depending on the amount of

alloying elements or deoxidizers (especially manganese or silicon) that are transferred to the

weld metal.

a. Active Fluxes - contain manganese and silicon. Active fluxes are readily trans-

ferred to the weld metal. The amount transferred depends on the amount of flux consumed per

unit of wire. Excessively high manganese and silicon transferred to the weld can cause weld

metal cracking. Active fluxes are recommended for single pass or limited multipass welding

applications. Changes in arc voltage can greatly effect the flux consumption per unit of wire

and the weld metal properties. It is, therefore, crucial to adhere to the manufacturer’s sug-

gested welding parameters.

b. Neutral Fluxes - produce little significant change in weld metal properties as aresult of arc voltage. The primary purpose for neutral fluxes is that they can be used on multi-

pass weldments, especially those that exceed one inch thickness. The disadvantage for

neutral fluxes is their low tolerance to rust and mill scale. Generally speaking, active fluxes are

used with carbon steel electrodes, while neutral fluxes are recommended for both carbon and

low alloy steels.


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LESSON VI

Costs


6.9.0.1 This AWS specification is entitled Specification for Carbon Steel Electrodes andFluxes for Submerged Arc Welding. It classifies the electrodes on the basis of their chemical

composition as shown in Figure 15A. The fluxes are classified on the basis of the mechanical

properties of the weld metal they deposit with a particular classification of electrode as shown

in Figure 15B.

Electrode When Used, Indicates Electrode MadeFrom Silicon-Killed (Deoxidized) Steel.

E X X X K

PercentCarbon

By Weight

8 = 0.10 Max.12 = 0.05 - 0.1513 = 0.07 - 0.1914 =15 =}0.10 - 0.20

PercentManganeseBy Weight

L = 0.25 - 0.60M = 0.80 - 1.40H = 1.70 - 2.20

ELECTRODE DESIGNATIONS FOR SUBMERGED ARC WELDING CARBON STEELFIGURE 15A

F X X X

A = As WeldedP = Postweld Heat Treatment

1150° for 1 Hour

Flux

F6XX F7XX

Tensile 60,000 70,000Strength to to

psi 80,000 95,000

YieldStrength 48,000 58,000

psi Min. Min.

Elongation 22 22% in 2" Min. Min.

FLUX DESIGNATIONS FOR SUBMERGED ARC WELDING CARBON STEELFIGURE 15B

Impact RequirementsCharpy V-Notch

Z No Requirement0 0° F2 -20 °F4 -40 °F5 -50 °F6 -60 °F8 -80 °F

}20 ft-lbs @


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LESSON VI

6.9.0.2 For example, when a manufacturer assigns the AWS classification EM12K to a

given wire or electrode, he certifies that his product is an electrode (E); containing a medium

manganese content of 0.80 to 1.40% (M); containing a carbon content of 0.05 to 0.15% (12);

and is made from a heat of silicon-killed steel (K).

6.9.0.3 When classifying a flux as to mechanical properties, it is necessary to also specify

the electrode or wire with which these properties are obtained. As an example, the classifica-

tion F7P6-EM12K certifies that the product is a submerged arc flux (F); will provide weld metal

of 70,000 to 95,000 psi tensile strength, a minimum of 58,000 psi yield strength and a mini-

mum of 22% elongation in two inches after the weldment has been subjected to a postweld

heat treatment of 1150°F for one hour (P); and will have a minimum charpy V-notch impact of

20 ft.-lbs. at -60°F when used with an EM12K wire.

6.9.0.4 The eleven types of carbon steel electrodes listed in AWS A5.17-89 are as follows:

A. Low Manganese Steel Electrodes

1) EL8

2) EL8K

3) EL12B. Medium Manganese Steel Electrodes

1) EM12

2) EM12K

3) EM13K

4) EM14K

5) EM15KC. High Manganese Steel Electrodes

1) EH11K

2) EH12K

3) EH14

6.9.0.5 The carbon and manganese content of these wires are shown in Figure 15. For

complete chemical composition of these wires, see AWS Filler Metal Specification A5.17-89.


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LESSON VI

6.10 ESAB WIRES AND FLUXES FOR CARBON STEEL

SUBMERGED ARC WELDING

6.10.1 Spoolarc 81 (AWS Class EM12K) - Spoolarc 81 is a general purpose submerged

arc wire for moderately clean material. Applications include low and medium structural carbon

steel, longitudinal and circumferential welds on low to medium strength pressure vessel steels

and some offshore and ship fabrication.





B. Typical Mechanical Properties (* See note following Unionmelt 80)

Weld UTS YS % CVN (ft-lbs) AWS/ASMEFlux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class

231 AW 82-90 75-80 25-29 24-29 F7A2-EM12K

429 AW 75-82 65-72 25-30 35-45 F7A2-EM12K

SR(a) 70-75 58-64 25-30 35-45 @-40°F F7P4-EM12K

80 AW 70-75 60-65 27-31 35-45 F6A2, F7A2-EM12K

(a) Stress-Relieved @1150°F - 1 hr.

6.10.2 Spoolarc 29S (AWS Class EM13K) - Spoolarc 29S has increased amounts of sili-

con for both improved puddle fluidity and rust and mill scale tolerance. This wire is not recom-

mended for material greater than 1" thickness. Applications include single pass high speed

fillets on both low and medium carbon steels.






Weld UTS YS % CVN (ft-lbs) AWS/ASMEFlux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class231(a) AW 85-94 77-83 25-29 25-30 @ 0°F. F7A0-EM13K429 AW 80-85 66-73 25-30 28-35 @-20°F. F7A2-EM13K(a) This combination of flux and wire is only recommended for single pass welding.


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LESSON VI

6.10.3 Spoolarc 80 (AWS Class EL12) - Spoolarc 80 has the least amount of manganese

and silicon and is therefore intended for clean material. The major advantage of this wire is the

improved ductility, ease of machining and improved crack resistance. Applications include high

speed fillets on axle housings and wheel rims and thick heavy sections on highly restrained

multipass weldments.





B. Typical Mechanical Properties

Weld UTS YS % CVN (ft-lbs) AWS/ASMEFlux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class

231(a) AW 71-77 60-69 26-31 15-25 @ 0°F. F7AZ-EL12

429 AW 64-69 55-60 26-32 45-55 @-20°F. F6A2-EL12

(a) This combination of flux and wire is only recommended for single pass welding.

6.10.4 Unionmelt 231 - Unionmelt Flux 231 is an active flux that is limited to a maximum

plate thickness of one inch or less and operated at less than 36 volts. Applications include single

and multipass flat and horizontal fillets over rust and mill scale. This flux can be used with Spoolarc

81, 29S and 80.

A. Typical Deposit ChemistryAWS/ASME

Wire Material C Mn Si Cu SFA 5.17

81 A516 0.08 1.20 0.55 0.11 F7A2-EM12K

29S(a) A285 0.08 1.30 0.70 0.10 F7A0-EM13K

80 A36 0.07 0.90 0.40 0.11 F7AZ-EL12


Spoolarc Weld UTS YS % CVNMaterial Wire Condition (ksi) (ksi) Elong. (ft.-lbs.)

A516 81 AW 82-90 75-80 25-29 24-29 @-20°F

A285 29S(a) AW 85-94 77-83 25-29 25-30 @ 0°F

A36 80 AW 71-77 60-69 26-31 15-25 @ 0°F

(a) Unionmelt Flux 231 and Spoolarc 29S are recommended for single pass welding only.


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LESSON VI

6.10.5 Unionmelt 429 - Unionmelt Flux 429 is a neutral bonded flux designed for multipass

welding. Weld metal chemistries are excellent both as-welded and stress-relieved. Applica-

tions include deep groove multipass welds found on pressure vessels and offshore oil fabrica-

tion. Commonly used with hand-held semi-automatic equipment. This flux can be used with

Spoolarc 81 and 29S.

A. Typical Deposit Chemistry

AWS/ASMEWire Material C Mn Si Cu SFA 5.17

81 A36 0.07 1.25 0.50 0.14 F7A2-EM12K

29S A285 0.06 1.28 0.70 0.12 F7A2-EM13K



A36 81 AW 75-90 75-80 25-29 24-29 @-20°F

SR(a) 70-75 58-64 25-30 35-45 @-40°F

A285 29S AW 80-85 66-73 25-30 28-35 @-20°F

(a) Stress-Relieved @1150°F - 1 hr.

6.10.6 Unionmelt 282 - Unionmelt Flux 282 is an active bonded flux designed for high speed

single pass welding on thin gauge material. The weld metal fluidity and high travel speeds make

this flux extremely versatile. Applications include longitudinal welds on structural steel, as well as

circumferential seams on spiral pipe. This flux is best used with Spoolarc 81 and 29S.

A. Typical Mechanical Properties (* See note following Unionmelt 80)

Spoolarc Wire Tested Per AWS A5.17-89

Spoolarc 81 Conforms to F7A0-EM12K (20 ft.-lbs. @ 0°F)

Spoolarc 29SConforms to F7A0-EM13K (20 ft.-lbs. @ 0°F)


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LESSON VI

6.10.7 Unionmelt 50 - Unionmelt Flux 50 is a neutral fused flux developed for high speed

welding of thin gauge material (usable on relatively clean steel only). In addition, this flux works

equally well for surfacing and build-up applications. Because this flux is a fused type, it is particu-

larly resistant to moisture pick-up. Applications include propane cylinders and hot water tanks.

This flux can be used with Spoolarc 81 and 80.


Spoolarc AWS/ASMEMaterial Wire C Mn Si SFA 5.17

A36 81 0.05 0.93 0.30 F7A2-EM12K

Stress-Relieved F6P4-EM12K

A36 80 0.05 1.17 0.42 F6A2-EL12



A36 81 AW 70-75 60-65 24-28 25-40 @-20°F

SR(a) 65-70 50-55 25-29 75-80 @-20°F

A36 80 AW 65-70 55-60 24-28 30-40 @-20°F

(a) Stress-Relieved @1150°F - 8 hrs.

6.10.8 Unionmelt 80 - Unionmelt Flux 80 is a neutral fused flux for multipass, heavy plate

welding applications. Superior mechanical properties on clean material is available in both

as-welded and stress-relieved conditions. The low moisture pick-up of this flux helps reduce the

handling and storage casts. Applications include carbon and low alloy steels used to fabricate

pressure vessels. This flux can be used with Spoolarc 81 and 80.


Spoolarc AWS/ASMEMaterial Wire C Mn Si SFA 5.17

A36 81 0.06 1.0 0.50 F6A2, F7A2-EM12K

A36 80 0.05 0.60 0.40 F6A2-EL12

B. Typical Mechanical Properties *


A36 81 AW 70-75 60-65 26-30 35-45 @-20°F

A36 80 AW 65-70 55-60 26-30 45-55 @-20°F

* NOTE: The data listed for both the deposit chemistry and mechanical properties are based on laboratory tests.Results may vary according to your specific welding parameters or base metal conditions. It is,therefore, important that the user run tests that closely duplicate their actual production conditions.


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LESSON VI

6.11 ELECTRODES AND FLUXES FOR SUBMERGED ARC

WELDING OF THE LOW ALLOY STEELS

6.11.0.1 In an earlier lesson, we learned that most low alloy coated electrodes have a mild or

carbon steel core wire, and the alloying elements, that produce the higher tensile strengths or

improved impact properties, are in the electrode coating. In the case of stainless steel coated

electrodes, a stainless steel core wire is used, and the elements that determine the specific

analysis of the weld metal are included in the coating. In submerged arc welding, the choice

exists as to the wire-flux combination that will produce the required end result.

6.11.1 Electrodes and Fluxes for Welding the Alloys - Electrodes for welding the low

alloy steels are available as low alloy solid wires or composite electrodes. Composite elec-

trodes are similar to flux cored electrodes, but since they are used with a granular flux, the core

contains mostly the necessary alloying elements. The outer sheath may be a carbon or alloy

steel. Submerged arc wires are available in diameters ranging from 1/16" to 1/4" diameter.

6.11.1.1 Welding the low alloy steels with the submerged arc process may be accomplished

in several different manners. They are:

a. A solid wire that has a sufficient amount of alloying elements included in the chemistry

of the wire as manufactured, and a neutral flux that shields the weld and influences bead

shape, but has a minimal affect on weld metal chemistry.

b. A composite wire that contains the necessary alloying elements in the core and/or the

steel sheath, used in conjunction with a neutral flux.

c. A solid carbon steel wire may be used, such as an EM12K type, in combination with a

flux that contains the necessary alloying elements to produce the desired low alloy weld

metal.


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®COPYRIGHT 2000 THE ESAB GRO

LESSON VI


6.12.0.1 This AWS specification is entitled Specification for Low Alloy Steel Electrodes andFluxes for Submerged Arc Welding. Since there are two types of welding wires, solid and

composite, each must be considered in a different manner. Solid wires are classified by their

as manufactured chemical analysis, but this is not possible with composite wires because the

outer steel sheath and the core ingredients combine to produce the resultant weld metal.

Therefore, composite wires are classified as to the weld metal chemical composition as are

coated electrodes.

6.12.0.2 The fluxes for welding low alloys with the submerged arc process are classified by

the weld metal mechanical properties they produce with a given wire or electrode. Figure 16

shows the classification of fluxes and electrodes under this specification.

Impact RequirementsCharpy V-Notch

Z No Requirement0 0° F2 -20 °F4 -40 °F5 -50 °F6 -60 °F8 -80 °F10 -100 °F15 -150 °F

}20 ft-lbs @

Tensile YieldStrength Strength Elongation

psi psi % in 2"F7XX 70,000 - 95,000 58,000 22F8XX 80,000 - 100,000 68,000 20F9XX 90,000 - 110,000 78,000 17F10XX 100,000 - 120,000 88,000 16F11XX 110,000 - 130,000 98,000 15F12XX 120,000 - 140,000 108,000 14

F X X X

Flux A = As WeldedP = Postweld Heat Treatment Time & Temp. per AWS A5.17-89

FLUX DESIGNATIONS

ELECTRODE DESIGNATIONS

FLUX AND ELECTRODE DESIGNATIONS FOR SUBMERGED ARC WELDING - LOW ALLOY STEELSFIGURE 16

Indicates Composite Electrode.Omission Indicates Solid Wire

Electrode

Classification of Electrode -2, 3, or 4 Numbers or Letters.

Chemical Composition of Weld Metal -1, 2, or 3 Numbers or Letters

Optional DiffusableHydrogen DesignatorUsed Only for Some Nuclear Requirements

E C X X X N - X N H X

1 or 2 Digits


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LESSON VI

6.12.1 Composition Requirements for Solid Low Alloy Electrodes - The listing in

Figure 17 indicates only the major alloying elements of each electrode type. For complete

chemical composition requirements, see AWS A5.23-90.

C = Carbon Ni = Nickel

Mn = Manganese Mo = Molybdenum

Cr = Chromium

ELECTRODECLASSIFICATION C Mn Cr Ni Mo Si

Carbon SteelEL12 0.04 - 0.14 0.25 - 0.60 — — — 0.10EM12K 0.05 - 0.15 0.80 - 1.25 — — — 0.10 - 0.35

Carbon-MolybdenumEA1 0.07 - 0.17 0.65 - 1.00 — — 0.45 - 0.65 0.20EA2 0.07 - 0.17 0.95 - 1.35 — — 0.45 - 0.65 0.20EA3 0.10 - 0.18 1.65 - 2.15 — — 0.45 - 0.65 0.20EA3K 0.07 - 0.12 1.60 - 2.10 — — 0.40 - 0.60 0.50 - 0.80EA4 0.07 - 0.17 1.20 - 1.70 — — 0.45 - 0.65 0.20

Chromium MolybdenumEB1 0.10 0.40 - 0.80 0.40 - 0.75 — 0.45 - 0.65 0.05 - 0.30EB2 0.07 - 0.15 0.45 - 0.80 1.00 - 1.75 — 0.45 - 0.65 0.05 - 0.30EB2H 0.28 - 0.33 0.45 - 0.65 1.00 - 1.50 — 0.40 - 0.65 0.55 - 0.75EB3 0.05 - 0.30 0.40 - 0.80 2.25 - 3.00 — 0.90 - 1.10 0.05 - 0.30EB5 0.18 - 0.23 0.40 - 0.70 0.45 - 0.65 — 0.90 - 1.20 0.40 - 0.60EB6 0.10 0.35 - 0.70 4.50 - 6.50 — 0.45 - 0.65 0.05 - 0.50EB6H 0.25 - 0.40 0.75 - 1.00 4.80 - 6.00 — 0.45 - 0.65 0.25 - 0.50EB8 0.10 0.30 - 0.65 8.00 - 10.50 — — 0.05 - 0.50

Nickel SteelENi1 0.12 0.75 - 1.25 0.15 0.85 - 1.25 0.30 0.05 - 0.30ENi2 0.12 0.75 - 1.25 — 2.10 - 2.90 — 0.05 - 0.30ENi3 0.13 0.60 - 1.20 0.15 3.10 - 3.80 — 0.05 - 0.30ENi4 0.12 - 0.19 0.60 - 1.00 — 1.60 - 2.10 0.10 - 0.30 0.10 - 0.30ENi1K 0.12 0.80 - 1.40 — 0.75 - 1.25 — 0.40 - 0.80

Other Low Alloy SteelEF1 0.07 - 0.15 0.90 - 1.70 — 0.95 - 1.60 0.25 - 0.55 0.15 - 0.35EF2 0.10 - 0.18 1.70 - 2.40 — 0.40 - 0.80 0.40 - 0.65 0.20EF3 0.10 - 0.18 1.70 - 2.40 — 0.70 - 1.10 0.45 - 0.65 0.30EF4 0.16 - 0.23 0.60 - 0.90 0.40 - 0.60 0.40 - 0.80 0.15 - 0.30 0.15 - 0.35EF5 0.10 - 0.17 1.70 - 2.20 0.25 - 0.50 2.30 - 2.80 0.45 - 0.65 0.20EF6 0.07 - 0.15 1.45 - 1.90 0.20 - 0.55 1.75 - 2.25 0.40 - 0.65 0.10 - 0.30EM2 0.10 1.25 - 1.80 0.30 1.40 - 2.10 0.25 - 0.55 0.20 - 0.60EM3 0.10 1.40 - 1.80 0.55 1.90 - 2.60 0.25 - 0.65 0.20 - 0.60EM4 0.10 1.40 - 1.80 0.60 2.00 - 2.80 0.30 - 0.65 0.20 - 0.60EW 0.12 0.35 - 0.65 0.50 - 0.80 0.40 - 0.80 — 0.20 - 0.35EG No Requirements

Single Figures are Maximums

MAJOR CHEMICAL COMPOSITION REQUIREMENTSSOLID WIRE SUBMERGED ARC WELDING ELECTRODES. AWS A5.23-90

FIGURE 17


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LESSON VI

6.12.1.1 Figure 17 lists two carbon steel wires (EL12 and EM12K) that are the same as

those listed in AWS A5.17-89, the specification for mild and carbon steels. They appear here

only because they can be used with fluxes that contain sufficient alloying elements to deposit a

low alloy weld metal.

6.12.1.2 Although all of the low alloy electrodes in AWS Specification A5.23-90 are listed

here, a complete knowledge of their uses and applications are beyond the scope of this

course. They are presented here so that you will be familiar with the various AWS designa-

tions.

6.12.1.3 As an example, a manufacturer of a solid wire electrode may assign the AWS

classification EB3. Under this specification, he certifies that this wire is an electrode (E), the

chemical composition is a chrome-moly type (B) containing a nominal 2-1/2% chromium and

1% molybdenum, and it meets the other chemical requirements (3).

6.12.1.4 The specification also lists the chemical composition of the weld metal which differs

slightly from the chemical requirements for the wire. The same designations are used for the

weld metal as for the electrode classification in Figure 17 except that the letter “E” is deleted.

For example, the weld metal is designated as A2, B3, Ni2, F2, N3, etc. Since classification of

the composite electrodes is based on the weld metal composition, the letters “EC” are placed

before the weld metal classification and the electrode designation for composite electrodes

would be ECA2, ECB3, ECNi2, etc.

6.12.1.5 An example of a complete flux electrode designation would be as follows:F8P10-ECNi2-Ni2. This designation refers to a flux (F) that will produce weld metal of a

minimum 80,000 psi tensile strength (8), when postweld heat treated (P), and satisfies a

charpy V-notch impact strength test of at least 20 ft.-lbs. at -100°F (10) when used with a

composite electrode (EC) of a nickel type (Ni) containing a nominal 2-1/2% nickel (2) and will

produce weld metal of the chemical composition specified under Ni2 in AWS Specification

A5.23-90 (Ni2).


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LESSON VI

6.13 SPOOLARC LOW ALLOY WIRES FOR SUBMERGED ARC WELDING

6.13.1 Manganese-Molybdenum Wires

6.13.1.1 Spoolarc 40A, 40B, and 40 (AWS Class EA1, EA2, and EA3) - These (Mn-Mo)

wires are designed for pressure vessel fabrication requiring postweld heat treatment and weld

metal tensile strength of 60 ksi, 70 ksi, and 80 ksi. They are generally used with Unionmelt 80,

124, and 429 fluxes.

6.13.2 Chromium-Molybdenum Wires

6.13.2.1 Spoolarc U515 and U521 (AWS Class EB2 and EB3) - Spoolarc U515 and

U521 wires are designed for welding 1-1/4% Cr - 1/2% Mo and 2-1/2% Cr - 1% Mo pressure

vessels. They can be used with Unionmelt 80, 124, and 709-5 fluxes.

6.13.3 Nickel Wire

6.13.3.1 Spoolarc ENi4 (AWS Class ENi4) - Spoolarc ENi4 is designed for single or

multipass welding on high strength steels and produces good low temperature toughness. It is

usable with Unionmelt 429, 439, 709-5, and 656 flux.

6.13.4 High Strength Wires

6.13.4.1 Spoolarc 44 (AWS Class EF2) - Spoolarc 44 is designed for single or multipass

welding on high strength steels of 80 ksi. The addition of nickel helps it produce good low

temperature toughness. It is usable with Unionmelt 709-5 and 656 fluxes.

6.13.4.2 Spoolarc 95, 100, and 120 wires (AWS Class EM2, EM5, and EF4) - Spoolarc

95, 100, and 120 are military grade, high strength, low temperature impact wires designed for

welding HY-80 and HY-100 steels. They are usable with Unionmelt 709-5 and 656 fluxes.

6.13.5 Special Purpose Wires

6.13.5.1 Spoolarc WS (AWS Class EW) - Spoolarc WS is designed for single and multi-

pass welding on weathering grade steels such as A588 and Cor-Ten. The weld chemistry

produces good “color match”, “weathering resistance”, and meets fracture critical code re-

quirements. It is usable with Unionmelt 429, 439, 709-5, and 656 fluxes.


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LESSON VI

6.14 UNIONMELT FLUXES FOR WELDING LOW

ALLOY STEELS6.14.1 Unionmelt 429 Flux - Unionmelt 429 flux is a bonded flux developed for single or

multipass butt and fillet welding on pressure vessel and structural steel fabrication. It operates

on either AC or DC, single or multiple wire operation. It has good performance in the as

welded or stress relieved condition on carbon and low alloy steels.

6.14.2 Unionmelt 439 Flux - Unionmelt 439 flux has similar performance to 429 flux but

will give higher toughness properties.

6.14.3 Unionmelt 656 Flux - Unionmelt 656 operates similar to 439 flux, but has less

tolerance for rust. It should be used on clean material. It will produce excellent low tempera-

ture toughness, better than 439 flux.

6.15 ALLOY SHIELD COMPOSITE ELECTRODES FOR

SUBMERGED ARC WELDING OF THE LOW ALLOY STEELS

6.15.0.1 ESAB produces a line of composite electrodes for welding several varieties of the

low alloy steels. These electrodes carry the brand name Alloy Shield and are used with a

neutral flux since the alloying elements are in the electrode core.

6.15.0.2 Alloy Shield electrodes are available in 3/32" - 5/32" diameters. Each size is

available on 60 lb. coils and for maximum productivity, 500 lb. pay-off packs.

6.15.1 Alloy Shield B1S (No AWS Class) - Alloy Shield B1S is an electrode for welding

the 1/2% Chrome - 1/2% Molybdenum steels. These steels are used principally in power

piping, boiler work and other moderately high temperature applications. Recommended flux isUnionmelt Flux 80. If other fluxes are used, the weld deposit analysis may vary.


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LESSON VI

A. Typical Chemical Analysis of the Weld Metal




Sulfur 0.025%

B. Typical Mechanical Properties of the Weld Metal

Stress Relieved 1 Hr. @1275°F





20 ft.-lbs. @32°F

6.15.2 Alloy Shield B2S (AWS A5.23 F8PZ-ECB2-B2) - Alloy Shield B2S is an electrode

for welding the 1% chromium - 1/2% molybdenum and the 1-1/4% chromium - 1/2% molybde-

num steels for high temperature applications such as power piping, boiler work and tubes,

plate forgings and castings covering a wide variety of ASTM steels. Recommended flux isUnionmelt Flux 80. If other fluxes are used, weld deposit analysis may vary.





Sulfur 0.024%

B. Typical Mechanical Properties of the Weld MetalStress Relieved 1 Hr. @1150°F





16 ft.-lbs. @30°F


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LESSON VI

6.15.3 Alloy Shield B3S (AWS A5.23 F9PZ-ECB3-B3) - Alloy Shield B3S is an electrode

for welding 1% chromium - 1% molybdenum and the 2-1/4% chromium - 1% molybdenum

steels. Used for welding in high strength, high temperature applications, such as power pip-

ing, boiler, and turbine work. Recommended flux is Unionmelt Flux 80. If other fluxes are used,

weld deposit analysis may vary.





Sulfur 0.023%

B. Typical Mechanical Properties of the Weld MetalStress Relieved 1 Hr. @1275°F





20 ft.-lbs. @32°F

6.15.4 Alloy Shield Ni1S (AWS Class A5.23 F7A6-ECNi1-Ni1) - Alloy Shield Ni1S is an

electrode for nominal 1% Ni weld metal where notch toughness is required in the weld deposit.

Recommended flux is Unionmelt Flux 651VF. If other fluxes are used, weld deposit analysis

may vary.


Carbon 0.06% Sulfur 0.019%

Manganese 1.18% Phosphorus 0.024%

Silicon 0.34% Nickel 0.86%

B. Typical Mechanical Properties of the Weld MetalAs Welded





60 ft.-lbs. @-40°F

57 ft.-lbs. @-60°F


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LESSON VI

6.15.5 Alloy Shield Ni2S (AWS 5.23 F8A6, F8P10-ECNi2-Ni2) - Alloy Shield Ni2S is a

nickel alloy electrode for applications where good impact properties are necessary at tem-

peratures as low as -100°F. The weld deposit contains 2-1/2% nickel. Recommended flux isUnionmelt Flux 651VF. If other fluxes are used, weld metal analysis may vary.






As Welded

Yield Point, psi 68,000 74,000




88 ft.-lbs. @ -40°F 92 ft.-lbs. @ -40°F

65 ft.-lbs. @ -60°F 72 ft.-lbs. @ -60°F

35 ft.-lbs. @-100°F 50 ft.-lbs. @-100°F

6.15.6 Alloy Shield M2S (AWS A5.23 F11A6-ECM2-M2) - Alloy Shield M2S is an elec-

trode for welding the T-1 and other similar high strength steels. Despite its high strength, the

weld metal has good impact properties. Recommended flux is Unionmelt Flux 651VF. If other

fluxes are used, the weld metal analysis may vary.



Manganese 1.6% Nickel 1.83%


Sulfur 0.014%


As Welded




Charpy V-Notch Impacts 62 ft.-lbs. @ 0°F

27 ft.-lbs. @-60°F


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LESSON VI

6.15.7 Alloy Shield M3S (AWS A5.23 F11A4-ECM3-M3) - Alloy Shield M3S is an elec-

trode for welding T-1 and other similar high strength steels requiring tensile strengths of

110,000 to 120,000 psi. It produces good low temperature impacts and is approved by the

American Bureau of Shipping. Recommended flux is Unionmelt Flux 651VF. If other fluxes are

used, the weld metal analysis may vary.





Sulfur 0.017% Molybdenum 0.61%






37 ft.-lbs. @-60°F

6.15.8 Alloy Shield WS (AWS Class A5.23 F7A2-ECW-W) - Alloy Shield WS is for

welding “weathering” grade steels. Weld deposit will color match to the weathering steel after

exposure to the atmosphere. Recommended flux is Unionmelt Flux 651VF. If other fluxes are

used, the weld metal analysis may vary.





Sulfur 0.013% Copper 0.49%






32 ft.-lbs. @-20°F


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LESSON VI

6.15.9 Alloy Shield F2S (AWS A5.23 F10P2-ECF2-F2) - Alloy Shield F2S wire devel-

oped for welding SAE 4130 and similar hardenable steels. Retains excellent properties after

stress relieving or quench and tempering. Good choice for oil field equipment requiring less

than 1% nickel. Recommended flux is Unionmelt Flux 709-5. If other fluxes are used, the weld

metal analysis may vary.



Manganese 1.63% Nickel 0.69%


Sulfur 0.012%

B. Typical Mechanical Properties of the Weld MetalStress-Relieved 12 hrs. @1150°F.





35 ft.-lbs. @-20°F

6.15.10 Alloy Shield 420SB (No AWS Class) - Alloy Shield 420SB was specially devel-

oped to match the analysis for continuous caster roll found in the steel making industry. Rec-

ommended flux is Unionmelt Flux S-420SB. If other fluxes are used, the weld metal analysis

may vary.




Silicon 0.20% Chromium 11.70%

B. Hardness of Deposited Weld Metal

1 Layer on 1045 Steel - 54 Rockwell C

2 Layers on 1045 Steel - 51 Rockwell C


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LESSON VI

APPENDIX A

LESSON VI - GLOSSARY OF TERMS

CompositeElectrode

- A filler metal electrode used in arc welding, consisting of more than one metal

component combined mechanically. It may or may not include materials which

protect the molten metal from the atmosphere, improve the properties of the

weld metal or stabilize the arc.

Work Harden - The development of hardness in metals as a result of cold working such as

forming, bending, or drawing.

Anneal - The process of heating a metal to a temperature below the critical range,

followed by a relatively slow cooling cycle to induce softness and remove

stresses.

Deoxidizers - Elements, such as manganese, silicon, aluminum, titanium, and zirconium,

used in welding electrodes and wires to prevent oxygen from forming harmful

oxides and porosity in weld metal.

Flux - Material used to prevent, dissolve, or facilitate removal of oxides and other

undesirable substances in welding, soldering, or brazing. In submerged arc

welding, the flux shields the molten puddle from the atmosphere which helps

to influence the mechanical weld metal deposit.

BondedFluxes

- Bonded fluxes are manufactured by binding an assortment of powder together

and then baking at a low temperature. The major advantage is that addi-

tional alloying ingredients can be added to the mixture.

FusedFluxes

- Fused fluxes are melted ingredients which have been chilled and ground to a

particular particle size. The advantage of this type flux is the low moisture

pick-up and improved recycling capabilities.


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