Repair and maintenance welding - ÖZMETAL A.Ş. ESAB ... Maintenance Welding Handbook. ESAB’s...
Transcript of Repair and maintenance welding - ÖZMETAL A.Ş. ESAB ... Maintenance Welding Handbook. ESAB’s...
STRENGTH THROUGH COOPERATION
Repair and maintenancewelding
2
Welding, an important repair method
The descriptions include details of
recommended consumables:
•MMA:OKcoveredelectrodes
•MIG/MAGwelding:OKAutrodsolid
wires
• FCAW:OKTubrodurflux-cored
wires
• TIGwelding:OKTigrodwires
Furtherinformationaboutrepair
weldingcanbefoundinESAB’sRepair
andMaintenanceWeldingHandbook.
ESAB’srangeofweldingconsumables
isoneofthemostextensiveinthe
market.Thewelding
consumables
catalogueprovides
detailed information
about product
information and
comprehensive
selection charts for
differentmaterials.
Furtherproduct
information can be
found on your local
ESABwebsite
underProducts/
Welding
consumables.
Thecataloguefeaturessome450
individualconsumables.
A. Consumablesformildsteels
B. Consumablesforlow-alloyedsteels
C. Consumablesforstainlessand
high-alloyedsteels
D. Consumablesforaluminiumalloys
E. Consumablesfornickel-based
alloys
F. Consumablesforcopper-based
alloys
G. Consumablesforcastiron
H. Consumablesfordissimilar
materials
I. Consumablesforhardfacing
J. Specialproducts
ESAB’sconsumablesfactorieshave
variousinternationalcertifications,
includingISO9001certifiedquality
managementsystems,manufacturer/
productapprovalsrequiredbythe
EuropeanPressureEquipment
Directiveandthe
ConstructionProduct
Directive,andISO
14001/OHSAS
18001certified
environmental,health
and safety
programmes.
Occupationalhealth
and fire safety must
begivenappropriate
consideration in
repairwelding.
Workingconditions
areoftenworsecomparedtonormal
productionenvironments.Information
about the health and safety aspects of
weldingconsumablesisprovidedin
thesafetydatasheetofeachproduct.
The sheets can be printed from your
localESABwebsite.
Weldingisthemostcommon
methodofjoiningmetals,widely
appliedinworkshopsforthe
manufactureofproducts.Welding
is also an important repair method
forrestoringdamagedandworn
workpiecesandotheritems.
Thisbrochureprovidesanoverview
of common applications of repair
andmaintenancewelding:
• Gougingandcutting
• Difficult-to-weldsteels
•Weldingdissimilarmetals
• Surfacingandhardfacing
•Weldingcastiron
•Weldingwearresistantsteels
•Weldingaluminium
An overview of repair
and maintenance
applications
• Basicsofrepairwelding
• Weldinginstructionsfor
different materials
• Hardfacing
• Illustratedapplications
• Consumablesproduct
data
• Applicationindex
3
Cr-ekv = %Cr + %Mo + 1,5%Si + 0,5%Nb
Ni-
ekv
= %
Ni +
30%
C +
0,5
%M
n
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
M+F
A + M
A+M+F
A+F
5 %
10 %
20 %
40 %
80 %
100 %
(1)
(A)(A1)
(2)
(B1)
(B)
(3)
Ferrite
Austenite
Martensite
0 %
Fer
rite
Schaeffler diagram. (1) Non-alloy steel S355,
(2) stainless steel AISI 316L, (3) dissimilar weld
welded without consumables, (A) electrode OK
48.00 for mild steels and (A1) its dissimilar weld,
(B) over-alloyed electrode OK 67.70 and (B1)
its dissimilar weld.
Gouging electrode OK 21.03
Thegougingandcuttingelectrodeis
commonly used in repair applications
fortheremovalofwelddefects,for
removingcrackspriortowelding,for
preparinggroovesandholesandfor
cuttingsheetsandbars.Thearc
gougingelectrodeisequallysuitable
fornon-alloyedsteelsandstainless
steels,castiron,aluminiumandcopper
alloys,exceptpurecopper.
Arcgougingisbasedonthesame
principleastheweldingelectrode;the
arcburnsbetweentheendofthe
electrodeandtheworkpiece.However,
thespecialcoatingofthearcgouging
electrodeformsapowerfulgasspray
whichblowsawaythematerialmelted
bythearc,providingashapesuchas
agroove.Theworkcanbecarriedout
usingordinaryMMAwelding
equipment;compressedairorspecial
electrodeholdersarenotrequired(air
carbonarcgouging).Theseelectrodes
requireveryhigharcvoltagestowork
properly.Whilecarbonarcgougingisa
lotmoreeffectiveatremovingmaterial,
itrequiresspecialequipmentanda
compressedairsupplywhichmaynot
bealwaysavailable.
Electrodediametersare2.5–5.0mm;
thevoltagerangeis130–180Ampsfor
aØ3.2mmelectrodeand170–230
AmpsforaØ4.0mmelectrode.The
arcisinitiatedbystrikingtheelectrode
moreorlessat90degreestothework
Gouging and cutting electrode
Dissimilar metals
piece and once the arc is
established the electrode must
havea10to15degreeinclination
totheworkpiece.Immediately
thereafteritshouldbemoved
rapidlybackandforthatthe
sametimemovinginthedirection
ofthedefect..Deepgroovescan
bemadebyrepeatedgouging.
Normally,weldingcanfollow
withoutfurtherpreparation;
however,whengougingstainless
steel,thecarbonisedsurfacelayer
shouldberemovedbygrinding.
Consumables
Theproductrangeincludesanumberofoveralloyedconsumables.
• 18%Cr-8%Ni-6%Mn(AWS307)
OK67.45
OKAutrod/Tigrod16.95
OKTubrod14.37
OKTubrod15.34
• 23%Cr-13%Ni
CrNioveralloyed(AWS309L)
OK67.60
OKAutrod/OKTigrod309LSi
Shield-Bright309L,309X-tra
• 23%Cr-13%Ni-3%Mo
Cr-Nioveralloyed(AWS309MoL)
OK67.70
OKAutrod/OKTigrod309MoL
Shield-Bright309MoLX-tra
•A high Ni alloy
Adissimilarjointofheat-resistingCrMosteelandstainlesssteel(forhightemperatures)
OK92.26
OKAutrod/Tigrod19.85
Inmanyapplications,thereisoftena
needtojoinnon-orlow-alloyedsteel
withausteniticstainlesssteel,e.g.
S355/AISI316.Thesearecalled
dissimilarjoints.Withtherightchoice
ofconsumables,thesejointsareeasy
toweld.Suitablefillermaterialsare
overalloyedstainlessconsumables
whichgiveaweldmetalthatmixes
withnon-stainlesssteeltoformahigh-
tensileausteniticoraustenitic-ferritic
welddespitebeing“tempered”.When
selectingconsumables,theSchaeffler
diagramcanbeusedtodeterminethe
microstructureoftheweld.
4
Bevel gear repair.
Drive shaft repair on a
heavy duty vehicle.
Repair of a broken
driveshaft.
Repair of a broken trans-
former support.
Removing a broken bolt. Hydraulic ram.
Repairandmaintenanceweldingoften
involvesrepairingso-called“difficult-to-
weld”steels.Theseincludehigh
carbonsteels,quenchedand
temperedsteels,tool-makingsteels,
wearresistantsteelsandspringsteels.
“Unknown”steelsareoftenincludedin
thisgroup–asaprecaution,ifthe
compositionisnotknownorthetype
ofsteelisunclear,thesesteelsshould
betreatedasdifficult-to-weldsteels.
Typicalapplicationsincludeshafts,
gears,machinecomponents,etc.
Intermsofweldability,acommon
characteristic of these steels is their
hightendencytohardenalongwith
hardandbrittleHAZstructures,which
resultinahighcrackingtendency
duringwelding.Preventingthese
requirespreheatingorpostheat
treatment,whichisoutofthequestion
inmanyrepaircases.
Weldingwithausteniticstainlessor
nickel-basedconsumablesisa
commonandeffectivemethodof
preventinghydrogencracks(cold
cracks).Theseweldmetalstolerate
highdilution,andtheyhaveahigh-
tensileausteniticoraustenitic-ferritic
microstructure.Furthermore,the
solubilityofhydrogen–thesourceof
cracking–issohighthatitstopsthe
damaginghydrogenfromenteringthe
heataffectedzone(HAZ),thereby
preventingtheformationofcracks
despitethehardeningoftheHAZ.The
most commonly used consumable in
repairweldingisaustenitic-ferritic
stainlesssteel29%-9%Ni.
Thereareotherinterestingapplications
fortheseconsumables,suchas
removingabrokenboltwithan
electrode,orrepairingascratched
hydrauliccylinderpiston.Anewbolt
headisbuiltontopofthebroken-off
bolt;thiscanthenbeusedtoturnthe
boltandpullitoutofthehole.
Scratchesonhydraulicramscanbe
builtupandgroundsmooth.
Difficult-to-weld steels
Consumable29%Cr-9%Ni(AWS312)
• Auniversalconsumableforrepairwelding
• Theweldmetalhasahightoleranceforimpurities
• Theweldmetaltolerateshighdilution
OK68.82:the“miracleelectrode”ofrepairwel-ding
OKAutrod312/OKTigrod312
18%Cr-8%Ni-6%Mn
• Ahigh-tensileweldmetal(AWS307)
OK67.45
OKAutrod16.95/OKTigrod16.95
OKTubrodur14.71,alsowithout shieldinggas
A high Ni alloy
• Thehighesttensilestrenghofallweldmetals
• Lowestcracksensitivity
OK92.26
OKAutrod19.85/OKTigrod19.85
5
Marinedieselexhaustmanifold.Newprice€ 820.00.
Repaired for € 225.00 Exhaustoutlet.Nosparesavailable.Repairnecessary.
Castironsareironalloyswhichcontain
2–5%carbonandsomesiliconand
manganese.Certaincastirongrades
mayalsocontainotherelements.The
mostcommongradesaregreycast
ironandductileiron.Graphite(carbon)
growsasflakesingreycastironand
asspheresinductilecastiron.Welding
castironisdifferentfromsteelwelding,
andmostcastirongradesaredifficult
toweld.Castironshavealowtensile
strengthanddeformabilitywhich
makesthembrittle.Forthatreason,
weldingstressescaneasilycause
cracksandflawsinweldjoints.Cast
ironhardenseasilyattheHAZaround
theweld.Inaddition,pieceswhich
needrepairingwilloftenhave
absorbedoilorothercontaminants,
whichalsomakesweldingdifficult.
Weldingisneverthelesspossible,and
cast iron pieces are commonly
repairedbywelding.
CastironisnormallyMMAweldedby
cold-weldingwhichmeansgenerating
aslittleheatasaspossibleinthework
piece.Inpractice,thismeanswelding
shortbeadsandhammeringthem
lightlytoreleasestresses.After
welding,eachmustbehandwarm
untiltouchablebeforeweldingthenext
beadinordertoreducestresses.
Bufferingisbeneficialinsomecases;
thisinvolvessurfacingthejointfaces
beforecompletingtherestofthejoint
ifpossible.Iftheworkinvolves
repairingacrack,holesshouldbe
drilledateachendofthecrackto
preventitfromprogressingfurther.
Nickelornickel-ironelectrodesare
used,sincetheseprovideasoft,high-
tensileandmachinableweldmetal.
Weldsshouldbestressrelievedby
peening.
Cast iron
Consumables for welding
cast iron
Ni consumable
• AslightlysofterweldthanNiFe
OK92.18
NiFe consumable
• AslightlystrongerweldthanNi
• LesssensitivetoimpuritiesthanNi
• CheaperthanNi
OK92.58orOK92.60
Nicore55,coredwire
6
Wear resistant steels
onlythesheetthicknessbutalsothe
hydrogencontentandheatinputof
theweld.Roughvaluesare:
400HB:
• fromapprox.20mm:75-150ºC
(dependingonplatethickness)
500HB:
• fromapprox.10mm:100-200ºC
(dependingonplatethickness)
RautaruukkiandSSABhaveproduced
goodbrochuresontheweldingof
thesesteels.
Consumablesareselectedonacase-
by-casebasisdependingonthe
propertiesrequiredfromtheweld.
Generally,softandhightensile
consumablessuchasOK48.00and
correspondingwiresareusedinjoint
welding.Theweldsareoftenlocated
inplaceswherethesesofter
consumablescanbeused.
Especiallywhenweldinglarge
thicknessofwearresistantsteel,the
needforpreheating–whichisrequired
forhardersteelgradesininstallation
conditions–canbeeliminatedby
usingausteniticstainless
consumables;themostcommonof
theseisthe18%Cr-8%Ni-6%Mn
composition.Ifahighstrengthweldis
required,low-alloyedhighstrength
consumablesareused,butforroot
runsnon-alloyedconsumablesshould
beused.Ifahighlywearresistantweld
isrequired,hardfacingconsumables
areusedtoprovidesuitablehardness
inthefinalpass,whenfillerpassesare
madewithsoftconsumables.Despite
theirhighresistanceagainstabrasion,
thesewearresistantsteelsmay
sometimesrequirehardfacingto
improvethewearresistanceofthe
surface-inmostcasesonlylocally.In
thiscase,weldingahigh-tensilebuffer
layerbeforehardfacingprevents
crackingofthebasemetalorthe
hardfacingweld,anditalsoprevents
thehardfacingweldfromcoming
loose.Suitableconsumablesare
austenitic stainless consumables such
as18%Cr-8%Ni-6%Mn(”AWS307”)
or23%Cr-13%Ni(”AWS309L”).
Consumablessuitableforhardfacing
includehardenable,highchromium
contentalloysteelsandsimilar,see
page9.
Wearresistantsteelsareusedin
applicationswherethewearresistance
providedbyregular,reasonablysoft
structuralsteelsisnotenough.Typical
applicationsincludestructureswhichare
exposedtoabrasionfromsoil,rockor
gravelinlocationssuchasquarries,
mines,loadersandearthmovers,e.g.
conveyors,lipshrouds,dumper
platforms,screens,chutes,etc.Modern
wearresistantsteels,suchas
Rautaruukki’sRaex400/500andSSAB’s
HARDOX400/500(thenumberrefersto
thesurfacehardnesswhichis400or
500HB)areeasytoweld.
RAEXAR400istwotothreetimesmore
wear-resistantandthe500isthreeto
fourtimesmorewear-resistantthan
structuralsteelS355.Wearresistant
steels are normally hardened and
sometimesquenched(i.e.temperedand
quenched).Duetothehardenabilityof
wearresistantsteels,thickersheets
mustbepreheatedtopreventcracking.
Theneedforpreheatingdependsonnot
Typical applications for wear resistant steels.
Consumable
• Undermatching(soft/tough)non-alloysteel
OK48.00
OKAutrod12.51
• Overalloyedstainlesssteel
18%Cr-8%Ni-6%Mn
OK67.45
OKAutrod16.95
OKTubrodur14.71
• Matchinglowalloyedsteel
OK75.75
OKAristoRod13.29
OKTubrod14.03ja15.09
• Hardfacingconsumable,
hardnessabout30-35HRC
OK83.28
OKAutrod13.89
OKTubrodur15.43
• Hardfacingconsumable,
hardnessabout50-60HRC
OK83.65
OKAutrod13.91
OKTubrodur15.50
7
Aluminium
Duetoitsleightweight,good
conductivity,highcorrosionresistance
andweldability,aluminiumiswidely
used in many industrial applications
fromshipbuildingtotransport
equipment,packingmaterials,andthe
electricalandaviationindustries.
Aluminiumisalight-weightmetal
whosespecificweightisapproximately
athirdofthatofsteel.
Aluminiumweldingisverycommon.
Productionweldinggenerallyinvolves
MIGorTIGwelding.MMAweldingis
usedrarely,generallyinsmallrepair
applicationsandespeciallywhengas-
shieldedarcweldingcannotbeused
orequipmentisnotavailable.
Themeltingpointofaluminiumis
around600°C.Aluminium’sthermal
conductivityisfourtimesthatofsteel,
whichmeansthatarelativelyhigh
amountofheatisrequiredwhen
weldingaluminium.Thickmaterials
requirepreheating.Thethermal
expansioncoefficientofaluminiumis
approximatelytwiceashighasthatof
steel,whichmeansthatdistortionfrom
weldingissimilarlyhigher.
Duetoitsgoodcorrosionresistance,
the aluminium surface has an
extremelythinoxidefilmwithamelting
pointofover2000°C.Thislayermust
beremovedfromtheapplicationarea
beforewelding–forexample,usinga
stainlesssteelbrush–andits
reformationduringweldingmustbe
prevented.InMIGandTIGwelding,
thearcbreakstheoxidefilmandthe
inertshieldinggas(argon)preventsits
formation.InMMAwelding,theflux
coatingoftheelectrodedissolvesthe
oxidefilmandprotectstheweldpool.
Propercleaningoftheweldingareais
important,asaluminiumishighly
susceptibletoporesintheweld.The
porosityisduetotheveryhigh
solubilityofhydrogeninmolten
aluminium.Astheworkhardens
rapidly,someofthedissolvedgases
remainintheweldandformpores.
Manyaluminiumalloysarefairly
susceptibletoheatcracks,which
meansthattheweldiseasilycracked
astheweldpoolhardens.Forthat
reason,therightchoiceof
consumablesisimperativetoavoid
creatingacracksensitivecomposition
intheweldpool.
Inadditiontopurealuminium,there
aredifferentaluminiumalloys,such
asAlMn,AlMg,AlSiandAlMgSi.
Recommendedconsumablesfor
aluminium alloys are specified in
thetableonpage11.
The consumable is chosen based
ontheworkpiecealloy.Dueto
theirhighcorrosionresistanceto
seawater,AlMgalloysareoften
referredtoassea-water
aluminiums,andtheyareusedin
boatsandships.
Consumables for aluminium
Consumable alloy type: AlSi12
• Usedforcastalloys
OK 96.50
OK Autrod/OK Tigrod 4047
Consumable alloy type: AlSi5
• UsedforAlMgSialloys
OK Autrod/OK Tigrod 4043
Consumablealloytype:AlMg5
• UsedforAlMg3,AlMg5 andAlMgSialloys
OK Autrod/OK Tigrod 5356
8
should be determined first before
choosingtheconsumable.
Abrasive wearoccurswhenhard
particlesslideacrossametalface,
removingmaterialfromthesurface.
Increasingthesurfacehardness
usuallyreduceswear.Suitable
consumablesincludehigh-carbon
contentalloysteelswhichprovidea
hardweld,i.e.ithardensduring
coolingafterwelding.Themost
commonalloyingelementsare
chrome,molybdenum,tungstenand
vanadium.Withmanyalloying
elements,carbonformscarbides
whosehardnesscanbeashighas
3000HV.
Metal-on-metalwear occurs
whentwometalsurfacesslide
againstoneanother–forexample,
inrotatingordraggingmetal
surfaces.Thehighsurfacepressure
betweentwometalsurfaces
generatessmallscale“microwelds”
(sticking).Asthemotioncontinues,
theweldfailsonthesideofthe
weakerbasemetal,causingsurface
wear.Low-alloysteelsaresuitable
foranti-wearapplications.
Impact wear occurswhenametal
surfaceissubjectedtoimpactswhich
causelocalbreakagesordistortion,
suchasinrockcrushing.The
magnitudeofweardependsonthe
strenghandhardnessofthemetal.
Manganesesteelisacommonand
idealmaterialduetothework
hardeningofitssurface,whichmeans
that the surface hardness increases
whiletheinsideremainstough.
Corrosion(“rusting”)hasmany
forms.Itcanbeuniformacrossthe
surfaceorlocalised.Corrosion
removesmaterialfromthemetal
surface.Corrosioncanbeprevented
byusingcertainstainlesssteels
whichcontainasufficientlevelof
chromeandinmanycasesnickel
andmolybdenum.
Wearandtearcausesconsiderable
costsindifferentindustriesasworn-out
materialsandequipmentrequire
repairing.Surfacingisacommonlyused
methodforrepairingworn-outpieces
andextendingtheirlife.Surfacingisalso
ausefulmethodforextendingthe
servicelifeofnewpartsbeforetheyare
putintoservice.Surfacingisoften
referredtoashardfacing,eventhough
hardnessisnotalwaysdesirablein
termsofwearresistance.Hardfacing
specificallyreferstosurfacingusinga
hardandwearresistantconsumable.
Dependingontheapplication,softer
consumables and corrosion resistant
consumables can also be used for
surfacing.
Therearevariousformsofwear,and
thisshouldbethemainfactorwhen
choosingconsumables.Theformsof
wearcanbedividedintothefollowing
categories:abrasion,metaltometal,
impactwear,corrosionandhigh
temperatures.Thereforetheconditions
Surfacing and hardfacing
9
Cracks, e.g. OK 84.78 Cracks, e.g. OK 84.78 No crackse.g. OK 67.45
e.g. OK 84.78Transverse cracks in a hardfacing layer.
High temperaturesmakematerials
softerandoxidizestheirsurface.High
chromecontentpreventsthereduction
ofhardnesstogetherwithcertainother
alloyingelements.Highchrome
contentpreventsoxidisation.
Avastrangeofsurfacingconsumables
isavailablewithdifferentcompositions,
characteristics and micro structures
anditisnotalwayseasytochoosethe
bestorthemosthard-wearing
consumable.Thereisnosingle
universalmaterial;consumablesare
selectedonacase-by-casebasis
dependingontheconditions.
Iftheweldistobemachinedusing
cuttingtoolsafterwelding,thismust
betakenintoaccountwhenchoosing
consumables.Thehardnesslimitfor
machinabilityisapproximately40HRC,
althoughcertainhigh-powermachines
and steel bits can be used to machine
harderwelds.
Inhardfacing,preheatingisoften
requiredeithertopreventthe
hardeningbasemetalfromcracking–
i.e.theweldbeadbecomingdetached
–ortopreventthehardfacing
consumablefromcracking.
Thepreheatingrequirementsof
hardfacingconsumablesarespecified
ontheproductpageofthe
consumablescatalogues.Theriskof
crackingcanbereducedbysurfacing
(“buffering”)theworkpiecesurfacefirst
usingahigh-tensileausteniticstainless
Consumable
Hardness range: 30–35 HRC
• A“soft”hardfacingconsumable
• Highmachinability
• Metal-on-metalwear:Slipsurfaces,shafts,rollers,wheels,gears,etc.
OK83.28
OKTubrodur15.43,alsoØ1.2mmandwithoutshieldinggas
OKAutrod13.89,Ø1.0and1.2mm
Hardness range: 50–60 HRC
• Universalhardfacingconsumable
• Resistanttobothimpactsand abrasion
• Excavationandearthmoving machinery,agriculturalandforestrymachinery,feedworms,etc.
OK83.50,alsoforweldingwithsmalltransformers
OK83.65,excellentwelding properties
OK84.58,reasonableresistancetocorrosion
OKTubrodur15.50,alsoØ1.2mm
OKTubrodur15.52,alsowithout shieldinggas
OKAutrod13.91,Ø1.0and1.2mm
Hardness range: 60–65 HRC
• “Chromeiron”
• Highresistanceagainstabrasionfromgranularmaterialsetc.
• Lowimpactstrength
• Feedworms,fanblades,drag buckets,etc.
OK84.78,easytoweld,high efficiency electrode
OKTubrodur14.70,alsowithout shieldinggas
Tools and hardfacing
• Hot-worktoolsteel
• Hotworktools,etc.
OK85.58
High-speed steel
• Bladesofcuttersandcuttingtools
• Woodcuttingblades
OK85.65
Hardfacing consumables for
corrosion resistance
• Stainlesssteel13%Cr
OK84.42
PZ6166
HardfacingofMnsteels
• Improvingsurfacewear resistance
OK84.58and84.78
OKTubrodur15.52and14.70
SurfacingofMnsteels
• Mnsteeltypeconsumables
13%Mn:OK86.08
13%Mn-3%Ni:OK86.28,OKTubrodur15.60
-Niimprovesthetensilestrengthoftheweld
14%Mn-18%Cr:OK86.30,OKTubrodur15.65
-Cralloyimprovesheatandcorrosion resistance
consumable;suitablematerialsare
specifiedinthepreviouschapter,
“Difficult-to-weldsteels”.
10
Base metal MMAwelding
MIG/MAGwelding
MAGcoredwirewelding
MAGcoredwirewelding
TIGwelding
OK OK AristoRod, OK Autrod
OK Tubrod(Metalcored)
OK Tubrod(Rutile cored)
OK Tigrod
Non-alloy structural steels (EN 10025-2)
S235xxx,S275xxx,S355xxx 48.00 12.50,12.51 14.12 15.14 12.64
Normalised fine-grain structural steels (EN 10025-3)
S275N,S355N,S420N 48.00 12.50,12.51 14.12 15.14 12.64
S460N 55.00 12.63,12.64 14.02 15.14 12.64
S275NL,S355NL,S420NL 48.08,55.00 13.28,(12.50,12.63)* 14.04 15.11,(15.17)* 13.28
S460NL 48.08,55.00 13.28,(12.63)* 15.11,(15.17)* 13.28
*)-40oC *)-40oC
Thermomechanical rolled fine-grain steels (EN 10025-4)
S275M,S355M,S420M 48.00 12.50,12.51 14.12 15.14 12.64
S460M 55.00 12.63,12.64 14.02 15.14 13.28
S275ML,S355ML,S420ML 48.08,55.00 13.28,(12.50,12.63)* 14.04 15.11,(15.17)* 13.28
S460ML 48.08,55.00 13.28,(12.63)* 15.11,(15.17)* 13.28
*)-40oC *)-40oC
Weatheringstructuralsteels(EN10025-5)
S235J0W,S235J2W 73.08 13.26 14.01 PZ6112,15.17 13.26
S355J0WP(esim.COR-TENA) 73.08 13.26 14.01 PZ6112,15.17 13.26
S355J0W,S355J2W(esim.COR-TENB) 73.08 13.26 14.01 PZ6112,15.17 13.26
Quenched and tempered structural steels (EN 10025-6)
S460Q,S460QL 48.08,55.00 12.63,12.64 14.02 15.17 13.28
S500Q,S500QL 74.78 55 14.02 15.11 13.13
S550Q,S550QL 74.78 55 14.03 DualShield55 13.29
S620Q,S620QL 75.75 69 14.03 DualShield62 13.29
S690Q,S690QL 75.75 69 14.03 15.09 13.29
S890Q,S890QL 75.78 89 Coreweld89
Ultra-strongstructuralsteels(Rautaruukki)
Optim900QC 75.78 89 Coreweld89
Optim960QC 75.78*) 89*) Coreweld89*)
Optim1100QC 75.78*) 89*) Coreweld89*)
*)Slightlyundermatchingconsumables
Heat-resisting non-alloy and alloy steels: plates (EN 10028-2) and tubes(EN 10216-2)
P235GH...P355GH 48.00 12.50,12.51 14.12 15.14 12.64
16Mo3 74.46 13.09 14.02 DualShieldMoL 13.09
13CrMo4-5 76.18 13.12 DualShieldCrMo1 13.12
10CrMo9-10 76.28 13.22 DualShieldCrMo2 13.22
X10CrMoVNb9-1 76.98 13.38 13.38
Wearresistantsteels
e.g.Hardox400...600andRaexAR400...500
Ifamatchingstrength/hardnessisnotrequired:
non-alloy,high-tensileconsumable 48.00 12.50,12.51 14.12 15.14 12.64
Matchinghardness:suitablehardfacingconsumable
for final passes 83.50 13.91 15.52
Matchingstrength:low-alloyconsumable 75.75 69 14.03 15.09 13.29
Austenitic stainless steels
18Cr-8Ni steels (“stainless”) Shield-Bright
1.4404(304L),1.4307(304L),1.4301(304)etc. 61.30 308LSi 15.30 308L,308LX-tra 308LSi
1.4541(321),1.4550(347) 61.30,61.81 308LSi,347 15.30 308L,308LX-tra 308LSi,347
18Cr-12Ni-3Mosteels(”acid-resistant”) Shield-Bright
1.4404and1.4432(316L),1.4401and1.4436(316)etc. 63.30 316LSi 15.31 316L,316LX-tra 316LSi
Recommended welding consumablesfor different base metals
11
Base metal MMAwelding
MIG/MAGwelding
MAGcoredwirewelding
MAGcoredwirewelding
TIGwelding
OK OK AristoRod, OK Autrod
OK Tubrod(Metalcored)
OK Tubrod(Rutile cored)
OK Tigrod
High-alloy special steels
1.4438(317L) 64.30 317L 317L
1.4539(e.g.Outokumpu904L) 69.33 385 385
1.4547(e.g.Outokumpu254SMO) 92.45 19.82 19.82
1.4652(e.g.Outokumpu654SMO) 92.59 19.81 19.81
Austenitic-ferriticstainlesssteels(duplexsteels)
1.4162(esim.OutokumpuLDX2101) 67.56 2307 2307
1.4462(esim.Outokumpu2205) 67.50 2209 15.37 14.27 2209
1.4410(esim.Outokumpu2507) 68.53 2509 14.28 2509
Aluminium and aluminium alloys
1050A(Al99,5),1070A(Al99,7),1200(Al99,0) 1070 1070
4045(AlSi10) 4043,4047 4043,4047
5019(AlMg5),5086(AlMg4),5754(AlMg3) 5356 5356
5083(AlMg4,5Mn0,7) 5183 5183
6060(AlMgSi),6061(AlMg1SiCu) 4043,5356 4043,5356
6063(AlMg0,7Si),6082(AlSi1MgMn) 4043,5356 4043,5356
7021(AlZn5,5Mg1,5Si),7029(AlZn4,4Mg1Si) 5356 5356
Cast iron
Differentcastirongradest 92.18,92.58 Nicore55
Dissimilar metals (“steel/stainless steel welding”)
Non-alloyorlow-alloy/austeniticstainlesssteel Shield-Bright
Workingtemperaturelessthan300oCandnoannealing 67.60,67.70 309LSi,309MoL 309L,309LX-tra 309LSi,309MoL
Workingtemperatureover300oCand/orannealing 92.26 19.85 19.85
Repair welding
Difficult-to-weldsteels,“unknown”steels,, 68.82,67.45 312,16.95 15.34 OKTubrodur14.71 312,16.95
highlyhardenablesteels,etc. 92.26 19.85 19.85
Mnsteels Hardenable alloy steels
20HRC(->45)* 30-50HR 50-60HRC 55-60HRC
OK86.08* OK83.27 OK83.50 OK83.53
OK83.28 OK83.65 OK84.84
OK86.28* OK83.29 OK84.58 OKTubrodur15.80
OK86.30* OK83.30 OKTubrodur15.52 OKTubrodur15.81
OKTubrodur15.60* OKAutrod13.89 OKAutrod13.90 OKTubrodur15.82
OKTubrodur15.65* OKTubrodur15.43 OKAutrod13.91
OKTubrodur15.40
OKTubrodur15.42
Stainless Cr steels Chrome irons
OK84.42 OKTubrodur15.73 OK84.78
OK84.52 OK84.80
OKTubrodur14.70
Austenitic CrNi steels AusteniticCrNiMnsteels Ferritic-austenitic CrNi steels Tool-making steels
OK67.70 OK67.42* OK68.81* OK85.58
OKAutrod309LSi OK67.45* OK68.82* OK85.65
OK67.52* OKAutrod312 OKTubrodur15.84
OKAutrod16.95*
OKTubrodur14.71*
Ni alloys Co alloys (“stellites”)
OK92.26* OK92.35*Stellite6 Stellite12 Stellite1
OKAutrod19.85* (”HastelloyC”)
(”Inconel600”)
Low
Low
Low
High
High
Thermal and corrosion resistance
Impactresistance
Hardness
High*Workhardeningconsumable
Selection of hardfacing consumables, comparison of properties
Otheralternativesexistformanybasemetals;askyourESABrepresentativeforfurtheradvice.
Arc gouging and cutting electrodeSpecialcoatedelectrodeOK21.01forarcgougingDifficult-to-weld steels and dissimilar metals
Consumable C(%) Si(%) Mn(%) Cr(%) Ni(%) Other(%)
OK electrode
67.45 0.1 0.5 6.0 18.5 8.5
67.60 0.03 0.7 0.9 24.0 13.0
67.70 0.03 0.7 0.9 23.0 13.0 Mo:2.8
68.82 0.12 1.0 0.9 29.0 9.0
92.26 0.02 1.0 6.6 15.8 >67 Nb:1.7
OK Autrod/Tigrod
309LSi 0.02 0.8 1.8 24.0 13.0
309MoL 0.02 0.5 1.6 22.0 15.0 Mo:2.8
312 0.10 0.5 1.7 29.0 9.5
16.95 0.1 1.0 6.5 18.5 8.5
19.85 0.05 0.5 3.0 20.0 >67 Nb:2.5
OK Tubrodur
14.71 0.1 0.1 5.5 19.0 9.0
Consumables for hardfacingConsumable C(%) Si(%) Mn(%) Cr(%) Ni(%) Hardness1)(HRC)
OK electrode
83.28 0.1 0.5 0.7 3.2 28-32
83.50 0.4 0.5 1.0 6.0 Ni:0.6 50-60
83.65 0.8 4.0 0.5 2.0 58-63
84.42 0.12 0.5 0.5 13.0 49-55
84.58 0.7 0.6 0.7 10.0 53-59
84.78 4.5 0.8 1.5 33 59-63
85.58 0.35 1.1 1.0 1.8 W:8,Co:2 42-50
85.65 0.9 1.5 1.3 4.5 Mo:7.5,W:1.8 59-61
OK Autrod
13.89 0.7 0.4 2.0 1.0 Ti:0.2 50-60
13.91 0.45 3.0 0.8 9.0 50-60
OK Tubrodur
14.70 3.5 0.4 0.9 22.0 Mo:3.5,V:0.4 48-59
15.43 0.14 0.5 1.1 1.0 Mo:0.5,Ni:2.2 30-40
15.50 0.7 0.8 0.8 5.5 Mo:1.0 55-62
15.52 0.4 0.3 1.2 5.0 Mo:1.2,Al:0.6 50-57
Cored wire
PZ6166 0.03 0.7 1.2 13 Ni:4.5,Mo:0.5 30-40
1)Hardnessofdepositedmetal
WeldingconsumablesforcastironConsumable C(%) Si(%) Mn(%) Ni(%) Fe(%)
OK electrode
92.18 0.9 0.9 0.6 >92 3.5
92.58 1.5 0.7 0.8 51 46
Cored wire
Nicore55 2.0 3.0 1.0 51 46
WeldingconsumablesforaluminiumalloysConsumable Si,Mg(%) Al(%)
OK electrode
96.50 Si:12 remainder
OK Autrod/Tigrod
4047 Si:12 remainder
4043 Si:5 remainder
5356 Mg:5 remainder
ESAB AB
Box8004,SE-40277Göteborg,Sweden.
Phone:+4631509000.Fax:+4631509390.
E-mail:[email protected]
www.esab.com
Welding consumables product data
Reg.No:XA00095820–01/2012.