User Reportage

THI Cebu Shipyard Maintains

High Japanese Quality
with an International Quality System
Tsuneishi Heavy Industries (Cebu) Inc. (THI), the The Welding Company of Kobe Steel has served
biggest shipyard in the Republic of the Philippines, was THI from the very start of its operation. B-14 and
established in 1994 as a joint venture between LB-52 for shielded metal arc welding, US-36 and
Tsuneishi Shipbuilding Co., Ltd. of Japan and a PFH-55E for submerged arc welding and DW-100 for
Philippine conglomerate, Aboitiz. THI has adopted the flux-cored arc welding are main welding consumables
similar fabrication processes as used in Tsuneishi used in the shipyard. More than 50 tons of Kobelco
Shipbuilding, Japan and the ships it builds are welding consumables are used per month, making THI
recognized as having the same quality as those built by the biggest customer for Kobe Steel in the Philippines.
the parent company. This high quality is consistently It is noticeable that over 50% of the welding
achieved by following the international quality consumables used here consist of DW-100. This is
assurance system ISO 9002, acquired in 1998. because they have employed this wire for many
applications as possible.

Above: THI Cebu is located Above: A slipway for building

on Cebu Island, and is the new ships
biggest shipyard in the
Philippines
Left: Floating docks for ship
repair

The THI Cebu shipyard is located about two hours The application of the wire includes welding hull
by car over the hill from Cebu City, the central city of shell plates by using the FBB one-side welding
Cebu Island in the southern part of the country. The process. The wire's superb usability and mechanical
ships built here are bulk carriers ranging from 23,000 properties are highly appraised.
to 45,000 DWT. Since the start of operation, 12 ships
have been delivered by continuous shipbuilding. The We wish to continue to be a good and useful
shipyard also is equipped with two floating repair supplier to THI by maintaining excellent technical and
docks for engaging in ship repair business, taking commercial services so that they will be more
advantage of the location as the center of the satisfied.
commercial sea routes in Eastern Asia. (Reported by T. Tanaka, GM,
Manila Office, Shinsho Corp.)

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 Preface
Message from the Editor
To our dearest readers of Kobelco Welding Today: Hall a year has quickly passed since we
hailed the Year 2000 with you as a turning point to a new era. The business environment
surrounding our welding industry is undergoing a rapid transformation. In various parts of the
world, big businesses are busing other companies or merging. Huge amounts of money are
invested to create gigantic enterprises called "mega-companies."
However, we Kobelco Welding Group will follow our own management philosophy that
places the interest of the customers and shareholders before every thing else. For this end, we
are firmly determined to unwaveringly continue investment in the fields of manufacturing
facility, research and development and human resources.
I am convinced that, in the 21st century, welding technology will achieve further development
along with technical innovation in base metals as seen in the development of enhanced high
strength steel. As a manufacturer, we will go on with research for new welding consumables and
development of new welding procedures worthy of the new era. Thus, we will continue our
efforts to keep on supplying welding consumables and related goods that will satisfy our
customers.
I wish all the dearest readers, their family and friends every piece of luck and prosperity.

Contents
User Reportage
THI: the biggest user of Kobelco welding consumables in the Philippines .............................................. 1
Message from the Editor
Technical innovation in steel materials will urge new welding technology ............................................. 2
Technical Report
MG-50 shines in steel construction, while MG-51T sparkles in auto fabrication .................................. 3-4
LB-62L: the best choice for welding 550N/mm2 strength steel for low temperature use ....................... 5-6
The ABC's of Arc Welding
Spray transfer arc: advantages and limitations .......................................................................................... 7
Kobelco Group News
A new edition/addenda of the ASME Code affects the AWS classification .............................................. 8
Feature Articles
KWAI celebrates its 10th anniversary at a good occasion of the AWS Welding Show .......................... 9
52,000 visitors to the Japan International Welding Show 2000 ................................................................ 10
Editorial Postscript ..................................................................................................................................... 10

Sri Siam Mongkol (SSM) was established in 1976: we have been

engaged in the welding electrodes business as a partner of Thai-Kobe
Welding since 1985. SSM is among the first registered Authorized
Distributors (AD) of the Thai Shinyokai Sales Network since it was
introduced to the Thai market one decade ago. As the Network is
continually growing and providing a competitive challenge, we have
been able to build up good relationships with all the Shinyokai
members by achieving the marketing targets of Thai-Kobe. With
operative marketing and good team-based management, the
Shinyokai's competencies will be achieved in the coming era of
globalization.

SRI SIAM MONGKOL CO., LTD., Preecha Hemapanpairo, MD

2
Technical Report

(AWS A5.18 ER70S-G)

MG-50 is one of the most popular solid wires for High Deposition Rates Contribute to
gas metal arc welding of mid- and heavy-thick mild High Welding Speeds
steel and 490N/mm2-class high strength steel with
CO2 shielding. Steel structures, construction The use of a higher current produces a higher
machinery, and industrial machinery are typical deposition rate, as in Fig. 2, thereby increasing welding
applications of MG-50. speeds, which can decrease welding costs. This is the
most important benefit of MG-50 derived from its
A Stable Arc at High Currents outstanding usability at high currents in flat and
horizontal fillet positions. However, to ensure the
A stable arc at high currents is the most important minimum tensile strength of 490N/mm2, the procedure
feature of MG-50. If a general solid wire is used at high should be controlled with heat input of 30 kJ/cm max
currents with CO2 shielding, it may generate much and pass-to-pass intervals causing a interpass
spatter, undercut and irregular bead appearance because temperature of 250C max.
of an unstable arc or irregular transfer of molten metal
in large drops from the tip of the solid wire across the
arc. In contrast, MG-50 generates less spatter and
undercut with smoother bead appearance due to
smoother molten metal transfer in smaller drops, even
though the transfer mode is of globular transfer. This is
owing to the specific chemical elements contained in
MG-50 a small amount of titanium in particular
plays such an important role.

Wide Bands of Welding Currents and

Arc Voltage Fig. 2 Deposition rates of MG-50 (wire extension: 15
mm for 1.2 mm; 20 mm for 1.6 mm)

MG-50 performs over wide bands of welding

currents and arc voltage, exhibiting the excellent arc Good Wire-Feeding and Seam-Tracking
stability. Figure 1 shows the proper current and voltage Minimize Downtime in Robotic Welding
ranges for 1.2- and l.6-mm wire. The smooth surface and consistent cast and helix of
MG-50 ensure smooth wire-feeding and seam-tracking
along welding lines, thereby minimizing downtime in
robotic welding and other automatic welding
processes. Because of such invaluable characteristics,
MG-50 has earned a consistent reputation from users
as in the steel structure,
construction machinery
and industrial machinery
industries.
Fig. 3
MG-50 maintains a
Fig. 1 Proper ranges of welding currents and arc persistently high
voltage for MG-50 (1.2 mm, 1.6 mm) reputation
in the steel structure
industry

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 Technical Report

(AWS A5.18 ER70S-6)

MG-51T: No. l solid wire for gas metal arc through) often results in damaged welds. Although an
welding in autos, motorcycles, containers and other excessive root opening and joint misalignment can also
sheet metal products. MG-51T uses either CO2 or cause burn through, an excessive welding current is
Ar+CO2 shielding in all position welding. more often the case. Figure 2 shows how to control
weld penetration in relation to welding currents.
Steady Short-Circuiting at Low Currents

Steady short-circuiting at low currents is the most

valuable feature of MG-51T. If a general solid wire is
used at low currents it may generate much spatter,
undercut and irregular bead appearance due to unsteady
short-circuiting in the molten metal transfer. In contrast,
MG-51T offers low spatter and undercut generation
with uniform bead appearance because of consistent
short-circuiting transfer of molten droplets between the
tip of the wire and the molten pool. This outstanding
feature is derived from the sophisticated design of
chemical composition and consistent quality surface of
MG-5 1T.
Fig. 2 Weld penetration of MG-51T as a function of
How to Create Steady Short-Circuiting welding currents with a short circuiting arc

Selection of proper welding currents and arc voltage

is essential for creating a steady short circuiting arc,
Outstanding Wire-Feeding and Seam-
Tracking Contribute to an Increase of
thereby facilitating all-position welding with MG-51T
Welding Efficiency
Fig. 1
The smooth surface and consistent cast and helix of"
MG-51T provides steady wire-feeding through liners
and tips and exact seam-tracking along welding lines,
which can decrease downtime for higher welding
efficiency in semi-automatic and automatic welding.
Due to such benefits, MG-51T has seen the market
expand in the auto, motorcycle, container and other
sheet metal industries.

Fig. 1 Proper ranges of welding currents and arc

voltage for MG-51T (0.9 mm, 1.2 mm)

Fig. 3
How to Adjust Weld Penetration MG-51T is one of the
most popular solid
It is important to control weld penetration in welding wires in the
sheet metals, because burn through (excessive melt- motorcycle industry

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Technical Report

(AWS A5.5 E8016-C1)

LB-62L: the best choice for welding ASTM A537 tensile strength and 0.2% proof strength are prone to
Cl-2 or other equivalent type of steel for decrease little by little as the cooling speed decreases.
low-temperature service. LPG spherical tanks are
typical applications of LB-62L.

Fig. 1 Some types of LPG storage tanks use ASTM

A537 CI-2 steel having a minimum tensile strength of
550N/mm2, and LB-62L is one of the most suitable
covered electrodes for this steel.

Steady Notch Toughness and Tensile

Strength Are Dependable Characteristics
of LB-62L

Notch toughness is one of the most important

Fig. 2 Impact absorbed energies of LB-62L (4.0)
qualities of materials used in low-temperature weld metal as a function of heat input in welding
equipment because it offers resistance against brittle double-V groove joints in flat, horizontal and
fractures under severe service conditions. Weld notch vertical-up positions. (As-weld; Power source: AC)
toughness, however, is commonly affected by variables
encountered in welding: heat input, plate thickness,
cooling speed, welding position and postweld heat
treatment.

LB-62L ensures sufficient notch toughness at low

temperatures down to minus 60C over a wide range of
such variables. Figure 2 shows Charpy impact absorbed
energies of the weld metal as a function of heat input.
The test results show a slight decrease with an increase
of heat input. However, the weld metal maintains an
adequate level of absorbed energy over the range of
heat input.

Figure 3 shows how the strength of the weld metal

Fig. 3 Strength of LB-62L (4.0) weld metal vs.
depends on the cooling speed in welding. Both the
cooling speed (As-weld; Power source: AC)

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 Technical Report
Table 1 shows the plate thickness and heat input
corresponding to the cooling speeds shown in Fig. 3.

Table 1 Welding conditions

Cooling speed Plate Average
Welding
at 540C thickness heat input
position
(C/sec) (mm) (kJ/cm)
2.8 12 26.6 Vertical up
5.9 25 38.0 Vertical up
6.4 12 17.4 Flat
15.3 32 27.4 Vertical up
18.4 25 21.5 Flat
I
22.0 32 19.2 Flat
25.2 32 16.8 Horizontal
Note: No preheating.

In general, cooling speed decreases in use of a

thinner base metal or a higher interpass temperature
when the heat input is kept constant. Therefore, in order
to attain targeted weld quality, heat input and interpass Fig. 5 The effect of postweld heat treatment on impact
temperature should properly be controlled according to absorbed energy of LB-62L (4.0) weld metal
the thickness of base metal in use and required qualities (Power source: DC-EP, Heat input: av. 38.7 kJ/cm,
for the weld. Welding position: Vertical up, Base metal: A537
CI-2, Groove preparation: double V)

LB-62L Maintains Adequate Tensile LB-62L Offers Extra-Low Hydrogen and

Strength Over Extended PWHT Moisture Resistant Characteristics

Some weld joints where residual stresses are prone to LB-62L offers extra-low hydrogen weld metal,
concentrate (e.g. a crown plate to nozzle weld joint of a which decreases the preheating temperature needed for
spherical tank) require postweld heat treatment preventing cold cracking. In addition, LB-62L picks up
(PWHT). As usual with ferritic weld metal, the strength less moisture due to its moisture resistant coating
of LB-62L weld metal decreases as PWHT temperature compared with conventional low-hydrogen electrodes
and soaking time increase. However, LB-62L weld Fig. 6. Such outstanding features can make quality
metal maintains adequate tensile strength over the control easier and more economical by reducing the
minimum tensile strength (550N/mm2) of A537 Cl-2 costs for preheating the work and redrying the
steel even after extended PWHT as shown in Fig. 4. In electrode.
addition, some types of weld metal lose notch
toughness due to embrittlement caused by PWHT.
LB-62L weld metal, however, maintains adequate notch
toughness even after PWHT as shown in Fig. 5.

Fig. 6 Test results of LB-62L and a conventional low-

hydrogen electrode on moisture pick-up under the
controlled atmosphere: 30C x 80%RH.

Fig. 4 Strength of LB-62L (5.0) all-deposited metal vs.

PWHT parameter (Power source: DC-EP, Heat input: av.
19 kJ/cm, Welding position: flat)

6
The ABC's of Arc Welding
Spray Transfer Arc:
Advantages and limitations

In gas metal arc welding (GMAW), the many

varieties of shielding gases, welding wires, and power
sources result in three different modes of metal transfer
across the arc. These modes are known as spray,
globular, and short-circuiting. Figure 1 shows
differences between the three metal transfer modes.
Each mode of metal transfer has specific advantages
and limitations.

Fig. 1 Three major molten metal transfer modes in gas

metal arc welding with solid wires
Fig. 2 Molten metal transfer modes and amount of
spatter in conventional GMAW with a solid wire.
(Source: Welding Journal)

As shown in Fig. 2, a spray transfer arc requires

relatively high welding currents (higher than the The work thickness and welding position limitations
"transition current" or "critical current" related to the of the spray transfer arc have been largely overcome
wire diameter). Argon or argon-rich gas mixtures (e.g. with specially designed power sources. These power
80%Ar+20%CO2) are necessary for shielding the spray sources produce controlled waveforms and frequencies
arc. The spray transfer mode results in a highly that pulse the welding current. During this pulse, one
directed, stable stream of discrete drops and is or more drops are formed and transferred. By reducing
essentially spatter free. the average arc energy and the wire-melting rate, the
The high arc energy associated with the spray pulsing makes the desirable features of spray transfer
transfer arc is not suitable for joining sheet metal due to available for joining sheet metals and welding thick
burn through or for welding steels in the vertical or metals in all positions.
overhead positions because of molten metal extrusion.
It is, therefore, used extensively for flat position
welding of various metals and alloys.

7
 KOBELCO Group News
A New Edition/Addenda of filler metals. Many of these specifications are identical
to and have the same numerical designation as AWS
ASME Code Affects the AWS specifications.
Classification for Kobelco
Welding Consumables A new edition/addenda of ASME Sec. II Part C
(1998 Edition and 1999 Addenda) was published as of
Construction of boilers, pressure vessels and piping July 1, 1999, adopting the AWS standards shown in
systems is often carried out under strict regulations Table 1. In order to keep the conformity with the new
(Boiler and Pressure Vessel Code) set forth by the edition and addenda of the ASME Code, Kobe Steel
American Society for Mechanical Engineers (ASME). has changed the AWS designations of the brands of
The ASME Code consists of a set of sections including welding consumables categorized in A5.11, A5.14,
Sec. II Part C (Material Specifications Welding A5.17, A5.23, A5.25, and A5.29 as shown in Table 2.
Consumables), which is a group of specifications for
various acceptable welding consumables and brazing

Table 1. AWS standards adopted by ASME Sec. II Part C 1998 edition and 1999 addenda

ANSI/AWS A 5.11/A5.11M-1997 Specification for Nickel and Nickel-Alloy Welding Electrodes for Shielded Metal Arc Welding

ANSI/AWS A5.14/A5.14M-1997 Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods

ANSI/AWS A5.17/A5.17M-1997 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding

ANSI/AWS A5.23/A5.23M-1997 Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding

ANSI/AWS A5.25/A5.25M-1997 Specification for Carbon and Low-Alloy Steel Electrodes and Fluxes for Electroslag Welding

ANSI/AWS A5.26/A5.26M-1997 Specification for Carbon and Low-Alloy Steel Electrodes for Electrogas Welding

ANSI/AWS A5.29-1998 Specification for Low-Alloy Steel Electrodes for Flux-Cored Arc Welding

(Note: A5.xx: US customary unit; A5.xxM: SI unit)

Table 2. New AWS classification for the brands affected by the new edition/addenda of ASME

Brand Old classification New classification

Covered electrode
NIC-70E AWS A5.11 ENiCrFe-9
NIC-70S AWS A5.11 ENiCrFe-9
NIC-1S AWS A5.11 ENiMo-8
TIG wire
TGS-709S AWS A5.14 ERNiMo-8
SAW consumable
US-709S AWS A5.14 ERNiMo-8
G-80/US-511 AWS A5.23 F9PZ-EG-B2 AWS A5.23 F7PZ-EG-B2
MF-29A/US-511 AWS A5.23 F9PZ-EG-B2 AWS A5.23 F7PZ-EG-B2
MF-200N/US-511N AWS A5.23 F9PZ-EG-B2 AWS A5.23 F7P0-EG-B2
MF-29N/US-511N AWS A5.23 F10PZ-EG-B2 AWS A5.23 F8P2-EG-B2
PF-200/US-511N AWS A5.23 F9PZ-EG-B2 AWS A5.23 F8P2-EG-B2
PF-200S/US-505 AWS A5.23 F8PZ-EG-B8
PF-200S/US-9Cb AWS A5.23 F10PZ-EG-G
Flux-cored wire
DWA-55L AWS A5.29 E80T1-K2 AWS A5.29 E81T1-K2M
DW-55LSR AWS A5.29 E80T1-K2 AWS A5.29 E81T1-K2
DW-55L AWS A5.29 E80T1-K2 AWS A5.29 E81T1-K2
DWA-55LSR AWS A5.29 E81T1-Ni1 AWS A5.29 E81T1-Ni1M
MXA-55T AWS A5.29 E80T1-K2 AWS A5.29 E81T1-K2M
DW-60W AWS A5.29 E80T1-W AWS A5.29 E81T1-W2
MX-60W AWS A5.29 E80T1 -W AWS A5.29 E80T1-W2
DW-588 AWS A5.29 E80T1 -W AWS A5.29 E81T1-W2

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Feature Article
Kobelco in the AWS Welding Show Attracts over
20,000 Visitors

The 47th Annual International Welding and At the ceremony, Tom Konohira (Chairman, KWAI),
Fabricating Exposition and the 81st AWS Annual Duke Kawaue (President, KWAI), Bryan Willingham
Convention was held at McCormick Place in (President, BMS) and Jack Barton (General Manager,
downtown Chicago, Illinois. This annual exposition is Koike Aronson) lined up on stage to kick off the party.
also known as the AWS Welding Show The party began with "Kagami-Wari," a traditional
and is one of the largest ceremony, in which a few
welding events in the world. executives break open a
Kobelco Welding of America barrel of Sake (a Japanese
(KWAI) was one of 617 traditional wine) with
exhibitors there, attending wooden mallets. After the
from April 26 to the 28th. lid is cracked, the Sake is
shared by everyone at the
KWAI's booth seemed to party. Following some
attract a lot of visitors who executives' witty remarks,
came looking for innovative everyone toasted a KWA's
Kobelco welding wires as prosperous future. With
well as technical assistance satisfaction or
on welding consumables and disappointment of attendees,
welding procedures. KWAI door prizes (including
emphasized Kobelco flux Poke-mon cards) were
cored wires, which offer passed out. A live band
high welding efficiency and provided music and a good
superior weldability, by time was had by the entire
demonstrating the wires in group at the party.
the demo booth. KWAI
exhibited new products, It has been over 40 years
including DW-50, classified since a Kobelco welding
as AWS A5.20 E71T-1, consumable was first
which offers better launched on the North
weldability in vertical up American market. KSL's
positions. DW-329AP is steady business expansion
another highlight, as a in the market led to the
special flux-cored wire for establishment of KWAI in
duplex stainless steel, Houston 10 years ago in
offering excellent order to provide better
weldability in all-position service for increasing
welding. This welding show customers. KWAI is forging
was a valuable occasion for ahead, targeting increased
the KWAI Chicago Sales business progress in the new
Office to promote its decade. Looking forward to
business in the Midwest. meeting you at the next
AWS Welding Show in
At this occasion, KWAI Cleveland, Ohio in 2001.
also held a reception for the
Kobelco Welding
Association (KWA), inviting
almost 100 members and
customers to celebrate its Reported by
10th anniversary. With hearty welcome and skillful demos, the KWAI Y. Nakai, KSL
booth attracted many visitors during the welding fair.

9
 Feature Article
With a Fresh Exhibition, Kobelco Attracts Numerous
Visitors in the Welding Show 2000

The Japan International Welding Show 2000 opened

at INTEX OSAKA on April 12 and ran through April
15. Perhaps reflecting the economic recession still
dragging on in Asia, the Show did not attract a high
turnout: 115 exhibitors in and out of Japan and 52,000
visitors during the tour days. Both figures are lower
than those attained at the last Show held in Tokyo in
1998.

The main theme of the Show this time was "The

Advanced Welding and Joining Technology Opens the
Door to the 21st Century Let's Think of the
Fundamentals of Production." Kobe Steel, in the role of
a welding industry leader, took part in the Show with
the slogan of "KOBELCO'S TECHNOLOGY
SPARKLES IN THE 21ST CENTURY." Highlights
from the field of welding consumables included
advanced flux-cored wires and solid wires for gas metal
arc welding. These include the DW-BF Series (a group
of flux-cored wires that facilitate 10mm-leg-length
horizontal fillet welds in one pass welding), MG-55 and
MX-55 (a solid wire and flux-cored wire offering good
mechanical properties in welding with high heat input Top: Attractive technical presentation using visual
and interpass temperatures). These wires contribute to aids and a welding robot on the main stage
Bottom: Business talk and technical service corners
the improvement of welding efficiency and reduction of
the total fabrication cost.
our clients in the new century. The next Japan
International Welding Show will be held in Tokyo in
As indicated in the Kobelco-Group's business slogan April 2002, when World Cup Football will be hosted
of QTQ (Quality Products, Technical Support, Quick by Japan. We give you a hearty welcome in advance.
Delivery), we are determined to pursue CS (Customer
Satisfaction) in order to make constant contributions to Reported by D. Hino, KSL

Editorial Postscript

The DW-BF Series consists of four different brands MG-55 and MX-55 ensure the minimum tensile
(DW-50BF, DW-60BF, DW-50WBF, and DW-60WBF) strength of 490N/mm2 in high efficient welding using
suitable for one-pass large-leg fillet welding of high high heat input of 40 kJ/cm max and less pass-to-pass
strength steel and atmospheric corrosion resisting steel intervals with a maximum interpass temperature of
respectively, particularly in bridge construction. 350C.

Publisher: The International Operations Dept., Welding Company, Kobe Steel, Ltd.
Printer: Fukuda Printing Co., Ltd.
Editor: KOBELCO WELDING TODAY Editorial Stall
URL: http://www.kobelco.co.jp

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