4.3 ESAB Product Catalogue 2013
4.3 ESAB Product Catalogue 2013
4.3 ESAB Product Catalogue 2013
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Welding Consumables
ESAB Product Catalogue of Welding & Cutting Products is an updated version of an
extensive product range for today’s conceivable welding application. ESAB pursues
a policy of continuous development and hence product specifications are subject
to change. The information given in this book is correct and accurate to the best of
our knowledge, however, ESAB India Limited is not responsible and liable for any
damages resulting from using this information/products. Further, we reserve the right
to change the spefications without notice.
i
OK AUTROD 13.20 SC 63 Consumables Guide for Terroweld CLH 157
OK AUTROD 16.10 64 ASTM Steels 109 Ferroloid 1 157
OK AUTROD 16.11 64 Quick guide for selection of Ferroloid 3 157
OK AUTROD 16.13 64 consumables 127 Ferroloid 4 158
OK AUTROD 16.30 65 OK 92.18 158
OK AUTROD 16.53 65 OK 92.58 159
SAW Flux Reclamation Consumables OK 92.60 159
OK FLUX 10.62 66 Conventional Hardfacing Alloys ESAB 802KG 160
OK FLUX 10.62L 66 Buffering 139 Steel and Dissimilar Joining Alloys
OK FLUX 10.71L 67 Duroid 250 140 Welding Dissimilar Steels 161
OK FLUX 10.81L 67 Duroid 350 140 Terroweld DMS 162
OK FLUX 10.81LS 68 Duroid 650 140 ESAB 116 162
OK FLUX 10.92L 68 Duroid 650 B 141 OK 53.18 162
Strip Cladding Consumables ESAB 600B 141 Terroweld DBL 163
STRIP & FLUX COMBINATIONS Duromangan 141 Terroweld DLH 163
FOR CLADDING 69 Low Heat Hardfacing Alloys Durochrome 164
Hard Surfacing Consumables Hardfacing 143 Terroweld DS1 164
WIRE & FLUX COMBINATIONS 70 Recommended Preheating 145 Terroweld DS2 164
Consumables for Ni Steels Asträ HTB 146 Terroweld DS3 165
9% Ni Steels for LNG Tank Fabrication 71 ESAB 116 Ni 146 Terroweld DS4 165
SMAW OK 83.28 146 Terroweld DS6 166
OK 92.26 72 OK 83.40 147 Terroweld S1 166
OK 92.86 72 OK 84.76 147 Terroweld S2 166
OK 92.59 73 OK 84.78 148 Terroweld S3 167
GMAW Terroweld EWR 148 ESAB CSA 167
OK AUTROD 19.81 74 ESAB 550 148 OK 68.82 168
OK AUTROD 19.82 74 Asträ MN 149 OK 68.53 168
GTAW Durobell 149 OK 69.33 169
OK TIGROD 19.81 75 Terroweld MN 150 Asträ ZF 169
OK TIGROD 19.82 75 Terroweld SHR 150 Terrochrome 169
OK TIGROD 19.85 76 Terrowed 35 151 Non-Ferrous Alloys
OK TIGROD 19.93 76 Terroweld 65 151 Welding Non-ferrous Alloys 170
SAW OK 84.80 151 ESAB CN1G 171
OK FLUX 10.16 77 OK 84.84 152 ESAB CN 182 171
Storage & Handling of Electrodes 78 Terroweld CRC 152 ESAB Monel 171
Approval in accordance with OK 84.52 152 OK 92.35 172
classification society rules 83 Cobalarc OK 93.60 172
Calculation of Electrode Cobalarc 153 OK 92.26 172
Consumption 84 Cobalarc 1M 154 OK 92.05 173
Data Sheet – Pipewelding 90 Cobalarc 9 154 OK 93.62 173
General Recommendations 92 Cobalarc 4 155 OK 93.66 174
GMAW 92 Cobalarc MX 155 Bronzoid 1 174
FCAW 94 Cast Iron Electrodes Cutting & Gouging Electrodes
SAW 103 Welding Cast Iron 156 Cutting and Gouging 175
ii
Terrocut 176 Selection of Hard Facing TIG Torches - Air water cooled 221
OK 21.03 176 Consumables 193 LPH 50 / 80 / 120 222
Flux Cored Wires ESAB Consumables for Joining Powercut 900 / 1600 222
OK Tubrod 14.17 177 of Dissimilar Metals 194 CPRA 800 (S) / 1200 (S) 223
OK Tubrod 14.18 177 Metal Identification Chart 195 Welding Automation
OK Tubrod 14.70 177 Thyristorised SAW
OK Tubrod 14.71 178 Arc Welding Equipment Power Sources - DC 224
OK Tubrod 15.40 178 Thyristorised SAW
OK Tubrod 15.41 178 MMA Transformers Power Sources - AC 224
OK Tubrod 15.52 179 Transweld 400 199 A2 / A6 Process controller PEH 224
OK Tubrod 15.60 179 THH 630 199 Orbital TIG Welding 225
OK Tubrod 15.73 179 MMA Rectifiers Tractor Automates - Migsytrac 226
OK Tubrod 15.80 180 RS 400 / 400S 200 Migsytrac - 2000 226
OK Tubrod 15.86 180 Esayweld SSR 400 / 600 200 Migsytrac - 3000 226
Gas Brazing Alloys LHJ 425 / 750 201 Tractor Automates - Railtrac 227
Brazing 181 Origo Arc 200 201 Tractor Automates - Trippletrac /
Rupatan 2 182 Buddy Arc 200 202 Multitrac / Mastertac 228
Rupatan 14 182 Buddy Arc 400i / 400i XC 202 Roller Beds 229
Rupatan 35 182 Origo Arc 4001i A24 203 Positioners 229
Rupatan 43 182 Caddy Arc 251i A34 203 Friction Stir welding 230
Rupatan 50 183 Origo Arc 410C / 650C / 810C 204 Robotics for Arc welding 231
Rupatan 60 183 LFD 1500 / 3000 204 Range of Robots 232
ESAB Silicon Bronze 183 EDW 350 / 400 / 500 205 Fusion Welding Methods
Ruf - Kut 183 Power Compact 255 206 Choice of Fusion Welding Method 233
Tig Filler Wires Migmatic 250 / Auto Mig 300 206 Welding Methods 233
Crystalloy 60 184 Auto K 400 / 600 207 MMA Manual Metal
Crystalloy 61 184 Auto K 400 / 600 Synergic 208 Arc Welding
Crystalloy 62 184 SCR 400 (S) 209 MMA Manual Metal Arc Welding 235
Crystalloy 80 184 Buddy Mig 500i 209 MIG / MAG Gas Metal
Crystalloy 81 185 MIG 3000i U6 MIG 3001i / 4001i 210 Arc Welding
Crystalloy 82 185 Aristo MIG 5000i 211 MAG Welding 237
Crystalloy 85 185 Aristo MIG U4000i / U5000i 212 MIG Welding 238
Crystalloy 90 185 Feed 3004w / 4804w U6 213 TIG (GTAW) Tungsten Inert
Hot Metal Spray Powders MIG Torches - Air / Water / cooled 214 Gas Welding
Powder Welding 186 Easyweld SSR 400-T / 400-T Pluse 215 TIG (GTAW Welding) 239
Castcoat 20 187 Buddy Tig 160 215 Common Faults in Arc Welding
Multiweld 40 187 Caddy TIG 2200i 216 Common Faults in Arc Welding 241
Borostrength 60 187 Origo TIG 3001i TA 24 216
Tungstrength 70 188 Aristo TIG 4000iw TA 6 217
ESAB wear plates 188 Caddy TIG 2200i AC/DC TA33 /
Industrial Gas Equipment
Conversion Chart 190 TA34 / AC/DC 218 Inlet Pressure Gauge
Comparative Hardness Scales 191 Origo TIG 3000i AC/DC A Typical Oxyfuel Gas Welding
Metal Selection Guide TA 24 AC/DC 219 and Cutting System 247
ESAB Consumables for Origo TIG 4300iw AC/DC Regulators
Different Repair Work 192 TA 24 AC/DC 220 Single Stage Regulators 250
iii
Double Stage Regulators 252
High Pressure Regulators 254
Pipe Line Regulators 256
Special Regulators 257
Cutting Blowpipes 258
Welding & Heating Blowpipes 260
Cutting Nozzles 262
Welding Tips 264
Flash Back Arresters 266
Small / Portable Cutting Machines 268
Accessories
Accessories 269
iv
Welding Consumables
Welding Consumables
Carbon Steel Electrodes
Welding Consumables
Weld Metal All Weld
A rutile coated general-purpose electrode for
Composition (Wt.%) Mechanical Properties
SMAW
C 0.08 YS (N/mm2) 430
Classification AWS A5.1: E6012 Si 0.20 UTS (N/mm2) 520
IS 814: ER4124 Mn 0.35 Elongation (%) 25
Impact (CVN)
DESCRIPTION @ +20ºC (Joules) 70
ESAB FERROSPEED is a rutile-coated general-purpose
electrode for welding structures that are not subjected CURRENT RANGE & PACKING DATA
to heavy dynamic loading and is specially designed for Size Length Current Range No. of Electrodes in a
higher tolerance to less cleaned plates and poor joint (mm) (mm) (Amps) Carton Cardboard box
fit-ups. The electrode has high current carrying capacity 3.15 450 95-150 150 600
and produces quality weld metal. 4.00 450 140-190 100 400
APPROVALS: ABS, BV, DNV, IBR, IRS, LRS & MMD 5.00 450 180-260 65 260
PACKING: Electrodes are packed in cartons and four of
WELDING CURRENT: DC+, AC 70V these cartons are shrink wrapped in a cardboard box.
3
ESAB FERROSPEED PLUS TYPICAL PROPERTIES
Welding Consumables
ESAB VORTIC is a medium coated general purpose CURRENT RANGE & PACKING DATA
mild steel electrode, especially designed for use in
vertical and over head positions. This is a rutile coated Size Length Current Range No. of Electrodes in a
electrode, with fast freezing slag and excellent slag (mm) (mm) (Amps) Carton Cardboard box
detachability even in deep grooves. 2.50 350 40-100 185 740
3.15 450 100-125 125 500
APPROVALS: IBR, IRS, LRS & MMD 4.00 450 135-175 90 360
WELDING CURRENT: DC+, AC 70V 5.00 450 150-260 60 240
4
ESAB 28 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A rutile coated all-round electrode for SMAW Composition (Wt.%) Mechanical Properties
Classification AWS A5.1: E6013 C 0.08 YS (N/mm2) 420
IS 814: ER4212X Si 0.25 UTS (N/mm2) 510
Mn 0.35 Elongation (%) 28
DESCRIPTION Impact (CVN)
@ 0ºC (Joules) 90
ESAB 28 is a medium heavy rutile coated mild steel
electrode designed for welding of unalloyed structural CURRENT RANGE & PACKING DATA
steels in all positions. The electrode gives smooth radio-
Size Length Current Range No. of Electrodes in a
graphic quality weld with low spatter and smoke. Slag
(mm) (mm) (Amps) Carton Cardboard box
is self detachable and the bead shape is uniform and
2.50 350 50-80 190 760
finely rippled.
3.15 350 60-130 120 480
APPROVALS: ABS, BV, DNV, IBR, IRS, LRS, MMD, 3.15 450 60-120 120 480
NPC, PDIL & TOYO 4.00 450 90-170 75 300
WELDING CURRENT: DC+, AC 50V 5.00 450 130-260 50 200
5
ESAB FERROWELD 1 TYPICAL PROPERTIES
Welding Consumables
6
OK 48.20 (SPL) TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A basic coated low-hydrogen MMAW electrode for
Composition (Wt.%) Mechanical Properties
NACE requirements
C 0.07 YS (N/mm2) 450
Classification AWS A5.1: E7018 Si 0.30 UTS (N/mm2) 540
Mn 1.10 Elongation (%) 30
DESCRIPTION Impact (CVN)
OK 48.20 (SPL) is a heavy basic coated, low hydrogen @ -30ºC (Joules) 100
all positional electrode for welding medium tensile &
fine grained carbon steels. The electrode meets NACE CURRENT RANGE & PACKING DATA
requirements. Size Length Current Range No. of Electrodes in a
(mm) (mm) (Amps) Carton Cardboard box
WELDING CURRENT: DC+, AC 70V 2.50 350 75-105 130 520
3.15 450 95-150 90 360
4.00 450 140-190 60 240
5.00 450 180-260 40 160
ESAB 36H (SPL) is a basic coated low hydrogen iron CURRENT RANGE & PACKING DATA
powder electrode for low temperature applications. It is Size Length Current Range No. of Electrodes in a
an all positional electrode for welding medium tensile (mm) (mm) (Amps) Carton Cardboard box
and fine grained carbon steels. 2.50 350 55-100 140 560
APPROVALS: ABS, IBR, LRS, NPC, PDIL & 3.15 450 70-130 90 360
TOYO 4.00 450 90-200 60 240
5.00 450 110-280 40 160
WELDING CURRENT: DC+, AC 70V
PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
7
ESAB 36H (SPL) M TYPICAL PROPERTIES
Welding Consumables
8
Gas Welding Fluxes
Welding Consumables
DESCRIPTION Aluminium and Aluminium alloys: Immediately
after welding wash the joints in warm water and brush
ESAB welding and brazing fluxes are well known and vigourously. When conditions allow, follow up by a rapid
are designed to obtain consistent and sound joints dip in a 5% solution of nitric acid; wash again, using hot
between steel, copper, brass, bronze and aluminium. water to assist drying.
Some of the common applications are found in manu-
facturing and repair of automobiles, refrigeration and air Copper and Brass:- Wash in boiling water followed
conditioning, tool manufacturing and other industries. by brushing. Where possible a 2% solution of nitric or
sulphuric acid is prefered to help in tifting the glassy
ESAB WELDING AND BRAZING FLUXES deposit, followed by a hot water wash.
9
Pipe Welding Electrodes
10
Low Alloy Electrodes
Welding Consumables
Weld Metal All Weld
A Ni-Cu alloyed low hydrogen electrode for SMAW Composition (Wt.%) Mechanical Properties
Classification AWS A5.5: E8018-G C 0.07 YS (N/mm2) 460
IS 1395: E55BG129Fe Si 0.40 UTS (N/mm2) 550
Mn 1.10 Elongation (%) 30
DESCRIPTION Ni 0.45 Impact (CVN)
Cu 0.40 @ -20ºC (Joules) 130
OK 73.08 is a Ni-Cu alloyed low hydrogen electrode,
which deposits a weld metal with good corrosion
resistance to sea water and flue gases. The weld metal CURRENT RANGE & PACKING DATA
has excellent mechanical properties. It is used for the
welding of weather proof steel and ship’s hull structural Size Length Current Range No. of Electrodes in a
(mm) (mm) (Amps) Carton Cardboard box
steel and shell plating of ice-breakers.
2.50 350 50-90 140 560
WELDING CURRENT: DC+, AC 90V 3.15 450 90-140 90 360
4.00 450 140-190 55 220
5.00 450 190-240 35 140
PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
11
OK 74.46 TYPICAL PROPERTIES
Welding Consumables
12
OK 76.18M TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A low carbon 1.25Cr-0.5Mo alloyed electrode for
Composition (Wt.%) Mechanical Properties
SMAW of creep resistant steels
C 0.03 YS (N/mm2) 450
Classification AWS A5.5: E7018-B2L Si 0.40 UTS (N/mm2) 540
IS 1395: E49BB2L26Fe Mn 0.60 Elongation (%) 24
Cr 1.25
DESCRIPTION Mo 0.55
OK 76.18M is a low carbon, basic coated hydrogen
controlled iron powder type electrode, used for welding
creep resistant steels of 1.25Cr-0.5Mo or similar type,
CURRENT RANGE & PACKING DATA
used in high temperature components of power plants,
boilers, oil-refineries, petrochemical plants etc. The Size Length Current Range No. of Electrodes in a
electrode welds with a stable arc, minimum amount (mm) (mm) (Amps) Carton Cardboard box
of spatter and smooth & even weld bead. OK 76.18M 2.50 350 70-110 130 520
deposits a weld metal resistant to both cracking 3.15 450 90-150 95 380
and porosity. The weld metal is resistant to scaling up 4.00 450 130-190 60 240
to 575°C. 5.00 450 150-260 35 140
WELDING CURRENT: DC+, AC 70V PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
13
OK 76.28M TYPICAL PROPERTIES
Welding Consumables
WELDING CURRENT: DC+, AC 70V PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
WELDING CURRENT: DC+ PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
14
ESAB KV7 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A 9Cr-1Mo alloyed low hydrogen electrode for
Composition (Wt.%) Mechanical Properties
SMAW of creep resistant steels
C 0.06 YS (N/mm2) 630
Classification AWS A5.5: E8018-B8 Si 0.35 UTS (N/mm2) 780
IS 1395: E55BB820 Mn 0.90 Elongation (%) 21
Cr 10.40
DESCRIPTION Ni 0.15
Mo 1.10
ESAB KV7 is basic coated low hydrogen electrode, for
welding creep resistant steels of 9Cr-1Mo type. The
weld metal is highly resistant to corrosion and hydrogen CURRENT RANGE & PACKING DATA
attack at high temperatures. The electrode runs with a
quiet, stable arc and gives a minimum amount of spat- Size Length Current Range No. of Electrodes in a
ter and superior weld appearance. It finds extensive use (mm) (mm) (Amps) Carton Cardboard box
in the power plants, oil refineries, chemical and petro- 2.50 350 70-100 135 540
chemical industries. 3.15 350 90-125 95 380
4.00 350 140-190 60 240
WELDING CURRENT: DC+
5.00 450 180-240 45 180
PACKING: Electrodes are packed in cartons and four
of these cartons are shrink wrapped in a cardboard box.
This electrode can also be made available in moisture
resistant vacuum packed cartons, which can be used
without redrying.
15
ESAB 98 TYPICAL PROPERTIES
Welding Consumables
16
ESAB 120 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A Cr-Ni-Mo alloyed low hydrogen electrode for
Composition (Wt.%) Mechanical Properties
SMAW of HSLA steels
C 0.06 YS (N/mm2) 790
Classification AWS A5.5: E12018M Si 0.25 UTS (N/mm2) 860
Mn 1.60 Elongation (%) 20
DESCRIPTION Cr 0.90 Impact (CVN)
Ni 2.35 @ -51ºC (Joules) 70
ESAB 120 is a Cr-Ni-Mo alloyed low hydrogen electrode,
Mo 0.40
for welding ultra high strength low alloy steels. The
electrode is designed to give a tough weld metal
avoiding risk of temper brittleness. The operational CURRENT RANGE & PACKING DATA
characteristics are excellent in all positions.
Size Length Current Range No. of Electrodes in a
APPROVALS: ABS (mm) (mm) (Amps) Carton Cardboard box
3.15 450 90-140 90 360
WELDING CURRENT: DC+, AC 70V 4.00 450 140-190 60 240
5.00 450 190-240 40 160
17
Stainless Steel Electrodes
18
ESAB 304B TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A basic coated extra low carbon stainless steel elec- Composition (Wt.%) Mechanical Properties
trode for SMAW of 18Cr-8Ni type steels
C 0.03 YS (N/mm2) 450
Classification AWS A5.4: E308L-15 Si 0.40 UTS (N/mm2) 570
DESCRIPTION Mn 1.50 Elongation (%) 40
Cr 19.00 Impact (CVN)
ESAB 304B is an extra low carbon, basic coated 19Cr- Ni 10.50 @ -196ºC (Joules) 30
10Ni stainless steel electrode with outstanding welding
properties in the vertical and overhead position. The weld
metal is highly resistant to cracking and porosity and CURRENT RANGE & PACKING DATA
has good impact toughness at very low temperatures. Size Length Current Range Packing
APPROVAL: NPC (mm) (mm) (Amps)
2.50 350 60-100 Weight Per Box: 10 Kg
WELDING CURRENT: DC+
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 180-210
in a Box: 5
PACKING: Electrodes are packed in heat sealed plastic
cartons and five of these cartons are shrink wrapped
in a card board box. This electrode can also be made
available in moisture resistant vacuum packed cartons,
which can be used without redrying.
19
OK 63.50 TYPICAL PROPERTIES
Welding Consumables
APPROVALS: NPC, PDIL & TOYO CURRENT RANGE & PACKING DATA
Size Length Current Range Packing
WELDING CURRENT: DC+, AC 70V
(mm) (mm) (Amps)
2.50 350 60-100 Weight Per Box: 10 Kg
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
PACKING: Electrodes are packed in heat sealed plastic
cartons and five of these cartons are shrink wrapped
in a card board box. This electrode can also be made
available in moisture resistant vacuum packed cartons,
which can be used without redrying.
A rutile based extra low carbon stainless steel Weld Metal All Weld
electrode for SMAW of 18Cr-12Ni-2.5Mo type steels Composition (Wt.%) Mechanical Properties
20
ESAB 316KCR TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
An extra low carbon stainless steel electrode
Composition (Wt.%) Mechanical Properties
depositing ferrite free weld metal
C 0.04 YS (N/mm2) 450
Classification AWS A 5.4: E316L-16 (Nearest) Si 0.40 UTS (N/mm2) 570
Mn 1.20 Elongation (%) 38
DESCRIPTION Cr 18.00
Ni 14.20
ESAB 316KCR is a specially designed extra low carbon
Mo 2.20
stainless steel electrode to deposit a ferrite free, fully
austenitic weld metal with better corrosion resistance to
hydrochloric, nitric and sulphuric acids. CURRENT RANGE & PACKING DATA
21
ESAB 309 TYPICAL PROPERTIES
Welding Consumables
22
ESAB 309LC TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A basic coated extra low carbon 23Cr-13Ni stainless
Composition (Wt.%) Mechanical Properties
steel electrode for SMAW
C 0.03 YS (N/mm2) 470
Classification AWS A 5.4: E309L-15 Si 0.75 UTS (N/mm2) 590
Mn 1.00 Elongation (%) 40
DESCRIPTION Cr 23.50
ESAB 309LC is an extra low carbon all positional basic Ni 13.70
coated electrode giving austenitic weld deposit of
23Cr-13Ni type. It is suitable for welding heat resistant
CURRENT RANGE & PACKING DATA
Cr-Ni alloyed steels and stainless steels to unalloyed or
low alloyed steels, where better toughness is required. Size Length Current Range Packing
(mm) (mm) (Amps)
WELDING CURRENT: DC+
2.50 350 60-100 Weight Per Box: 10 Kg
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
23
ESAB 309Mo TYPICAL PROPERTIES
Welding Consumables
A basic coated extra low carbon stainless steel Weld Metal All Weld
electrode for SMAW of similar composition steels & Composition (Wt.%) Mechanical Properties
dissimilar steels C 0.03 YS (N/mm2) 500
Classification AWS A 5.4: E309LMo-15 Si 0.70 UTS (N/mm2) 600
Mn 0.70 Elongation (%) 34
DESCRIPTION Cr 23.50
Ni 13.50
ESAB 309LMo is an extra low carbon, basic coated all Mo 2.50
positional stainless steel electrode, giving an austenitic
weld deposit of 23Cr-13Ni-2.5Mo type. The weld metal
has excellent resistance to corrosion and oxidation CURRENT RANGE & PACKING DATA
at elevated temperatures up to 1100°C in continuous Size Length Current Range Packing
service, coupled with good strength and toughness.
(mm) (mm) (Amps)
WELDING CURRENT: DC+ 2.50 350 60-100 Weight Per Box: 10 Kg
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
PACKING: Electrodes are packed in heat sealed plastic
cartons and five of these cartons are shrink wrapped
in a card board box. This electrode can also be made
available in moisture resistant vacuum packed cartons,
which can be used without redrying.
24
ESAB 309Cb TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A Nb stabilised stainless steel electrode for SMAW
Composition (Wt.%) Mechanical Properties
of similar composition steels & dissimilar steels
C 0.04 YS (N/mm2) 510
Classification AWS A 5.4: E309Nb-15 Si 0.80 UTS (N/mm2) 630
Mn 1.00 Elongation (%) 30
DESCRIPTION Cr 23.50
ESAB 309Cb is a basic coated stainless steel electrode Ni 13.50
giving austenitic weld deposit of 23Cr-13Ni type. Nb 0.70
Columbium provides immunity against weld decay. The
C-Nb ratio is carefully controlled to provide stabilization CURRENT RANGE & PACKING DATA
against intergranular corrosion.
Size Length Current Range Packing
WELDING CURRENT: DC+ (mm) (mm) (Amps)
2.50 350 60-100 Weight Per Box: 10 Kg
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
PACKING: Electrodes are packed in heat sealed plastic
cartons and five of these cartons are shrink wrapped
in a card board box. This electrode can also be made
available in moisture resistant vacuum packed cartons,
which can be used without redrying.
25
ESAB RSW TYPICAL PROPERTIES
Welding Consumables
A rutile based high alloyed universal electrode for Weld Metal All Weld
joining steels of unknown composition Composition (Wt.%) Mechanical Properties
26
ESAB CHROMWELD G TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A rutile coated 18Cr-8Ni-4Mn stainless steel Composition (Wt.%) Mechanical Properties
electrode for SMAW
C 0.06 YS (N/mm2) 470
DESCRIPTION Si 0.80 UTS (N/mm2) 630
Mn 4.50 Elongation (%) 38
ESAB CHROMWELD G is a rutile coated stainless steel Cr 18.40
electrode depositing an 18Cr-8Ni-5Mn work hardening Ni 8.20
type weld metal. The electrode is specially designed for Mo 0.30
applications involving good work hardening properties
and for joining of high tensile steels.
CURRENT RANGE & PACKING DATA
WELDING CURRENT: DC+, AC 70V
Size Length Current Range Packing
(mm) (mm) (Amps)
2.50 350 60-100 Weight Per Box: 10 Kg
3.15 350 80-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
27
OK 68.10 TYPICAL PROPERTIES
Welding Consumables
28
ESAB 430 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A basic coated stainless steel electrode depositing
Composition (Wt.%) Mechanical Properties
a ferritic 17Cr weld metal for SMAW
C 0.03 UTS (N/mm2) 520
Classification AWS A 5.4: E430-15 Si 0.60 Elongation (%) 22
Mn 0.35
DESCRIPTION Cr 16.50
Ni 0.35
ESAB 430 is a basic coated stainless steel electrode
giving ferritic weld metal of 17Cr type for welding steels
of similar composition. CURRENT RANGE & PACKING DATA
WELDING CURRENT: DC+ Size Length Current Range Packing
(mm) (mm) (Amps)
2.50 350 70-100 Weight Per Box: 10 Kg
3.15 350 90-120 Weight Per Carton
4.00 350 120-170 (Packet): 2 Kg
No. of Cartons (Packets)
5.00 350 160-210
in a Box: 5
29
OK 68.55 TYPICAL PROPERTIES
Welding Consumables
30
GTAW Consumables
Welding Consumables
Wire Composition All Weld
A Cu coated solid rod for GTAW (Wt.%) Mechanical Properties
3.15 1000 3
WELDING CURRENT: DC-
PACKING: The rods are packed in tubes weighing 5 kg
SHIELDING GAS: Ar
and four of them in a cardboard box.
31
OK TIGROD 13.09 TYPICAL PROPERTIES
Welding Consumables
32
OK TIGROD B2L TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
A Cu coated low carbon 1.3Cr-0.5Mo alloyed solid rod (Wt.%) Mechanical Properties
for GTAW of creep resistant steels
C 0.03 YS (N/mm2) 540
Classification AWS A5.28: ER70S-B2L Si 0.60 UTS (N/mm2) 630
Mn 0.60 Elongation (%) 25
DESCRIPTION Cr 1.30 Impact (CVN)
OK TIGROD B2L is a low carbon GTAW solid rod suitable Mo 0.50 @ -20ºC (Joules) 150
for welding creep resistant steels of the type 1.25Cr- Cu 0.15
0.5Mo. It provides excellent mechanical properties as
well as high creep resistance. PACKING DATA
33
OK TIGROD B3L TYPICAL PROPERTIES
Welding Consumables
34
OK TIGROD 13.28 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
A Cu coated 2.4Ni alloyed solid rod for GTAW (Wt.%) Mechanical Properties
35
OK TIGROD 13.37 TYPICAL PROPERTIES
Welding Consumables
1.6 1000 3
2.0 1000 3
2.4 1000 3
36
OK TIGROD 16.10 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
An extra low carbon stainless steel solid rod for (Wt.%) Mechanical Properties
GTAW of 18Cr-8Ni type steels
C 0.03 YS (N/mm2) 400
Classification AWS A5.9: ER308L Si 0.40 UTS (N/mm2) 580
Mn 1.75 Elongation (%) 45
DESCRIPTION Cr 19.80 Impact (CVN)
OK TIGROD 16.10 is a corrosion resistant, chromium- Ni 9.50 @ -196ºC (Joules) 60
nickel alloyed solid rod for welding austenitic chromium-
nickel alloys of 18Cr-8Ni type. OK TIGROD 16.10 has
good general corrosion resistance. The alloy has a low
PACKING DATA
carbon content which makes it particularly suitable to
the applications, where there is a risk of intergranular Size Length Packing
corrosion. The alloy is widely used in the chemical and (mm) (mm) (5 Kg.)
food-processing industries, as well as for pipes, tubes
and boilers. 1.6 1000 3
2.0 1000 3
APPROVALS: NPC, PDIL & TOYO 2.5 1000 3
3.15 1000 3
WELDING CURRENT: DC-
PACKING: The rods are packed in tubes weighing 5 kg.
SHIELDING GAS: Ar
SHIELDING GAS: Ar PACKING: The rods are packed in tubes weighing 5 kg.
37
OK TIGROD 16.13 TYPICAL PROPERTIES
Welding Consumables
SHIELDING GAS: Ar or He or Ar/He PACKING: The rods are packed in tubes weighing 5 kg.
APPROVALS: NPC, PDIL & TOYO PACKING: The rods are packed in tubes weighing 5 kg.
SHIELDING GAS: Ar
38
OK TIGROD 16.53 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
An extra low carbon 24Cr-13Ni stainless steel solid (Wt.%) Mechanical Properties
rod for GTAW
C 0.03 YS (N/mm2) 410
Classification AWS A5.9: ER309L Si 0.45 UTS (N/mm2) 580
Mn 1.75 Elongation (%) 35
DESCRIPTION Cr 23.50 Impact (CVN)
OK TIGROD 16.53 is a corrosion resistant, chromium- Ni 12.20 @ -60ºC (Joules) 100
nickel alloyed solid rod for joining stainless steels to
PACKING DATA
non-alloy or low-alloy steels and for welding austenitic
stainless alloys of the 24Cr-13Ni types. The alloy is also Size Length Packing
used for welding buffer layers on C-Mn steels. (mm) (mm) (5 Kg.)
1.6 1000 3
APPROVALS: NPC, PDIL & TOYO 2.0 1000 3
2.5 1000 3
WELDING CURRENT: DC-
3.15 1000 3
SHIELDING GAS: Ar
PACKING: The rods are packed in tubes weighing 5 kg.
39
OK TIGROD 4043 TYPICAL PROPERTIES
Welding Consumables
40
OK TIGROD 5356 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
A Mg alloyed aluminium solid rod for GTAW (Wt.%) Mechanical Properties
Classification AWS A5.10: R5356 Si <0.25 YS (N/mm2) 120
Mn 0.15 UTS (N/mm2) 265
DESCRIPTION Cr 0.13 Elongation (%) 26
Cu <0.10
OK TIGROD 5356 is the most widely used welding alloy Ti 0.11
and can be classified as a general-purpose type filler Zn <0.10
alloy. OK TIGROD 5356 is typically chosen because of Fe <0.40
its relatively high shear strength. The 5XXX alloy base Mg 5.00
material, welded with OK TIGROD 5356, with weld pool
chemistry greater than 3% Mg and service temperatures PACKING DATA
in excess of 65°C, is susceptible to stress corrosion
cracking. The alloy is non-heat treatable. Size Length Packing
(mm) (mm) (5 Kg.)
APPROVALS: CE, CWB, DB & VdTŰV
1.6 1000 3
WELDING CURRENT: AC 2.0 1000 3
2.4 1000 3
SHIELDING GAS: Ar or Ar/He
3.2 1000 3
41
OK TIGROD 19.30 TYPICAL PROPERTIES
Welding Consumables
2.0 1000 3
3.2 1000 3
42
GMAW Consumables
Welding Consumables
Wire Composition All Weld
A Cu coated solid wire for GMAW (Wt.%) Mechanical Properties
43
OK ARISTOROD 13.09 TYPICAL PROPERTIES
Welding Consumables
WELDING CURRENT: DC+ PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5/15.0 kg.
SHIELDING GAS: 100%CO2 or 80%Ar/20%CO2
44
OK ARISTOROD 13.16 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
A non Cu coated 1.3Cr-0.5Mo alloyed solid wire for (Wt.%) Mechanical Properties
GMAW of creep resistant steels
C 0.10 YS (N/mm2) 490
Classification AWS A5.28: ER80S-B2 Si 0.60 UTS (N/mm2) 580
Mn 0.60 Elongation (%) 21
DESCRIPTION Cr 1.35
OK ARISTOROD 13.16 is a non copper coated chromium- Mo 0.50
molybdenum alloyed (1.3Cr-0.5Mo), solid wire for
GMAW of creep resistant steels like SA387 Grade 11, CURRENT RANGE
A335 Grade P11 or similar materials. OK ARISTOROD Size Current Voltage
13.16 is a high purity wire with a guaranteed Bruscato (mm) (Amp) (V)
factor X<15. It is treated with ESAB´s unique advanced
1.2 120-350 20-33
surface characteristics (ASC) technology, taking MAG
welding operations to new levels of performance and all- PACKING: The wire can be supplied in plastic or wire
round efficiency, especially in robotic and mechanised basket spool packed in a cardboard box weighing 18 kg
welding. Characteristics features include excellent start or Marathon Pac weighing 250 kg.
properties; trouble free feeding at high wire speeds
and lengthy feed distances; a very stable arc at high
welding currents; extremely low levels of spatter; low
fume emission; reduced contact tip wear and improved
protection against corrosion of the wire.
A Cu coated 2.5Cr-1Mo alloyed solid wire for GMAW Wire Composition All Weld
(Wt.%) Mechanical Properties
of creep resistant steels
C 0.09 YS (N/mm2) 590
Classification AWS A5.28: ER90S-B3 Si 0.60 UTS (N/mm2) 720
Mn 0.60 Elongation (%) 22
DESCRIPTION
Cr 2.50 Impact (CVN)
OK AUTROD 13.17 is a copper coated chromium- Mo 1.00 @ -40ºC (Joules) 50
molybdenum alloyed (2.5Cr-1Mo), solid wire for GMAW Cu 0.25
of creep resistant steels like SA387 Grade 22, A335
Grade P22 or similar materials. The wire has high purity CURRENT RANGE
chemistry with a guaranteed Bruscato factor X < 15.
Size Current Voltage
WELDING CURRENT: DC+ (mm) (Amp) (V)
SHIELDING GAS: 100%CO2 or 80%Ar/20%CO2 or 1.0 80-280 18-28
Ar/1-5O2 1.2 120-350 20-33
45
OK AUTROD 13.28 TYPICAL PROPERTIES
Welding Consumables
46
OK AUTROD 16.10 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
An extra low carbon stainless steel solid wire for (Wt.%) Mechanical Properties
GMAW of 18Cr-8Ni type steels
C 0.03 YS (N/mm2) 420
Classification AWS A5.9: ER308L Si 0.45 UTS (N/mm2) 590
Mn 1.70 Elongation (%) 36
DESCRIPTION Cr 20.00 Impact (CVN)
A corrosion resistant, chromium-nickel alloyed solid Ni 9.80 @ -196ºC (Joules) 50
wire for welding austenitic stainless alloys of 18Cr-8Ni
type. OK AUTROD 16.10 has good general corrosion CURRENT RANGE
resistance. The alloy has a low carbon content which
Size Current Voltage
makes it particularly suitable to the applications, where
(mm) (Amp) (V)
there is a risk of intergranular corrosion. The alloy
is widely used in the chemical and food-processing 0.8 50-180 16-22
industries, as well as for pipes, tubes and boilers. 1.2 80-280 19-28
1.6 100-380 19-33
APPROVALS: NPC
PACKING: The wire can be supplied in plastic spool
WELDING CURRENT: DC+ packed in a cardboard box weighing 12.5/15.0 kg.
SHIELDING GAS: Ar/O2 or Ar/CO2
47
OK AUTROD 16.13 TYPICAL PROPERTIES
Welding Consumables
WELDING CURRENT: DC+ PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5/15.0 kg.
SHIELDING GAS: Ar/O2 or Ar/CO2
48
OK AUTROD 16.53 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
An extra low carbon 24Cr-13Ni stainless steel solid (Wt.%) Mechanical Properties
wire for GMAW
C 0.03 YS (N/mm2) 420
Classification AWS A5.9: ER309L Si 0.40 UTS (N/mm2) 600
Mn 1.70 Elongation (%) 37
DESCRIPTION Cr 23.50 Impact (CVN)
A corrosion resistant, chromium-nickel alloyed solid Ni 12.50 @ -60ºC (Joules) 80
wire for joining stainless steels to non-alloy or low-alloy
steels and for welding austenitic stainless alloys of the CURRENT RANGE
24Cr-13Ni types. The alloy is also used for welding
Size Current Voltage
buffer layers on C-Mn steels.
(mm) (Amp) (V)
WELDING CURRENT: DC+
0.8 50-180 16-22
SHIELDING GAS: Ar/O2 or Ar/CO2 1.2 80-280 19-28
1.6 100-380 19-33
49
OK AUTROD 4043 TYPICAL PROPERTIES
Welding Consumables
50
OK AUTROD 5356 TYPICAL PROPERTIES
Welding Consumables
Wire Composition All Weld
A Mg alloyed aluminium solid wire for GMAW (Wt.%) Mechanical Properties
Classification AWS A5.10: ER5356 Si <0.25 YS (N/mm2) 120
Mn 0.15 UTS (N/mm2) 265
DESCRIPTION Cr 0.13 Elongation (%) 26
OK AUTROD 5356 is the most widely used welding alloy Cu <0.10
Ti 0.11
and can be classified as a general purpose type filler
Zn <0.10
alloy. OK AUTROD 5356 is typically chosen because of Fe <0.40
its relatively high shear strength. The 5XXX alloy base Mg 5.00
material, welded with OK AUTROD 5356, with weld pool
chemistry greater than 3% Mg and service temperatures
in excess of 65°C is susceptible to stress corrosion CURRENT RANGE
cracking. The alloy is non-heat treatable. Size Current Voltage
APPROVALS: ABS, BV, CE, CWB, DB, DNV, GL, LR, (mm) (Amp) (V)
RINA & VdTÜV 0.8 60-170 13-24
0.9 60-170 13-24
WELDING CURRENT: DC+ 1.0 90-210 15-26
SHIELDING GAS: Ar or Ar/He 1.2 140-260 20-29
1.6 190-350 25-30
2.4 280-400 26-31
51
OK AUTROD 19.30 TYPICAL PROPERTIES
Welding Consumables
52
FCAW Consumables
Welding Consumables
Weld Metal All Weld
All position rutile, low-hydrogen flux cored wire for Composition (Wt.%) Mechanical Properties
mild and medium tensile steels
C 0.06 YS (N/mm2) 480
Classification AWS A5.20: E71T-1C/E71T-1M Si 0.50 UTS (N/mm2) 610
Mn 1.25 Elongation (%) 24
DESCRIPTION Impact (CVN)
DUAL SHIELD 7100 LH is a multi-purpose all positional @ -20ºC (Joules) 60
rutile, low hydrogen cored wire for use with CO2 or Ar/
CO2 shielding gas. The wire is suitable for all mild and CURRENT RANGE
medium tensile steels. The running characteristics
are exceptional with a stable arc, low spatter and flat Size Current Voltage
welds. (mm) (Amp) (V)
1.2 150-350 23-35
APPROVALS: ABS, BV, DNV, IRS & LRS
1.6 150-450 22-36
WELDING CURRENT: DC+ PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5/15.0 kg.
SHIELDING GAS: 100%CO2 or 80%Ar/20%CO2
53
OK TUBROD 15.14A TYPICAL PROPERTIES
Welding Consumables
APPROVALS: ABS, BV, CCS, DNV, KR, LR, NK & TUV 1.2 140-300 21-30
1.4 150-360 21-32
WELDING CURRENT: DC+ 1.6 160-410 22-34
SHIELDING GAS: 100%CO2 or 75%Ar/25%CO2 PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5/15.0 kg
or select sizes in Marathon Pac weighing 100/200/
300 kg.
Basic slag type flux cored wire for mild steel and Weld Metal All Weld
490N/mm2 class high tensile strength steel Composition (Wt.%) Mechanical Properties
54
COREWELD 70 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
Metal cored wire for mild steel and 490N/mm2 class Composition (Wt.%) Mechanical Properties
high tensile strength steel
C 0.05 YS (N/mm2) 450
Classification AWS A5.18: E70C-6M Si 0.60 UTS (N/mm2) 550
Mn 1.35 Elongation (%) 30
DESCRIPTION Impact (CVN)
COREWELD 70 is a metal cored wire that combines the @ -18ºC (Joules) 60
high deposition rates of a flux cored wire with the high @ -30ºC (Joules) 40
efficien-cies of solid wire. The wire exhibits low levels of
spatter, slag and fumes. CURRENT RANGE
Size Current Voltage
APPROVALS: ABS, BV, DNV, GL & LR
(mm) (Amp) (V)
WELDING CURRENT: DC+ 1.2 140-350 20-33
1.4 150-430 21-34
SHIELDING GAS: 100%CO2 or 75%Ar/25%CO2
1.6 300-500 27-35
PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5/15.0 kg or
select sizes in Marathon Pac weighing 100/200/300 kg.
55
DUAL SHIELD 8000-B2 TYPICAL PROPERTIES
Welding Consumables
56
OK TUBROD 15.24 TYPICAL PROPERTIES
Welding Consumables
Weld Metal All Weld
A 1Ni alloyed basic flux cored wire Composition (Wt.%) Mechanical Properties
57
SHIELD-BRIGHT 308L TYPICAL PROPERTIES
Welding Consumables
SHIELDING GAS: 100%CO2 or 75%Ar/25%CO2 PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5 kg.
58
SHIELD-BRIGHT 309L TYPICAL PROPERTIES
Welding Consumables
Flux cored wire for welding dissimilar steels Weld Metal All Weld
Composition (Wt.%) Mechanical Properties
Classification AWS A5.22: E309LT1-1(4)
C 0.03 YS (N/mm2) 420
DESCRIPTION Si 0.80 UTS (N/mm2) 580
Mn 1.10 Elongation (%) 40
SHIELD-BRIGHT 309L is a flux cored wire for welding Cr 22.70
steels of similar composition, stainless steel to carbon Ni 12.30
or low alloy steels and for the first layer cladding of car-
bon and low alloy steels. CURRENT RANGE
APPROVALS: ABS, BV, CCS, DNV, KR, LR & NK Size Current Voltage
WELDING CURRENT: DC+ (mm) (Amp) (V)
1.0 100-170 21-27
SHIELDING GAS: 100%CO2 or 75%Ar/25%CO2 1.2 130-250 23-31
1.6 160-320 24-33
PACKING: The wire can be supplied in plastic spool
packed in a cardboard box weighing 12.5 kg.
59
SHIELD-BRIGHT 316L TYPICAL PROPERTIES
Welding Consumables
60
SAW Wires
Welding Consumables
Wire Composition (Wt.%)
A copper coated mild steel wire for SAW
C 0.06
Classification AWS A5.17: EL8/EL12 Si 0.02
Mn 0.50
DESCRIPTION
OK AUTROD 12.08L is a copper coated, mild steel PACKING DATA
solid wire for submerged arc welding of mild and Size Packing
medium tensile steels. It can be used in combination (mm) 25 Kg
OK Flux 10.71L or OK Flux 10.81L or OK Flux 10.81LS,
2.00 3
depending on the application and mechanical property
2.50 3
requirements.
3.15 3
4.00 3
5.00 3
61
ESAB SA10K TYPICAL PROPERTIES
Welding Consumables
62
OK AUTROD 12.33L TYPICAL PROPERTIES
Welding Consumables
Wire Composition (Wt.%)
A copper coated Mo alloyed solid wire for SAW
C 0.10
Classification AWS A5.23: EA3K Si 0.60
Mn 1.75
DESCRIPTION
Mo 0.45
OK AUTROD 12.33L is a copper coated, molybdenum
alloyed solid wire for the submerged arc welding of high PACKING DATA
tensile steels. It can be used in combination with OK Flux Size Packing
10.62 or OK Flux 10.71L, depending on the application (mm) 25 Kg
and mechanical property requirements.
2.00 3
3.15 3
4.00 3
63
OK AUTROD 16.10 TYPICAL PROPERTIES
Welding Consumables
An extra low carbon stainless steel solid wire for Wire Composition (Wt.%)
SAW of 18Cr-8Ni type steels C 0.03
Si 0.45
Classification AWS A5.9: ER308L Mn 1.80
Cr 20.70
DESCRIPTION
Ni 9.80
A corrosion resistant, chromium-nickel alloyed solid wire
for welding austenitic stainless alloys of 18Cr-8Ni type. PACKING DATA
OK Autrod 16.10 has good general corrosion resis- Size Packing
tance. The alloy has a low carbon content which makes (mm) 25 Kg
it particularly suitable to the applications, where there is
2.00 3
a risk of intergranular corrosion. The alloy is widely used
2.50 3
in the chemical and food-processing industries, as well
3.15 3
as for pipes, tubes and boilers. OK AUTROD 16.10 can
4.00 3
be used in combination with OK FLUX 10.92L.
PACKING: The wire can be supplied in corrugated
cardboard box weighing 25 Kg.
An austenitic stainless steel solid wire for SAW of Wire Composition (Wt.%)
25Cr-20Ni type steels C 0.10
Si 0.45
Classification AWS A5.9: ER310 Mn 1.60
Cr 26.80
DESCRIPTION
Ni 20.60
A corrosion-resistant, chromium-nickel alloyed solid wire
for welding heat-resistant austenitic stainless steels of PACKING DATA
25Cr-20Ni type. OK AUTROD 16.13 has good general Size Packing
oxidation resistance, especially at high temperatures, (mm) 25 Kg
due to its high Cr content. The alloy is fully austenitic
and is therefore sensitive to hot cracking. Common ap- 2.50 3
plications include indus-trial furnaces, boiler parts and 3.15 3
64
OK AUTROD 16.30 TYPICAL PROPERTIES
Welding Consumables
Wire Composition (Wt.%)
An extra low carbon stainless steel solid wire for
SAW of 18Cr-12Ni-2.5Mo type steels C 0.03
Si 0.40
Classification AWS A5.9: ER316L Mn 1.70
Cr 18.50
DESCRIPTION Ni 11.80
A corrosion resistant, chromium-nickel-molybdenum Mo 2.70
alloyed solid wire for welding austenitic stainless alloys of
PACKING DATA
the 18Cr-8Ni and 18Cr-12Ni-2.5Mo types. The alloy has
very good resistance to corrosion in acid and chlorinated Size Packing
envi-ronments. The alloy has a low carbon content (mm) 25 Kg
which makes it particularly suitable to the applications,
where there is a risk of intergranular corrosion. The 2.50 3
alloy is widely used in the chemical and food-processing 3.15 3
industries, as well as in shipbuilding and various types 4.00 3
of architectural structures. OK AUTROD 16.30 can be
used in combination with OK FLUX 10.92L. PACKING: The wire can be supplied in corrugated
cardboard box weighing 25 Kg.
65
SAW FLUXES
OK AUTROD
0.08 0.20 0.70 1.10 0.50 500 610 26 80 -30
13.10 SC
OK AUTROD
0.08 0.20 0.60 2.00 0.85 530 620 25 80 -30
13.20 SC
PACKING: OK FLUX 10.62L is packed in plastic lined paper bag containing 25 Kg.
66
OK FLUX 10.71L DESCRIPTION
Welding Consumables
OK FLUX 10.71L is a basic agglomerated, slightly Si and
An agglomerated slightly Si and Mn alloying basic Mn alloying flux for submerged arc welding. It is specially
flux for SAW designed for fillet welding and single and multi pass butt
welding of mild, medium and high tensile steels. The
Classification
AWS A5.17: F6A2-EL8/EL12
flux is of aluminate basic type and it has a very high
F7A4/F6P5-EM12K
current carrying capacity on both AC and DC with very
F7A4/F7P6-EH10K
good operating characteristics. OK FLUX 10.71L is also
F7A4/F7P5-EH14
suited to narrow gap welding due to the excellent slag
AWS A5.23: F8A2/F7P0-EA2-A4 detachability and smooth side-wall blending.
F9A0/F8P0-EA3K-A3
BASICITY INDEX: 1.5
OK AUTROD
0.06 0.20 0.90 - 390 450 25 70 -30
12.08L
OK AUTROD
0.08 0.40 1.35 - 450 540 30 35 -40
12.22L
OK AUTROD
0.07 0.40 1.80 - 500 590 27 40 -40
12.40L
OK AUTROD
0.08 0.40 1.25 0.50 550 610 24 50 -30
12.24L
OK AUTROD
0.07 0.75 2.00 0.40 630 700 25 35 -18
12.33L
PACKING: OK FLUX 10.71L is packed in plastic lined paper bags containing 25 Kg.
PACKING: OK FLUX 10.81L is packed in plastic lined paper bag containing 25 Kg.
67
OK FLUX 10.81LS DESCRIPTION
Welding Consumables
PACKING: OK FLUX 10.81LS is packed in plastic lined paper bag containing 25 Kg.
An agglomerated non-alloying basic flux for SAW of OK FLUX 10.92L is a basic non-alloying agglomerated
stainless steels flux for the submerged arc welding of stainless steels
and high-alloyed Cr-Ni-Mo steels.
BASICITY INDEX: 2.1
OK
AUTROD 0.03 0.50 1.10 18.00 8.80 0.40 610 32 50 -60
16.11
OK
AUTROD 0.03 0.50 1.40 17.00 10.00 2.10 570 32 60 -60
16.30
OK
AUTROD 0.03 0.45 1.45 21.00 11.00 580 35 50 -60
16.53
PACKING: OK FLUX 10.92L is packed in plastic lined paper bag containing 25 Kg.
68
Strip Cladding Consumables
STRIP & FLUX COMBINATIONS required, Electroslag Strip Cladding (ESSC) is used.
Welding Consumables
These strips are finding increasing use in petroleum
FOR CLADDING industry in hydrocracking, hydro-sulphurisation and
catalytic refining processes and in the chemical and
Stainless steel strips and Fluxes for Submerged Arc petrochemical industries.
and Electroslag Cladding
Fluxes for SASC and ESSC
DESCRIPTION
Nowadays, the two most productive systems for surfac- Process Product Basicity Density
ing large components that are subject to corrosion or Index Kg/dm3
wear are submerged arc and electroslag cladding, us-
SASC OK Flux 10.05 1.1 0.7
ing a strip electrode. Both processes are characterised
ESSC OK Flux 10.10 4.0 1.0
by a high deposition rate and low dilution.
Dimension & packing
TYPICAL APPLICATIONS
They are suitable for surfacing flat and curved objects Product Type Size Weight
such as heat exchanger plates or pressure vessels
of different kinds. Submerged Arc Strip Cladding Strips OK Band 60 x 0.5 mm 25 or 50 Kg coils
(SASC) is the most frequently - used process, but if Fluxes OK Flux - 25 Kg bags
higher productivity and restricted dilution rates are Other sizes available on request.
Notes:
1) Other types of strips also available on demand.
2) OK Flux 10.05 and OK Flux 10.10 have to be redried at 300-305°C for 2 hours before use.
3) Typical Weldmetal composition is available on demand.
4) OK Band 309L ESW together with OK Flux 10.10 produces 308L type weld deposit (single layer).
5) OK Band 309LNb ESW together with OK Flux 10.10 produces 347 type weld deposit (single layer).
6) OK Band 309LMo ESW together with OK Flux 10.10 produces 316L type weld deposit (single layer).
69
Hard Surfacing Consumables
70
Consumables for Ni Steels
Welding Consumables
DESCRIPTION
LNG Storage tanks are usually fabricated from 9% Ni steels to provide a combination of properties at a reasonable
price. Quenched & tempered 9% Ni Steels has excellent low temperature properties and is not susceptible to under
bead cracking or excessive hardening in the HAZ on account of its low carbon. Esab offers a complete range of
proven consumables, which have been used in over 30 global installations.
APPLICATIONS
The SMAW electrodes are designed to weld on AC, largely to eliminate the magnetic arc blow problem of 9% nickel
steels. SAW is preferred for cicumferential welds and SMAW for the vertical welds. Smaller diameter wires (1.6mm)
deliver better impact values. 9% nickel steels can be welded without pre and post weld treatment up to 60 mm, as
per ASME code, OK 92.55 is Preferred, when higher impact values are specified.
71
Consumables for Ni Steels
SMAW
72
OK 92.59 TYPICAL WELDMETAL PROPERTIES
Welding Consumables
Weldmetal Typical Mechanical properties
Classification AWS A5.11 ENiCrMo-13 Composition (%) of all Weldmetal
C <0.02 YS 430 N/mm2
DESCRIPTION
Si <0.2 UTS 770 N/mm2
OK 92.59 is designed for welding alloy 59, C-276 and Mn <0.2 EL 40%
625 Ni-based materials. It is also suitable for welding Cr 23.0 Impact Values +20OC 70J
superaustenitic steels like AISI/ASTM S31254 and Ni 62.0 -196OC 60J
S32654. Mo 15.5
Fe <1.0
WELDING CURRENT: DC+
CURRENT DATA
Diameter Length Welding Arc voltage,
(mm) mm Current, A V
2.5 300 50-70 20
3.2 350 60-90 21
4.0 350 80-120 22
73
Consumables for Ni Steels
GMAW
74
Consumables for Ni Steels
GTAW
Welding Consumables
Wire Typical Mechanical properties
Classification SFA/AWS A5.14 ERNiCrMo-13 Composition (%) of all Weldmetal
C <0.01 YS 550 N/mm2
DESCRIPTION Si <0.1 UTS 800 N/mm2
Bare Ni-Cr-Mo rod for welding high - alloyed materials of Mn <0.5 EL 45%
the 20Cr-25Ni typewith 4-6% Mo and Ni based alloys of Cr 23.0 Impact Values -110OC 120J
a similar type. It can also be welded in combination with Ni >56.0
Mo 15.5
carbon steels. The weld metal has very good corrosion
Fe <1.5
resistance over a wide range of applications in oxidising
and reducing media.
PACKING DATA
APPROVALS: VdTÜV Diameter Length Packing
(mm) mm (5 Kg)
WELDING CURRENT: DC- 1.6 1000 3
2.0 1000 3
2.4 1000 3
75
OK TIGROD 19.85 TYPICAL WELDMETAL PROPERTIES
Welding Consumables
76
Consumables for Ni Steels
SAW
Welding Consumables
from the flux to the welding metal, thereby minimising
BASICITY INDEX: 2.4 the risk of hot cracking when welding with nickel - based
DESCRIPTION alloys. OK FLUX 10.16 can only be used on DC when
butt welding with nickel-based alloy wires. Reverse po-
OK FLUX 10.16 is an agglomerated, non-alloying flux
larity (DC-) should preferably be used in order to mini-
for submerged arc welding. OK FLUX 10.16 is specially
mise the dilution for the base material and the risk of hot
designed for butt welding with nickel based alloyed wire
cracking in the weld metal.
and cladding with nickel based alloy strips. The well -
77
STORAGE AND HANDLING It is recommended not to redry covered electrodes more
Welding Consumables
Redrying temperatures and holding times are specified Check if the protective foil still contains a vacuum. If the
on the label and in the product specification. vacuum has been lost, redry the electrodes before use.
The redrying temperature is the temperature in the bulk Cut open the protective foil at one end.
of the electrodes. Do not take out more than one eletrode at a time,
The redrying time is measured from the point at which thereby, ensuring that the remaining electrodes are still
the redrying temperature has been reached. protected inside the package. Put the top back on the
plastic capsule.
Do not stack more than four layers of electrodes in the
Discard or redry electrodes that have been exposed to
redrying oven.
the atmosphere in an opened VacPac® for more than
8 hours.
78
STORAGE AND HANDLING RECOMMENDATIONS Addition of new flux must be done with the
Welding Consumables
FOR OK TUBROD / DUAL SHIELD / COREWELD / proportion of at least one part new flux to three parts
CORED WIRES. recycled flux.
Cored wire should be stored in conditions which prevent Foreign material such as millscale, dross etc. should
the accelerated deterioration of products or packaging. be removed by a suitable system such as sieving.
All cored wires should avoid direct contact with water
or moisture. This could take the form of rain or the Redrying
condensation of moisture on a cold wire.
When handled and stored as above, the ESAB
Cored wires must be stored in dry conditions. The relative fluxes can normally be used as they are.
humidity and temperature should be monitored and the
If, however, a severe application is considered,
temperature should not fall below the dew point.
as given by the applicable material specification,
To avoid condensation, the wire should be kept in the redrying of the flux is recommended.
original packaging and, if necessary, left to warm up to
Furthermore, if the flux, due to unfavourable handling
at least the ambient temperature before opening the
or storage, has picked up moisture, redrying
package.
can return the flux to its original state regarding
Other hydrogen-containing substances, such as oil, moisture.
grease and corrosion, or substances that could absorb
Redrying shall be performed as follows:
moisture must also be avoided on the wire surface.
Agglomerated fluxes : 300 +/- 25OC for about
Products must be stored in such a way as to avoid
2-4 hours.
damage during storage.
Redrying must be done on shallow plates with a
STORAGE AND HANDLING RECOMMENDATIONS
flux height not exceeding 50 mm. Redried flux, not
FOR OK FLUX
immediately used, must be kept at 150 +/- 25OC
ESAB fluxes, have a guaranteed as-manufactured before use.
moisture content from the factories. This moisture content
is well - controlled by internal ESAB specifications. Before
transport, each pallet is shrink wrapped in plastic foil.
This precaution action is done in order to maintain the
as-manufactured moisture content as long as possible.
Flux should never be exposed to direct wetness such
as rain or snow.
Storage
Recycling
79
HANDWELDING ELECTRODES To determine elevated working temperatures, please
Welding Consumables
Tensile properties Hydrogen forms from water in the surroundings and from
the electrode coating. The water is divided into oxygen
Unless otherwise stated, tensile properties refer to all and hydrogen in the arc and the hydrogen in particular
weld metal test pieces prepared according to the rules has a strong tendency to dissolve in the weld metal and
of the classification societies using 4 and 5 mm diameter initiate cold cracking.
electrodes.
Conclusion : Dry basic electrodes when there is risk of
Welding current cold cracking.
Maximum and minimum values are given. The most Labelling
suitable welding current depends largely on the size
of the workpiece, the welding position and the type of The electrode type is clearly marked on the coating of
joint. each electrode near the grip end, e.g. ESAB 36H.
Cold cracking
2. Sufficient stress
80
GENERAL INFORMATION The evenness of the weld and the smooth transition
Welding Consumables
of the base material make joints produced with rutile
Choice of suitable electrode electrodes at least as good in terms of fatigue strength
as unmachined joints. Unalloyed rutile electrodes,
The electrodes in this catalogue are placed into groups irrespective of thier efficiency, can be recommended
according to the type of alloy deposited. Within each for welding mild steel with a nominal tensile strength
group of electrodes for welding mild, low-alloy and of 440 MPa (45 kg/mm2). When it comes to the tensile
stainless steels, there are several cases in which many strength of the deposit, rutile electrodes can also be
different electordes are designed for welding the same used for welding steels with a nominal tensile stength
type of steel. So, for each steel grade, there are often of more than 440 MPa (45 kg/mm2), but, as a general
a large number of electrode types to choose from, all rule, only electrodes producing a weld metal with a low
of which produce similar weld metal compositions but hydrogen content, e.g. basic, rutile basic or zircon-basic
have different coatings, welding properties, welding electrodes, should be used to weld these steels.
speeds and weld metal quality. This large choice makes
it possible to choose the electrode which produces the Unalloyed basic electrodes
right weld metal quality at the lowest cost.
Unalloyed basic electrodes give moderate welding
When selecting an electrode, the first rule is to select speed in the flat position but are faster than other types
one which produces a weld metal quality equal to or bet- when welding vertically upwards. The reason for this is
ter than that of the base material and, when necessary, that basic electrodes can be deposited at a higher cur-
is approved for the material in question. Welding posi- rent in the vertical position than other types of electrode.
tion and type of joint are other factors which influence In addition, the amount of weld metal deposited per elec-
the choice of electrode, as different welding positions trode is greater than that of other electrodes which can
and types of joint. be used in this position. This results in a smaller number
of electrode changes. The normal result is therefore a
General information about the influence of coating higher fusion rate and higher arctime factor when weld-
type on welding properties, welding speed and weld ing vertically upwards with basic electrodes compared
metal quality with other types.
Rutile electrodes giving about 100% weld metal recovery The slag is normally not quite as easy to remove as the
are easy to strike and use and are particularly suitable slag from acid or rutile electrodes, but, in spite of this,
for short welds in mild steel, for fillet welds, for welding it can be classed as easily detachable. The slag from
sheet steels and for bridging large joint gaps. The welds basic electrodes has a lower melting point than that
have a fine finish and spatter losses are negligible. The from rutile or acid electrodes. The risk of slag inclusions
welding speed is moderate. during normal production welding is therefore unusually
small when basic electrodes are used, even if the slag
Unalloyed electrodes
is not completely removed between beads during multi-
Unalloyed rutile electrodes are not normally recom- run welding.
mended for welding steel with a nominal tensile strength
The weld metal from basic electrodes has a low hy-
exceeding 440 MPa (45 kg/mm2). Rutile electrodes are
drogen content and usually has good toughness even
relatively insensitive to moisture.
at low temperatures. Basic electrodes are less likely
High-efficiency rutile electrodes to produce either hot cracks or cold cracks compared
with other types of electrode. The superiority of basic
High-efficiency rutile electrodes generally produce a electrodes from this point of view appears when welding
higher welding speed, which increases as the weld met- manganese alloyed structural steels, pressure-vessel
al recovery increases. Eg. ESAB C23S. steels and ship’s plate with a nominal tensile strength of
490-530 MPa (50-54 kg/mm2). The higher the harden-
They are all easy to use, produce excellent slag de- ability of the steel to be welded, the greater the neces-
tachability, fine bead appearance and are particularly sity to use basic electrodes and the greater the need for
suitable for welding horizontal/vertical fillets. The weld low moisture content in the coating.
metal has tensile properties which are as high as, or
somewhat higher than, those of the weld metal from un-
alloyed basic electrodes but have lower elongation and
impact strength.
81
Cellulose electrodes
Welding Consumables
82
Approval in accordance with Toughness level
Welding Consumables
classification society rules Each steel category is divided into three to five toughness
levels represented by the first digit in the grade (1, 2, 3,
Welding materials are normally classified by ESAB 4 or 5)
in accordance with a standard, e.g. AWS and EN. To
verify mechanical properties they are also approved -1 suitable for grade A steel
in accordance with the rules of the classification (impact tested at 20OC)
societies.
-2 suitable for grade A, B and C steels
Classification (impact tested at 0OC)
The Classification of welding products refers to -3 suitable for grade A, B, D and E steels
standards and, when a welding product is classified, (impact tested at -20OC)
its type, properties and field of application are given.
-4 suitable for grade A, B, D, E and F steels
The manufacturer verifies the correct classification of
(impact tested at -40OC)
a product by internal testing and / or by witness of an
outside orgainisation. -5 suitable for grades A, B, D, E and F steels
(impact tested at -60OC)
Approval
Other frequently used abbreviations
Ship owners and partners in offshore enterprises require
welding consumables to be approved in accordance T two-run welding (submerged arc
with the rules of the classification societies. Approval is welded with one run from each side)
also required by clients in accordance with national or
international standards for boiler and pressure vessels M multi-run welding (submerged arc
as well as other standards to be verified by an authorized or automatic gas-shielded arc
approval institutute. welding)
Approved welding products are entered on the “List of S semi-automatic, gas-shielded and flux
Approved Welding Consumables: distributed annually - flux - cored arc welding
by the societies and other institutes.
H5, H10, H15 low - hydrogen welding consumables
This catalogue provides information about the welding
position, current/polarity, low hydrogen and grading. DP deep penetration
Non-alloyed and low-alloyed steels Stainless steel and other high-content alloyed
steels
Consumables are divided into three categories based
on their tensile strength level: Grades of stainless steel for which the welding
consumable is approved are indicated with respect
Normal stength steel : Indicated by the numbers 1, 2 to one or more of the types of stainless steels : 304L,
or 3 (e.g. 3.3M) that the electrode is to be used in steel 304LN, 316LN and so on.
with a minimum yield strength (ReH) of 305 and a tensile
strength (Rm) of 400-560 MPa. The abbreviation SS/CMn indicates approval for joining
any of the austenitic types of stainless steel to any ofthe
High strength Steel : Indicated by 2Y, 3Y, 4Y, 5Y (ReH normal strength or higher tensile ship steels. Dup/CMn
min 375 and Rm 490-660 MPa) and 2Y40,3Y40, 4Y40 indicates approval for joining any of the duplex types of
(ReH min 400 and Rm 510-690 MPa) stainless steel to any of the normal strength or higher
tensile ship steels.
Extra high strength steel : Indicated by 3Y42, 4Y42,
5Y42 up to 5Y69 and so on for the different strength The system described for grading the consumables in
steel categories, where the numbers 42....69 symbolize accordance with the rules of the classification societies
a yield strength in MPa indicating that the electrodes changes as new steels appear on the market and
can be used for extra high tensile steels. sometimes there are changes to the approval ratings
which might mean that the handbook may not be
currently up-to date. To ensure that valid information
is used, please request the latest issued Product Data
Sheet for the consumables and / or the latest edition
of the “List of Approved Consumables” and approval
certificates from the most recent annual repeat test.
83
Calculation of electrode consumption
Welding Consumables
In the tables, joint cross section, theoretical joint volume and kg weld metal per metre length of welded joint are given.
The electrode consumption per metre of welded joint is obtained by dividing the number of kg of weld metal by N,
where N is the kg of weld metal per kg of electrode and is given for each electrode on thier respective pages.
1 0 2 0.02
1.5 0.5 3 0.02
2 1 4 0.03
Flat 3 1.5 7 0.05
4 2 17 0.13
5 2 21 0.16
6 2.5 27 0.21
Flat 7 3 36 0.28
1 0 2.5 0.02
1.5 0.5 4 0.03
2 1 5 0.04
Horizontal-Ver tical 3 1.5 9.5 0.07
4 2 22 0.17
5 2.5 25 0.20
6 3 32 0.25
Horizontal-Ver tical 7 3 42 0.33
4 2 9 0.07
5 2 10.5 0.08
6 2.5 13 0.10
7 3 16 0.13
4 2 10.5 0.08
5 2 16 0.13
6 2.5 18 0.14
Overhead 7 3 21 0.16
84
Calculation of electrode consumption
Single V-joints: volumes and weld metal weights
The first run and backing run V-joints: Weld metal weights
Position Plate thickness Weight/length Electrode diam
mm kg/m mm
Flat 6–12 0.10 3.25
Flat > 12 0.15 4
Vertical > 8 0.15 3.25
Horizontal-Vertical > 8 0.15 3.25
Overhead > 10 0.10 3.25
Welding Consumables
85
Calculation of electrode consumption
Welding Consumables
Plate Section
thickness size
mm mm2 cm3/m kg/m cm3/m kg/m cm3/m kg/m cm3/m kg/m
2 2 3.5 0.03 3 0.02 3.5 0.03 3.5 0.03
3 4.5 7 0.05 7 0.05 7 0.05 7.5 0.06
4 8 9 0.07 9 0.07 9.5 0.07 10.5 0.08
5 12.5 13 0.10 13.5 0.11 14.5 0.11 16 0.13
6 18 18.5 0.15 19.5 0.15 21 0.16 22 0.17
7 24.5 25.5 0.20 26.5 0.21 27.5 0.22 31.5 0.25
8 32 33 0.26 34.5 0.27 36 0.28 40.5 0.32
9 40.5 41.5 0.33 43 0.34 45.5 0.36 51 0.40
10 50 51.5 0.40 53.5 0.42 56 0.44 64 0.50
11 60.5 63 0.49 67 0.53 72 0.57 78.5 0.62
12 72 74.5 0.58 79 0.62 84.5 0.66 93 0.73
15 113 116 0.91 123 0.97 132 1.04 141 1.11
18 162 167 0.31 174 1.37 190 1.49 204 1.60
20 200 206 1.62 206 1.62 227 1.78 252 1.98
22 242 248 1.95 255 2.00 275 2.16 204 2.39
25 323 329 2.58 331 2.60 370 2.90 405 3.18
Throat Section
thickness size
mm mm2 cm3/m kg/m cm3/m kg/m cm3/m kg/m cm3/m kg/m
2 4 5 0.04 6 0.05 5.5 0.04 5.5 0.04
2.5 6.5 7.5 0.06 8.5 0.07 8 0.06 8.5 0.07
3 9 10.5 0.08 12.5 0.10 11 0.09 12 0.09
3.5 12.5 14 0.11 16 0.13 15 0.12 16.5 0.13
4 16 18 0.14 21 0.16 19.5 0.15 22 0.17
4.5 20.5 22.5 0.18 26 0.20 24.5 0.19 26.5 0.21
5 25 27.5 0.22 31.5 0.25 30.5 0.24 33 0.26
5.5 30.5 33.5 0.26 37 0.29 36 0.28 40.5 0.32
6 36 40 0.31 42 0.33 43 0.34 47.5 0.37
6.5 42.5 46.5 0.37 49.5 0.39 51 0.40 56 0.44
7 49 54.5 0.43 57 0.45 56 0.44 65 0.51
7.5 56.5 60.5 0.47 65 0.51 64 0.50 73.5 0.58
8 64 70 0.55 73.5 0.58 76.5 0.60 82.5 0.65
9 81 88 0.69 94 0.74 95 0.75 109 0.86
10 100 108 0.85 114 0.89 116 0.91 130 1.02
11 121 131 1.03 138 1.08 143 1.12 157 1.23
12 144 155 1.22 162 1.27 169 1.33 188 1.48
13 169 179 1.41 190 1.49 195 1.53 220 1.73
14 196 207 1.62 224 1.76 227 1.78 257 2.02
15 225 237 1.86 248 1.95 264 2.07 294 2.31
86
The weight of welding electrodes or welding wire neces-
Welding Consumables
sary to complete a given weld joint may be calculated by PROCESS DEPOSITION
the formula: EFFICIENCY
P WL Submerged Arc 99%
=
E Gas Metal Arc (98% Ar, 2% O2) 98%
P = Weight of electrode or wire required
Gas Metal Arc (75%Ar, 25% CO2) 96%
W = Weight per unit length of weldmetal
Gas Metal Arc (CO2) 93%
L = Length of weld (meter)
E = Deposition efficiency Metal Cored Wires 93%
WEIGHT PER UNIT LENGTH OF WELDMETAL Gas Shielded Flux Cored Wires 85%
For calculating the weight of weldmetal requires, we Self Shielded Flux Cored Wires 82%
consider the following items.
* Shielded Metal Arc (Stick 300 mm long) 59%
1. Area of cross-section of the weld
* Shielded Metal Arc (Stick 350 mm long) 62%
2. Length of the weld
* Shielded Metal Arc (Stick 450 mm long) 66%
3. Volume of the weld in cubic centimetre
* Includes 2” stub loss.
4. Weight of the weldmetal per cubic centimetre
It must be remembered that when deposition tests are per-
The area of the cross-section (the triangle) in the fillet formed in the laboratory, the deposition efficiency is calculated
weld shown below is equal to one half the base times by the formula:
the height. The volume of the weld is equal to the area
Weight of metal deposited
times the length, and the weight of the weld then, is the
volume times the weight of the material (steel) per cubic Deposition Efficiency = Weight of electrode consumed
centimetre.
This does not take stub loss into consideration. The
chart below shows how the length of the stub effects the
laboratory-established efficiency.
87
The following tables show the estimated weight of consumables for some of the common weld joints.
Welding Consumables
88
WElGHT PER METER OF WELDMETAL FOR FILLET WELDS AND ELEMENTS OF COMMON BUTT JOINTS
Welding Consumables
INSTRUCTION
2. Divide the cross-section into right triangles, rectangles and sketch in the desired reinforcement.
3. Dimension the thickness, angles, angle leg length, root opening and the length and height of the reinforcement.
4. Total the weight per meter of each of the elements from the chart for the weight per meter of the weld.
89
DATA SHEETS - PIPE WELDING
Welding Consumables
Joint Preparation
The most common steels used for oil and gas cross-
country pipelines conforming to API 5 L, 5 LS, and 5
LX.
90
Table 1, shows the chemical requirements to API Table 1: Chemical requirements
Welding Consumables
Standard 5 LX for the individual line pipe steel
grades. Chemistry of the pipe material is an important API 5 LX Ladle analysis %
consideration prior to welding; otherwise difficulties may Grade
be experienced on high strength pipe material from the Cmax. Si Mn Nbmin. Vmin. Ti
high carbon and manganese contents, particularly in
X42 0.28 - <1.25 - - -
cold weather. It is therefore advisable, depending on
the surrounding temperature and weather conditions, to X46 0.28 - <1.25 - - -
preheat the entire pipe circumference before applying X52 0.28 - <1.25 - - -
the stringer bead.
X56 0.26 - <1.35 0.005 0.02 0.03
Table 2, Shows the physical requirements to API 5 LX. X60 0.26 - <1.350 .005 0.02 0.03
Composition and characteristics of cellulose X65 0.26 - <1.35 0.005 0.02 -
pipeline electrodes X70 0.23 - <1.60 - - -
Cellulose electrodes contain a high amount of
organic material; about 35% of the coating consist of Table 2: Physical requirements
cellulose powder, which in the arc is transformed into a
Tensile strength
shielding gas at high pressure. This results in a fierce, API 5 LX Yield stress min. Elongation
min.
concentrated arc giving deep penetration. This is one
Grade N/mm2 (psi) N/mm2 (psi) min.%
of the reasons why cellulose pipeline electrodes - even
X42 290 (42) 410 (60) 25
in large electrode diameters - can be used for vertical
down welding with excellent results. X46 315 (63) 430 (63) 23
Welding current ranges (DC positive or negative) X52 360 (66) 450 (66) 22
X56 385 (56) 490 (71) 22
ESAB AWS Electrode diameters (mm)
X60 415 (60) 520 (74) 22
Designation Classification and currents (amp)
X65 450 (65) 550 (77) 20
3.25 4.0 5.0
X70 485 (70) 580 (85) 20
Pipeweld 6010 A5.1:E 6010 50-150 120-200 160-250
OK 22.46 P A5.1:E 7010-G 50-150 120-200 160-250
OK 22.47 P A5.1 :E 8010-G 5O-150 120-200 160-250
X46 X X X
X52 X X X X X
X56 X X X X X
X60 X X X X X X X
X65 X X X X
X70 X X X X
91
General recommendations Choice of welding Process
Welding Consumables
Carbon dioxide, CO2, is the cheapest and most Spray arc welding (welding with finely divided free
commonly used gas and, in most cases, it produces flight drop transfer) is carried out at higher currents
satisfactory welds in both mild and low alloy steel. and voltages than short arc welding and is therefore
generally faster and more economical than short arc
Mixed gas, of which the most commonly used consists welding for plate thicknesses exceeding 2 - 3 mm. It
of 80% Ar + 20% CO2, is clearer than pure CO2 but is only used for weldingin the horizontal or horizontal/
produces a softer arc, quieter welding, better bead vertical positions. The gas consumption is 6-10 litres/
appearance and less spatter. It is therefore often used, min for short arc welding and 12-20 litres/min for spray
in spite of its higher price, for welding sheet steel 0.8-1.5 arc welding. The higher the welding current, the higher
mm thick, which is more difficult to weld with pure CO2. the gas flow required.
A further advantage of mixed gas is the higher quality, in
particular notch toughness, compared with CO2. For this Welding technique
reason, mixed gas is often recommended for welding The welding gun is normally held in the right hand, which
low-alloy steels, such as creep-resistant steels, even means that the weld is made from right to left with the
in thicknesses greater than 1.5 mm. Mixed gas of the gun directed away from the deposited weld at an angle
80/20 type, in which the argon is of a lower purity, is also of 75-80O between the electrode and the workpiece,
available. These gases are less expensive than those thereby giving the operator a good view of the weld pool
based on pure argon and can often be used with equally and the joint. This produces a smoother weld bead than
good results. if the gun is directed towards the finished weld.
One drawback of argon/CO2 mixtures is that they lead Abbreviations
to increased ozone formation, compared with pure CO2,
when used as shielding gas in arc welding. MIG welding = metal inert gas welding = metal arc
welding in an atmosphere consisting mainly of an inert
Another drawback when using the mixture is that the gas such as argon.
current load capacity of the welding gun is reduced by
about 30% compared with welding with CO2. MAG welding = metal active gas welding = metal arc
welding in an atmosphere consisting of an active gas,
Shielding gas for stainless and heat resistant usually carbon dioxide. Gas mixtures containing 20% or
steels more CO2 are usually classified as active.
Argon containing 1% oxygen is normally used for
welding stainless and heat-resistant steels, but argon
containing 2% O2 or 5% O2 is also available. The latter
produces a more fluid weld pool.A shielding gas which
consists of 98% argon + 2% CO2 has gained favour for
MIG welding stainless steels. It can often replace argon/
helium mixtures, Which are used to help fusion when
welding thick stainless steel, and can very often replace
argon/oxygen mixtures.
92
DATA SHEET - GTAW/GMAW
Welding Consumables
Solid wire classification for GTAW/GMAW
ER 70 S - X
E indicates a filler
wire/rod
x C Mn Si S P Ti Zr AI Cu
2 0.07 0.90 0.40 0.035 0.025 0.05 0.02 0.05 0.5
/1 .40 /0.70 -0.15 -0.12 -0.15
3 0.06 0.90 0.45 0.035 0.025 - - - 0.5
/0.15 /1.40 /0.75
4 0.06 1.00 0.65 0.035 0.025 - - - 0.5
/0.15 /1.50 /0.85
6 0.06 1.40 0.80 0.035 0.025 - - - 0.5
/0.15 /1.85 /1.15
7 0.07 1.50 0.50 0.035 0.025 - - - 0.5
/0.15 /2.00 /0.80
Chemical Compositions are not specified, however requirements shall be agreed to by the
G
purchaser & supplier.
93
GENERAL RECOMMENDATIONS
Main Features
Economics
94
There are a number of factors to be considered and can setting for a given wire size will cater to 90% of flat and
Welding Consumables
be summarised as follows: HV applications. The weld cross-section is controlled
by the travel speed whereas solid wire would require
Downhand Rutile Flux Cored Wires are easy to considerable current resetting to achieve the same
usewith a smooth arc action giving excellent weld flexibility.
appearance with easy slag detachment.
Plate preparation
Positional Rutile Flux Cored Wires when used with
Argon rich gas offer spray transfer welding with a Due to superior sidewall fusion obtained particularly
high level of operator appeal. from the metal cored wires the combined angles of
preparations can generally be reduced. A V-butt joint for
Basic Flux Cored Wires produce a higher and more instance that would normally need a 60° included angle
consistent level of mechanical properties. They for manual arc welding can be reduced to 45° thereby
also produce radiographic standard deposits with saving plate and hence weldmetal to fill the joint.
ease when compared to both rutile and metal cored
wires.
OPERATING CONDITIONS
Polarity
95
WELDING TECHNIQUES
Welding Consumables
Torch angles
96
Torch angles and manipulation Torch angles and manipulation
Welding Consumables
Vertical butt-welds Vertical fillet welds
A torch angle of 100 above the horizontal may be used for Triangular weaves for single pass fillets. If necessary
root passes to assist arc stability and penetration control. subsequent weld runs should be deposited using
techniques similar to that for Filling vertical butt joints.
No weaving is necessary for single pass fillets when
using OK Tubrod 15.15
Single Pass
97
Travel Speed recommended and this type of wire is eminently suitable
Welding Consumables
98
Metal cored wire necessary to reduce the amount of heat in the weld pool
Welding Consumables
to accommodate poor fit-up or out of position welding.
Electrode extension An increase in the stickout length and the extra electrical
resistance that results will produce a cooler less fluid
This term describe the distance between the contact tip weld pool. Similarly any decrease in electrode extension
of the torch and the work piece, some times described will have the effect of increasing welding current and this
as ‘electrode stickout’. The current conditions should characteristic can be of benefit in controlling penetration;
be set for the job in hand but during welding it may be especially where inconsistent fit-up is encountered.
99
When operating with dip transfer an extension of 12 mm
Welding Consumables
EXTENSION MM 12 18 25 25
WIRE FEED M/Min 5.8 5.8 5.8 8.4
CURRENT AMPS 350 320 280 350
DEP RATE KGS/HR 4.7 4.7 4.7 6.5
100
DATA SHEET - FCAW
Welding Consumables
Flux cored wires classification E71T-X, E80T-X
x C Mn Ni Cr Mo V AI
Carbon - Molybdenum steel electrodes
A1 0.12 1.25 - - 0.40-0.65 - -
Chromium - Molybdenum steel electrodes
B2 0.05 - 0.12 1.25 - 1.0-1.5 0.40-0.65 - -
B2L 0.05 1.25 - 2.0-2.5 0.90-1.20 - -
B3 0.05 - 0.12 1.25 - 2.0-2.5 0.90-1.20 - -
B3L 0.05 1.25 - 2.0-2.5 0.90-1.20 - -
Nickel steel electrodes
Ni1 0.12 1.50 0.80-1.10 0.15 0.35 0.05 1.80*
Ni2 0.12 1.50 1.75-2.75 - - - 1.80*
Ni3 0.12 1.50 2.75-3.75 - - - 1.80*
Manganese - Molybdenum steel electrodes
D1 0.12 1.25-2.00 - - 0.25-0.55 - -
D2 0.15 1.65-2.25 - - 0.25-0.55 - -
D3 0.12 1.00-1.75 - - 0.40-0.65 - -
All other low alloyed electrodes
K2 0.15 0.50-1.75 1.00-2.00 0.15 0.35 0.05 1.80*
K4 0.15 1.20-2.25 1.75-2.60 0.20-0.60 0.20-0.65 0.03 -
W2 0.12 0.5-1.3 0.4-0.8 0.45 - 0.70 - - Cu = 0.3-0.75
101
Cored Wire Fault Finding
Welding Consumables
Incorrect tip size Check and replace Root face too large
Damaged liner or tip Replace
LACK OF FUSION
Incorrect types, size and pressure Refer equipment manual
of Direction and speed of travel Refer to notesillustration
Check tension and slacken if
feed rolls necessary Incorrect torch angle Refer to noteslillustration
Spool brake too tight Remove obstruction or replace Check against recommended values
Incorrect parameters or torch for
Blocked liner the wire in question and notes on
manipulation torch
SLAG INCLUSIONS manipulation
Incorrect welder technique Refer to notes
EXCESSIVE SPATTER
Direction of travel Refer to recommended technique
Dirty plate Clean plate-wire brush or grinding
UNDERCUT Voltage too high for amperage Check against recommended values
Travel speed too fast Reduced travel speed or check being
used
parameters Check against recommended flow
Shielding gas pressure too high rates
Incorrect torch angle Refer to notes on torch angels
Voltage too high Reduce voltage Check size or replace worn contact
Poor current pick-up tip.
102
General recommendations for 3. The arc voltage must be kept constant. Increased
Welding Consumables
arc voltage results in higher flux consumption. If
Submerged Arc Welding the flux contains alloying elements, the amount
transferred to the weld metal will increase as the
1. The flux must be dry. Agglomerated fluxes must arc voltage increases.
be protected from moisture pick-up.
4. As a general rule, multi-run deposits made at
In tropical, humid areas, re-drying agglomerated moderate welding currents have better mechanical
fluxes at 250-350OC before use is recommended. properties than one-or two-layer deposits made at
The remaining flux in the welding machine container high currents in similar plate thicknesses.
should be removed and stored in a dry cabinet and
should therefore not be left in the open container N.B. The chemical analysis given in this catalogue are
durifng the night. for all weld metal deposited with DC+, 580 A, 29 V, 33
m/h, except for OK Flux 10.92, where DC+, 420 A, 27
During the transport of fluxes, a maximum of two V and 30 m/h has been used (wire Ø4 mm) and for OK
pallets should be stacked to prevent the grains Flux 10.90, where DC+, 300A, 30V, 24 m/h has been
being crushed. used (wire Ø2.4 mm).
2. The fusion faces and the plate in the vicinity of the The mechanical properties are obtained according to
joint should be clean and dry. The cleaner the joint, the welding conditins given in EN 756 (i.e. the same
the better the chances of obtaining a satisfactory welding data as in EN 760).
weld. Rust, mill scale, paint, oil and residue from
arc-air gouging or grining can adversely affect the Other welding conditions may produce weld metal
quality of the weld metal. The more impurities on analysis and mechanical properties which differ from
the fusion faces, the greater the risk of weld metal those given in the handbook.
defects.
103
DATA SHEET - SAW
SAW Classification
Welding Consumables
Indicates a solid
electrode
Indicates the minimum tensile
strength of the weldmetal, welded
in accordance with AWS
specifictions.
F X X X - E X X X
Indicates Flux
xxx C Mn Si
Low Manganese Electrodes
EL8 0.10 0.25/0.60 0.07
EL8K 0.10 0.25/0.60 0.10/0.25
EL12 0.04/0.12 0.25/0.60 0.10
Medium Manganese Electrodes
EM12 0.06/0.15 0.80/1 .25 0.10
EM12K 0.05/0.15 0.80/1.25 0.10/0.35
EM13K 0.06/0.16 0.90/1.40 0.35/0.75
EM14K 0.06/0.19 0.90/1.40 0.35/0.75
EM15K 0.10/0.20 0.80/1.25 0.10/0.35
High Manganese Electrodes
EH11K 0.07/0.15 1.40/1.85 0.80/1.15
EH12K 0.06/0.15 1.50/2.00 0.25/0.65
EH14 0.10/0.20 1.70/2.20 0.10
104
Welding data and joint preparation
Welding Consumables
Typical welding data and recommended joint preparation for submerged arc welding mild steel and carbon-manga-
nese structural steels with OK Flux 10.40, OK Flux 10.47, OK Flux 10.70, OK 10.71, OK Flux 10.72, OK Flux 10.76
and OK Flux 10.81.
105
Typical welding data and for submerged arc fillet welding mild steel and carbon-manganese structural steels with OK
Welding Consumables
≥15 4 – 36 750 45
≥20 4 – 36 750 40
Twin wire
– 2x1.6 4 32 800 120
– 2x2.0 5 34 300 110
Two welding heads + ~
– 4 4 +32 800 140
~38 700
– 4 4 +32 800 140
~38 700
– 4 4 +32 800 140
~38 700
– 4 5 +32 800 90
~35 700
106
Submerged arc welding “18/8” stainless steel. Joint preparation and typical welding data for filler materials OK Autrod
Welding Consumables
16.10 + OK Flux 10.92, 10.93 and similar OK - combinations.
5 10 4 1 34 500 40
2 34 600 50
70° 12 4 1 34 500 35
2 34 600 40
5 14 4 1 34 550 35
2 34 600 35
107
Table 3: Typical welding data for different types of joint OK Flux 10.61 Land 10.62
Welding Consumables
* First side
** Second side
6.0 5 32 800 30
6.5 5 31 850 30
7.0 5 30 900 30
3.5 4 29 650 60
4.5 4 29 650 50
5.5 4 29 650 40
108
CONSUMABLES GUIDE FOR ASTM STEELS
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-27/A-27M All ESAB 36H, OK ESAB MW1, Dualshield
74.46, ESAB 56 OK Tigrod S2 7100 LH
A-36/A-36M All ESAB 28, ESAB ESAB MW1, Dualshield OK Flux 10.81L/
36H, ESAB 56 OK Tigrod S2 7100 LH, 10.71,
OK Tubrod 15.00 OK Autrod 12.08L/
12.22L / 12.40L
A-53/A-53M Type F - OK 53.18 , ESAB ESAB MW1, Dualshield
Grade A 36H, ESAB 28 OK Tigrod S2 7100 LH,
OK Tubrod 15.00
Type E ESAB 28, ESAB MW1, Dualshield
and S - OK 53.18 OK Tigrod S2 7100 LH
Grade A
Type E OK 53.18 , ESAB MW1, Dualshield
and S - ESAB 36H, OK Tigrod S2 7100 LH,
Grade B ESAB 28 OK Tubrod 15.00
A-105/A-105M All ESAB 28, ESAB MW1, OK Dualshield OK Flux 10.81L
ESAB 36H , Aristorod 12.50, 7100 LH /10.71,
Pipeweld 6010 R OK Tigrod S2 / OK Autrod 12.08L/
S2 spcl 12.22L / 12.40L
A-106/A-106M Grade A ESAB 28, ESAB MW1, OK Dualshield OK Flux 10.81L,
Pipeweld 6010 R Aristorod 12.50, 7100 LH OK Autrod 12.08L
OK Tigrod S2 /
S2 spcl
Grade B ESAB 28, ESAB MW1, OK Dualshield OK Flux 10.81L
and C ESAB 36H , Aristorod 12.50, 7100 LH /10.71, OK Autrod
Pipeweld 6010 R, OK Tigrod S2 / 12.08L/12.22L /
OK 48.20 Spl S2 spcl 12.40L
A-134/A-134M ESAB 36H ESAB MW1, Dualshield OK Flux 10.71 /
OK Aristorod 7100 LH 10.74/10.81LS,
12.50 OK Autrod
12.08L/12.24L
A-135/A-135M Grade A ESAB 28, ESAB MW1, OK Dualshield 7100 OK Flux 10.81L,
and B Pipeweld 6010 R Aristorod 12.50 LH OK Autrod 12.08L
, OK Tigrod S2 /
S2 spcl
A-178/A-178M Grade A ESAB 28 ESAB MW1,OK Dualshield 7100 OK Flux 10.81LS,
Tigrod S2 LH OK Autrod
12.08L/12.22L
Grade C ESAB 36H ESAB MW1, OK Dualshield 7100 OK Flux 10.81LS,
and D Aristorod 12.50 , LH , OK Tubrod OK Autrod
OK Tigrod S2 15.00 12.08L/12.22L
A-179/A-179M Grade C ESAB 36H ESAB MW1, OK Dualshield 7100 OK Flux 10.81LS,
and D Aristorod 12.50 , LH , OK Tubrod OK Autrod
OK Tigrod S2 15.00 12.08L/12.22L
A-181/A-181M Class 60 ESAB 28 ESAB MW1,OK Dualshield 7100 OK Flux 10.81LS,
Tigrod S2 LH OK Autrod
12.08L/12.22L
Class 70 ESAB 36H ESAB MW1, OK Dualshield 7100 OK Flux 10.81LS,
Aristorod 12.50 , LH , OK Tubrod OK Autrod
OK Tigrod S2 15.00 12.08L/12.22L
109
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
110
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-203/A-203M Grade A Filarc 75S , OK Tigrod / OK Tubrod 15.27 OK Autrod 13.27,
and B OK 73.68 Autrod 13.28 OK Flux 10.62
Grade D, OK 73.79 OK Autrod 13.49,
E and F OK Flux 10.63
A-204/ A-204M Grade A OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
and B Autrod 13.09 OK Flux 10.62
Grade C OK 76.18 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
Autrod 13.09 OK Flux 10.62
A-209/ A-209M Grade T1, OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
T1a, T1b Autrod 13.09 OK Flux 10.62
A-210/ A-210M Grade A1, ESAB 28, ESAB ESAB MW1, Dualshield OK Autrod
C 36H OK Tigrod S2 7100 LH 12.22/12.40L ,
OK Flux 10.71
A-213/ A-213M T2, T11, OK 76.18, OK OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
T17 76.18 M 13.16, OK Flux 10.62
OK Tigrod B2L
T5b, T5c ESAB KV4, ESAB OK Tigrod 13.32
KV4L
T9 ESAB KV7 OK Tigrod 13.37
T91 ESAB KV7M, OK OK Tigrod 13.38 Dualshiled B9 OK Autrod 13.35,
76.98 OK Flux 10.93
T21 , 22 OK 76.28 , OK OK Tigrod Dualshield 9000B3 OK Autrod 13.20
76.28M 13.17, and OK Flux 10.62
OK Tigrod B3L
TP201, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
202, 304 308L OK Flux 10.92L
TP304H OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10
308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
TP304N, ESAB 304B(N) OK Tigrod
LN 16.10N
TP309Cb ESAB 309Cb
TP309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
TP310S OK 67.13 OK Tigrod 16.13
TP316, OK 63.50 OK Tigrod 316H Shieldbright 316,
316H Xtra
TP316L OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
Xtra OK Flux 10.92L
TP317L OK 64.30 OK Tigrod 317L Shieldbright 317L
Xtra
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
TP321H, OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H, OK Flux 10.92L
348H
111
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-214/ A-214M ESAB 28, ESAB MW1, Dualshield OK Autrod
ESAB 36H OK Tigrod S2 7100 LH 12.22L, OK Flux
10.71/10.81L
A-216/ A-216M Grade OK 76.18 OK Autrod Dualshield 8000B2 OK Autrod 13.10,
WCA 13.16 OK Flux 10.62
Grade ESAB 98 OK Tigrod / OK Autrod 13.44,
WCB and Aristorod 13.29 OK Flux 10.62
WCC
A-217/ A-217M Grade OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
WC1 Autrod 13.09 OK Flux 10.62
Grade ESAB 98 OK Tigrod / OK Autrod 13.44,
WC4 Aristorod 13.29 OK Flux 10.62
Grade OK 76.28 OK Tigrod / Dualshield 9000B3 OK Autrod 13.20,
WC5 and Autrod 13.17 OK Flux 10.62
WC9
Grade OK 76.18 OK Tigrod / Dualshield 8000B2 OK Autrod 13.10,
WC6 and Autrod 13.16 OK Flux 10.62
WC11
C5 ESAB KV4 OK Tigrod /
Autrod 13.32
C12 ESAB KV7 OK Tigrod /
Autrod 13.37
C12A ESAB KV7M OK Tigrod / Dualshield B9 OK Autrod 13.35,
Autrod 13.38 OK Flux 10.93
CA15 OK 68.10 OK Tigrod / Arcaloy 409-Ti OK Autrod 410,
Autrod 410 OK Flux 10.92L
A-225/ A-225M Grade C ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
and D 13.29 OK Flux 10.62
A-234/ A-234M Grade Ferroweld W2 Dualshield 8100W
WPB,
WPC
Grade OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09,
WP1 Autrod 13.09 OK Flux 10.62
Grade OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
WP12- OK 76.18 M 13.16, OK Flux 10.62
CL1, OK Tigrod B2L
WP12-
CL2,
WP11-
CL1,
WP11-
CL2,
WP11CL3
Grade OK 76.28 , OK Tigrod Dualshield 9000B3 OK Autrod 13.20
WP22- OK 76.28M 13.17, and OK Flux 10.62
CL1, OK Tigrod B3L
WP22CL3
Grade ESAB KV4, OK Tigrod 13.32
WP5 ESAB KV4L
112
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
Grade ESAB KV7 OK Tigrod 13.37
WP9
Grade ESAB KV7M, OK Tigrod 13.38 Dualshield B9 OK Autrod 13.35,
WP91 OK 76.98 OK Flux 10.93
A-240 Grade OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
201, 202, 308L OK Flux 10.92L
301, 302,
304
Grade OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10
304H 308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
Grade OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
304L OK Flux 10.92L
Grade ESAB 304B(N) OK Tigrod
304N, LN 16.10N
Grade OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309S Autrod 16.53 OK Flux 10.92L
Grade ESAB 309Cb
309Cb
Grade OK 67.13 OK Tigrod 16.13
310S
Grade OK 310 MoL OK Tigrod
310MoLN 16.13NF
Grade OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316, 316L Xtra OK Flux 10.92L
Grade OK 64.30,ESAB OK Tigrod Shieldbright 317L
317, 317L(N) 317L /N Xtra
317L,
317LN
Grade OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321, 347, OK Flux 10.92L
348
Grade OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
321H, OK Flux 10.92L
347H,
348H
Grade OK 68.10 OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410,
405, 409, OK Flux 10.92L
410, 410S
Grade ESAB 430 OK Tigrod 430 Arcaloy 436
430
A-249/ A-249M TP201, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
202, 304 308L OK Flux 10.92L
TP304L, OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10
304H 308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
TP304N, ESAB 304B(N) OK Tigrod
LN 16.10N
TP309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
113
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
TP309Cb ESAB 309Cb
TP310S OK 67.13
TP316, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316L Xtra OK Flux 10.92L
TP317, OK 64.30 OK Tigrod 317L Shieldbright 317L
317L Xtra
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
TP321H, OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H, OK Flux 10.92L
348H
A-250/A-250M Grade T1, OK 74.46 OK Tigrod / Dualshield 7000A1 OK Autrod 13.09 ,
T1a, T1b Autrod 13.09 OK Flux 10.62
Grade T2, OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
T11, T12 OK 76.18 M 13.16, OK Flux 10.62
OK Tigrod B2L
Grade OK 76.28, OK Tigrod Dualshield 9000B3 OK Autrod 13.20
T22 OK 76.28M 13.17, and OK Flux 10.62
OK Tigrod B3L
A-266/A-266M Grade 1 ESAB 36H ESAB MW1, Dualshield 7100 OK Autrod 12.40
OK Tigrod S2 LH and OK Flux 10.71
Grade 2 , OK 76.18 OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
3 and 4 13.16, OK Flux 10.62
OK Tigrod B2L
A-268/A-268M TP405, OK 68.10, OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410,
409, 410 OK 68.15 OK Flux 10.92L
TP410 OK 68.25 OK Tigrod PZ 6166 / Shield- OK Autrod 16.79,
(UNS S 410NiMo bright 410NiMo OK Flux 10.93
41500)
TP429, ESAB 430 OK Tigrod 430 Arcaloy 436 OK Autrod 430,
430 OK Flux 10.92L
A-276 Type 201, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
202, 302, 308L OK Flux 10.92L
304, 308
Type 304L OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
OK Flux 10.92L
Type ESAB 304B(N) OK Tigrod
304N, LN 16.10N
Type 309, OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309S Autrod 16.53 OK Flux 10.92L
Type 310, OK 67.13
310S
Type 314, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316 Xtra OK Flux 10.92L
Type 317 OK 64.30 OK Tigrod 317L Shieldbright 317L
Xtra
Type 327, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
114
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
Type 405 OK 68.10, OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410,
OK 68.15 OK Flux 10.92L
Type 429, ESAB 430 OK Tigrod 430 Arcaloy 436 OK Autrod 430,
430 OK Flux 10.92L
UNS OK 68.25 OK Tigrod PZ 6166 / Shield- OK Autrod 16.79,
S41500 410NiMo bright 410NiMo OK Flux 10.93
A-283/A-283M Grade A ESAB 28, ESAB ESAB MW1, OK Dualshield OK Autrod 12.22L /
and B 36H Tigrod S2, OK 7100LH, OK 12.40L,
Aristorod 12.50 Tubrod 15.14A, OK Flux 10.71
Dualshield T5
Grade C ESAB 36H ESAB MW1, OK Dualshield OK Autrod 12.22L /
and D Tigrod S2, OK 7100LH, OK 12.40L/SA10K,
Aristorod 12.50 Tubrod 15.14A, OK Flux 10.71/
Dualshield T5 10.61L
A-285/A-285M Grade A ESAB 8018-G OK Tigrod OK Tubrod 15.24 OK Autrod 12.24,
13.09, OK Flux 10.71
OK Autrod 13.14
Grade B ESAB 98 OK Aristorod / Dualshield II- OK Autrod 12.34,
and C Tigrod 13.29 101TC OK Flux 10.71
A-299/A-299M ESAB 8018-G OK Aristorod / Dualshield II- OK Autrod 12.34/
Tigrod 13.29 101TC 12.24, OK Flux
10.71/10.62
A-302/A-302M Grade A OK 74.78 OK Tigrod / OK Tubrod 14.02 OK Autrod 12.34
Aristorod 13.08 and 12.44,
and 13.09 OK Flux 10.62
Grade B , OK 74.86 OK Autrod - OK Autrod 13.40,
C and D 13.25 OK Flux 10.62
A-311/A-311M 1018, ESAB 28, ESAB ESAB MW1, Dualshield OK Flux 10.81L
1117 36H , OK 48.20 Spl OK Aristorod 7100 LH /10.71, OK Autrod
12.50, 12.08L/12.22L /
OK Tigrod S2 / 12.40L
S2 spcl
A-312/A-312M TP304 OK 61.50, ESAB OK Tigrod Shieldbright 308, OK Autrod 16.10 /
,TP304H 308H 16.10, OK Ti- 308L 308H,
grod 308H OK Flux 10.92L
TP304L , ESAB 304B(N) OK Tigrod 16.10 OK Autrod 16.10;
TP304N OK Flux 10.92L
TP316, OK 63.50 OK Tigrod 316H Shieldbright 316, OK Autrod 16.30 ,
316H Xtra OK Flux 10.92L
TP316L, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316LN Xtra OK Flux 10.92L
TP317, OK 64.30 OK Tigrod 317L Shieldbright 317L OK Autrod 317L,
317L Xtra OK Flux 10.92L
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
A-333/A-333M Grade 1 ESAB 36H(Spl) OK Tigrod Dualshield OK Autrod 12.24,
and 6 S2(Spl)/ OK 7100LH/ OK Flux 10.62
Autrod 13.23 OK Tubrod 15.19
115
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
Grade 3 ESAB 8016 C2 , OK Tigrod / - OK Autrod 13.27,
and 4 OK 73.79 Autrod 19.81 OK Flux 10.62
Grade 7 Filarc 75S OK Tigrod 13.28 - OK Autrod 13.27,
and 9 OK Flux 10.62
Grade 8 OK 92.45, OK Tigrod / - OK Autrod 19.82/
OK 92.55 Autrod 19.82 ; 19.85, OK Flux
19.85 10.16 / 10.90
Grade 10 Filarc 88S OK Tigrod 13.28 Filarc PZ 6138 OK Autrod 13.27,
OK Flux 10.62
A-334/A-334M Grade 1 ESAB 36H(Spl) OK Tigrod Dualshield OK Autrod 12.24,
and 6 S2(Spl)/ OK 7100 LH/ OK Flux 10.62
Autrod 13.23 OK Tubrod 15.19
Grade 3 ESAB 8016 C2 OK Tigrod / - OK Autrod 13.27,
Autrod 19.81 OK Flux 10.62
Grade 7 Filarc 75S OK Tigrod 13.28 - OK Autrod 13.27,
OK Flux 10.62
Grade 8 OK 92.45, OK Tigrod / - OK Autrod
OK 92.55 Autrod 19.82 ; 19.82/19.85, OK
19.85 Flux 10.16 / 10.90
A-335/A-335M Grade P1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 ,
and P2 OK Autrod 13.09
Grade P5, ESAB KV4, OK Tigrod 13.32
P5b, P5c ESAB KV4L
Grade P9 ESAB KV7 OK Tigrod 13.37
Grade OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
P11, P12 OK 76.18 M 13.16, OK Flux 10.62
OK Tigrod B2L
Grade OK 76.28 , OK Tigrod Dualshield 9000B3 OK Autrod 13.20,
P21, P22 OK 76.28M 13.17, OK Flux 10.62
OK Tigrod B3L
Grade ESAB KV7M, OK Tigrod 13.38 Dualshiled B9 OK Autrod 13.35,
P91 OK 76.98 OK Flux 10.93
A-336/A-336M F1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 ,
OK Autrod 13.09
F3V ESAB KV11
F11 OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
classes OK 76.18 M 13.16, OK Flux 10.62
2&3, F12 OK Tigrod B2L
F5, F5A ESAB KV4, ESAB OK Tigrod 13.32 Dualshiled B6
KV4L
F6 OK 68.10 , OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410,
OK 68.15 OK Flux 10.92L
F9 ESAB KV7 OK Tigrod 13.37 Dualshiled B9 OK Autrod 13.35,
OK Flux 10.93
F91 ESAB KV7M, OK Tigrod 13.38 Dualshiled B9 OK Autrod 13.35,
OK 76.98 OK Flux 10.93
116
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
F21, F22 - OK 76.28, OK Tigrod Dualshield 9000B3 OK Autrod 13.20
classes 1 OK 76.28M 13.17, and OK Flux 10.62
and 3 OK Tigrod B3L
F304 , OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10
304H ESAB 308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
F304L OK 61.30, OK Tigrod Shieldbright 308L, OK Autrod 16.10,
ESAB 304B 16.10, 308L Xtra OK Flux 10.92L
OK Autrod 16.10
F304N, ESAB 304B(N) OK Tigrod
F304LN 16.10N
F309H OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53,
Autrod 16.53 OK Flux 10.92L
F310 , OK 67.13 OK Tigrod 16.13
F310H
F316, OK 63.50 OK Tigrod 316H Shieldbright 316,
316H Xtra
F316L OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30,
Xtra OK Flux 10.92L
F321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
F321H, OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H , OK Flux 10.92L
348H
A-350/A-350M LF1 , LF2 ESAB 36H OK Tigrod S2 Dualshield T5 OK Autrod 12.40
Class 2 and OK Flux 10.71L
LF2 ESAB 36H(Spl) OK Tigrod S2 Dualshield OK Autrod 12.24,
Class 1 (Spl)/ 7100LH/ OK Flux 10.62
OK Autrod 13.23 OK Tubrod 15.19
LF3 Class ESAB 8016 C2 OK Tigrod / - OK Autrod 13.27,
1 and 2 , Autrod 19.81 OK Flux 10.62
LF9
LF5 Class Filarc 88S OK Tigrod 13.28 Filarc PZ 6138 OK Autrod 13.27,
1 and 2 OK Flux 10.62
LF6 Class Filarc 88S OK Tigrod 13.28 Filarc PZ 6138 OK Autrod 13.27,
1 and 2 OK Flux 10.62
LF6 Class OK 73.08 OK Tigrod 13.09 OK Tubrod 15.24 OK Autrod 12.24,
3 OK Flux 10.71
LF787 OK 75.75 OK Aristorod Dualshield T-115 OK Autrod 13.43,
Class 2 13.26 OK Flux 10.62
A-351/A-351M CF3, OK 61.30 , ESAB OK Tigrod 16.10, Shieldbright 308L, OK Autrod 16.10,
CF3A 304B OK Autrod 16.10 308L Xtra OK Flux 10.92L
CF3M, OK 63.30 OK Tigrod 16.30, Shieldbright 316L, OK Autrod 16.30,
CF3MA, OK Autrod 16.30 316L Xtra OK Flux 10.92L
CF3MN
117
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
CF8, OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10 /
CF8A, ESAB 308H 16.10, 308L 308H,
CF8C, OK Tigrod 308H OK Flux 10.92L
CF10
CF8M, OK 63.50 OK Tigrod 316H Shieldbright 316, -
CF10M Xtra
CH8, OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
CH10, Autrod 16.53 OK Flux 10.92L
CH20
CK20, OK 67.13 OK Tigrod / Shieldbright 310 -
HK30, Autrod 16.13 Extra
HK40
A-352/A-352M LCA, Ferroweld W2 - - -
LCB, LCC
LC1 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62,
OK Autrod 13.09
LC2 OK 73.68 OK Tigrod 13.28 - -
LC2-1 ESAB 120 - - -
LC3 OK 73.79 - - -
LC9 OK 92.45, OK Tigrod / - -
OK 92.55 Autrod 19.82 ;
19.85
CA6NM OK 68.00 , OK Tigrod 410 PZ 6166 / Shield- OK Autrod 16.79,
OK 68.25, NiMo bright 410NiMo OK Flux 10.93
ESAB 410NiMo
A-353/A-353M OK 92.45, OK Tigrod / - OK Autrod 19.82,
OK 92.55 Autrod 19.82, 19.85/OK Flux
19.85 10.16, 10.90
A-358/A-358M Grade OK 61.50, OK Tigrod 16.10, Shieldbright 308, OK Autrod 16.10 /
304, 304H ESAB 308H OK Tigrod 308H 308L 308H,
OK Flux 10.92L
Grade OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
304L OK Flux 10.92L
Grade ESAB 304B(N) OK Tigrod
304N, LN 16.10N
Grade OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309S Autrod 16.53 OK Flux 10.92L
Grade ESAB 309Cb
309Cb
Grade OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316, 316L Xtra OK Flux 10.92L
Grade OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321, 347, OK Flux 10.92L
348
A-369/A-369M FPA, FPB ESAB 28, ESAB MW1, Dualshield OK Flux 10.81L
ESAB 36H, OK Aristorod 7100 LH /10.71, OK Autrod
OK 48.20 Spl 12.50 12.08L/12.22L /
12.40L
118
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
FP1,FP2 OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 ,
OK Autrod 13.09
FP11, OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
FP12 OK 76.18 M 13.16, OK Flux 10.62
OK Tigrod B2L
FP21, OK 76.28 , OK Tigrod Dualshield 9000B3 OK Autrod 13.20
FP22 OK 76.28M 13.17, and OK Flux 10.62
OK Tigrod B3L
FP5 ESAB KV4 OK Tigrod / Dualshield B6
Autrod 13.32
FP9 ESAB KV7 OK Tigrod / Dualshield B9 OK Autrod 13.35
Autrod 13.37 and OK Flux 10.93
FP91 ESAB KV7M , OK Tigrod / Dualshield B9 OK Autrod 13.35
OK 76.98 Autrod 13.38 and OK Flux 10.93
A-372/A-372M Grade A ESAB 36H OK Tigrod S2, Dualshield 7100 OK Flux 10.81L
ESAB MW1 LH /10.71, OK Autrod
12.08L/12.22L /
12.40L
Grade B OK 73.08 OK Tigrod 13.09, Dualshield 7000A1 OK Flux 10.62 ,
OK Autrod 13.14 OK Autrod 13.09
Grade ESAB 118 OK Tigrod / Dualshield T-115 OK Autrod 13.43
C, D Aristorod 13.13 and OK Flux 10.62
Grade E, ESAB 118 OK Tigrod / Dualshield T-115 OK Autrod 13.43
F, G, H, J Aristorod 13.13 and OK Flux 10.62
(Class 55)
Grade E, ESAB 120 OK Aristorod
F, G, H, 13.31
J (Class
65),
Grade K,
M Class
A,B
A-376/A-376M TP304, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
TP304N 308L OK Flux 10.92L
TP304H OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10
ESAB 308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
TP304LN OK 61.30 , OK Tigrod 16.10, Shieldbright 308L, OK Autrod 16.10,
ESAB 304B OK Autrod 16.10 308L Xtra OK Flux 10.92L
TP316, OK 63.50 OK Tigrod 316H Shieldbright 316,
TP316H Xtra
TP316L, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316LN Xtra OK Flux 10.92L
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321H, OK Flux 10.92L
347,
347H, 348
119
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-387/A-387M Grade OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
2,12,11 OK 76.18 M 13.16, OK Flux 10.62
OK Tigrod B2L
Grade 22, OK 76.28 , OK Tigrod Dualshield 9000B3 OK Autrod 13.20
22L OK 76.28M 13.17, and OK Flux 10.62
OK Tigrod B3L
Grade 5 ESAB KV4, OK Tigrod 13.32 Dualshield B6
ESAB KV4L
Grade 9 ESAB KV7 OK Tigrod 13.37 Dualshield B9 OK Autrod 13.35,
OK Flux 10.93
Grade 91 ESAB KV7M , OK Tigrod 13.38 Dualshield B9 OK Autrod 13.35,
OK 76.98 OK Flux 10.93
A-403/A-403M WP/CR OK 61.50 OK Tigrod 16.10 Shieldbright 308 OK Autrod 16.10 /
304, 304N OK Flux 10.92L
WP/CR OK 61.30 , OK Tigrod Shieldbright 308L, OK Autrod 16.10,
304L ESAB 304B 16.10, 308L Xtra OK Flux 10.92L
OK Autrod 16.10
WP/CR ESAB 308H OK Tigrod Shieldbright 308L OK Autrod 308H,
304H 308H OK Flux 10.92L
WP/CR OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
309 Autrod 16.53 OK Flux 10.92L
WP/CR OK 63.50 OK Tigrod 316H Shieldbright 316,
316, 316N Xtra
WP/CR OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316L, Xtra OK Flux 10.92L
316LN
WP/CR OK 64.30 OK Tigrod 317L Shieldbright 317L
317L, Xtra
317LN
WP/CR OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321, 347, OK Flux 10.92L
348
WP/CR OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
347H, OK Flux 10.92L
348H
A-409/A-409M TP304 OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
308L OK Flux 10.92L
TP304L OK 61.30 , OK Tigrod Shieldbright 308L, OK Autrod 16.10,
ESAB 304B 16.10, 308L Xtra OK Flux 10.92L
OK Autrod 16.10
TP309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
TP309Cb ESAB 309Cb
TP310S OK 67.13 OK Tigrod 16.13
TP316 OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
TP316L OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
Xtra OK Flux 10.92L
120
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
TP317 OK 64.30 OK Tigrod 317L Shieldbright 317L
Xtra
TP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
347, 348 OK Flux 10.92L
A-414/A-414M Grade A, ESAB 28, ESAB MW1, Dualshield
B, C,D, E ESAB 36H OK Tigrod S2 7100 LH
and F
A-420/A-420M WPL 6 ESAB 28, OK Tigrod S2 / Dualshield OK Flux 10.81L
OK 48.20 Spl S2 spcl 7100 LH /10.71, OK Autrod
12.08L/12.22L /
12.40L
WPL 9 OK 73.08 OK Tigrod 13.16 OK Tubrod 15.24
A-423/A-423M Grade 1 OK 76.18, OK Tigrod Dualshield OK Autrod 13.10,
OK 76.18 M 13.16, 8000B2, OK Flux 10.62
OK Tigrod B2L OK Tubrod 15.24
Grade 2 OK 73.08 OK Tubrod 15.24
A-426/A-426M CP2, OK 76.18, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
CP11, OK 76.18 M 13.16, OK Flux 10.62
CP12 OK Tigrod B2L
CP5, OK 67.67, OK Autrod/ Shieldbright 309L OK Autrod 16.53 ,
CP5b, ESAB 309 Tigrod 16.53 OK Flux 10.92L
CP21
A-430/A-430M FP304, OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10
FP304H, ESAB 308H 16.10, 308L / 308H, OK Flux
FP304N OK Tigrod 308H 10.92L
FP316, OK 63.50 OK Tigrod 316H Shieldbright 316,
FP316H, Xtra
FP316N
FP321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
FP321H, OK Flux 10.92L
FP347
FP347, OK 61.80 OK Tigrod 347H Shieldbright 347 OK Autrod 347H,
FP347H OK Flux 10.92L
FP16-8-
2H
A-451/A-451M CPF3, OK 61.30 OK Tigrod 16.10 Shieldbright 308L OK Autrod 16.10 /
CPF3A OK Flux 10.92L
CPF8, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
CPF8A 308L OK Flux 10.92L
CPF3M OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
Xtra OK Flux 10.92L
CPF8M OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
CPF10MC OK 63.80
CPF8C OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
OK Flux 10.92L
CPH8, OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
CPH20 Autrod 16.53 OK Flux 10.92L
CPK20
121
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-479/A-479M 302, 304, OK 61.50 OK Tigrod 16.10 Shieldbright 308, OK Autrod 16.10,
304H, 308L OK Flux 10.92L
304N
304L, OK 61.30 , OK Tigrod Shieldbright 308L, OK Autrod 16.10,
304LN ESAB 304B 16.10, 308L Xtra OK Flux 10.92L
OK Autrod 16.10
309S OK 67.67 OK Tigrod / Shieldbright 309L OK Autrod 16.53 ,
Autrod 16.53 OK Flux 10.92L
309Cb ESAB 309Cb
310S OK 67.13 OK Tigrod 16.13
316, 316N OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
316L, OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
316LN Xtra OK Flux 10.92L
321, OK 61.80 OK Tigrod 16.11 Shieldbright 347 OK Autrod 16.11,
321H, OK Flux 10.92L
347, 348
403, 410, OK 68.10, OK Tigrod 410 Arcaloy 409-Ti OK Autrod 410,
414, 405, OK 68.15 OK Flux 10.92L
430
A-487/A-487M 11A, 12A, ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
16A, 4B, 13.29 OK Flux 10.62
4D, 4E,
8B
8C, 9B, ESAB 120
9D, 10A,
11B, 12B,
13B, 6A,
6B, 7A,
14A, 10B
A-508/A-508M 1, 1A, 2, ESAB 98 OK Tigrod / OK Autrod 13.44,
3, 2A, 3A, Aristorod 13.29 OK Flux 10.62
4B
4,5 ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
13.29 OK Flux 10.62
4A, 5A ESAB 120
A-513/A-513M 1008- Pipeweld 6010R, ESAB MW1, Dualshield 7100LH OK Autrod 12.24,
1035 Pipeweld 6010 OK Tigrod S2 OK Flux 10.71
plus,
A-515/A-515M All ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
36H , Pipeweld Aristorod 12.50, 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-516/A-516M All ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
36H , Pipeweld Aristorod 12.50 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 , OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-517/A-517M All ESAB 118, ESAB OK Aristorod Dualshield T-115 OK Autrod 13.43,
120 13.29 OK Flux 10.62
122
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
A-533/A-533M Type A OK 74.46 OK Tigrod 13.09 Dualshield 7000A1 OK Flux 10.62 ,
OK Autrod 13.09
Type B ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
13.29 OK Flux 10.62
Type C OK 73.08 OK Tigrod 13.16 OK Tubrod 15.24
and D
A-537/A-537M Class 1 ESAB 36H, ESAB MW1, Dualshield
OK 73.08, OK Tigrod S2 7100 LH
OK 48.20 (spl)
Class 2 Filarc 75S, OK Tigrod / OK Tubrod 15.27 OK Autrod 13.27 ,
OK 73.68 Autrod 13.28 OK Flux 10.62
A-541/A-541M 1,1A ESAB 36H, OK ESAB MW1, Dualshield
74.46, ESAB 56 OK Tigrod S2 7100 LH
2,3,4 OK 73.08 OK Tigrod 13.16 OK Tubrod 15.24
3V, 22b ESAB 98 OK Tigrod / OK Autrod 13.44,
Aristorod 13.29 OK Flux 10.62
2A, 3A, ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
7B, 22C, 13.29 OK Flux 10.62
7,8
22D, 7A, ESAB 120
8A
A-543/A-543M 1B, 1C, ESAB 118 OK Aristorod Dualshield T-115 OK Autrod 13.43,
3B, 3C 13.29 OK Flux 10.62
2B, 2C ESAB 120
A-556/A-556M A2 Pipeweld 6010R, ESAB MW1, Dualshield 7100LH OK Autrod 12.24,
Pipeweld 6010 OK Tigrod S2 OK Flux 10.71
plus,
A-557/A-557M B2, C2 ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
36H , Pipeweld Aristorod 12.50, 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-562/A-562M ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
36H , Pipeweld Aristorod 12.50, 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
A-568/A-568M All Pipeweld 6010R, ESAB MW1, Dualshield OK Autrod 12.24,
Pipeweld 6010 OK Tigrod S2 7100 LH OK Flux 10.71
plus,
A-572/A-572M 42, 50, ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
55, 60 36H , Pipeweld Aristorod 12.50, 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
65 OK 73.08 OK Tigrod 13.16 OK Tubrod 15.24
A-573/A-573M 58,65 ESAB 28, ESAB ESAB MW1, OK Dualshield OK Flux 10.81L
36H , Pipeweld Aristorod 12.50, 7100 LH /10.71, OK Autrod
6010 R, OK 48.20 OK Tigrod S2 / 12.08L/12.22L /
Spl S2 spcl 12.40L
70 OK 73.08 OK Tigrod 13.16 OK Tubrod 15.24
123
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
124
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
J80, J90, ESAB 118, OK Tigrod Dualshield 8000B2 OK Autrod 13.10,
J100, OK 76.18, 13.16, OK Flux 10.62
K75, K85, OK 76.18 M OK Tigrod B2L
L65, L70,
L75, M70,
M75, N75
A-675/A-675M 45, 50, ESAB 36H, ESAB MW1, OK Dualshield OK Flux 10.81L
55, 60 OK 48.20 Spl Aristorod 12.50, 7100 LH /10.71, OK Autrod
OK Tigrod S2 / 12.08L/12.22L /
S2 spcl 12.40L
65,70 ESAB 98 OK Tigrod / OK Autrod 13.44,
Aristorod 13.29 OK Flux 10.62
A688-88a TP304 OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10
ESAB 308H 16.10, OK Ti- 308L / 308H, OK Flux
grod 308H 10.92L
TP304L, OK 61.50, OK Tigrod Shieldbright 308, OK Autrod 16.10
304H ESAB 308H 16.10, 308L / 308H, OK Flux
OK Tigrod 308H 10.92L
TP304LN OK 61.30, OK Tigrod Shieldbright 308L, OK Autrod 16.10,
ESAB 304B 16.10, 308L Xtra OK Flux 10.92L
OK Autrod
16.10
TP316 OK 63.50 OK Tigrod 316H Shieldbright 316,
Xtra
TP316L OK 63.30 OK Tigrod 16.30 Shieldbright 316L, OK Autrod 16.30 ,
Xtra OK Flux 10.92L
TP316LN ESAB 317 LN OK TIGROD
13.09
A691-85a CM-65, OK 74.46 OK TIGROD OK TUBROD
CM-70 13.09 15.22
CM-75, OK 73.08 OK TIGROD
CMSH-70 13.14
CMSH-80 OK TUBROD
15.24
0.5CR., OK 76.18 OK TIGROD OK TUBROD
1CR 13.16 15.20
1.2 CR OK TUBROD
15.20
2.25 CR OK 76.28 OK Tigrod
13.17,
OK Tigrod B3L
A695-81 Grades ESAB 36H, OK Tigrod S2 Dualshield 7100
35&40 OK 48.20 Ultra
A696-85 B Pipeweld 6010R, OK Tigrod S2 Dualshield 7100
Citoflex, Pipeweld Ultra
6011
125
Recommended Consumables
Welding Consumables
ASTM Class or
Designation grade SMAW GTAW/GMAW FCAW SAW
C ESAB 36H, ESAB MW1, Dualshield 7100
OK 48.20 OK Tigrod S2 Ultra
A-724-88 All Esab 118 OK Tubrod 15.24
A727-87 OK 74.46 OK Tigrod 13.09 DS 7000 A1
A737-87 B OK 73.08 OK Tigrod 13.14 OK Tubrod 15.24A
C Esab 118 OK Tubrod 15.27A
A738-87a A Ferroweld W DS 8100W
B&C DS 8100W
B11 OK 76.18 OK Tigrod 13.16 OK Tubrod 15.20
A739-81a
OK 76.28 OK Tigrod 13.17 OK Tubrod 15.22
B22
A-765-87 I OK 73.08 OK Tigrod 13.14 OK Tubrod 15.24
II OK 73.68 OK Tubrod 14.04
126
1. MMA electrodes for mild and low-alloyed steels
–40°C Charpy V
OK 73.08
–60°C Charpy V
Welding Consumables
127
128
Welding Consumables
2. Solid wires
Welding Consumables
129
130
Welding Consumables
4. Cored wires
OK Tubrod 14.12 metal-cored all
Coreweld 70 Ultra positions
Mild steel Yes Requirements 375 MPa (55 000 psi) basic all
min. yield stress OK Tubrod 15.00/Dualshield T5
positions
No
OK Tubrod 15.12 rutile flat & HV
OK Tubrod 15.18
OK Tubrod 15.14A rutile all
Dualshield 7100LH/Ultra positions
OK Tubrod 14.02 metal-cored all positions
Medium & high- Yes Requirements 450 MPa (65 000 psi) Coreweld Ultra/70
tensile steel min. yield stress
OK Tubrod 15.14 rutile all positions
Dualshield 7100LH/Ultra rutile all positions
OK Tubrod 15.24 basic all positions
No
550 MPa (80 000 psi) OK Tubrod 15.19 rutile all positions
Dualshield II 81 K2 rutile all positions
Mild steel Yes Requirements min. yield 375 MPa (55 000 psi) OK Tubrod 14.00S/OK Flux 10.71
stress OK Tubrod 15.00S/OK Flux 10.71
No
No 1.0 Mo 2.25 Cr
–50°C Charpy V
OK Tubrod 15.24S/OK Flux 10.62
OK Tubrod 15.25S/OK Flux 10.62
–60°C Charpy V
Welding Consumables
131
132
Welding Consumables
EN 10088-1 Designation Werkstoff. No AISI C Cr Ni Mo Other elements MIG OK Autrod TIG OK Tigrod
Austenitic
X10CrNi18-8 1.4310 302 < 0.12 18 8 16.10 16.10
X5CrNi18-10 1.4301 304 < 0.07 18 10 16.10 16.10
X6CrNiTi18-10 1.4541 321 < 0.08 18 11 Ti 0.7 16.11 16.11, 16.10
X6CrNiNb18-10 1.4550 347 < 0.08 18 11 Nb 0.7 16.11 16.11, 16.10
X8CrNiS18-9 1.4305 303 < 0.12 18 9 S 0.2 16.53 16.53, 309L
X2CrNi18-9 1.4307 304L < 0.03 18 10 16.10 16.10
X2CrNiN18-10 1.4311 304LN < 0.03 18 10 N 0.15 16.10 16.10
304N < 0.08 18 9 N 0.15 16.10 16.10
X3CrNiMo17-13-3 1.4436 316 < 0.05 18 12 2.5 16.30 16.30
X5CrNiMo17-12-2 1.4401 316 < 0.05 18 12 2.5
X2CrNiMo17-12-2 1.4404 316L < 0.03 18 12 2.5
X2CrNiMo18-14-3 1.4435 316L < 0.03 18 13 2.5 16.38 16.38
X6CrNiMoTi17-13-2 1.4571 316Ti < 0.08 18 12 2.5 Ti 0.7 318Si, 16.30 318Si, 16.30
X2CrNiMoN17-13-3 1.4429 316LN < 0.03 18 12 2.5 N 0.5 16.30 16.30
X12CrMnNiN 1.4372 202 < 0.15 18 5 Mn 8 16.95 16.95
X2CrNiMo18-15-4 1.4438 S31703 < 0.03 18 16 3.5 317L 317L
X1NiCrMoCuN25-20-5 1.4539 N08904 < 0.03 20 25 4.5 Cu 1.5 385 385
X1CrNiMoCuN20-18-7 1.4547 S31254 < 0.02 20 18 6.2 Cu 0.8, N 0.2 19.81, 19.82 19.81, 19.82
X1NiCrMoCu31-27-4 1.4563 N08028 < 0.02 27 31 3.5 Cu 1.5 19.81, 19.82 19.81, 19.82
- 1.4652 S32654 < 0.02 24 22 7.3 Cu 0.5, N 0.5 19.81 19.81
X9CrNiSiNCe21-11-2 1.4835 S30815 < 0.10 21 11 N 0.17 + Ce 310 310
Austenitic-ferritic (Duplex)
1.4162 S32101 0.03 21.5 1.5 Mn 5 16.86 16.86
X2CrNiN23-4 1.4362 S32304 < 0.03 23 4 N 0.10 16.86 16.86
X2CrNiMoN22-5-3 1.4462 S31803 < 0.03 22 5 3 N 0.10 16.86 16.86
X2rNiMoN25-7-4 1.4410 S32750 < 0.03 25 7 4 N 0.25 16.88 16.88
X2CrNiMoCuWN25-7-4 1.4501 S32760 < 0.03 25 6 3 N 0.25 W 0.7 16.88 16.88
EN 10088-1 Designation Werkstoff. No AISI C Cr Ni Mo Other elements MIG OK Autrod TIG OK Tigrod
Ferritic-martensitic
X6Cr13 1.4000 403 < 0.08 13 16.10 16.10
X2CrNi12 1.4003 S41050 < 0.03 12 0.7 16.10 16.10
X12Cr13 1.4006 410 0.1 13 16.53 16.53
Ferritic
X6Cr17 1.4016 430 < 0.08 16.5 430Ti, 430LNb, 16.10 430Ti, 16.10
16.10 16.10
X6CrTiNb18 1.4509 441 < 0.03 18 Ti, Nb 430Ti, 430LNb 430Ti
X6CrTi17 1.4510 439 < 0.8 17 Ti 430Ti 430Ti
X2CrMoTi18-2 1.4521 S44400 < 0.03 18 2 16.30 16.30
- - 446 < 0.20 26 16.13 16.13
Welding Consumables
133
134
Welding Consumables
7. The most common fluxes and wires for SAW of stainless steels
European standard German DIN 17440 England France SS USA Recommended SAW
EN 10082-1 AFNOR steel AISI consumables
Designation No Designation Werkst. BS 970; NFA 35-572 to No OK Flux + OK Autrod
steel steel Nr. 1=Part 1 NFA 35-578
BS 1449;
2=Part 2
X 6 Cr 13 1.4000 X 7 Cr 13 1.4000 403 S 17 Z 6 C 13 2301 403 10.92L+16.10 or 308H/10.92L+16.10
X 12 Cr 13 1.4006 X 10 Cr 13 1.4006 410 S 21 Z 12 C 13 2302 410 10.92L+16.10 or 308H/10.92L+16.10
X 20 Cr 13 1.4021 X 20 Cr 13 1.4021 420 S 37 Z 20 C 13 2303 420 10.92L+16.10 or 308H/10.92L+16.10
X 30 Cr 13 1.4028 X 30 Gr 13 1.4028 420 S 45 Z 30 C 13 2304 – 10.92L+16.10 or 308H/10.92L+16.10
X 6 Cr 17 1.4016 X 6 Cr 17 1.4016 430 S 17 Z 8 C 17 2320 430 10.92L+16.11 or 308H/10.92L+16.10
X 17 Cr Ni 16-2 1.4057 X 20 Cr Ni 17 2 1.4057 431 S 29 Z 15 CN 16.02 2321 431 10.92L+16.11 or 10.92L+16.11
– 1.47491) – Z 10 C 24 2322 446 10.92L+16.13
X 8 Cr Ni Mo 27 5 21) 1.44601) – – 2324 329 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni N 23-4 1.4362 – – 2327 S32304 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni Mo N 22-5-3 1.4462 – – 2377 S31803 10.92L+2209 or 2509/10.94+2509
X 2 Cr Ni Mo N 25-7-4 1.4410 – – 2328 S32750 10.94+2509
X 2 Cr Ni Mo Ca WN 25-7-4 1.4501 – – – S32760 10.94+2509
X 10 Cr Ni 18-8 1.4310 – – 302 S 31 Z 10 CN 18.09 2331 302 10.92L+16.10 /10.92L+16.10
X 5 Cr Ni 18-10 1.4301 X 5 Cr Ni 18 10 1.4301 304 S 31 Z 6 CN 18.09 2332 304 10.92L+16.10 /10.92L+16.10
X 5 Cr Ni 18-10 (1.4301) (X 5 Cr Ni 18 10) (1.4301) (304 S 15) (Z 6 CN 18.09) 2333 (304) 10.92L+16.10 /10.92L+16.10
X 6 Cr Ni Ti 18-10 1.4541 X 6 Cr Ni Ti 18 10 1.4541 321 S 31 Z 6 CNT 18.10 2337 321 10.92L+16.11 or 10.92L+16.11
X 6 Cr Ni Nb 18-10 1.4550 X 10 Cr Ni Nb 18 10 1.4550 347 S 31 Z 6 CNNb 18.10 2338 347 10.92L+16.11 or 10.92L+16.11
X 3 Cr Ni Mo 17-13-3 1.4436 (X 5 Cr Ni Mo 17 13 3) 1.4436) (316 S 33) (Z 6 CND 17.12) 2343 (316) 10.92L+16.30 or 10.92L+16.30
X 5 Cr Ni Mo 17-12-2 (1.4401) (X 5 Cr Ni Mo 17 12 2 (1.4401) (316 S 31) (Z 6 CND 17.11) 2347 (316) 10.92L+16.30 or 10.92L+16.30
X 2 Cr Ni Mo 17-12-2 1.4404 X 2 Cr Ni Mo 17 13 2 1.4404 316 S 11 Z 2 CND 17.12 2348 316 L 10.92L+16.30 or 10.92L+16.30
X 6 Cr Ni Mo Ti 17-12-2 1.4571 X 6 Cr Ni Mo Ti 17 12 2 1.4571 320 S 31 Z 6 CNDT 17.12 2350 316 Ti (10.92L+16.30) or (10.92L+16.30)
X 2 Cr Ni 18-9 1.4307 X 2 Cr Ni 18 10 1.4306 304 S 11 Z 2 CN 18.10 2352 304 L 10.92L+16.10 or 308H/10.92L+16.10
X 2 Cr Ni Mo 18-14-3 1.4435 X 2 Cr Ni Mo 18 14 3 1.4435 316 S 3 Z 2 CND 17.13 2353 316 L 10.92L+16.10 or 10.92L+16.10
(EN 10095) 1.4845 X 12 Cr Ni 25 211) 1.48451) (310 S 24) (Z 12 CN 25-20) 2361 310 S 10.92L+310
X 8 Cr Ni 25-21
X 2 Cr Ni Mo 18-15-4 1.4438 X 2 Cr Ni Mo 18 16 4 1.4438 – Z 2 CND 19.15 2367 317 L 10.92L+317L or 10.92L+317L
X 2 Cr Ni N 18-10 1.4311 X 2 Cr Ni N 18 10 1.4311 – Z 2 CN 18.10 Az 2371 304 LN (10.92L+16.10) or (10.92L+16.10)
X 2 Cr Ni Mo N 17-13-3 1.4429 X 2 Cr Ni Mo N 17 13 3 1.4429 – Z 2 CND 18.10 Az 2375 316 LN (10.92L+16.30) or (10.92L+16.30)
1) not standard
Welding Consumables
9. MIG and TIG wires for aluminium
Base material
135
Reclamation Consumables
Reclamation Consumables
Conventional Hardfacing Alloys
BUFFERING
Buffer layers are used as intermediate deposits between
the base material and the actual hardfacing weldmetal
so that the following aspects are taken care of:
Reclamation Consumables
Spalling in subsequent hard layers is avoided cobaltbased alloys, there should be a buffering by
an austenitic consumable for one or two layers. The
Prevention of cracks or relief checks from the compression stresses generated in the subsequent hard
hardfaced layers running into the base material layers during cooling are thus accommodated, reducing
the risk of cracks in the hard weld metal.
BUILD-UP LAYERS
In case of heavy wear, the component has to be built-
up to its original dimensions. But hardfacing layers are
limited to 2-3 layers. In that case, a similar type of alloy
can be used to build it up before applying the hardfacing
Generally, austenitic consumables are widely used as deposit. Otherwise, alternate layers of hard and ductile
ductile buffer layers in hardfacing applications. The deposits can be made finishing off with the hard layer.
choice of consumables depends on the base material E.g. hammers, crushers, cold shearing tools, and
and the type of hardfacing alloy given the wear factors. excavator teeth.
The hardfacing layer tends to sink under high load
conditions if the base material is a soft one like mild
steel. This can result in the hardfacing layer spalling off.
A tough and strong buffer layer is applied to prevent this
occurence.
139
DUROID 250 subsequent matching. Other applications are pump
housing, rail ends (medium Mn steel) for railways and
Machinable build-up prior to hardfacing tramways, forging dies, wheels, axles, and couplings.
A smooth running rutile coated general-purpose Suitable for use as a supporting buffer between a
hardfacing electrode, depositing a tough air-hardening top layer of harder weld metal and a soft mild steel
alloy weld metal, suitable for resisting moderate friction, base. Recommended for hardfacing components and
abrasion and impact. machine parts, which must be easily machinable after
hardfacing.
ALLOY BASE: Fe, Cr, Mn
PROPERTIES
SPECIAL FEATURES
Hardness : 24-27 HRC
Smooth arc with low spatter.
Normally machinable weld metal. CURRENT RANGE : (AC 50, DC±)
Reclamation Consumables
140
DUROID 650B Smooth arc with low spatter.
It is very easy to use in all positions. · Excellent weld
No-problem abrasion resistance even for thicker bead appearance.
plates
APPLICATIONS
A high alloyed basic hardfacing electrode depositing
a nonmachinable air-hardening weld metal. The weld Coal cutter blades, rock drills, drill bits, oil expeller
deposit is resistant to severe abrasion and moderate worms, cane & bamboo cutting knives, excavator teeth,
impact between metal to mineral wearing stresses. It hot & cold punching dies, bucket lips, dipper teeth,
also resists scaling upto temperatures around 300°C impellers, muller ploughs, chutes, conveyors, shears &
and also moderate corrosion. croppers, pulping knives, ploughshares, road graders,
crusher hammers, caterpillar treads & shoes, etc. This
Apart from applications on mild and medium carbon electrode is specially recommended for applications
steels Duroid 650B, being basic coated, can also be involving metal to mineral wear.
Reclamation Consumables
used over high carbon and alloy steel base metals and
on jobs of thicker cross-section. Requirement of pre- PROPERTIES
heat can be lowered or avoided altogether to obtain weld Hardness : 57-59 HRC
deposit free from cracks, porosity and slag inclusions
when normal welding practice for basic coated electrode CURRENT RANGE : (AC 70, DC±)
is followed. Size Length Current Range
(mm) (mm) (Amp)
ALLOY BASE: Fe, Cr, Mn, Mo, V
3.15 450 100-140
SPECIAL FEATURES
4.00 450 120-180
Can be used on thicker sections without the need of 5.00 450 160-250
buffering.
141
Superior arc stability than available grades of Mn Welding should be done in stringer beads directing
Steel electrodes. the arc towards the weld pool keeping the heat input
It is very easy to use in all positions. to the base metal minimum. Skip welding/back step
welding can also be adopted.
APPLICATIONS
The weld bead can be peened with ball pen hammer
Austenitic manganese steel components, crusher jaws, immediately after welding.
crusher hammers, crusher mantles, dredger bucket
Quenching has no adverse effect on welding and
teeth, cement grinder rings, manganese steel railway
should be adopted whenever possible after slag
points & crossings, manganese steel components used
removal and peening. If possible the Mn steel job
in the mining industry.
can be submerged in water during welding.
PROPERTIES
Hardness : As deposited : 24-26 HRC CURRENT RANGE : (AC 70, DC±)
Reclamation Consumables
142
Low Heat hardfacing Alloys
Reclamation Consumables
A higher hardness level does not necessarily results from the sliding action of free
imply improved wear resistance or longer life. The moving hard particles along a surface.
effectiveness of any hardfacing alloy depends of its Material is removed by scratching or
suitability in the operating conditions. micro-machining process. Eg. chutes,
mineral conveyors.
So the appropriate hardfacing alloy has to be selected
considering the following aspects: c) High stress abrasion: It occurs where
abrasive particles are forced between
the wear factors
two metal parts and crushed under
the base material of the component heavy loads. The wear involves
surface damage accompanied by
the surface finish required
plastic deformation. Eg. rock drills,
the process to be used scraper blades, ball mills.
WEAR FACTORS Erosion This wear is similar to abrasion but the
Wear factors are the action of different agents on particles are carried by a fluid stream like
the metallic surface leading to degeneration and water, steam, etc., generally at a higher
disintegration of the metal. A number of wear factors velocity compared to low-stress abrasion.
exist, which act individually or in combination. The weld Eg. slurry transport systems, shot blasting
metals have to be selected properly to counter these equipment.
factors effectively. Cavitation When a liquid is subjected to rapid changes
The major types of wear factors are as follows: of pressure, vapour or gas bubbles form in
the lower pressure regions of the liquid.
Friction Wear from metal parts that roll or slide Entering high pressure areas at any metal/
against each other. It accounts for 15% of liquid interface, these bubbles collapse and
the total spectrum of industrial wear. This the immense force causes cyclic stress
type of wear is likely to be most severe and fatigue on the metal surface. E.g. ship
when parts rub together under load with propellers, pump impellers.
little or no lubrication. Generally, contact
between surface materials of the same Heat When metals are exposed to high
hardness will result in excessive wear. E.g. temperature for long periods, they lose
shafts against bearing surfaces, chain links their durability mainly due to thermal fatigue
against a roll, sprockets, steel mill rolls. cracking. Moreover, the metals tend to
lose their strength and hardness at higher
Impact The sudden action of a very large force temperatures. These factors add up to
for a very short time period gives rise to wear. Eg. hot forging dies, extrusion dies,
wear after some time. The mechanism stamping dies, sinter crushing equipment.
is attributed to fatigue failure that has an
incubation period prior to the appearance of Corrosion It involves reaction between a metallic
surface damage. E.g. crusher rolls, impact surface and a corrosive environment
hammers, railway points and crossings. whence the former is dissolved away
leading to wear. In the presence of
Abrasion About 50% of all industrial wear is abrasion any mechanical force, the corrosion
in different forms. The wear takes place products may be removed leading to
when metal is removed from a surface virgin surface coming in contact with the
by the cutting or gouging action of hard
(Contd...)
143
corrosive environment again causing checks”, which are formed across the bead as the bead
continued wear. E.g. valves, seating rings, releases the stress generated while the hard weld metal
screw conveyors. cools. These relief checks are not harmful to the deposit
but may propagate into the base metal if the component
Oxidation In an oxidizing atmosphere, possibly
is subjected to heavy impact or flexing.
aided by high temperatures, the metal
surface builds up an oxide layer, which is So, the issues of acceptability of relief checks and
mostly brittle in nature. This may break finishing requirements should be addressed to when the
due to expansion and the entire oxidation hardfacing deposit is decided.
operation is repeated. E.g. blast furnace WELDING PROCESSES
parts, exhaust valves of internal combustion
Shielded Metal Arc Welding : Covers the widest range
engines, hot working shears.
of weld metals
BASE MATERIAL is a versatile process for
Reclamation Consumables
The two main groups of base materials for hardfacing on - site repairs and out-
are: of-position work
Carbon or low-alloy steels: These steels require is inexpensive
preheating, post-weld heat treatment, slow cooling Flux - Cored Arc Welding : the same range of alloys
for hardfacing according to the chemical composition available as in case of
and the section thickness. The general guidelines coated electrodes
for preheating are given at the end of this section.
on-site use is possible
Austenitic manganese steels: These steels should
self-shielded wires do
be welded without any preheating or post-weld heat
not require any additional
treatment at all. The interpass temperature should
shielding gas
be kept as low as possible.
high deposition rate
SURFACE FINISH
Submerged Arc Welding : high deposition rate
The surface finish requirements must be kept in mind
no spatter loss
while selecting the hardfacing alloy as they cover the
entire range from easily machinable to non-machinable. product range limited
Additionally, many of these deposits will contain “relief positional welding not
possible
144
RECOMMENDED PREHEATING TEMPERATURES IN OC
This chart is given as an indicative guide
Base Plate Steel Low alloy Tool steel Cr-steel Cr-steel Stainless 14% Mn
Material thickness 5-12% Cr >12% Cr steel steel
Filler (mm) <90 HRB 95 HRB- 30-43 HRC 32-51 HRC 95 HRB- -96 HRB 25-51
material 30 HRC 30 HRC HRC
Low-alloy Steel 20 N 100 150 150 100 N N
- 30 HRC
Reclamation Consumables
95 HRB 60 100 180 250 300 200 N N
Stainless Steel 20 N N N N N N N
Mn Steel 20 N N N X X N N
20-60 N N *100 X X N N
20 HRC 60 N N *100 X X N N
N = Not necessary
L = Preheating when large areas are surfaced
X = This combination is not used
145
ASTRÄ HTB APPLICATIONS
Joining and surfacing of hydel turbine blades, valve
Resistance to corrosion, cavitation and erosion seats, pump casings, gates, key-ways, machine
Astra HTB is the only machinable alloy that resists components exposed to corrosive atmosphere,
corrosion, cavitation along with erosion by suspended matching parts for which shape retention in service is of
particles on the strength of the unique recipe of this paramount importance.
electrode. The alloy also shows great resistance to PROPERTIES
deform in service and hence maintains shape and
angularity of the original machined component at room UTS : 85-90 kg/mm2
temperature and also upto 700°C. Elongation : 18-24%
Astra HTB endures in high temperature service as Hardness : 42-45 HRC
well. It offers best combination of machinability, friction
CURRENT RANGE : (AC 70, DC±)
Reclamation Consumables
ESAB 116 Ni It is suitable for build-up and repair of new, worn out
or cracked steel structures, components, and heavy
Hot forge die repair high strength joining equipment. Repair of forge dies, moulds and tools,
A basic coated electrode suitable for build-up and repair high strength joining of carbon-steel earth moving
of open and closed hot forge dies, moulds and tools. equipments, truck frames, penstocks.
The deposit is insensitive to hot cracking. PROPERTIES
The electrode has very good strength and hardness upto UTS : 62-70 kg/mm2
400°C. It can also be used for high strength joining. Elongation : 32-36%
ALLOY BASE: Fe, Mn, Ni Hardness : 37-41 HRC
SPECIAL FEATURES
Resists annealing.
CURRENT RANGE : (AC 70, DC±)
Excellent weld bead appearance. Size Length Current Range
Resists metal-to-metal wear and deformation at high (mm) (mm) (Amp)
temperatures.
4.00 450 120-175
APPLICATIONS 5.00 450 150-230
Recommended for joining of high tensile steels of 6.30 450 200-260
8.00 450 240-300
strength of the order of 80 kg / mm2.
OK 83.28 APPLICATIONS
Parts of rolling mills, grooved rolls and clutches, shafts,
Joining and build-up on rails cog wheels, links and rollers for tractors, bearing
A basic coated electrode suitable for hardfacing in journals. Joining and build-up of machinable carbon-
metal-to-metal wear applications. It has got very good manganese steel railway tracks. This electrode can also
resistance to impact and therefore can be used as a be used for joining hardenable steels.
build-up and support layer for subsequent harder PROPERTIES
deposits.
Hardness : 29-31 HRC
It is a special electrode, having good machinability, for
special build-up on carbon-manganese steel rail tracks. CURRENT RANGE : (AC 70, DC±)
ALLOY BASE: Fe, Cr, Si, Mn Size Length Current Range
(mm) (mm) (Amp)
SPECIAL FEATURES
2.50 350 60-90
Superb resistance to metal to metal friction.
3.20 450 100-140
Extreme impact toughness for heavy build-up. 4.00 450 130-190
5.00 450 180-260
146
OK 83.40 Smoothest running electrode of its class.
Low tendency to moisture absorption.
Infinite fissure-free build-up for impact loading Marginal work hardening.
A smooth running touch welding low heat input electrode
depositing a tough air hardening machinable multi- APPLICATIONS
alloyed weld metal for low stress abrasion and good Hammers, wobblers, railway equalizer beams, crane
impact. wheels, excavators, sprockets, rollers, pump shafts, gear
The deposit is free from surface micro-cracks even teeth, concrete mixer blades, rims, carbon-alloyed rails,
for higher build-up. It has high endurance limit and is dies, striking tools and other machine parts subjected to
suitable for compressive and fatigue loading. heavy shock loading and pounding in service.
Special additives in electrode coating make it smooth It is the right consumable to use for providing buffer
running and easily maneuverable. Superior bead finish layers where impact and abrasion occur together.
Reclamation Consumables
is obtained independent of welder skill. PROPERTIES
The flux is devoid of hygroscopic elements, making it Hardness : 28-35 HRC
ideal for site conditions.
CURRENT RANGE : (AC 50, DC±)
ALLOY BASE: Fe, Mn, Cr, Ni
Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
Micro-crack free surface even for higher build-up.
3.15 450 90-130
Very good resistance to metal-to-metal wear and 4.00 450 120-170
fatigue. 5.00 450 150-220
147
OK 84.78 APPLICATIONS
Highly recommended for earthmoving, construction,
Maximum abrasion resistance cement and agriculture industries.
OK 84.78 gives an alloy rich deposit, which offers best Road rippers, earth moving parts, excavator blades,
resistance to high-pressure abrasion by gritty particles. crushing mills, edge runners, chutes, mixer blades,
The stainless bead is temper resistant upto 600°C. The screw conveyors, asphalt phasing screws, coal mill
deposit resists corrosion and oxidation even at elevated exhauster fan blades, plough shares, tampers, scrapers,
temperature. feeding screws, grader blades, pug mill knife etc.
Relief cracks, transverse to the weld bead, are PROPERTIES
desirable. Hardness : 57-60 HRC
ALLOY BASE: Fe,C,Cr
CURRENT RANGE : (AC 70, DC±)
SPECIAL FEATURES
Reclamation Consumables
(Contd...)
148
Typical applications are shear blades, roll face repairs, CURRENT RANGE : (AC 70, DC±)
tools for hot trimming and cold punching, lifting tongs for Size Length Current Range
billets, high-speed steel dies and tools. (mm) (mm) (Amp)
PROPERTIES 3.15 350 80-120
Hardness : As deposited : 49-52 HRC 4.00 350 120-170
5.00 350 170-230
After tempering at
600°C for 1 hr. : 53-56 HRC
Reclamation Consumables
joining
Crushers, earthmoving equipment, hammers, shovel
High efficiency electrode with special coating, to resist track pads, wear plates, building up manganese steel
massive impact by mineral or metal along with moderate components, buffering before carbide hardfacing
to good resistance to mineral abrasion. deposit.
Despite the common tendency of cracking in manganese
steel, this high purity bead remains ductile and crack- PROPERTIES
free even after die penetration tests. Hardness : As deposited : 22-23 HRC
The alloy also shows reluctance to necking in tensile Work hardened : 42-44 HRC
specimen. In abrasion area also it is superior to all the CURRENT RANGE : (AC 70, DC±)
above except high-density pre-formed carbides. Size Length Current Range
ALLOY BASE: Fe, Mn, Ni (mm) (mm) (Amp)
SPECIAL FEATURES 3.15 450 110-165
Ripple free deposit. 4.00 450 140-200
5.00 450 180-250
DUROBELL APPLICATIONS
Repair and reclamation of seat area of blast furnace
Blast furnace bell and BLT chute reclamation bells & hoppers, BLT chutes,tong-pins, hot shears,
Durobell is a hardfacing electrode depositing a furnace rollers, knives, valve seats, idler rollers of hot
molybdenum-nickel enriched alloy steel that provides strip mills etc.
excellent resistance to both impact and abrasion. The PROPERTIES
weld deposit exhibits secondary hardening at high
temperature that leads to retention of hardness at 500°C Hardness : As deposited : 53-55 HRC
– 550°C. The alloy is amenable to heavy build-up and At 500°C : 46-50 HRC
the deposit is crack-free. The weld bead is machinable
with tungsten carbide tools. CURRENT RANGE : (AC 70, DC±)
ALLOY BASE: Fe, C, Ni, Mo Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
Machinability with abrasion resistance. 3.15 450 90-120
Smooth arc with low spatter. 4.00 450 115-175
5.00 450 160-225
Excellent weld bead appearance.
149
TERROWELD MN PROPERTIES
Hardness : As deposited : 22-24 HRC
Low heat build-up on manganese steel Work hardened : 42-45 HRC
This is a low heat input electrode suitable for surfacing, WELDING PROCEDURE
building up and joining of austenitic manganese
steels of plain & alloy types. The austenitic deposit 14% Mn steel should never be preheated for
is more resistant to cracking, deformation and heat welding.
embrittlement. The deposit is tough to withstand metal Welding should be done in stringer beads directing
to metal impact. It resists wear under rolling abrasion at the towards the weld pool.
high contact pressures. Heat input to the base metal should be kept minimum,
ALLOY BASE: Fe, C, Mn, Ni if required skip welding/back step welding can be
SPECIAL FEATURES adopted.
Reclamation Consumables
Graphite free coating avoids carbon pick-up. The weld bead must be peened with ball pen hammer
immediately after welding.
Deposit gives high strength, combined with excellent
resistance against impact. Quenching has no adverse effect on welding and
should be adopted whenever possible after slag
Smooth are, fine ripples and a fluid but controlled removal and peening. If possible the Mn steel job
slag, which is easily detachable. can be submerged in water during welding.
APPLICATIONS
Manganese steel shovel bucket teeth & lips, pulverizing CURRENT RANGE : (AC 70, DC±)
hammers, beaters, grinding ring & rollers, gyratory Size Length Current Range
crusher mantle and liners, cone and ring, jaw crusher (mm) (mm) (Amp)
plates etc.
3.15 450 80-100
4.00 450 110-160
5.00 450 180-225
150
TERROWELD 35 APPLICATIONS
Hardfacing of rollers, tractor idler wheels, brake shoes,
Low heat deposit for impact and pressure mine car wheels, drive sprockets, conveyor parts, gear
A hardfacing electrode for operation at low heat teeth, briquette press, crane wheels, concrete mixer
input depositing a tough air hardening alloy, giving a blades, mill pinions, knife edges etc.
combination of moderate abrasion and good impact PROPERTIES
resistance as encountered in rolling, reciprocating and
sliding systems. Hardness : 33-36 HRC
ALLOY BASE: Fe, Cr, Mn CURRENT RANGE : (AC 50, DC±)
SPECIAL FEATURES Size Length Current Range
(mm) (mm) (Amp)
Low heat formulation.
Tough machinable deposit. 3.15 450 75-110
Reclamation Consumables
4.00 450 110-160
5.00 450 140-185
OK 84.80 APPLICATIONS
Exhaust fans
Complex high pressure abrasion upto 800°C Ash ploughs
OK 84.80 is a high-recovery electrode which deposits a Conveyor screws
high density of wear-resistant carbides in an austenitic
matrix, resistant to extreme abrasion up to 800°C. Sinter plant components
While this electrode is best to solve most critical wear
CURRENT RANGE : (DC+, AC 65V)
problem at high temperature, at room temperature also
it performs batter than any chrome-carbide electrodes. Size Length Current Range
The weld metal is resistant to oxidation and corrosion (mm) (mm) (Amp)
upto 1100° C. 3.25 450 90-120
ALLOY BASE: Fe,C,Si,Mn,Cr,Mo,Nb,W,V 4.00 450 110-220
5.00 450 190-290
151
OK 84.84 Distribution of light micro carbides for resistance to
abrasion by fine particles.
64 HRC in a single layer for extreme abrasion APPLICATIONS
OK 84.84 has been developed with unique alloying Side ribs of oil drill bit and tricone rock roller bit. New line
generating a microstructure so far unknown to concrete mixture paddies, dredger bucket tooth area.
metallurgists all over the world. This carbide system Concrete mixer paddies, dredger bucket tooth area.
assumes a high packing density leaving virtually no
matrix unsheltered. Dilution of carbide in base metal is PROPERTIES
minimal as expected from the super convex bead shape. Hardness : 62-64 HRC on first layer
This results in full harness attainment in one layer itself
CURRENT RANGE : (DC+, AC 70)
and uniform hardness throughout the bead..
ALLOY BASE : Fe, Si, C, Cr, Ti, B Size Length Current Range
(mm) (mm) (Amp)
Reclamation Consumables
SPECIAL FEATURES
Hardness of 64 HRC in the first layer. 3.20 450 100-150
4.00 450 110-200
Full and uniform hardness in one layer only.
OK 84.52 APPLICATIONS
The electrode is suitable for hardfacing, shafts, racks
Low heat input electrode for abrasion and corrosion and pinions, links and pins, valve seats of cast steel,
resistant mixer arms, feed gears, knives, loading buckets and
A hard surfacing electrode depositing carbides in a track rollers.
fully martensitic matrix. The deposit is highly resistant PROPERTIES
to abrasion and corrosion. It has comparatively easy
striking and re-striking properties with smooth and stable Hardness : 54-60 HRC
arc and low spatter. CURRENT RANGE : (DC(+), AC OCV 65V)
ALLOY BASE : C, Si, Mn, Cr
Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
Resistant to abrasion and corrosion.
3.20 450 110-150
Positional welding possible. 4.00 450 145-200
Supplied in vacuum packed wrappers. 5.00 450 190-270
152
Cobalarc
Reclamation Consumables
the preformed carbides are put inside a hollow mild for oxidation. The outer coating contains ingredients
steel tube. that burn in the welding arc and generate copious
In hardfacing controlling the heat input is amount of fumes, which provides the shielding to the
important because greater dilution will lower the weld pool.
hardness of the deposit. In this respect, Cobalarc This outer coating has one more function. Since it
gives a major headway because only a thin walled contains non-hygroscopic stabilizers the mild steel
tube has to be melted instead of a solid wire. So tube is free from rusting giving these electrodes an
the heat requirement will be considerably less and indefinite shelf life. The rigid tube also protects the
automatically the heat input will really be low. preformed carbides from degeneration over time.
The low heat input also reduces the heat-affected
zone in the base metal.
153
COBALARC 1M Non-hygroscopic coating needs
precaution – infinite shelf life.
no storage
12-14% manganese steel components. applications which call for oxidation resistance.
SPOT COLOUR: YELLOW
PROPERTIES
ALLOY BASE: Fe, C, Cr, Si
Hardness : 55-59 HRC
SPECIAL FEATURES
Exceptional resistance to severe abrasion and CURRENT RANGE : (AC 70, DC±)
moderate impact. Size Length Current Range
Oxidation resistance at elevated temperatures. (mm) (mm) (Amp)
Unmatched deposition rates - high integrity 5.0 400 90-130
deposits. 6.3 450 120-140
Compared to solid cored electrodes, the current 8.0 450 140-170
requirement is low so the dilution by parent metal is 10.0 450 180-200
contained to a minimum.
154
COBALARC 4 Unmatched deposition rates - high integrity
deposits.
Preformed tungsten carbides for high pressure Compared to solid cored electrodes, the current
abrasion requirement is low so the dilution by parent metal is
Cobalarc 4 is the ultimate in welding technology. contained to a minimum.
It has autogenous fume shielding over preformed Non-hygroscopic coating needs no storage
carbides in a tubular form, which gives the user genuine precaution – infinite shelf life.
low heat input and infinite shelf life by dint of its non- APPLICATIONS
hygroscopic coating.
Rock drill bits, oil well drills, churn drills, sand gravel
The electrode deposits fine tungsten carbide embedded chutes, coal cutter bits and picks, bulldozer end plates,
in a hard and tough martensitic-austenitic matrix, which grader end bits, feed screens, scraper for sand and
is suitable for extreme abrasion with low to moderate refractory materials, fan and pump impellers, pug mill
Reclamation Consumables
impact. It resists all forms of abrasion and wear. augers and knives, choppers, post hole auger teeth,
Deposition efficiency is very high when compared with feed screws, mixer blades/paddles etc.
coated electrode.
SPOT COLOUR: PINK PROPERTIES
ALLOY BASE: Fe, W, C, Co Hardness : 57-63 HRC
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC±)
Exceptional resistance to severe abrasion and Size Length Current Range
moderate to heavy impact at low to medium (mm) (mm) (Amp)
temperatures.
5.0 400 90-120
Low spatter level.
6.3 450 120-140
155
Cast Iron Electrodes
156
TERROWELD CLH APPLICATIONS
Pump housing, machine casing, rotor bodies, cast
Buffer for oil soaked & dirty cast iron frames & cover, gear box, flywheel, oil soaked castings,
A cast iron welding electrode for operation at low heat ash pipes, oxidized cast iron furnace equipment, discs,
input depositing a non-machinable weld. The electrode etc.
is recommended for buttering of oily, greasy, and dirty
cast iron to avoid contamination in the final welding. It PROPERTIES
is suitable for non-critical welding in cast iron with high UTS : 55-60 kg/mm2
preheat.
WELDING PROCEDURE
It is also suitable for welding in deep holes and tight cor-
Preheat the job uniformly to 250°-350°C.
ners for all types of sections giving good colour match-
ing as the deposit oxidizes in a similar fashion. Stringer bead to be used.
Reclamation Consumables
ALLOY BASE: Fe, Mn, Si
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC±)
Spray type deposit insensitive to contamination. Size Length Current Range
(mm) (mm) (Amp)
Good colour match.
Can be used in final layer to give hardness and wear 3.15 450 100-130
resistance. 4.00 450 130-170
5.00 450 160-200
FERROLOID 1 APPLICATIONS
Repairing of cracks and for depositing buffer layer
Excellent colour match with all cast irons prior to building up with nickel-copper types of weld
Ferroloid 1 is a monel-cored electrode depositing metal, rebuilding of broken, cracked, worn-out cast iron
a weldmetal, which bonds easily and matches in castings, gear teeth, pump impellers, pump casing etc.
colour with cast iron. Weld deposit is soft, ductile and Pipes, especially with heavy wall thickness, can be
machinable. It is very effective for defect correction in welded in circumferential positions without cracks.
foundries. It is excellent for joining cast iron to steel.
PROPERTIES
ALLOY BASE: Ni, Cu, Fe
UTS : 35-40 kg/mm2
SPECIAL FEATURES
Smooth and stable arc with low spatter. · Excellent CURRENT RANGE : (AC 50, DC±)
colour match. Size Length Current Range
Good machinability. (mm) (mm) (Amp)
Slag is easily detachable. 3.15 350 75-95
4.00 350 100-130
5.00 350 130-160
FERROLOID 3 APPLICATIONS
Joining of cast iron components, welding of cast iron
Strength joints in grey and nodular cast iron to steel, rectification and build-up of defective castings
A nickel-alloyed machinable electrode for welding and giving good colour matching. Repairing of complicated
repairing of all cast irons. The electrode deposits a high and cracksensitive castings involving hydrostatic
strength weld metal combined with good toughness of pressure and dissimilar thickness, heavy sections
the weld joint, thus making it suitable for joining cast iron and joints under restraint such as pumps, differential
to mild steel. housing, cast iron dies etc.
ALLOY BASE: Ni, Fe, Si PROPERTIES
SPECIAL FEATURES UTS : 37-43 kg/mm2
Strength joints with low heat. WELDING PROCEDURE
Good machinability. Clean the weld area of all scales, grease and dirt.
Slag easily detachable. The smallest possible electrode diameter and the
lowest possible current should be used.
(Contd...)
157
Skip welding sequence may be used. CURRENT RANGE : (AC 50, DC±)
When welding thick sections and malleable irons, Size Length Current Range
preheating to about 250-300°C is advisable to (mm) (mm) (Amp)
minimize the shrinkage stresses and cracking.
3.15 350 65-95
On completion the casting should be allowed to cool 4.00 350 85-115
slowly. 5.00 350 140-160
FERROLOID 4 APPLICATIONS
Reclamation of castings and machine parts, filling-in of
Nickel based ductile electrode for cast iron blow holes in castings, joining cast iron to steel etc.
A Nickel-cored electrode depositing an almost pure
Reclamation Consumables
PROPERTIES
nickel weld metal suitable for joining and repairing gray
cast irons as well as for joining cast iron to steel, giving UTS : 28-31 kglmm2
an easily machinable deposit.
ALLOY BASE: Ni,Si CURRENT RANGE & PACKING DATA
SPECIAL FEATURES Size Length Current Range
(mm) (mm) (Amp)
Smooth and stable arc with low spatter. · Excellent
weld bead appearance. 3.15 350 65-95
Slag is easily detachable. 4.00 350 80-130
5.00 350 90-140
OK 92.18 PROPERTIES
UTS : 36-38 kg/mm2
State-of-the-art fail-safe cast iron electrode
WELDING PROCEDURE
OK 92.18 is the latest generation low heat electrode for
most fail-safe welding of cast iron. It deposits an ex- Welding area should be cleaned of scales, grease,
tremely soft and ductile weld metal. The weld metal has oil impurities and dirt.
very high crack-resistance and easy machinability. The Cracks should be absolutely removed by gouging or
welding arc is smooth, stable and with a controlled pen- cutting with OK 21.03.
etration to ensure reduced base metal dilution. Welding should be done in stringer beads/skip
ALLOY BASE: Ni,Si, Fe, welding/backstep welding.
SPECIAL FEATURES When welding thick sections, preheating upto
Superb slag detachability. 150-200°C will keep the weld more ductile.
Excellent weld bead appearance. Reinforcing studs should be used when the volume
of weld metal required is more.
Preheat is seldom necessary.
Light peening of the weld metal is advisable at hot
Barium Free stage to minimize shrinkage stresses.
APPLICATIONS
Ductile repairs and build-up of cast iron components, CURRENT RANGE : (AC 50, DC±)
salvaging of casting defects like blowholes, pit marks Size Length Current Range
& scratches, reclaiming gears and pulleys, water pump (mm) (mm) (Amp)
housings, cylinder blocks, lathe beds. Buttering cast
3.20 350 90-140
iron sections before joining with iron-nickel alloy con-
4.00 350 110-170
sumables.
158
OK 92.58 and pulleys, sliding tables for machine tools, cylinder
blocks.
Strength welding for all cast irons
PROPERTIES
OK 92.58 is a new generation alloy electrode for welding
and repairing of malleable and grey cast irons, and UTS : 44-47 kg/mm2
difficult-to-weld cast irons viz. S.G. iron. WELDING PROCEDURE
The weldmetal is machinable, possesses high strength Clean the weld area of all scales, grease and dirt.
coupled with good toughness, thus making it suitable
The smallest possible electrode diameter and the
for joining cast iron to steels and filling-up cavities in
lowest possible current should be used.
castings.
Skip welding sequence may be used to limit the
ALLOY BASE: Ni, Fe, Mn, Si
heating of the base metal.
SPECIAL FEATURES
Reclamation Consumables
Although mostly preheating is not required, when
Smooth bead consists of fine ripples. welding thick sections and malleable irons, preheat-
Excellent slag peel-off. ing to about 250-300°C is advisable to minimize the
Barium Free shrinkage stresses and cracking.
APPLICATIONS Just after welding the joint can be lightly peened and
Joining of cast iron components, welding of cast iron should be allowed to cool slowly.
to steels, rectification and build-up of defective castings CURRENT RANGE : (AC 50, DC±)
giving good colour match. Repairing of complicated and
Size Length Current Range
cracksensitive castings involving hydrostatic pressure
(mm) (mm) (Amp)
and dissimilar thickness, heavy sections and joints
under restraint such as pumps, differential housings, 3.20 350 60-120
cast iron dies, etc. Other applications are cast iron gears 4.00 350 90-150
OK 92.60 PROPERTIES
UTS : 56-61 kg/mm2
The last word in cast iron welding
WELDING PROCEDURE
OK 92.60 is latest development in cast iron welding.
With a specially designed slag it can weld extremely Clean the weld area of all scales, rust, grease and
difficult to weld cast irons, in all positions. The refining dirt.
action of the slag prevents hot shortness in high sulphur Use the smallest possible electrode diameter.
cast iron, giving a sound radiographic joint. OK 92.60 has high current capacity, so for big jobs
The weld deposit produced has exceptional strength use sufficient current for proper base metal fusion
over those created by run-of-the-mill cast iron electrodes. and bonding.
For repairing thick joints in cast iron it provides fail-proof One may use skip welding sequp.nce to limit the
performance and prolonged service life. heating of the base metal.
It can also be used for radiographic quality joints between Although preheating is not required in most cases,
cast iron and stainless steel/mild steel/manganese steel/ when welding complicated castings preheat to about
Inconel alloys. 250-300OC to minimize the shrinkage stresses gen-
ALLOY BASE: Ni, Fe, Mn erated in the base metal.
SPECIAL FEATURES Just after welding peen the joint lightly with ball pen
High quality joints in any critical cast iron repairs. hammer and cool slowly.
Nitrogenous slag gives clean inclusion-free joint.
CURRENT RANGE : (AC 50, DC±)
Barium Free.
Size Length Current Range
APPLICATION
(mm) (mm) (Amp)
OK 92.60 is applicable for any cast iron application -
joining buffering and surfacing. Applications involving 3.25 350 75-150
high joint strength and fatigue in service condition should 4.00 350 90-175
be welded only with this grade.
159
ESAB 802 KG ingot moulds etc. Rectification and build-up of defective
castings in cast iron foundry giving good colour matching
Economical strength welding of cast iron and also for welding of cast iron to steel.
A nickel-iron alloy, low heat input electrode designed PROPERTIES
to weld all weldable cast irons. Weld metal is fully UTS : 38-40 kg/mm2
machinable with good strength that helps in the
rectification of defects in heavy casting and for welding CURRENT RANGE : (AC 50, DC±)
of cast iron to mild steel. Suitable for nodular cast iron
repairs. Size Length Current Range
(mm) (mm) (Amp)
ALLOY BASE: Ni, Fe, Si
2.50 350 40-65
SPECIAL FEATURES
3.15 350 50-90
Versatility in usage. 4.00 350 80-125
Reclamation Consumables
160
Steel and Dissimilar Joining Alloys
Reclamation Consumables
steel or any nickel based consumable. Otherwise, the Welding theory says that all these steels can be
lower alloyed surface can be buttered with an over- welded with matching ferritic consumables with proper
alloyed stainless weld metal and then the groove can be preheating and post-weld heat treatment (PWHT).
filled up with a consumable matching with the stainless But repair welding, by nature, does not always allow
side. The welding can usually be performed without preheating or PWHT. Therefore, the safest way is to weld
preheating. However, if there is any recommendation with austenitic stainless or nickel-based consumables.
for that particular grade of steel, then that has to be The risk of cracking due presence of hydrogen is
followed. neutralized by the greater solubility of hydrogen in
WELDING MANGANESE STEELS austenite and also by the higher ductility of the weld
Manganese steel typically contains 11-14% manganese metal. For welding steels of unknown composition,
and 1.0-1.4% carbon. Some other grades can have the best choice is a ferritic-austenitic duplex type of
other minor alloying elements. This steel has an ability consumable.
to workharden e.g. under high impact and/or high WELDING TOOL STEELS
surface pressure. These steels have to be reconditioned Tool steels have a higher carbon content along with
by repairing cracks or breakages, rebuilding worn out chromium, nickel, molybdenum, vanadium and are
portions and hardfacing to extend service life. generally heat-treated to achieve certain specific
Weldability of manganese steel is governed by the fact properties.
that it tends to become brittle when reheated and slow- The repair welding of tool steels without changing
cooled. Consequently, the interpass temperature should their inherent properties is very difficult. This calls
not exceed 200°C. As a result, during welding of these for use of consumables producing a weld metal with
steels, the following matters should be noted : matching composition, microstructure and properties.
the heat input should be as low as possible But practically, this is very difficult as it involves scaling
stringer beads should be used change of dimension and time.
simultaneous working with several components The welding is simplified by using specific consumables
should be done, as far as practicable developed for tool steels:
the component can be cooled by putting it in cold Shock resistance, toughness, Straight chrome
water abrasion resistance martensitic deposit
Welding manganese steel involves anyone of the fol- Hot strength, abrasion Fine carbides in
lowing cases: resistance at high temperature martensitic matrix
joining manganese steel to itself or to unalloyed, low Edge retention at high High speed
alloy steel temperature, impact toughness steel deposit
rebuilding worn out surfaces The welding is done by preheating the job to 200-500°C
For joining manganese steels and manganese steels to (as per the type of steel) and maintaining it during the
carbon steels, austenitic stainless consumables have to course of the welding. The preheating and PWHT to be
be used to obtain a tough and strong joint. followed can be found in different international standards
like SAE/AISI.
Prior to surfacing also it is advisable to add a buffer
layer of austenitic stainless consumables. On top of
that regular 13% manganese type deposit is put as the
surfacing layer.
161
TERROWELD DMS APPLICATIONS
Joining thin sheets at high speed, welding boiler quality
High speed touch welding electrode for x-ray steels, ship plates, and general repair and maintenance
quality operation of containers, air conditioning units, ducts,
Auto-run Terroweld DMS is characterized by ‘Push-arc’ tanks, bus bodies, for great finish and shiny bead
that speeds up the output even for unskilled welders. The appearance.
low heat electrode is preferred to any similar electrode
due to its very high speed of welding and ability to PROPERTIES
weld thin sheets without burn-through. Terroweld DMS UTS : 47-52 kg/mm2
is suitable for touch welding in all positions, so even Elongation : 24-28%
unskilled welders can give X-ray quality welds.
CURRENT RANGE : (AC 50, DC±)
No slag cleaning is required by the welder since
Reclamation Consumables
the nonsynthetic slag detaches itself from the bead Size Length Current Size Length Current
automatically. (mm) (mm) Range (mm) (mm) Range
ALLOY BASE: Fe, Mn, Si (Amp) (Amp)
ESAB 116 steel, and chemical plant parts where Ni-Cr-Mo steels
are used. It is suitable for build-up and repair of forge
Low heat electrode for very high tensile strength dies. The maintenance of strength upto 538°C renders
joining it usable on steam turbine rotors that operate upto this
A medium-to-heavy coated electrode, Esab 116 gives temperature.
a hydrogen-controlled deposit for welding high-tensile PROPERTIES:
low-alloy steels. The deposit has excellent resistance UTS : 95 – 106 kg/mm2
to creep and has a high corrosion resistance. It is used Elongation : 15 - 18%
regularly for repairs of hot dies.
CURRENT RANGE (AC 70, DC±):
SPECIAL FEATURES
Resists annealing Size Length Current Range
Stupendous weld strength (mm) (mm) (Amp)
Weld deposit is insensitive to hot cracking 2.50 350 60-90
APPLICATIONS 3.15 450 100-140
Recommended for joining and repair of machine parts 4.00 450 130-180
fabricated out of high tensile steels. It is also suitable 5.00 450 170-230
for automotive parts, specific grades of armour plate
(Contd...)
162
PROPERTIES CURRENT RANGE : (AC 50, DC+)
UTS : 44-48 Kg/mm 2
Size Length Current Range
Elongation (l = 4d) : 28-32% (mm) (mm) (Amp)
Reclamation Consumables
Terroweld DBL deposits a high strength low alloy weld on pipes, flanges, pressure vessels, cross members,
metal recommended for building up and joining of low, gun plates, steel castings, heavy machine components,
medium carbon and low alloy steels. It is also suitable etc.
for giving buffer layers on medium and high carbon Perfect in welding steels like free-cutting steels, where
steels prior to hard surfacing. sulphur and other alloys are added.
The weld deposit is extremely ductile and crack resistant.
Produces excellent result in highly constrained heavy PROPERTIES
machinery joining. UTS : 52-55 kg/mm2
Low heat formulation suitable for joining thin section Elongation : 28-32%
without risk of burn-through.
CURRENT RANGE : (AC 50, DC±)
ALLOY BASE: Fe, Mn, Si, Ni
Size Length Current Size Length Current
SPECIAL FEATURES
(mm) (mm) Range (mm) (mm) Range
Super-ductile weld. (Amp) (Amp)
Suitable for high speed welding. 3.15 450 90-135 3.15 350 90-135
Bonds easily with parent metal. 4.00 450 140-165 4.00 350 140-165
5.00 450 170- 220 5.00 350 170- 220
163
DUROCHROME APPLICATIONS
Welding of high strength alloy steels, dissimilar joints,
Dissimilar and unknown steel strength joining rebuilding of chemical agitator blades, shafts, rolling
Esab Durochrome is an electrode for welding complex mill spindles, bucket lips, steel mill wobblers, coupling
dissimilar alloys and high strength steels with low heat boxes, mill hammers, bar mill guides, sinter plant parts,
input giving sound joints, free from any cracks and etc.
fissures. The electrode is also suitable for depositing Joining and surfacing of high carbon, low and high alloy
buffer layers prior to hard surfacing on high strength and steels, tool steels, spring steels, manganese steels,
high alloy steels. case hardening steels, etc.
The deposit is corrosion resistant and resists high PROPERTIES
temperature oxidation. It provides excellent metal to
metal frictional resistance. UTS : 77-82 kg/mm2
Elongation : 30-35%
Reclamation Consumables
(Contd...)
164
Repair and surfacing of gears, spindles, worn out CURRENT RANGE : (AC 70, DC±)
sprockets, valves, rolls, pinions, hot dies, reinforcing Size Length Current Range
of manganese steel components, salvaging of broken (mm) (mm) (Amp)
rolling mill spindles, hydel turbine blades, trash beams,
etc. 2.50 350 60-90
3.15 350 70-100
PROPERTIES
4.00 350 100-130
UTS : 72-80 kg/mm2 5.00 350 110-140
Elongation : 29-34%
Reclamation Consumables
Strength joining for dissimilar and unknown steels box casing, rolling stock couplings, universal coupling,
Terroweld DS3 deposits a high ferrite stainless steel chassis frames, shovel booms, wobblers, kiln tyres,
deposit suitable for joining, building up and buffering hammer shafts etc.
applications. The specially designed microstructure of Also used as a buffer layer before hard surfacing of
the weld deposit ensures superior resistance to crack, mining and earth-moving machinery.
corrosion and oxidation. The electrode is suitable for PROPERTIES
joining dissimilar, unknown and difficult to weld steels.
It is suitable for welding thick sections with deep groove UTS : 80-86 kg/mm2
in all positions. Weld deposit is of excellent quality Elongation : 30-34%
ensuring fail-safe performance.
ALLOY BASE: Fe, Cr, Ni, Mn, Si
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC±)
Deposit gives high strength, combined with excellent Size Length Current Range
resistance against impact, friction. (mm) (mm) (Amp)
165
TERROWELD DS6 for separate electrodes for joining the points & cross-
ings and hardfacing.
Single electrode for railway points and crossings PROPERTIES
Terroweld DS6 is a heavy-coated basic electrode for UTS : 59-65 kg/mm2
applications, which demand resistance to high abra- Elongation : 18-22%
sion coupled with heavy to moderate impact. It is a very
smooth running electrode having very good slag de- Hardness : As deposited : 22-26 HRC
tachability and bead appearance. Work hardened : 40-44 HRC
The weld deposit consists of fine austenite grains with WELDING PROCEDURE
about 5% carbide precipitated at the grain boundaries. Welding is recommended to be done by stringer
ALLOY BASE: Fe, Cr, Ni, Mn, Mo beads.
SPECIAL FEATURES All precautions, as necessary for welding manganese
Reclamation Consumables
166
SPECIAL FEATURES WELDING PROCEDURE
Suitable for all position welding. The weld area should be cleaned of all dirt, grease
Finely rippled bead with minimum spatter and easy and oil.
detachability of slag. Stringer beads are preferable, maintaining a short
APPLICATIONS arc.
Terroweld S2 is recommended for corrosion resistance Smaller size of electrode should be used wherever
welds on 18/8 Mo stainless steel, especially 316 & 316L practicable.
types. It is also suitable for protective overlay on 315, CURRENT RANGE : (AC 70, DC±)
318, 329 steels for medium hardness, for high corro- Size Length Current Range
sion resistance, for restrained joints and crack sensitive (mm) (mm) (Amp)
alloys.
2.50 350 45-70
PROPERTIES
Reclamation Consumables
3.15 350 60-100
UTS : 62-64 kg/mm2 4.00 350 90-130
Elongation : 34-39% 5.00 350 110-160
167
WELDING PROCEDURE If required the Mn steel job may be submerged in
14% Mn steel should never be preheated for water during welding.
welding.
CURRENT RANGE : (AC 70, DC±)
Heat input to the base metal should be kept
minimum. Size Length Current Range
(mm) (mm) (Amp)
The weld bead may be peened with ball pen hammer
just after welding. 3.15 350 100-150
4.00 350 150-200
Quenching has no adverse effect on welding and
5.00 350 200-250
should be adopted whenever possible after slag
removal and peening.
OK 68.82
Reclamation Consumables
APPLICATIONS
Joining unknown steels, steels of limited weldability, and
Versatile electrode for joining any steel to any steel dissimilar steel joining.
OK 68.82 deposits a high strength oxidation and corrosion Reclamation of shafts, universal coupling, gear teeth,
resistant weld metal suitable for dissimilar steel joining pump casings, rolling mill spindles, buffer layers prior to
and building-up applications. The weld metal, being free hardfacing in mining and earthmoving equipment, coal
from dilution effects and having high strength combined pulverisers, pinions, crusher roller gears etc.
with good elongation, can successfully join thick section
of any unknown steel and steels which are difficult PROPERTIES
to join. UTS : 79-86 kg/mm2
The high scaling temperature of weld metal makes the Elongation : 22-29%
electrode usable for working at high temperatures.
CURRENT RANGE : (AC 70, DC±)
ALLOY BASE: Fe, Cr, Ni, Mn
Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
Extremely smooth running performance.
2.50 350 50-80
‘Fail-safe’ alloying.
3.15 350 75-110
Bonds with any steel. 4.00 350 100-140
Self-releasing slag. 5.00 350 130-160
168
OK 69.33 corresponding composition. This type of steel has better
resistance to sulphuric acid. OK 69.33 is recommended
Increased resistance to acid corrosion for Swedish Standard steel SS 2562. Avests 254 SLX
OK 69.33 is a basic-rutile stainless steel electrode which UHB 904L. Sandvik 2RK 65, 2 RN 65. This electrode
deposit weld metal with batter corrosion resistance to can be successfully applied in the pipe line, storage
sulphuric acid than lower alloyed weld metal of AISI 316L tank, pump and other equipments handling sulphuric,
and 317L type. The weld metal of OK 69.33 also has phosphoric, acetic, oxalic, formic and fatty acids.
good resistance to intergranular and pitting corrosion. PROPERTIES
ALLOY BASE: C, Si, Mn, Cr, Ni, Mo, Cu Yield stress : 38-42 Kg/mm2
SPECIAL FEATURES: UTS : 56-60 kg/mm2
Fully austeristic deposit. Elongation : 35%
Increased resistance to sulphuric, phosphoric, ace- CURRENT RANGE : (DC+, AC>65
Reclamation Consumables
tic acid. Size Length Current Range
All positional, smooth arc and ripple free welding. (mm) (mm) (Amp)
APPLICATIONS 2.50 300 60-90
OK 69.33 is designed for welding of stainless steel with 3.20 350 85-130
4.00 350 120-180
TERROCHROME APPLICATIONS
Welding of high strength alloy steels, difficult-to-weld steels,
Value-for-money dissimilar steel strength joining dissimilar joints, re-building of chemical agitator blades,
This is a rutile electrode for welding complex dissimilar shafts, rolling mill spindles, bucket lips, coupling boxes,
alloys and high strength steels with low heat input, giving mill hammers, bar mill guides, sinter plant parts etc.
sound joints free from any cracks and fissures. Also PROPERTIES
suitable for depositing buffer layers prior to surfacing on UTS : 79-85 kg/mm2
high strength and high alloy steels. The deposit is corrosion
resistant and resists high temperature oxidation. Elongation (l=4d) : 20-30%
SPECIAL FEATURES: CURRENT RANGE : (DC±, AC 70
Smooth arc, a ripples and a fluid, controlled, and Size Length Current Range
(mm) (mm) (Amp)
easily detachable slag.
The duplex stainless steel weld metal is tolerant to 2.50 350 40-65
dilution from hostile base metals. 3.15 350 55-95
4.00 350 85-135
Excellent crack resistance and high strength 5.00 350 110-165
169
Non-Ferrous Alloys
WELDING NON-FERROUS
ALLOYS
NICKEL AND NICKEL ALLOYS
Nickel and nickel based alloys are used in industrial
applications for:
corrosion resistance
heat resistance and high temperature properties
cryogenic properties
Preheating is not normally required unless there is a risk
of porosity from moisture condensation. PWHT is not
Reclamation Consumables
170
ESAB CN 1G APPLICATIONS
ESAB CN1 G is ideally suited for joining Inconel, Incoloy,
Excellent high temperature and corrosion etc. and their combination with stainless steels.
resistance
PROPERTIES
Esab CN1 G is an electrode designed to deposit weld with
excellent resistance to corrosion and oxidation. It provides UTS : 60-64kg/mm2
superior strength at temperatures above 650°C. YS : 40-44 kg/mm2
ALLOY BASE: Ni, Cr, Fe, Mn, Mo Elongation : 30-40%
SPECIAL FEATURES CURRENT RANGE : (AC 70, DC+)
Smooth and stable arc with low spatter loss. Size Length Current Range
(mm) (mm) (Amp)
Excellent resistance to acid corrosion.
Superior strength at higher temperatures.
Reclamation Consumables
3.15 350 80-120
4.00 350 100-160
5.00 350 140-190
171
OK 92.35 APPLICATIONS
Repair and hardfacing of hot pressing tools, hot forging
Strength, hardness and impact properties at high dies, hot shear blades, hot trimming dies, joining of
temperature and corrosive media Nimonic and Inconel alloys, valves, stirrers and pump
OK 92.35 is a nickel based superalloy electrode, which components requiring wear, oxidation and corrosion
offers resistance to most common acids. resistance.
The weld metal obtained is machinable and retains Also recommended for overlaying or joining dissimilar
hardness even after prolonged heating at high temper- superalloys like Hastalloy, Inconel, etc., and for joining
atures. Tensile strength of the weld metal at 800°C is these alloys to mild, low alloyed and stainless steels.
about ten times higher than mild steel which implies that PROPERTIES
resistance to deformation from static and cyclic loading
is much superior. UTS : 54-62 kg/mm2
Hardness : 25-30 HRC
Reclamation Consumables
OK 93.60 APPLICATIONS
Hardfacing parts subject to wear at elevated
Resistance to high temperature wear temperatures, also in corrosive environment. Surfacing
A cobalt base electrode depositing a Co-Cr-Walloy high of hot rolls, kneading rolls, press screws, band screws,
in carbon. The weld metal has excellent resistance skid buttons, dies, valves, burner nozzles, drawing
to friction, abrasion, impact, corrosion, oxidation valves, seats, steam ends etc.
and abrasion at high temperature. The alloy resists PROPERTIES
spalling due to thermal cycling exceptionally and is
characterized by its spatterless smooth arc and easy Hardness : at 20°C : 52-55 HRC
slag detachability. at 600°C : 40-44 HRC
at 800°C : 30-34 HRC
ALLOY BASE: C, Cr, W, Fe, Co
CURRENT RANGE : (DC+, AC)
SPECIAL FEATURES
Size Length Current Range
Only solution to complex wear system. (mm) (mm) (Amp)
Minimal loss of costly weld metal by minimizing
3.20 350 70-110
spatter
4.00 350 110-160
Shining bead finish.
172
PROPERTIES CURRENT RANGE : (DC+)
UTS : 64-68kg/mm2 Size Length Current Range
(mm) (mm) (Amp)
YS : 40-42 kg/mm2
Elongation A4, % : 40% 2.50 300 50-80
3.20 350 90-130
4.00 350 120-150
5.00 350 150-200
Reclamation Consumables
UTS : 46-53 kg/mm2
joining nickel and nickel and nickel alloys. The weld
deposit other than being highly ductile is resistant Elongation (l=4d) : 25-30%
to most common acids. It has smooth and pleasing
welding performance with low spatter and easy slag CURRENT RANGE : (DC+, AC70)
detachability.
Size Length Current Range
SPECIAL FEATURES (mm) (mm) (Amp)
Corrosion resistance.
3.15 350 60-120
Bonds with all ferrous and nickel-base metals. 4.00 350 90-170
APPLICATIONS
Joining nickel and nickel alloys, disimilar joining of nickel
with steels and copper as well as copper alloys. The
173
OK 93.66 WELDING PROCEDURE
Clean weld area for oil, grease and other impurities.
High temperature chemical inertness Preheat job wherever possible.
OK 93.66 deposits a highly crack resistant weld metal Hold electrode perpendicular to work piece and weld
of Stellite Gr. 6 type. The electrode is characterized by in stringer beads.
its spatter less smooth arc and easy slag detachability.
The weld metal has excellent resistance to friction, Maintain interpass temperature 300°C or lower.
abrasion, impact, corrosion and oxidation and abrasion Cooling should be slow.
at high temperature. These features make it suitable PROPERTIES
for combined wear conditions. The alloy resists spalling
Hardness : At 20°C As deposited : 39-42 HRC
due to thermal cycling and has good sliding properties.
Work Hardened : 43-46 HRC
ALLOY BASE: Cr, Co, C, W
At 750°C As deposited : 19-22 HRC
Reclamation Consumables
SPECIAL FEATURES
Work Hardened : 38-43 HRC
Retains about 40 HRC hardness at 750°C.
Only solution to complex wear system. CURRENT RANGE : (AC 70, DC+)
Exceptional resistance to corrosion.
Size Length Current Range
APPLICATIONS (mm) (mm) (Amp)
Hardfacing of parts subject to wear at elevated
3.20 350 70-100
temperatures and also in corrosive environment like hot 4.00 350 110-160
forging tools, hot shear blades and dies, cutting edges,
grab tongs, hot punches, knives, chemical valve seats,
steam ends, pump sleeves, wear pads, screw conveyors,
etc. in chemical, petroleum and sugar industries and
also in steel plants.
BRONZOID 1 APPLICATIONS
Welding and surfacing of copper brass and bronze,
Excellent welding of copper alloys cracked engine jackets, cylinder heads, electrical fit-
Bronzoid 1 is an electrode that provides an alloy suit- tings, propeller blades, pump parts, bearing bushing,
able for welding brass, bronze, deoxidized copper, cast shaft, castings, stampings and valves. Filling cavities in
iron, steels and dissimilar metals. copper alloy castings, joining copper and bronze to cast
It has easy slag detachability and produces homoge- iron overlays and steel.
neous and sound weld metal free from porosity and PROPERTIES
cracks. Excellent colour match on bronze. UTS : 28-36 kglmm2
ALLOY BASE: Cu, Sn, P Elongation : 18-26%
SPECIAL FEATURES
Smooth and stable arc with almost no spatter loss. CURRENT RANGE : ( DC+)
The deposit can be machined to a smooth finish with Size Length Current Range
low coefficient of friction. (mm) (mm) (Amp)
Resistance to marine and steam corrosion. 3.15 450 60-120
4.00 450 90-170
5.00 450 125-230
174
Cutting and Gouging Electrodes
Reclamation Consumables
later. Gouging of manganese steel can also be suitably
done.
175
TERROCUT APPLICATIONS
Cutting of mild steels, low carbon steels, manganese
Precision cutting electrode steels, cast iron, copper, manganese, aluminium, nickel
Specially designed electrode producing a highly forceful and their alloys, casting risers, gates, dressing for filling
and concentrated arc, which can be efficiently used for up, etc. Absolutely suitable for burning rivets, disman-
cutting and piercing holes in carbon steels, cast irons tling work at site and for cutting out unwanted metal in
and manganese steels. castings.
Terrocut does not heat up the material excessively due CURRENT RANGE : (AC 70, DC±)
to ionizing additives in coating design. This results in
Size Length Current Range
lower heat affected zone. (mm) (mm) (Amp)
SPECIAL FEATURES
3.15 300 160-250
High cellulose roaring arc. 4.00 350 220-300
Reclamation Consumables
OK 21.03 APPLICATIONS
Cutting, chamfering, gouging, and piercing of steel, cast
Single electrode for gauging,percision cutting and iron, copper and its alloys, aluminium and its alloys,
chamfering manganese, stainless steel, zinc, nickel and its alloys.
OK 21.03 has a specially developed coating which Used for beveling, for joint preparation, gouging of
produces a strong gas jet that blows away the molten cracks and back gouging of root runs especially when
material so that the electrode is absolutely suitable for welding of steel structures, storage tanks, etc. and for
gouging, cutting, chamfering, piercing, drilling holes. removal of unnecessary metal in castings.
It can be used in all positions except in vertical up. PROCEDURE
Grooves are even and smooth and subsequent welding Strike arc perpendicular to work piece.
can follow without further preparation since the volume
of slag is almost nil. Tilt the electrode at 10-15° and push forward.
With this electrode, the cutting and gouging activity can Move the electrode sequentially up and down to melt
be taken up without the necessity of any gas or special and remove metal.
electrode holder.
CURRENT RANGE : (AC 70, DC±)
SPECIAL FEATURES
Size Length Current Range
Roaring arc force. (mm) (mm) (Amp)
Thinner coating than other gouging electrodes -
better positional properties. 3.15 350 160-180
4.00 350 220-270
Excellent performance even under water. 5.00 350 240-320
Sharp and clean kerfs.
176
Flux Cored Wires
Reclamation Consumables
SPECIAL FEATURES Size Welding Current Voltage
No shielding gas is required. (mm) position (Amps) (Volts)
Equally suitable for flat and drooping characteristic 1.2 F.H.V.O 100-280 24-26
power sources. 1.6 F.H.V.O 110-350 22-28
2.0 F.H.V.O 220-400 25-29
177
CURRENT RANGE :
Diameter Welding Current Voltage
(mm) position (Amps) (Volts)
joining and cladding of 14% manganese steel. The weld UTS : 65-72 kg/mm2
metal, which is austenitic in nature, is ideal for buffering
applications on manganese steels and hardenable Elongation : 32-35%
steels for better impact toughness. Hardness : 20-22 HRC
ALLOY BASE: Fe, C, Cr, Mn, Ni CURRENT RANGE :
SPECIAL FEATURES Diameter Welding Current Voltage
(mm) position (Amps) (Volts)
Stainless steel wire - no risk of rusting.
Tremendous impact toughness. 1.6 F.H 150-300 30-37
2.4/2.8 F.H 300-450 30-37
178
OK TUBRODUR 15.52 APPLICATIONS
It is used widely for cost effective surfacing of earthmoving
Flux-cored wire imparting abrasion resistance equipment, agricultural implements and other material
OK Tubrodur 15.52 is an open-arc/gas-shielded/self- handling applications like augers, mixer blades and
shielded flux-cored wire, which deposits a martensitic vessels, scraper blades, cement mill crushers, and
weld metal containing some grain boundary carbides. quarrying components. It is specifically designed for
It works excellent for combined wear of low-pressure hardfacing of feed screws and ring grooves on diesel
abrasion and impact. The weld metal can only be motor pistons.
machined by grinding. PROPERTIES
This can also be used safely for multilayer build-ups. Hardness : 56-60 HRC
ALLOY BASE: Fe, C, Cr, Mn, Mo, Si
CURRENT RANGE : (DC+)
SPECIAL FEATURES
Reclamation Consumables
Diameter Welding Current Voltage
Flexibility of operation - can be used with or without (mm) position (Amps) (Volts)
shielding gas.
1.6 F.H 150-300 22-28
High hardness ensures resistance to abrasive 2.4 F.H 280-460 23-30
wear.
179
WELDING PROCEDURE FOR SUBMERGED ARC When multi-pass welding is being done, the inter-
WELDING pass temperature should preferably not fall below
OK Tubrodur 15.73 should be deposited on DC (±). 300°C.
Negative polarity gives a higher deposition rate and CURRENT RANGE : (DC±)
less fusion of the base material and is recommend-
Diameter Welding Current Voltage
ed when the minimum possible dilution of the weld (mm) position (Amps) (Volts)
metal is desired.
Except at the start, preheat is not required while 1.6 F.H 150-300 24-30
hardfacing solid carbon steel shafts having diameter 2.4 F.H 280-460 24-32
3.0 F 300-450 25-33
upto about 200 mm.
4.0 F 400-600 30-36
Reclamation Consumables
180
Gas Brazing Alloys
Reclamation Consumables
ment of the flux also affects the quality of the brazed
joint. Paste flux is the most common from and is usually Copper Neutral
spread over the surfaces to be joined. It is also painted Cupro-nickel Reducing
on the pre-placed brazing filler materials. Inconel Slightly reducing
Cast Iron Neutral
Wrought Iron Neutral
Monel Slightly reducing
181
RUPATAM 2 engineering for joints in motor windings, wires and
cables, braided conductor, system and other conductor
Brazing of copper and copper alloys assemblies where any risk of corrosion by flux must be
SPECIAL FEATURES avoided.
Strong clean ductile joints in copper and copper FLUX
alloys without flux. No flux for brazing of copper. In other cases use
Flame should be slightly oxidizing on copper and Rupatam A.
neutral on alloys. PROPERTIES
APPLICATIONS Melting Range 638 - 694OC
Extensive employment of the alloy in electrical Available DIA - (mm) - 1.6, 2.5, 3.15
Reclamation Consumables
RUPATAM 14 APPLICATION
Extensive employment of the alloy in electrical
Brazing of brass, bronze, molybdenum and silver engineering for joints in motor windings, wires and
SPECIAL FEATURES cables, braided conductor and other conductor
Rupatam 14 is used for obtaining strong, clean, and assemblies where any risk of corrosion by flux
high tensile brazed joints in brasses, bronzes. It also constituents must be avoided.
effectively joins silver and molybdenum. FLUX
It is not recommended for ferrous metals or alloys No flux for brazing of Cu. In other cases use
of high nickel content due to the possibility brittle Rupatam A.
phosphide formation. PROPERTIES
Flame should be slightly oxidizing on Cu and neutral Melting Range : 643-802oC
on Cu alloys. Available DIA - (mm) - 1.6, 2.5, 3.15
The deposit obtained has a high tensile strength.
RUPATAM 35 APPLICATION
It is an alloy suitable for general purpose work on
Brazing joints having non-uniform clearances engineering metals with excellent capillary flow with
SPECIAL FEATURES better ductility for filling gaps.
It can be used in operations requiring a slightly FLUX
higher brazing temperature. Rupatam A
The alloy is a free-flowing one with melting range for PROPERTIES
ensuring a good joint for joints where clearances are Melting Range : 607-702°C
not even uniform.
Available DIA - (mm) - 1.6, 2.0, 2.5, 3.15
RUPATAM 43 APPLICATION
Rupatam 43 can be used in brazing steel, copper,
Single brazing alloy for a range of applications brass, gunmetal, tin bronzes, aluminium and magne-
SPECIAL FEATURES sium bronzes, copper nickel alloys and nickel silver of
This alloy can be used in brazing operation requiring all varieties.
a low temperature giving a quick and complete FLUX
penetration. Rupatam A
It produces neat joints of very high strength that PROPERTIES
need little or no finishing. Melting Range : 608-617°C
It is essentially for use on joints that are closely Available DIA - (mm) - 1.6, 2.5, 3.15
fitted.
182
RUPATAM 50 APPLICATION
This alloy is ideally suited and used extensively for braz-
Brazing tungsten carbide tips ing carbide tool tips to tool shanks as it wets the tip beau-
SPECIAL FEATURES tifully. It is also suitable for brazing stainless steels.
This alloy has a wide wetting range, hence the solid FLUX
and the liquid portions do not separate. Rupatam A
Good corrosion resistance - brazing stainless PROPERTIES
steels. Melting Range : 632-688OC
Rupatam 50 is ideal for bridging gaps. Available DIA - (mm) - 1.6, 2.5, 3.15
RUPATAM 60 APPLICATION
This alloy is ideally suited and used extensively for braz-
Reclamation Consumables
Brazing alloy for joints requiring high electrical con-
ductivity ing electrical components requiring high electrical con-
SPECIAL FEATURES ductivity.
For brazing in applications needing high degree of FLUX : Rupatam A
electrical conductivity. PROPERTIES
Good colour match on silver. Melting Range :690-735OC
It is essentially for use on joints that are closely fitted. Available DIA - (mm) - 1.6, 2.5, 3.15
brazing tubular and sheet metal joining of steel, copper,
ESAB SILICON BRONZE galvanized iron. Also used for fusion welding of brass
Economic high strength brazing alloy and bronze. Use an oxidising flame.
SPECIAL FEATURES FLUX
Economy brazing for ferrous metals, copper and Brazotectic
copper alloys. PROPERTIES
Exceptional joint strength. Melting Point (approx.) : 875°C
APPLICATION UTS : 42-48 kg/mm2
Esab Silicon Bronze is an alloy that is ideally suited for Available DIA - (mm) - 1.6, 2.0, 2.5, 3.15, 4.0, 5.0
Esab Ruf-Kut deposits hard tungsten carbide in a tough to neutral for heating the tinned area.
but ductile nickel-silver matrix that results in maximum The carbide-bearing end is introduced into the flame
abrasion and impact resistance from media like sand, and the alloy is allowed to melt and flow on to the
earth, gravel and other minerals. This gives rise to a substrate. The temperature of bonding is 750-800°C.
superior cutting action. The carbides are angular and The carbide deposition to be uniformly maintained by
varied in size embedded in the matrix, which resists ex- rotating the rod.
tensive compressive stresses and impact loading. The work should be continued to heat, slightly ahead
High tensile strength and shear strength provides shock- of the overlay.
absorbing characteristics. Good tinning qualities. Overheating is to be avoided.
APPLICATIONS Cooling should be slow and the flux residue has to be
‘Widely used in oil, earth moving, agriculture, dredg- removed.
ing, brick and cement industries to overlay drills, ream- CARBIDE MESH SIZES
ers, stabilizers, core bits, augers, mill hammers, plough
-3.2 mm to +1.5 mm; -5.0 mm to +3.2 mm
shares, dredge bucket lips, crusher rolls, mixer blades
and pipe forming shoes. -6.0 mm to +5.0 mm; -10.0 mm to +6.0 mm
183
TIG Filler Wires
CRYSTALLOY 60 APPLICATIONS
Resurfacing and hardfacing of parts subjected to wear
TIG filler for resistance to combined complex wear at elevated temperatures and in corrosive environment.
Crystalloy 60 is an alloy that exhibits excellent resistance Valves, valve seats, hot forging tools, hot shear blades
to friction, abrasion, impact, corrosion & oxidation and & dies, hot punches, steam ends, pump sleeves, wear
abrasion at high temperature. Resistance to spalling pads, screw conveyors, etc. in chemical, petroleum,
due to thermal cycling is exceptional. The alloy has sugar and steel plants.
good sliding properties. PROPERTIES
Good resistance to abrasion, impact and oxidation, fric- Hardness As deposited Work Hardened
tion makes it suitable for combined wear. At 20°C: 39-42 HRC 43-46 HRC
ALLOY BASE: C,Cr,Co,W,Fe,Ni,Mo,Mn At 750°C: 19-22HRC 38-43 HRC
SPECIAL FEATURES
Reclamation Consumables
APPLICATIONS
Valves, valve seats, hot forging tools, hot shear blades
& dies, hot punches, steam ends, pump sleeves, wear
CRYSTALLOY 62 APPLICATIONS
Surfacing hot rolls, kneading rolls, press screws, band
TIG filler for resistance to high temperature wear saws, feeder screws, wood-working tools, valves, valve
Crystalloy 62 is an alloy that exhibits excellent resis- seats, hot forging tools, hot shear blades & dies, hot
tance to friction, abrasion, impact, corrosion, & oxidation punches, steam ends, etc.
at high temperature. The alloy has good sliding proper- PROPERTIES
ties giving rise to exceptional abrasion resistance. Hardness As deposited
Good resistance to abrasion, impact and oxidation, fric- At 20°C: 44-49 HRC
tion makes it suitable for combined wear.
At 600°C: 36-41 HRC
ALLOY BASE: C,Cr,W,Fe,Co
AVAILABLE DIA. (MM)
SPECIAL FEATURES
1.6, 2.4, 3.2, 4.0
Retains 40 HRC hardness at 600°C
Machinable by cemented carbide tools
CRYSTALLOY 80
exceptionally in both types of acids: reducing and
TIG filler for corrosion resistant monel coating oxidizing.
Crystalloy 80 gives a ductile and crack resistant weld It joins corrosion resistant Monel alloy used in petroleum
deposit that meets rigid requirements on corrosion and ammonium sulphate industry. This alloy is also used
resistance against seawater. The alloy also works by power plants and any plant that handles seawater.
(Contd...)
184
APPLICATIONS PROPERTIES
Seawater corrosion resistant overlay, joining Monel UTS: 50-56 kg/mm2
metal Elongation: 42-48%
AVAILABLE SIZES
1.2, 1.6, 2.0, 2.4, 3.2 mm
Reclamation Consumables
AVAILABLE SIZES (mm):
ALLOY BASE: Ni,Ti ,Al
1.2, 1.6, 2.4, and 3.2
SPECIAL FEATURES:
Corrosion resistance
Bonds with all ferrous and nickel-base metals
APPLICATIONS:
Joining nickel and nickel alloys, dissimilar joining of
nickel with steels and copper as well as copper alloys.
185
Hot Metal Spray Powders
Hot metal powder alloys are mostly nickel-based. Nickel Advantages of powder spray:
when added with boron gives hardness due to formation Thin layer can be given with hardness upto 65 HRC
of borides. The percentage of boron can be monitored (upto 0.15 mm thickness).
to achieve a particular hardness range. Boron also Coating is uniform; hardly any post-machining
brings down the melting point of nickel and helps the required.
powder to fuse much below melting point of steel.
For enhanced protection against wear and increased No heat treatment is required.
corrosion resistance, silicon along with other special Self-fluxing: no slag cleaning required.
alloys is added. Some cobalt-based powders are also For machine parts, life obtained is much higher.
available but are not as costeffective as nickel-based The limitations are:
powders. Tungsten carbide is added to a nickel boride
Not economic for thicker build-up on big jobs.
matrix to combat highpressure abrasion.
Not applicable for aluminium, magnesium
components.
For big jobs furnace preheating and melting is
required.
186
CAST COAT 20 ALLOY BASE: Ni, B, Si, Fe
SPECIAL FEATURES
Buffer for coating on cast irons and machinable Machinable deposit.
build-up on steels
Good resistance to corrosion and oxidation.
Cast Coat 20 extends the benefit of powder coating to
Allowable build-up: 20 mm.
cast irons. It has excellent machinability and can be
used for original or worn out components. For higher Coverage for a 1 mm thick layer: 650 cm2/500 gms.
hardness requirements, it can be used as buffer APPLICATIONS
layer to be coated by harder alloy grades. This Cast This powder is used for casting defect repairs, brazing
Coat technology saves castings from being scraped and joining cast iron components, building up funnels
and abraded. The wettability and fluidity adds to the or moulds in the glass industry, cast iron cylinder
advantage of being used for brazing and joining. The heads, engine blocks, housings, manifolds, and vessels
inertness of the base alloy can be utilized with much
Reclamation Consumables
handling acetic acid.
success to counter corrosion and oxidation related
PROPERTIES
problems in the industry.
Hardness : 20-22 HRC
The powder can also be used as a superbly machinable
build-up and buffer layer on steels for subsequent Melting Point : 1100°C
coating by harder powders or welded alloy deposits.
oxidation.
187
TUNGSTRENGTH 70 Economic repair in case of chronic abrasion related
jobs.
Ultimate abrasion protection technology Non-machinable deposit - can only be ground by
A protective coating by TungStrength 70 can effectively silicon carbide or diamond wheel. · Allowable build-
enhance component life and reduce spares inventory up: 1.2 mm.
holding. As it retains its hardness upto 450°C, it can Coverage for a 1 mm thick layer: 460 cm2/500 gms.
solve regular abrasion problems faced by maintenance APPLICATIONS
engineers. TungStrength 70 exhibits a slag free deposit
and better surface coverage. The composite alloy TungStrength 70 provides a hard deposit for prolonged
system based on tungsten carbide ensures better life on machine parts viz. shear blades, die frames, wire
microstructural properties and ease of bonding with any drawing rolls, pulleys & capstans, wear rings, crusher
ferrous and nickel based material. teeth, guide rolls, conveyors, chains, mixer blades and
paddles.
Reclamation Consumables
188
Type Item Description Alloy Hardness Applications
base (HRC)
Chrome - C Complex carbides in a tough matrix for C, 58-60 Crusher parts, bucket
resistance to severe abrasion and moderate Cr, HRC lips, conveyor screws
impact loads Mn, Mo
Micro - C Dense micro carbides in a hard martensitic C, 58-64 Mixer blades, scrapers,
matrix resisting severe coarse and fine Mn, HRC mill parts, pipes
particles abrasion. Cr, Mo, Ti
Therm - C High temperature carbides in an austenitic C, 62 - 64 Sinter plant parts, chutes,
matrix to resist complex wear at elevated Cr, HRC boiler flue gas ducts
temperatures. Retains hardness upto Mn, Mo,
Reclamation Consumables
800OC. Nb, V
Esab Hard Wear Plate is a quality, quenched and C, -380-440 Bodies, buckets &
HT 4 tempered plate designed for abrasion Cr, BHN cuting edges, wear parts
resistance and impact. This plate can be Mn, Si, of mining machines,
used for all material handling equipment. Mo, B concrete mixing plants
feeders & funnels, cutting
edges wearing parts of
concrete mixing plants
feeders & funnels, cutting
edges
Esab STH Esab STH plates, by virtue of their superior C, -450-480 Screen Duct Liner Pipe
plate manufacturing Process and metallurgy, have Cr, Ni BHN wear plate
proved their excellence in the cut-throat alloy (Micro-
world of abrasion, erosion, heat & corrosion. hardness)
Compare to any stainless steel Esab STH
plates exhibit high life factor. When overlaid
plates, have sticking problem of material
causes slow down in production ESAB STH
plates exhibits higher Productivity factor.
Esab Sinter ESAB Sinter Mn wear plate is an Extremely C, 400 BHN- Hammer, Liners guide,
MN high impact moderate abrasion resistant Mn, Cr, 500 BHN Jaws crusher liners
plate designed to sustain complex wear of Si, P (work
impact & abrasion. Easily weld able metal hardened)
which is Difficult to bend
189
CONVERSION CHART PROPERTIES OF COMMON
METALS
To Convert from To Multiply by
All the given values are correct for these elements
Mass kg Ib 2.205 in their pure form
metric tonne ton 1.102
Name Symbol Melting Sp. Gravity
Force N kgf 0.102 Point (OC)
Ibf 224.8 Aluminium AI 658 2.58
Stress MPa kgf/mm2 0.102 Boron B 2300 2.5
ksi 0.145
Reclamation Consumables
190
COMPARATIVE HARDNESS SCALES
This chart is given as an indicative guide
Reclamation Consumables
110 105 62.3 420 399 42.7
115 109 430 409 43.6
120 114 66.7 440 418 44.5
125 119 450 428 45.3
130 124 71.2 460 437 46.1
135 128 470 447 46.9
140 133 75.0 480 (456) 47.7
145 138 490 (466) 48.4
150 143 78.7 500 (475) 49.1
155 147 510 (485) 49.8
160 152 81.7 520 (494) 50.5
165 156 530 (504) 51.1
170 162 85.0 540 (513) 51.7
175 166 550 (523) 52.3
180 171 87.1 560 (532) 53.0
185 176 570 (542) 53.6
190 181 89.5 580 (551 ) 54.1
195 185 590 (561 ) 54.7
200 190 91.5 600 (570) 55.2
205 195 92.5 610 (580) 55.7
210 199 93.5 620 (589) 56.3
215 204 94.0 630 (599) 56.8
220 209 95.0 640 (608) 57.3
225 214 96.0 650 (618) 57.8
230 219 96.7 660 58.3
235 223 670 58.8
240 228 98.1 20.3 680 59.2
245 233 21.3 690 59.7
250 238 99.5 22.2 700 60.1
255 242 23.1 720 61.0
260 247 (101 ) 24.0 740 61.8
265 252 24.8 760 62.5
270 257 (102) 25.6 780 63.3
275 261 26.4 800 64.0
280 266 (104) 27.1 820 64.7
285 271 27.8 840 65.3
290 276 (105) 28.5 860 65.9
295 280 29.2 880 66.4
300 285 29.8 900 67.0
310 295 31.0 920 67.5
320 304 32.2
330 314 33.3
340 323 34.4 940 68.0
350 333 35.5
191
Metal Selection Guide
Hard Facing
192
SELECTION OF HARD FACING CONSUMABLES
Low Resistance against Abrasion High
Low
Reclamation Consumables
Terroweld MN* OK 83.40 OK Tubrodur Cobalarc 4
OK Tubrodur 15.60* OK Tubrodur 15.40 15.52 OK Tubrodur 15.80
OK Tubrodur 15.41
OK 84.78
Astra HTB OK Tubrodur 15.73 Terroweld SHR OK 84.80
Heat
Esab 116 Ni Cobalarc 1M
OK Tubrodur 14.70
and
Corrosion
Resistance
Esab 550
Terroweld DS4* Esab CSA* OK 68.82 Terroweld EWR
Terroweld DS1* Cobalarc 9
OK Tubrodur 14.71* Cobalarc MX
Ni-based* Co-based
Esab CN182* OK 92.35* OK 93.66
Esab CN1G* OK Tubrodur 15.86
High
193
ESAB CONSUMABLES FOR JOINING OF DISSIMILAR METALS
Material Mild Steel Stainless 14% Ni-Cr-Alloys Ni-Cr-Alloys Bronzes Cast Iron
Mild Steel OK OK Esab CSA Esab CN182 Esab CN182 Bronzoid1 Esab CN182
High 68.82 68.82
Strength
Steel OK Tubrodur
Reclamation Consumables
15.66
Stainless Esab CSA Esab CSA Esab CN182 Esab Monel Bronzoid1 OK
Cr-Ni Steel OK Tubrodur OK Tubrodur 92.58
14.71 14.71
OK Tubrodur
15.66
194
METAL IDENTIFICATION CHART
Magnet File Surface Colour Grinding sparks Metal type Welding tips
Soft
Reclamation Consumables
Malt-grey Red feathery Cast iron Pre-heating
cast iron colour lines Peening
Slow cooling
Magnetic
Dark grey Long Yellowish- High carbon steel Pre-heat heavy
white lines with Low alloy steel sections to
starts 150°C
Hard
Shiny grey Yellowish-red 13% Cr steel Can be
Non-Magnetic
Shiny Very light No visible Aluminium alloys Pre-heat coarse
sparks materials to
150-200°C
Hard sparks
195
Arc Equipment
Arc Equipment
Welding and Cutting
W
Equipment
TRANSWELD 400 THH 630
Welding Transformer for Shop and Site Application Welding Transformer for Industrial and Fematic Welding
Natural air cooled for increased safety of the Heavy-duty fan cooled welding transformers for
transformer. MMA welding with basic, rutile and high recovery
electrodes.
Horizontal shunt core design ensures longer
operational life of the shunt-core moving Horizontal shunt core design ensures longer opera-
mechanism. tional life of the shunt-core moving mechanism.
Arc Equipment
Well-spaced coils for adequate airflow to the Well-spaced coils for adequate airflow to the
transformer ensures longer service life. transformer ensures longer service life.
Robust and compact construction to withstand rough Robust construction and rubber wheels for easy
handling at sites. mobility.
Ideal for TIG welding with optional TIG Ideal for TIG welding with optional TIG
attachments. attachments.
Mains supply, V/Ph, Hz 415 / 2 Lines of 3, 50 Mains supply, V/Ph, Hz 415 / 2 Lines of 3, 50
Open circuit voltage, VAC (Max) 80 Open circuit voltage, VAC (Max) 73 - 80
Output at 60% duty cycle, A 300 Output at 60% duty cycle, A 500
199
RS 400/400S EasyWeld SSR 400 / 600
The All Purpose Thyristorised MMA Welding Fully Thyristorised Heavy Duty Thyristorised MMA
Rectifier Welding Rectifier
Reliable and high performance thyristorised MMA
welding rectifier for construction, fabrication, projects Compact and high capacity thyristorised rectifiers
and pipe welding. with outstanding welding characteristics.
RS 400S burns MSGP and E7018 electrodes and output with spatter level close to zero.
RS 400 can burn any class of MMA electrodes
including E6010. Hot Start, prevention against electrode freezing and
Suitable for long lead welding with any type of protection against HF interference.
electrode.
True vertical welding characteristics.
Robust construction with large rubber wheels - ideal
for site applications.
Remote Control to adjust welding current during
Remote Control to adjust welding current during welding.
welding.
Ideal for TIG welding with optional TIG Ideal for TIG welding with optional TIG
attachments. attachments.
Technical Data RS 400 RS 400S Technical Data EasyWeld EasyWeld
SSR 400 SSR 600
Mains supply,
Ph x V, Hz 3 x 415 ± 10%, 50 3 x 415 ± 10%, 50 Mains supply, Ph x V, Hz 3 x 415±10%, 50 3 x 415±10%, 50
200
LHJ 425 / 750 Origo Arc 200
Heavy Duty MMA Welding Rectifiers for Welding Single Phase Portable Inverters for MMA Welding
and Gouging
Heavy-duty diode based MMA welding rectifiers for Burns 2.5/3.15 mm electrodes of any class
MMA welding and arc gouging (LHJ 750). continuously including E6010.
Stepless current control by hand crank.
Practical and rugged design - convenient to use.
Fan cooled for optimum cooling of the power source
Arc Equipment
larger operational life.
Can be used with longer input supply cable - provides
Rugged construction - body made of powder-coated
a larger area of operation.
steel to suit all weather application.
Large rubber wheels and handle - easy maneuver- Suitable for Scratch TIG.
ability.
Suitable for Scratch TIG.
Technical Data LHJ 425 LHJ 750 Technical Data Origo Arc 200
201
Buddy Arc 200 Buddy Arc 400i / 400i XC
Portable Inverter Welder for MMA and Scratch TIG Compact and Powerful Inverter MMA Welder
Portable inverter power source for MMAW and IGBT based inverter power sources for MMAW and
Scratch TIG. Scratch TIG.
IGBT based single phase inverter power source. Adjustable current, arc force and hot start.
Outstanding performance with MSGP electrodes. Suits any MMA application – MSGP and LH
electrodes by 400i and 6010 by 400i XC as well.
Arc Equipment
Technical Data Buddy Arc 200 Technical Data Buddy Arc 400i / 400i XC
Mains voltage, V, Ph, Hz 230 ± 10%, 1, 50 Mains voltage, V, Ph, Hz 400 ± 10%, 3, 50
Output at 60% duty cycle, A 135 Output at 60% duty cycle, A 400
202
Origo Arc 4001i A24 Caddy Arc 251i A34
Heavy Duty Inverters for MMA Welding Portable inverter power sources for MMA Welding
Burns MMA electrodes of any class. Burns up to 4.0 mm electrodes of any class continuously.
Control panel A24 comes with digital display and Rugged design - impact resistant polymer design.
finer controls.
Built-in PFC to eliminate harmonics, digital display,
Adjustable arc-force and hot start options Arc Plus II regulator.
available.
Arc Equipment
VRD (Reduced CCV <35V) for enhanced safety.
Dust filter and laquered electronics - increased
reliability. Adjustable arc force, hot start and 2 job memories.
Live TIG start for smooth and safe operation in TIG. Handles 100m long mains cable.
Fuse (slow), A 20
Fuse (slow), A 16
Open circuit voltage, VDC (Max) 91
Open circuit voltage, VDC (Max) 65
Welding current range, A 16 - 400
MMA MIG / MAG 20 - 400 Welding current range, A (TIG/MMA) 4 - 250 / 3 - 250
203
Origo Arc 410c / 650c / 810c A12 LFD 1500/3000
Offshore Multi-operator power source
Chopper Based DC Power Sources for MMAW / For indoor and site use
AAG / GTAW
Portable regulater Recode.
Robust construction to handle tough working
conditions.
Built-in arc force, hot start and anti stick functions. Technical Specifications LFD 1500 LFD 3000
Arc Equipment
Digital VA meter to display the welding parameters. Welding Line voltage - selectable 50 - 60 V 50 - 60 V
Enclosure IP 22 IP 22
Welding current range, A 20 - 400 20 - 650 20 - 800
Enclosure class IP 23 IP 23 IP 23
Application class S S S
Dimensions, l x w x h, mm 1310 x 800 x 780 1310 x 800 x 780 1310 x 800 x 780
Special CVCC variants of the above are available in the 400 / 500 /
650A segment.
204
EDW 350 / 400 / 500
Engine Driven Welder + Power Unit
Arc Equipment
Starter 12V Lucas 12V Lucas 12V Lucas
Battery capacity, Ah 75 120 120
Governor Mechanical Mechanical Mechanical
Power at 1500 rpm, BHP 30 58 58
Fuel Diesel Diesel Diesel
Fuel tank volume, ltr 75 80 80
Fuel consumption, ltr/hr 3.2 4.5 4.5
Welding Output
Open circuit voltage, VDC 90 90 90
Welding current range, A 10 - 350 10 - 400 10-500
Output at 60% duty cycle, A 300 400 400
Electrode type All including All including All including
cellulosic cellulosic Cellulosic
Electrode size, mm 4.0 / continuous 5.0 / continuous 5.0 / continuous
Auxiliary Output
3Ph supply, kVA, V/Ph, Hz 7.5, 415 / 3, 50 10, 415 / 3, 50 10, 415 / 3, 50
1Ph supply, kVA, V/Ph, Hz 2.5, 230 / 1, 50 5, 230 / 1, 50 5, 230 / 1, 50
Size
Dimensions, l x w x h, mm 2600 x 1030 x 1800 2900 x 1400 x 2010 2900 x 1400 x 2010
Weight approximate, Kg 900 1250 1270
Undercarriage with tow bar 2 wheels as 2 wheels as 2 wheels as
standard standard standard
Noise Level
DB at 1 m distance 75 75 75
Compliance CPCB CPCB CPCB
205
Power Compact 255 Migmatic 250 / Auto Mig 300
Compact MIG / MAG Welding Package Power Source for MIG / MAG Welding
Compact MIG/MAG with enclosed wire feeder. Rugged and reliable design.
Spot, stitch and continuous welding operations. Continuous welding with 0.8mm wire on MS/SS.
Adjustable burn back control Auto Mig 300 is specially designed for automotive
industry for high speed/high current application on
Ideal for thin sheet fabrication and automotive industry. 24x7 basis.
Arc Equipment
Technical Data Power Compact 255 Technical Data Migmatic 250 Auto Mig 300
Dimensions, l x w x h, mm 840 x 375 x 736 Type of cooling Forced Air Forced Air
Weight, Kg 90 Dimensions,
l x w x h, mm 620 x 390 x 580 620 x 390 x 580
Wire Feeder (Enclosed)
Weight, Kg 78 87
Wire feed speed, m/min 1.5 - 22
Wire Feeder Migmatic Migmatic
Wire diameter, mm / type 0.8 - 1.2 / MS
Wire feed speed,
m/min 1.5 - 22 1.5 - 22
Wire diameter,
mm / type 0.8 - 1.2 / MS 0.8 - 1.2 / MS
Weight, Kg 6 6
206
Technical Data Auto K 400 Auto K 600
Power Source
Thyristorised Power Sources for MIG / MAG Drive system DC motor DC motor
Welding
Speed control Stepless Stepless
Compact yet thyristorised rugged power sources for Wire feed mechanism Double roll quick Double roll quick
high quality manual or mechanized MIG/MAG. changeover type changeover type
Arc Equipment
Hex phase rectification gives almost ripple free Length, m (Standard) 5 5
welding output free from spatter.
Length, m (Optional) 10 / 15 / 20 10 / 15 / 20 / 30
Fresh Tip Treatment (FTT) control eliminates Wire feed speed, m/min 1.5 - 16 m/min 1.5 - 16 m/min
formation of globules at the wire tip during weld stop
condition. Wire diameter, mm / type 0.8 - 1.2 0.8 - 1.6
Weight, Kg 7 9
Fresh Arc Start (FAS) control instantaneously
enhances the arc-striking rate for better arc striking.
207
Technical Data Auto K 400 Synergic Auto K 600 Synergic
Power Source
Adjustment of
welding current Stepless Stepless
Remote Current
Regulator type RCU-AUTO K 400 RCU AUTO K 600
Synergic Pendant
Auto K 400 / 600 Synergic Wire and gas combinations Wire Wire Dia Gas
mode.
Arc Equipment
Length of interconnection, 5 5
Separate adjustment for crater. mtr
Wire type MS / Al / FC MS / AI / FC
Mounted on rubberized wheels for better mobility
along with gas cylinder base. Weight, Kg 7 9
208
SCR 400(S) Buddy Mig 500i
MIG / MAG Welding units for Shipyard Rugged and Reliable Inverter MIG/MAG
IGBT based Inverter MIG/MAG.
Heavy-duty thyristorised power sources designed
Arc Equipment
specially to meet the welding applications for High duty cycle – 387A @ 100%, ideal for operating
shipyards. on 24 x 7.
Wire feeder interconnection up to 50m available. Stepless inductance – better arc performance.
Feeder mounted remote – easy parameter control.
Suitable for all types of wires - Solid/flux-cored.
Welding voltage and wire feed speed by remote and
Light weight and compact wire feeder for reaching crater voltage and crater current control on panel.
all locations.
Versatile – Excellent performance on MS, SS and Al.
Standard 2-roll quick changeover mechanism or
Wide mains voltage tolerance – operates over 340 –
optional 4-roll drive.
460V input supply, stable welding controls.
Outstanding welding performance. Protected against thermal overloading and over/
under voltage.
209
MIG C3000i U6
MIG 3001i/4001i + Aristo Feed 3004w U6
Lower power rating
m wire.
Higher rated current at 100% duty cycle for continuous usage of 0.8mm
Digital Display
Pulse and Synergic Pulse MIG / MAG
Remote control option
Technical Data MIG C3000i MIG 3001i (w) MIG 4001i (w)
Mains voltage V, Hz 400, 3-50 / 60 4-300, 50/60 400, 3-50/60
Fuse, slow A 16 16 20
Mains cable, Ø mm2 4x4 4x4 4x4
Setting range A MIG / MAG 16-300 16-300 20-400
MMA 16-300 16-300 16-400
TIG 4-300 4-300 4-400
Permitted load MIG / MAG at
35% duty cycle A/V 300 300 400
Arc Equipment
210
Technical Data Mig 5000i
Power Source
Enclosure class IP 23
Application class S
Weight, Kg 68 / 88*
Aristo Mig 5000i (w)
Arc Equipment
Cooling Unit*
Heavy-duty Multi-process Inverter Power Sources
for MIG/MAG (Pulse / Synergic / Non-Pulse), MMA Cooling power, W** 2500*
Welding and Arc Gouging
Coolant quantity, ltr 5.5*
Inverter power source for applications demanding
Maximum water flow, ltr/min 2*
high level of performance.
* Applies to water cooled models Aristo Mig 5000iw only
Robust construction, body made of aluminium
to prevent corrosion and handle tough working ** At 40 Deg C temperature difference and flow rate 1.5 ltr/min
environments.
211
Technical Data Mig U4000iw Mig U5000iw
Power Source
Enclosure class IP 23 IP 23
Application class S S
Cooling Unit
212
Technical Data Control Panel U6 Pendant U8_2 Plus
2/4 Stroke X X
Crater filling X X
Creep start X X
Hot start X X
Inductance X X
# Can also be used with Aristo Mig 4000i / 5000i without TIG functionalities
Wire Feeders for Aristo Mig U4000iw / U5000iw
Arc Equipment
Digital V/A meter for displaying welding parameters.
Wire type MS / Al / FC MS / Al / FC
Weight, Kg 15 19
213
Technical Data PSF 250 PSF 305 PSF 405 PSF 505
Wire diameter, mm 0.6 - 1.0 0.8 - 1.2 0.8 - 1.6 1.0 - 2.4
MIG Torches - Air / Water Technical Data PSF 410w PSF 510w
214
EasyWeld SSR400-T / 400T-Pulse Buddy Tig 160
Thyristorised Power Source for DC TIG and MMA Portable Inverter Welder for DC TIG and MMA
Arc Equipment
True vertical welding characteristics.
2/4 stroke control in TIG.
Built-in HF for smooth start in TIG.
Higher OCV for better arc striking. Current and arc force control in MMA.
Heavy-duty design, suitable for manual well as
mechanized TIG applications of any kind. Generator compliant – runs on generator power.
215
Caddy TIG 2200i TA33 / TA34 Origo Tig 3001i TA24
Inverter Power Sources for DC TIG/Pulse TIG/MMA
Single Phase Portable Inverters for DC TIG / Pulse
Inverter power sources for MMA, DC TIG (TA23) and
TIG / MMA Welding
also DC Pulse TIG (TA24) with excellent welding
Rugged design - impact resistant polymer design. output.
Robust and compact construction.
Built-in PFC to counter harmonics, Arc Plus II Digital display of the welding parameters.
regulator for smooth output, handles 100m long
2 job memories (TA24).
mains cable.
All positional welding.
TIG - Start by HF/Lift Arc, up/down slope, pre/ Burns MMA electrodes of any class of size up to
post gas. 4.0 mm continuously.
Trolley, remote hand / foot control optional.
Arc Equipment
TA34 - Manually set pulse parameters in TIG. Technical Data Tig 3001i (TA24)
216
Technical Data Tig 4000iw (TA6)
Enclosure class IP 23
Application class S
Inverter Power Sources for DC TIG / Pulse TIG / MMA Standards of compliance IEC / EN 60974 -1 / -3 / -10
also DC Pulse TIG (TA6) with excellent welding Cooling power, W** 2000
output.
Coolant volume, ltr 5.5
Arc Equipment
TIG start mode HF / Lift Arc
10 job memories (TA6).
2/4 Stroke 2/4
Welding thin sheets using pulse TIG (TA6).
Slope up, sec 0-5
All positional welding with high efficiency and
Slope down, sec 0 - 10
quality.
Gas pre-flow, sec 0-5
Suitable for manual and mechanized TIG
Gas post-flow, sec 5 - 25
applications.
Pulse / background current, A 4 - 400
Burns MMA electrodes of any class of size up to
Pulse / background time, sec 0.001 - 0.1
6.3 mm.
* Applies to water cooled models Aristo Tig 4000iw TA6 only
Trolley, remote hand / foot control optional.
** At 40 Deg C temperature difference and flow rate 1 ltr/min
217
Technical Data Tig 2200i AC/DC Tig 2200i AC/DC
(TA33 AC/DC) (TA34 AC/DC)
Enclosure class IP 23 IP 23
Portable power sources with wide functionalities. Control Panel TA33 TA34
AC balance, % -- 50 - 98
218
Technical Data Tig 3000i AC/DC, TA24 AC/DC
Enclosure class IP 23
Application class S
Weight, Kg 42
Inverter Power Sources for AC/DC TIG / DC Pulse Slope up, sec 0 - 10
TIG / MMA
Slope down, sec 0 - 10
Designed to weld any metal e.g. aluminium, copper,
Gas pre-flow, sec 0-5
stainless steel and its alloys with high performance.
Arc Equipment
Gas post-flow, sec 5 - 25
Digital display, 2 job memories.
Pulse / background current, A 4 - 300
QWave - High performance AC welding with low
Pulse / background time, sec 0.01 - 2.5
noise.
AC balance, % 50 - 98
Electrode preheating - excellent arc start and
extended electrode life-time. AC frequency, Hz 10 - 152
Burns MMA electrodes of any class of size up to 4.0 Cooling power, W* 1800
mm continuously.
Coolant volume, ltr 4.2
Trolley, remote hand / foot control optional. Max flow, ltr/min 4
Weight (empty), Kg 19
219
Technical Data Tig 4300iw AC/DC,
TA24 AC/DC
Enclosure class IP 23
Application class S
AC/DC Weight, Kg 95
QWave - High performance AC welding with low Pulse / background current, A 4 - 430
noise. Pulse / background time, sec 0.01 - 2.5
Arc force, hot start, polarity switch for welding in * At 40 Deg C temperature difference and flow rate 1.0 ltr/min
MMA.
220
Technical Data TXH 201 / 201r / 201V
Connection OKC 50
Length, m 4/8
TIG Torches - Air / Water Cooled Size of TIG rod, mm 1.0 - 3.2 1.0 - 4.8 1.0 - 4.8
Rating, A@% duty cycle 250 @ 60% 400 @ 35% 430 @ 35%
TXH 201 4/8m Air Cooled
Length, m 4/8 4/8 4/8
Arc Equipment
Rugged construction - trouble free operation with
minimum maintenance.
221
LPH 50 / 80 / 120 PowerCut 900 / 1600
Rugged Power Sources for Air Plasma Cutting Inverter Power Sources for Air Plasma Cutting
Faster and economical on Al, SS and CS below 20 Inverter based power source, excellent cutting
mm. output.
Cutting can be done from gauge thickness to thick Robust and compact construction.
plates.
Cuts thin sheets of gauge thickness to thick
Very safe and convenient. plates.
No distortion even on sheets below 6 mm. Cutting packages with mechanized cutting torch
Arc Equipment
Mains supply, PhxV, Hz 3x415, 50 3x415, 50 3x415, 50 Mains supply, PhxV, Hz 3x400, 50 3x400, 50
OCV, VDC (Max) 320 310 310 OCV, VDC (Max) 275 278
Pressure, bar 4.5 - 7 4.5 - 7 4.5 - 7 Air supply, ltr/min / bar 150/5.2 165/5.5
Enclosure class IP23 IP23 IP23 Type of cooling Forced Air Forced Air
Type of cooling Forced Air Forced Air Dimensions, lxwxh, mm 516x275 x409 800x318x419
Dimensions, lxwxh, mm 680x325 x515 760x390 x845 760x390 x845 Weight, Kg 39.5 42.7
222
CPRA 800(S) / 1200(S)
CPRA 1000T / 1200T
Power Sources for SAW
Power and control units are housed separately for the easy of servicing.
Heavy-duty design ensures stable wire feeding and good welding output.
Available in standard tractor mountable version and optional boom mountable version.
Nozzle designed suitably for a no. of applications e.g. linear / fillet welding etc.
User-friendly control panel with controls within easy reach of operator, for adjustment of
parameters, while welding in progress.
Creep feed start for non-explosive and smooth start of the welding.
Arc Equipment
Technical Data CPRA 800(S) CPRA 1200(S) CPRA 1000T CPRA 1200T
Power Source
* Optional
223
Welding Automation
LAF 635 LAF 1000 LAF 1000M LAF1250M LAF 1250M LAF 1600M LAF 1600M
Mains supply, V/Hz 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60 400/50-60
Max output at 60% duly cycle, A 800/44 1000/44 1000/44 - - - -
Max output at 100% duty cycle, A 630/44 800/44 800/44 1250/44 1250/44 1600/44 1600/44
Setting range, A/V, MIG/MAG 50/17-630/44 50/17-1000/45 50/17-1000/45 60/17-1250/44 60/17-1250/44 - -
Setting range, A/V, SAW 30/21-800/44 40/22-1000/45 40/22-1000/45 40/22-1250/44 40/22-1250/44 40/22-1600/46 40/22-1600/46
Open circuit voltage, V 54 52 52 51 51 54 54
No load power, W 150 145 145 220 220 220 220
Efficiency at max current 0.84 0.84 0.84 0.87 0.87 0.86 0.86
Power factor at max current 0.90 0.95 0.95 0.92 0.92 0.87 0.87
Voltage, 3 ph 60 Hz, V 400/415 400/415/500 230/400/415/ 400/415/500 230/400/415/ 400/415/500 230/400/415/
500 500 500
Voltage, 3 ph 60 Hz, V 440 400/440/550 230/400/440/ 400/440/550 230/400/440/ 400/440/550 230/400/440/
550 550 550
Endosure class, protection IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23
External dimensions, LxWxH, mm 670x490x1090 646x552x1090 646x552x1090 774x598x1428 774x598x1428 774x598x1428 774x598x1428
Weight, kg 260 330 330 490 490 585 585
Arc Equipment
Excellent arc ignition characteristics and good weld- Enclosure class, protection IP 23
ing properties.
External dimensions, LxWxH, mm 355x210x164
Ideal for SAW.
TAF 800 TAF 1250
Mains supply, V/Hz 42 (AC)/50-60
Max output at 100% doty cycle, A 800 1250
Weight, kg 5.5
Setting range, A/V 300/28- 400/28-
800/44 1250/44
Max power consumption, VA 900
Open circuit voltage, V 71 72
Efficiency at max current 0.86 0.86
Power factor at max current 0.75 0.76
Voltage, 1 ph 50 Hz, V 400/415/500 400/415/500
Voltage, 1 ph 60 Hz, V 400/440/550 400/440/550
Enclose class, protection IP 23 IP 23
External dimensions, LxWxH, mm 774x598x1228 74x598x1228
Weight kg 495 608
224
Orbital TIG Welding more. It consists of an articulated carriage that travels
around the pipe on a rack adapted to match the diam-
A21 PRB/PRC/PRD 160/ POC 12-60, Aristo Mech eter of the pipe. To ensure maximum flexibility it is built
Tig 4000iw in modular form.
Arc Equipment
A21 PRC welding head has a weaving movement and
arc voltage control, which produces higher productivity Aristo MechTig 4000iw is designed to work together
and better welding quality, particularly when welding with the Aristo MechControl 2 and 4. This is a 400A
thick-walled tubes. heavy-duty inverter based power source having com-
pact design with outstanding welding characteristics.
Connection cables up to 8m provide a working range
of 16m.
225
It is a small, compact, motor-operated trolley designed
for the mechanisation of GMAW, gas metal arc welding,
in particular. The permanent magnet built-in magnet,
which can be switched on/off, holds the tractor in the
correct position on the work-piece.
Weight, kg 8.5
Power, W 20
Weight, kg 7
Weight, kg 17
226
Quick set-up and easy operation
Quick assembly and easy operation Railtract FW1000, Flexi Weaver, for oscillated welding.
The Railtrac FW 1000 can be delivered in a “FW1000
Programmable with five programs L” version if the welding process need to be done with a
lower welding speed than with FW1000.
Calibrated setting values in cm, mm and sec
Welds and outs in all positions on magnetic and
Programmable “backfill” for crater filling
non-magnetic materials
Arc Equipment
Railtrac FR1000
227
A2 Multitrac with
Weight, kg 47 47 43 43
Tractor Automats - Trippletrac /
Multitrac / Mastertac
A2 Trippletrac
A6 Mastertrac
228
Roller Beds Positioners
Esab offers a wide range of roller beds with capacity Esab offers a comprehensive range of positioners for
varying from 5 - 250 tons. The roller beds have mechan- automatic welding. These very versatile welding tools
ical adjustment for circular work-pieces and self-aligning enable welding to be carried out in the optimum posi-
roller beds, which automatically adapt o the roller bed tions to benefit the quality of the work. The positioners
diameter. These roller beds are designed to operate in can be integrated with A2/A6 automatic welding equip-
combination with A2/A6 automatic welding equipment ment.
and Esab’s columns and booms.
Arc Equipment
229
Friction Stir Welding Friction Stir Welding
Legio Friction Stir Welder Super Stir Friction Stir Welder
The LEGIO combines the latest technology with proven The SuperStir program includes a variety of machines
quality. The modular system makes it possible to as- developed from a standarized SuperStir base unit
semble welding stations to suit the most varied Friction having working ranges of 0.5x1.5m (19.7x59in) up to
Stir Welding applications. 10x20m (33x66 ft) within the same concept.
The LEGIO system consists of five basic designs in a This includes customized models of various designs for
Arc Equipment
series of seven sizes, covering a welding depth of 1.2 specific customer requirements in different production
mm (.045 in) to 60 mm (2.4 in). These basic types can areas.
be supplemented with different types of equipment to
suit the most varied production needs and give maxi- These different designs are used worldwide in R&D
mum flexibility to any production line. centers for joining of extrusions to panels, in production
of pressure vessels as well as small parts for the auto-
The versatile Legio family includes linear motion with motive and electronic industries.
single or dual (over /under) heads, with or without tables.
Dual axis (x-y) model is available with or without table.
Tables include a whole pattern for attaching fixtures.
230
Robotics for Arc Welding
Esab offers a wide range of automated welding solu-
tions using a range of robots from ABB. Robotics can
provide a cost-effective and modular solution for a va-
riety of welding applications with increased productivity.
The various advantages of using robotics are:
Pre-program Offline
Arc Equipment
New programs can be created, programs can be stimu-
lated or robots can be pre-programmed for a specific
functionality.
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Range of Robots IRB 2400L
IRB 140 Slim yet robust arm-based, 6-axis robot. All the IRB
2400 industrial robots are ideal for arcwelding applica-
ABB’s fastest and smallest arm-based industrial robot. tions. Features unlimited axis 6. IRB 2400L load capac-
Highly flexible with slim wrist, 6-axis robot able to reach ity is 7 kg; reach 1.8 meters. IRB 2400/10 load capacity
into narrow, small spaces. Easy-to-mount equipment. is 10 kg; reach 1.5 meters. IRB 2400/16 load capacity;
Robust and compact. The standard IRB 140 can be 16 kg; reach: 1.5 meters.
mounted at any angle without modification for optimum
reach and efficiency. Load capacity: 5 kg; supplemen-
tary load is: 1.5 kg; reach: 0.81 meters.
Arc Equipment
IRB 4400
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CHOICE OF FUSION WELDING
METHOD
When choosing welding methods, you need to pay
attention to several factors:
Arc Equipment
environment (outdoors, indoors with or without draft),
possibilities to rotate, lift, transport or otherwise
move the workpiece.
Welding Methods
MMA-welding-manual Metal Arc Welding or Manual SAW-welding (submerged Arc Welding).
stick electrode welding.
1. Electrode from spool
1. Gas shield from the electrode coating
2. Electrode coating 2. Flux
3. Core Wire
4. Metal drops 3. Molten pool. Diagram shows the electrode surround-
5. Molten pool ed by flux and a cover of melted flux
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Arc Equipment
MMA Manual Metal Arc Welding
Manual Metal Arc welding, also called hand welding, interfere through magnetic arc blow.
is still the best known and most common method of 5. Use a static welding converter (rectifier or inverter)
welding. for welding of heavy plates if the mains supply is
Manual Metal Arc welding is noted for: weak.
6. Use gravity welding for mass production of long
1. Low investment cost.
straight fillet welds.
2. Low cost of filler material in relation to kgs. weld
7. Weld vertical down instead of up whenever
deposit. 3. Filler material (stick electrodes) are easily
possible.
available in a wide range of types and dimensions.
4. Less strict demands on edge preparation and Equipment
Arc Equipment
purity of the parent material than by other welding The equipment consists of power source, welding cable,
methods. electrode holder and return cable. Below is a survey of
5. The same equipment can be used for all non-alloyed, the characteristics of different power sources.
low alloyed and stainless welding construction Welding transformers
steels. Also for cast iron, modular iron and weldable
They give alternating currency (AC) and are the least
non-ferrous metals.
expensive power sources. They have a high efficiency
6. Short set-up times, good at piece fabrication.
80-90% for the most commonly used transformers for
7. Can be used in all positions. Also in narrow spaces
welding. They are used for welding of unalloyed, low-
with hard to get at welding points.
alloyed stainless steels and cast iron but not for e.g
8. Often gives a more machineable weld deposit than
aluminium.
Gas Metal Arc Welding.
9. Reasonable heat input to the parent material. Certain electrodes have better welding characteristics
This gives reasonable grain growth and thus a on alternating current (AC) than on direct current (DC).
transformation zone less exposed to brittle fracture Among these electrodes you find in particular the high
than other methods working with higher heat input. recovery types, and notably the larger dimensions.
The efficient and economical use of the Manual Metal Welding rectifiers
Arc welding method can be summed up in the following In this case a rectifier has been added to the transformer,
seven recommendations. thus supplying DC. It costs approximately twice as much
1. Weld in the horizontal position with high recovery as a transformer of corresponding size. For modern
stick electrodes whenever possible. This minimizes rectifiers, the efficiency is 60-80%.
both weld time and energy consumption. For both rectifiers and transformers, the efficiency is
The use of roller beds and positioners can often lower, the lower the used current is. Vice-versa a higher
contribute to a shorter weld time by making horizontal utilization of the capacity of the power source gives
welding possible. a higher efficiency. The rectifier may be used for all
2. Use sufficiently strong power sources to make weldable materials.
possible the use of fast welding high recovery Welding converters
electrodes.
One electric motor (AC) is coupled to a generator (DC).
3. Save on electricity by using power sources with high
Generally, a more expensive solution than a rectifier of
efficiency and low no load rating.
corresponding size. The efficiency is 50-60%.
4. Use welding transformers for heavy plates,
framework and in other cases when DC welding will Its range of use is the same as that of the rectifier.
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Engine driven generators For fillet welds with 4-5 mm effective throat thickness,
the maximum weld speed is 0.5 m/min when using OK
These normally provide DC. They are more expensive Femax high recovery electrodes.
than converters and as a rule heavier.
For gravity welding using 600-700 mm long electrodes,
The smaller types normally have 2-stroke petrol engines, you can reach a speed of up to 60m/manhour when
whereas larger ones have diesels. In both cases the welding straight fillet joints. For gravity welding, AC is
engine drives the DC generator. always used. The effective throat thickness may be
varied by using different electrode dimensions.
Welding inverters
Range of application-Material types
This is the most recent development within Manual
Metal Arc welding. Inverters produce DC or AC/DC. The Manual Metal Arc welding is used for all unalloyed, low
efficiency is high - 80-90%. The cost is somewhat higher alloyed and stainless common structural steels according
than that of a conventional thyristor regulated rectifier. to Swedish Standard (SS) and other comparable steels.
See also “Standards, Classification System and Codes”
The Inverter’s main components are:
in the ESAB Welding handbook-Filler Materials.
A rectifier which turns the incoming 3-phase AC
These steels comprise:
(sometimes only 1-phase AC) into DC.
Common structural steel.
An inverter which changes this DC into HIGH
FREQUENCY AC. Pressure vessel steel.
A transformer which takes this current down to a Ship plate.
lower voltage (20-50 V).
Cast steel and machine steel.
A rectifier which transforms the AC into DC suitable
for welding. Manual Metal Arc welding is also used for:
Arc Equipment
The inverter’s main features are low weight and volume. Spherolitic cast iron.
Since both efficiency and power factors are high, smaller
mains cables and fuses may be used in comparison to Malleable iron.
conventional rectifiers. Weldable non-ferrous metals.
Productivity-Welding Speed Range of application-Plate thickness
A modern high recovery electrode, such as OK Femax Metal Arc welding is used for plate thicknesses from
38.95, 6.0 mm and an efficient power source, such as about 2 mm to the thickest normally used.
THH 630, can reach a weld deposit of 13 kgs/hour when
welding horizontally. Maximum weld deposit for OK
Femax 33.80, dia 6.0 mm, is about 8.5 kgs/hour.
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MIG/MAG Gas Metal Arc Welding
MAG WELDING
Gas metal arc welding with active gas Spray Arc welding IS tne best method for plate thickness
For this method it is significant that DC is used, and above 3 mm.
that the electrode is a wire which is automatically fed to Spray Arc welding is only used in horizontal and vertical
workpiece. The arc is surrounded by the shielding gas. butt position.
The negative pole of the power source is connected to Productivity-Welding speed
the workpiece. The welding speed of MAG welding is measured in kgs
Arc Equipment
MAG welding takes place in a shielding gas zone of weld deposit per hour. When welding horizontal fillet
consisting of Carbon Dioxide (C02) or a gas mixture weld in thick materials, MAG welding is slower than
consisting of 80% Ar!Jon and 20% Carbon Dioxide. Manual Metal Arc welding using high efficiency stick
The Argon/C02 mixture is costlier than pure C02’ But electrodes.
it gives a softer arc, smoother weld and less spatter. MAG welding is suitable for thin plates. You can also
The mixture also contributes to a higher strength and weld medium size plate, piece constructions and small
ductility of the weld metal. to medium sized crossbar jobs with good economy.
The Argon/C02 mixture is therefore generally preferred The advantages of MAG welding are:
for welding of thin plate and often for low alloyed steel. 1. No stoppages for change of stick electrodes (in
The electrodes are usually solid wires with diameters comparison with Manual Metal Arc welding)
0.6, 0.8, 1.0, 1.2 or 1.6 mm, usually on spools of 5-15 2. Less distortion due to shrinking in comparison with
kgs, or flux cored wires with diameters 1.2, 1.4, 1.6, 2.0 Manual Metal Arc welding. The advantages are:
or 2.4 mm on spools of 15 and 25 kgs. less straightening work after welding
Short Arc welding means a low arc voltage giving a often simpler welding fixtures
short arc. Practically all metal transfer through the arc is possibly a better bead appearance
completed by short-circuiting globules. 3. Smaller joint volumes when compared to Manual
Metal Arc welding because of the thinner electrode.
Spray Arc welding needs more than 200 A and 25 V. On
A 6.0 mm coated high recovery stick electrode may
the whole, the metal transfer is by free-flight globules
have an outside diameter of about 15 mm.
being forcefully propelled through the arc.
4. There is no de-slagging. A certain quantity of metal
Short Arc welding is the best method for: oxide is found as “slag isles” on the bead. The origin
Thin plate. is a chemical reaction between Mn, Si and C02’
Thin pipes. They should be removed, if strict rules apply to the
Root runs in butt joints with edge preparation. surface of the weld.
5. There is no risk of hydrogen brittleness in quenching
With Short Arc welding you weld in all positions. steels caused by moisture in a stick electrode
Welding vertical down should be limited to thin plate. coating.
There is a risk of insufficient penetration which grows 6. The weld deposit quality may well be compared with
with a growing plate thickness. This is more apparent at what can be achieved with normal basic electrodes.
vertical down than in other welding positions.
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Range of application - Materials - Plate thickness MIG WELDING
All unalloyed and low alloyed steels may be welded. Gas Metal Arc welding with Inert (non-active) Gas
Use Short Arc from about 0.8 to 3 mm and Spray Arc In MIG welding, as in MAG welding, you work with
from about 3 mm plate thickness. Short Arc as well as Spray Arc. The most common gas
is Argon, but mixtures of Argon and Helium are also
MAG welding with flux cored wires is done with plate used. When welding stainless steel, it is often difficult
thicknesses from about 8 mm for longer beads and up to achieve a good penetration. If some few per cents of
to 10 mm for shorter (less than 0.5 m). Oxygen are added to the mixture, this disadvantage is
overcome and the arc will be stabilized.
Helium-Argon mixtures give a “hotter” weld than pure
Argon. These mixtures are therefore often preferred for
thick copper and aluminium materials.
For aluminium welding of medium thickness, pure Argon
is used.
Welding positions are: Short Arc-all positions, Spray
Arc-horizontal position.
The radius of action is 3-16 m from the wire reel,
depending on machine model.
The equipment is the same as for MAG welding.
The shielding gas Argon wth 2% C02 has given as
good results as Helium with Argon, when welding
heavy stainless plate. Since Argon witn 2% C02 is
less expensive than Argon/Helium, the former gains in
Arc Equipment
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TIG (GTAW) Tungsten Inert Gas Welding
TIG is a welding method where the electric arc is created TIG is used both for manual and mechanized welding.
between a non-melting electrode and the workpiece in For manual welding, the welding consumable is fed by
an atmosphere of inert gas. That means that the gas hand, as for oxyacetylene welding. In equipment for
does not take part in any chemical reaction during mechanized welding, a feed unit is used for wire. The
welding. welding wire is on a spool and is automatically fed to the
welding torch.
The arc melts the parent metal and the welding
consumable, if any. The molten pool, as well as the TIG welding is used from 0.5 mm material thickness and
electrode, is protected from Oxygen and ‘Nitrogen in the up to 5-6 mm. For heavier material, TIG is often used for
air by the shielding gas. This gas is usually Argon, but root beads in order to make sure of a perfect root pass.
Helium or mixtures of Helium and Argon are also used. No other method equals TIG in this respect. Consecutive
beads are made with more productive methods and
TIG welding is done with DC or AC. DC negative pole
Arc Equipment
filler materials such as Gas Metal Arc, Submerged Arc
is used for all metals which do not form oxides which or Manual Metal Arc with high recovery electrodes.
are difficult to weld, like e.g aluminium and magnesium.
They are instead welded with AC, the positive amplitude With plate thickness of less than 1 mm, you often use
of which has a good breakdown effect of the oxide. flange butt joints and edge joints. Butt joints are welded
up to 3-4 mm thickness. Above that, you use, V- or
The name of this method was taken from the first letters U-joints. Sometimes also x-joints. In this case the
of Tungsten Inert Gas. groove angle should be 60° and the unbevelled edge
1-1.5 mm.
Range of application
A general rule for selecting the welding current is:
The TIG process is noted for high weld quality, purity
Aluminium 45 A, copper 70 A, steel 50 A per mm
of weld material and an even surface. It is used where
thickness.
quality demands are high, e. g. within the nuclear and
process industries, but also for difficult-to-weld materials TIG is used in all positions.
such as titanium, monel, copper-nickel etc. The largest
range of application is for stainless steels and light Productivity-Welding speed
metals.
Manual TIG welding : about 30 cm/min
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Range of application - plate thickness - edge
preparation
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Common Faults in Arc Welding
Weld faults are in most cases hidden deep under the has been put into the production before theoretical and
surface of the weld, and therefore difficult to detect. practical training have been carefully accomplished.
The most common and reliable methods of detection
presently used are ultrasonic and X-ray tests. These A common cause of incomplete penetration with Gas
methods permit quality control of the weld without Metal Arc welding is usually too low travel speed. This
changing or destroying it. You can expose most faults gives a molten pool too large for the arc to melt the joint
with respect to type, size and position. walls.
The X-ray test has also proven to be of great importance On the other hand, incomplete penetration is not rare
to the welder himself. It has been established that certain when thick stick electrodes are used in Manual Metal
faults, which the welder perhaps makes more or less Arc.
unconsciously, gradually disappear if he is shown X-ray
pictures and informed of what they reveal.
Incomplete penetration will occur if the welder strikes the
In other words, the X-ray picture is an excellent
arc against one of the fusion faces and lets the molten
educational means. It makes the weld so to speak
pool run down onto the other, cold face. It may also
‘’transparent” and shows it in full length. The welder can
occur if too low current is used on very thick material.
easily learn from the fault, since you can conclude how
Then the heat supply will not be sufficient to melt the
the fault arose from the nature and position them. In
parent material.
this way, the welder can steadily manage to eliminate
possible shortcomings and improve his craftmanship. Slag inclusions
The most common faults are pinholes, slag inclusion, On an X-ray picture, slag inclusions stand out as lines.
undercuts, root defects, incomplete penetration, and The picture below shows a cross section of the weld.
cracks. Here, the de-slagging has been incomplete between the
beads. When the top bead was welded, pieces of slag
Above all, incomplete penetration, slag inclusion,
from the previous bead were not melted. Instead, the
undercuts and root defects can be linked to lack of skill
top bead sealed them in.
Arc Equipment
and precision on behalf of the welder.
You will observe this on the X-ray picture as typical
Incomplete penetration that is incomplete fusion between
lines.
weld and parent material, may easily occur at Gas Metal
Arc welding if not done professionally. In most cases, The risk of creating this fault is greater if the underlaying
the cause is a too short training period. The welder bead is strongly convex. If, for some reason, a strongly
convex bead is welded, it is recommended to grind off
some of it. Then the risk of fault is eliminated.
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Please pay special attention to multi-bead welds! check Undercut will always mean a weakening of the joint.
carefully that there exist no sharp angles between the Therefore please always weld so that undercut is
different beads. If so, it may be impossible to remove avoided. If, in spite of all precautions, this cannot be
the slag or melt down slag deposits all the way to the achieved, then in most cases the undercut should be
bottom when laying the next bead. welded up.
The pictures below shows a multi-bead weld which is In undercut, it is common to find slag deposits remaining
incorrectly done. Narrow grooves have been created inside the weld. But the X-ray film will reveal slag
beween the beads. The same weld, but correctly done, inclusions.
is shown further on.
Root defects
Undercut
242
removed, the defect is closed-in by the backweld. It will in connection with the gouging of the root before the
then be revealed by the X-ray or ultrasonic inspection. back bead is welded.
In Submerged Arc welding, the penetration in the joint It should, however, also be noted that cracks may ap-
is an important factor. When root defects appear, the pear in the weld or the parent material which have noth-
penetration has been inefficient. ing to do with the welding procedure.
If, in the case of double-sided welding, the beads have Examples of this are hot cracks or solidification cracks
not met at the bottom, there could be several reasons which run along in the middle of the weld. These are
such as: common at fillet welds, where a difficult tension situation
is at hand.
The joint had a too big unbevelled edge.
The reason for these cracks may be parent material.
Too small groove angle. This could be difficult-to-weld steel, having too high
contents of Carbon, Sulphur and possibly Phosphorus.
Possibly both these causes together.
These elements give certain segregation effects when
Too low welding current. the molten pool solidifies.
Too high or low welding speed. Acid electrodes are especially sensitive to impurities.
Rutile electrodes are less sensible and basic ones are
The two beads are not exactly facing each other. practically nonsensitive.
Cracks Unlimited weldable steels have maximum proportions
of Carbon 0.20%, Sulphur 0.05% and Phosphorus
In most cases, cracks are not directly dependant on the
0.04%. If parent metals containing more of these are to
welder’s skill. But a weld can be done in such a way
be welded, basic electrodes should be used. Then you
that formation of cracks is promoted. If there are faults
will avoid hot tears also by high proportions of these
in the weld, of course the risk of cracks is.greater due to
elements.
tension or other influences than if the weld is completely
Arc Equipment
homogeneous. The same advice is given also for the use of basic
electrodes if you have to weld a material where the
composition is unknown.
Hot tear
243
pressure and the direction was oriented up through
the middle of the molten pool. This is the last portion to
become solidified.
Pinholes
244
Industrial Gas Equipment
Gas Equipment
Inlet Pressure Gauge
Gas Equipment
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248
Gas Equipment
249
Gas Equipment
Single Stage Regulators
Gas Equipment
250
251
Gas Equipment
Double Stage Regulators
Gas Equipment
252
253
Gas Equipment
High Pressure Regulators
Gas Equipment
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255
Gas Equipment
Pipe Line Regulators
Gas Equipment
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Special Regulators
Gas Equipment
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Cutting Blowpipes
Special Features
NM Type Nozzle : Much safer, virtually no backfire due to mixing of gases in the 3 seat
nozzle only. Making chances of backfire/flashback very remote.
Angle Head : Forged fom brass rods - much stronger and longer life.
Tubes for O2 & Fuel Gas : Seamless Stainless Steel
Lever for Cutting Oxygen : Stainless steel Lever, positioned for convenient handling by operator.
Provided with a Latch Facility to avoid operator fatigue.
Filter : S.S. Filter at inlet (oxygen side)
Handle : Metallic instead of plastic - longer life, much better appearance and
grip.
Knobs : Metallic - better grip, longer life.
Weight of cutter : Much lighter - lower fatigue to operator, weight only 1.44 Kg. (without
nozzle).
Gas Equipment
NM250 NM400
Cutting Capacity 300mm thick M.S. 450mm thick M.S.
Type of Cutter Nozzle-Mixing Nozzle-Mixing
Suitable for Acetylene or LPG Acetylene or LPG
Fuel Gas with suitable nozzle with suitable nozzle
Length 450mm 675mm
Angle Head 90° 75°
Standard set l Blowpipe - 1 No. l Blowpipe - 1 No.
includes l Cutting Nozzle - ANM (3/64”) 1 No. l Cutting Nozzle - ANM (5/64”) 1 No.
l Nut & Nipple for hose connection l Nut & Nipple for hose connection
(10mm) - 1 each for O2 & Fuel gas (10mm) - 1 each for O2 & Fuel gas
l Guarantee Card l Guarantee Card
l Data Card for cutting l Data Card for cutting
l Data Card for Gouging
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259
Gas Equipment
Welding & Heating Blowpipe
Gas Equipment
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261
Gas Equipment
Cutting Nozzles
Gas Equipment
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263
Gas Equipment
Welding Tips
Gas Equipment
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Gas Equipment
Flashback Arrestors
ESAB FRT
The ESAB cylindrical flashback arrestors, are of advanced design giving a higher flow rate. The
FRT model is designed to be connected to the regulator or tapping point, model is equipped with a
large cylindrical flame arresting element, an automatic reset non-return valve and a heat sensitive
thermal cut-off.
Gas Equipment
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Gas Equipment
Small / Portable Cutting Machines
8 x 20 mm.
Specifications:
Optional: i) Circle cutting attachments ii) Extra for torches iii) Aluminium tracks
268
Accessories
Gas Equipment
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270
Gas Equipment
PPE & Welding Accessories
274
ELECTRODE HOLDERS & CLAMPS
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276
PPE & Welding Accessories
PERSONAL PROTECTION
HELMETS, MASKS & SCREENS
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278
PPE & Welding Accessories
RESPIRATORY EQUIPMENT
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PPE & Welding Accessories
SPECTACLES, GOGGLES & VISORS
PPE & Welding Accessories
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281
PPE & Welding Accessories
WELDING CURTAINS
(Single / Strip)
(Single / Strip)
(Single / Strip)
PPE & Welding Accessories
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283
PPE & Welding Accessories
WELDING GLOVES
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PPE & Welding Accessories
WELDING CLOTHING
285
PPE & Welding Accessories
WELDING BLANKETS
SAFETY FOOTWEAR
Features:
l EN complaint Safety Footwear for General Engineering,
Chemical, Cement, Construction, Catering & Safety Industry
l Breathable Full Grain Leather Upper, Comfortable, Elegant
l Light Weight
l Imported Mesh Lining
l Imported 200 joules Steel Toe cap EN 12568
l Moulded full socks
PPE & Welding Accessories
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QMS CERTIFICATES
Certificates
287
NOTES
Notes
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Notes
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Notes
World leader in welding and cutting
technology and systems.
ESAB operates at the forefront of Environmental, Health & Safety
welding and cutting technology. Over Management Systems across all our
one hundred years of continuous global manufacturing facilities.
improvement in products and
processes enables us to meet the At ESAB, quality is an ongoing
challenges of technological advance process that is at the heart of all our
in every sector in which ESAB production processes and facilities
operates. worldwide.