The Australian Welding Guide PDF

THE AUSTRALIAN
WELDING
GUIDE
The Ultimate Welding
Reference Guide 2012
welding.com.au
1
FOR OVER 50 YEARS
With a proven history of over 50 years in the Australian market,
WIA has built a reputation for delivering high quality filler
metal products for the industrial user. Known for their quality,
consistency and performance, WIA filler metal products are
preferred by operators across a wide range of industry sectors.
WIA offers an extensive range of consumables for various

welding processes and applications. Choose from mild
steel and low hydrogen electrodes to specialised flux cored
wires and hardfacing products.
Backed by a team of technical professionals who understand

our customers’ needs, we are committed to delivering
welding products that offer peak performance in operability,
mechanical properties and productivity, and backed by the
delivery of technical expertise and support.
WIA is ISO 9001 certified. It’s your guarantee of the highest

levels of quality, satisfaction and efficiency when you
choose WIA products.
2 welding.com.au 1300 300 884

WELDING
INDUSTRIES
OF AUSTRALIA
AN ITW COMPANY
USING THIS GUIDE
PRODUCT SECTION
The front section of this guide contains comprehensive product
information on the range of WIA consumables. Access the latest
information on WIA filler metal products, including technical data
sheets at welding.com.au.
TECHNICAL REFERENCE SECTION
Designed as a portable reference tool for welding engineers, design
and costing personnel, workshop supervisors, welding specialists
and students, the Technical Reference Section incorporates the
information welding professionals need to have on hand.
VIEWING THIS GUIDE AS AN INTERACTIVE PDF
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all CONTENTS pages contain ‘clickable’ links to help you navigate
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DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products,

and does not operate as a provider of consultancy or other technical services or advice
related to welding. The information provided in this document is offered as a guide only.
Every effort has been made to ensure the information contained in this booklet was
correct at the time of printing. WIA does not accept responsibility for errors or information
which is found to be misleading. Prior to using WIA products, it is the purchasers’
responsibility to ensure the products selected are suitable for the application.
1
2
CONTENTS
Introduction 1
ELECTRODES 5
General Purpose Electrodes - Mild Steel
Hydrogen Controlled Electrodes
Iron Powder Electrodes
Cellulose Electrodes
Stainless Steel Electrodes
Cast Iron Electrodes
Gouging and Cutting Electrodes

WIRES 33
Solid MIG Wires – Mild Steel
Solid MIG Wires – Low Alloy Steel
Solid MIG Wires – Aluminium
Metal Cored Gas Shielded Wires
Flux Cored Gas Shielded Wires
Flux Cored Self Shielded Wires
HARDFACING PRODUCTS 65
Hardfacing Electrodes
Hardfacing Solid MIG Wires
Hardfacing Self Shielded Flux Cored Wires
Hardfacing Gas Shielded Flux Cored Wires
TECHNICAL INFORMATION 86
3
CONTENTS
ELECTRODES
General Purpose Electrodes - Mild Steel
Austarc 12P................................................................. 6-7
Austarc 13S................................................................. 8-9
Hydrogen Controlled Electrodes

Austarc 16TC............................................................10-11
Austarc 18TC........................................................... 12-13
Austarc 77................................................................ 14-15
Iron Powder Electrodes

Austarc 24................................................................ 16-17
Cellulose Electrodes
Austarc 11................................................................ 18-19
Stainless Steel Electrodes

Staincord 309Mo-16................................................. 20-21
Staincord 316L-16.................................................... 22-23
Unicord 312............................................................. 24-25
Cast Iron Electrodes

Supercast Ni............................................................ 26-27
Suercast Ni/Fe......................................................... 28-29
GOUGING AND CUTTING ELECTRODES

Austarc C&G............................................................ 30-31
5
CONTENTS
AUSTARC 12P
SUMMARY
• General Purpose Rutile Type Electrode
• Versatile/All Positional Capabilities Including Vertical Down
• Smooth Performance on Low OCV AC Welding Machines
IDENTIFICATION
Coating - Brown Tip - Red Imprint - WIA 4313A
CLASSIFICATION
• AS/NZS 4855-B - E43 13 A
• AWS A5.1: E6013
DESCRIPTION AND APPLICATION

Austarc 12P is a smooth running, rutile type electrode for
all positional welding of mild steel. It is characterised by a
moderately forceful and extremely stable arc. Superb arc
starting and restriking on low voltage AC welding machines.
A stiff fast freezing slag for all positional (especially vertical

down) fillet welding capabilities. Typical applications include,
the all positional welding of galvanised gates/fences, steel
furniture, trailers and wrought iron.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT ARC VOLTAGE
SIZE (mm) LENGTH (mm) RANGE *(A) RANGE **(V)
2.0 300 40-60 19
2.5 300 60-85 20
3.2 380 90-130 21
4.0 380 130-180 22
5.0 450 180-230 23
*Recommended for DC +/- or AC (minimum 45 OCV) operation.

**Voltage is determined by arc current and electrode arc length.
Arc voltage shown is typical and is only to be used as a guide.
6
CONTENTS
2G 3G
ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

4G 1F 4F
1G 2F
3G
SHIPPING APPROVALS
LR 2Ym ABS 2 DNV 2
TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

C Mn Si Fe
0.07 0.5 0.3 Bal
TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

Yield Stress 450 MPa
Tensile Strength 500 MPa
Elongation 26%
CVN Impact Values 70J @ 0°C
In as welded condition.
PACKAGING DATA
PACKAGING APPROX
ELECTRODE (KG) NO. OF PART
SIZE (mm) RODS PER NUMBER
Packet Carton KG
2.0 2.5 12.5 103 12P20
2.5 2.5 12.5 67 12P25
3.2 5.0 15 31 12P32
4.0 5.0 15 20 12P40
5.0 5.0 15 11 12P50
7
CONTENTS
AUSTARC 13S
SUMMARY
• General Purpose/Rutile Type Electrode
• Versatile/All Positional (especially vertical up) Capabilities
• Ideal for Down Hand Fillet Welding of Mild Steel
IDENTIFICATION
Coating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A
CLASSIFICATION
• AS/NZS 4855-B - E43 13 A
• AWS A5.1: E6013

Austarc 13S is the popular “blue and white striped” general
purpose electrode for smooth mitre fillet welding applications.
13S has a soft and stable arc and produces flat, uniform fillet
welds with ease and a self peeling slag action.
Austarc 13S is formulated primarily for fillet welding in all

down hand positions. It is ideal for the general purpose and
structural welding of sheet and plate steels (galvanised or
otherwise) and tubular components, including trailers, duct
work, hoppers and storage tanks, etc.
OPERATIONAL DATA
2.0 300 40-60 19
2.5 300 60-85 20
3.2 380 100-130 21
4.0 380 140-180 22
5.0 450 180-230 23
6.0 450 230-290 24

8
CONTENTS
2G 3G
ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR 2m ABS 2 DNV 2

C Mn Si Fe
0.07 0.55 0.45 Bal

Elongation 26%
PACKAGING DATA
PACKAGING APPROX
Packet Carton KG
2.0 2.5 12.5 99 13S20
2.5 2.5 12.5 63 13S25
3.2 5.0 15 29 13S32
4.0 5.0 15 10 13S40
5.0 5.0 15 6 13S50
6.0 5.0 15 6 13S60
9
CONTENTS
AUSTARC 16TC
SUMMARY
• Basic/Twin Coated (TC) Manual Arc Electrode
• Low Hydrogen, “H10” Status
• Versatile/All Positional (Especially Vertical Up) Capabilities
• Reliable, Low Temperature Impact Toughness
• Easy to Strike and Re-Strike
IDENTIFICATION
Coating - Light Grey Tip - Bronze Imprint - WIA 4916A
CLASSIFICATION
• AS/NZS 4855-B - E49 16-A U H10
• AWS A5.1: E7116-1 H8
Austarc 16TC is a smooth running, basic low hydrogen electrode,
developed for all positional (except vertical down) welding, using
AC or DC power sources. The electrode gives exceptional arc
stability and weldability for its class and produces high quality weld
deposits with reliable notch toughness to -40°C. Austarc 16TC is
manufactured using a unique twin coating extrusion process, which
produces electrodes with two concentric flux coatings. Arc stabilising
elements are concentrated in the inner coating of the electrode for
significantly improved arc stability on AC welding machines.
Other features of 16TC include, a smooth rippled weld profile with
excellent edge wetting and a fluid, easily removed glassy slag. Austarc
16TC deposits X-ray quality weld metal with typical diffusible
hydrogen levels of 5-8 mls of hydrogen per 100 gms of deposited
weld metal, for “as manufactured” product, thus satisfying the “H10”
low hydrogen category of AS/NZS 4855 and “H8” of AWS A5.1.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT *Please note, 2.5 and
SIZE (mm) LENGTH (mm) RANGE *(A) 3.2 Austarc 16TC are
recommended for
2.5 300 60-90 DC+ or AC (minimum
3.2 380 90-135 45 OCV) operation,
4.0 380 140-190 whereas 4.0, 5.0 and
6.0mm sizes require a
5.0 450 190-240 minimum of 55 OCV for
6.0 450 250-310 stable AC operation.
10
CONTENTS
2G 3G
ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LRS 4Ym H10 ABS 3 H10 DNV 3Y H10
C Mn Si P S Fe
0.06 1.2 0.4 0.015 0.010 Bal

Elongation 28%
CVN Impact Values 130J @ -20°C 110J @ -40°C
PACKAGING DATA
PACKAGING APPROX
SIZE (mm) RODS NUMBER
Packet Carton PER KG
2.5 2.5 12.5 61 16TC25
3.2 5.0 15 29 16TC32
4.0 5.0 15 19 16TC40
5.0 5.0 15 10 16TC50
6.0 5.0 15 7 16TC60
MATERIALS TO BE WELDED
CODE TYPE
AS 1163 C250, C350, C450
AS 1397 G250, G300, G350, G450
Structural AS 1450 C/H200, C/H250, C/H350, C/H450,
Steel AS/NZS 3679.1 250, 300, 350, 400
AS/NZS 3678.1 200, 250, 300, 350, 400, 450,
AS/NZS 3679.2 A1006, XK1016, WR350
Pressure
Equipment AS 1548 7-430, 7-460, 5-590, 7-490
Steel
HAI, HA3, HA4N, HA200, HA250,
Fine Grain
AS/NZS 1594 HA300, HA1006, HA1010, HA1016,
Steel
HA350, HA400
Cast Steel AS2074 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2
Pipe Material API 5LX X42, X46, X52, X60
11
CONTENTS
AUSTARC 18TC
SUMMARY
• Basic Twin-Coated (TC) Iron Powder Electrode
• Very Low Hydrogen H5 Status
• Suitable for all Positional Welding Except Vertical Down
• Excellent Low Temperature Fracture Toughness
• Easy to Strike and Re-Strike
IDENTIFICATION
Coating - Light Grey Tip - Blue Imprint - WIA 4918-1A
CLASSIFICATION
• AS/NZS 4855-B - E49 18-A U H5
• AWS A5. 1: E7018-1

Austarc 18TC is a basic iron powder electrode used primarily on
C-Mn and low alloy structural steels. The unique twin-coat design
for 18 type low hydrogen electrode offers excellent AC arc stability
and superb DC+ arc transfer, excellent re-strike, reduced spatter
level and extraordinary ease of use for out-of-position welding.
Typical applications include oil and gas, pipe welding, structural

steel construction, off-shore where Ni-alloying is prohibited,
mining equipment, heavy girders and earth moving plant repair
and maintenance.
OPERATIONAL DATA
ELECTRODE ELECTRODE WELDING CURRENT
SIZE (mm) LENGTH (mm) RANGE *(A)
2.5 300 60-90
3.2 380 90-135
4.0 380 140-190
*Please note, the recommended welding polarity for

Austarc 18TC is DC + or AC (Min. 50 OCV).
SHIPPING APPROVALS
LRS/Pending DNV/Pending
12
CONTENTS
2G 3G

4G 1F 4F
1G 2F
C Mn Si P S Fe
0.06 1.55 0.54 0.010 0.02 Bal

Elongation 24%
CVN Impact Values 87J @ -50°C
PACKAGING DATA
PACKAGING APPROX
2.5 2.5 12.5 45 18TC25
3.2 5.0 15 26 18TC32
4.0 5.0 15 17 18TC40
MATERIALS TO BE WELDED
CODE TYPE
AS 1163 C250, C350, C450
AS 1397 G250, G300, G350, G450
AS 1450 C/H200, C/H250, C/H350, C450
AS 1450 250, 300, 350, 400
Structural C/H200, C/ 200, 250, 300, 350, 400, 450,
Steel H250, A1006, XK1016, WR350
AS/NZS 3679.1 250, 300, 350, 400
AS/NZS 3678.1 200, 250, 300, 350, 400, 450,

AS/NZS 3679.2 A1006, XK1016, WR350
Pressure
Equipment AS 1548 7-430, 7-460, 5-590, 7-490
Steel
HA1, HA3, HA4N, HA200, HA250,
Fine Grain
AS/NZS 1594 HA300, HA1006, HA1010, HA1016,
Steel
HA350, HA400
C2, C3, C7A-1, C1, C4-1, C4-2,
Cast Steel AS2074
C7A-2
Pipe Material API 5LX X42, X46, X52, X60
13
CONTENTS
AUSTARC 77
SUMMARY
• Basic Coated Iron Powder Electrode
• Low Hydrogen Status
• Suitable for All Positional Welding Except Vertical Down
• Excellent Low Temperature Fracture Toughness
IDENTIFICATION
Coating - Light Grey Tip - Black Imprint - WIA 4918-1A
CLASSIFICATION
• AS/NZS 4855-B - E49 18-1 U H5
• AWS A5.1: E7018-1

The Austarc is a smooth running basic type of low hydrogen
iron powder electrode used for all positional welding except
vertical down. The arc is very quiet with little spatter and the
welds are exceptionally smooth with excellent wash in at the
toes of the weld, thus giving minimum undercut. This electrode
is used where the highest restrained work pieces are fabricated
for mining equipment, pressure vessels, heavy girders, earth
moving plant, repair and maintenance etc.
For the highest weld quality with low hydrogen levels, Austarc
77 electrodes should be baked at 400˚C for one hour to obtain
<5mL/100g weld metal. After baking, the electrodes should be
used from a hot box set at 100 -150˚C.
OPERATIONAL DATA
2.5 305 60-105 20
3.2 380 90-145 22
4.0 380 140-200 24
5.0 455 180-300 26

14
CONTENTS
2G 3G

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR 4Ym H5 ABS 3Y H5

C S Mn P Si Fe
0.05 0.011 1.28 0.022 0.30 Bal

Elongation 30%
PACKAGING DATA
PACKAGING APPROX
Packet Carton KG
2.5 2.2 11 45 7725
3.2 5.0 15 26 7732
4.0 5.0 15 17 7740
5.0 5.0 15 9 7750
15
CONTENTS
AUSTARC 24
SUMMARY
• High Iron Powder, Rutile Type Electrode
• High Deposition Rates and Efficiencies
• Suitable for Fast Downhand Fillet and Butt Welding
IDENTIFICATION
Coating - Brown Tip - Yellow Imprint - WIA 4924A
CLASSIFICATION
• AS/NZS 4855-B - E49 24 A
• AWS A5.1: E7024

Austarc 24 is a high iron powder, rutile type electrode designed
for the fast down hand welding of mild steel using AC or DC power
sources. Features include high deposition rates/efficiencies and
flat to slightly concave fillet welds with excellent “edge wash” and
slag detachability. With its smooth running, positive re strike and
high current carrying capacity, Austarc 24 is the ideal fillet welding
electrode for down hand positions aimed at higher productivity.
Austarc 24 is suited to long, heavy fillet and butt welding

applications using a touch welding or `short arc’ technique.
Such applications include the production welding of tanks,
structural members/frames and truck and tractor bodies etc.
OPERATIONAL DATA
3.2 380 120-170 24
4.0 450 200-240 25
5.0 450 270-320 26

16
CONTENTS
ELECTRODES - IRON POWDER ELECTRODES
1F
1G 2F
SHIPPING APPROVALS
LR 2Ym ABS 2 DNV 2

C Mn Si Fe
0.06 0.7 0.4 Bal

Elongation 27%
In as welded condition
PACKAGING DATA
PACKAGING APPROX
Packet Carton KG
3.2 5.0 15 18 2432
4.0 5.0 15 12 2440
5.0 5.0 15 6 2450
17
CONTENTS
AUSTARC 11
SUMMARY
• High Cellulose Coating
• All Positional/High Penetration
• Ideal for Site Welding
IDENTIFICATION
Coating - White Tip - Brown Imprint - WIA 4311A
CLASSIFICATION
• AS/NZS 4855-B - E4311A
• AWS A5.1: E6011

Austarc 11 is a high cellulose electrode developed for all
positional welding on both AC and DC power supplies.
Features include: Forceful, deep penetrating arc with

fast freezing slag. Particularly suited for vertical and incline
pipe welding where complete root penetration is required.
The thin brittle slag is easily removed.
Austarc 11 is recommended for specific applications including

pipeline welding and storage tank construction where either
the “Stove Pipe” or “Flick” techniques can be used to obtain
full root penetration in critical structural joints.
OPERATIONAL DATA
2.5 300 60-95 20
3.2 380 90-125 21
4.0 380 115-175 22
5.0 450 160-220 23

18
CONTENTS
2G 3G
ELECTRODES - CELLULOSE ELECTRODES

4G 1F 4F
1G 2F
3G
SHIPPING APPROVALS
LR 3M ABS 3

C Mn Si Fe
0.13 0.5 0.1 Bal

Elongation 32%
PACKAGING DATA
PACKAGING APPROX
Packet Carton KG
2.5 2.5 12.5 66 1125
3.2 5.0 15 33 1132
4.0 5.0 15 21 1140
5.0 5.0 15 14 1150
19
CONTENTS
STAINCORD 309Mo-16
SUMMARY
• All Positional, Rutile Type Stainless Steel Electrode
• Moisture Resistant Flux Coating/”Extra” Low Carbon Deposit
• Suitable for the Dissimilar Welding of Stainless Steel to
Mild/Low Alloy Steels.
IDENTIFICATION
Coating - Grey Tip - Black Imprint - WIA 309MO-16
CLASSIFICATION
• AS/NZS 4854-B - E309LMo-16
• AWS A5.4: E309MoL-16

Staincord 309Mo-16 is an extra low carbon, rutile type electrode
exhibiting superior all positional (except vertical down performance
with an improved moisture resistant coating for weld metal of
high radiographic integrity. The smooth arc action of Staincord
309Mo-16, together with low spatter and excellent slag control/
detachability, promotes exceptional weld appearance and profile.
Staincord 309Mo-16 is a Molybdenum bearing, highly alloyed

23Cr/12Ni/2.5Mo stainless steel electrode for welding matching
309 and 309Mo base metals. Major applications of Staincord
309 Mo-16 also involve the welding of a wide range of 300
and 400 series stainless steels to mild/low alloy steels. 309M
is also suitable for general welding applications with alloyed
and non-alloyed dissimilar ferrous metal combinations.
OPERATIONAL DATA
2.5 300 50-75 22
3.2 350 75-110 26
4.0 350 110-150 28

20
CONTENTS
2G 3G
ELECTRODES - STAINLESS STEEL ELECTRODES

4G 1F 4F
1G 2F
3G

C Mn Si Cr Ni Mo Fe
0.025 0.8 0.7 23.5 13.0 2.4 Bal

Elongation 38%
PACKAGING DATA
PACKAGING APPROX
2.5 2.5 12.5 86 SC309MO25
3.2 2.5 12.5 55 SC309MO32
21
CONTENTS
STAINCORD 316L-16
SUMMARY
• All Positional, Rutile Type Stainless Steel Electrode
• Moisture Resistant “Colour Coated” Flux Coating
• Extra Low Carbon Weld Deposit
• For the Critical Welding of Matching Type 316 and 316L Steels
IDENTIFICATION
Coating - Pink Tip - Green Imprint - WIA 316L-16
CLASSIFICATION
• AS/NZS 4854-B - ES316L-16
• AWS A5.4: E316L-16

New generation Staincord 316L-16 is an extra low carbon, rutile
type electrode exhibiting superior all positional (except vertical
down) performance with an improved moisture resistant “Pink”
flux coating for weld metal of high radiographic integrity. The
smooth arc action of Staincord 316L-16, together with low spatter
and excellent slag control/detachability, promotes exceptional
weld appearance and profile. Other features include high arc
stability and easy restriking on low voltage AC welding machines.
Staincord 316L-16 deposits Molybdenum bearing, 19Cr/12Ni/2.5Mo
filler metal to meet the requirements for welding type 316 and 316L
stainless steels in critical applications. Staincord 316L-16 is also
recommended for the general purpose welding of common 300
series stainless steels, such as 301, 302, 304 and 304L. It is also
suitable for the general welding of ferritic stainless steel alloys,
such as 409, 444 and 3Cr12.
22
CONTENTS
2G 3G

4G 1F 4F
1G 2F
OPERATIONAL DATA
2.0 300 30-50 20
2.5 300 50-75 21
3.2 350 75-110 26


C Mn Si Cr Ni Mo Fe
0.025 0.7 0.7 18.5 12.0 2.4 Bal

Elongation 40%
PACKAGING DATA
PACKAGING APPROX
Packet Carton KG
2.0 2.5 12.5 86 SC31620
2.5 2.5 12.5 55 SC31625
3.2 2.5 12.5 27 SC31632
23
CONTENTS
UNICORD 312
SUMMARY
• Universal AC/DC Maintenance Electrode for
Welding Ferrous Metals
• Ideal for Joining Dissimilar Steel Components
• Suitable as a Buffer Layer Prior to Hard Surfacing
• Stable Performance on Low OCV Welders
IDENTIFICATION
Coating - Grey Tip - Red Imprint - Unicord 312
CLASSIFICATION
• AS/NZS 4854-B - ES312-16
• AWS A5.4: E312-16

Unicord 312 is a basic, rutile type electrode depositing a
29%Cr/9%Ni stainless steel weld metal for the high strength
welding of a wide range of alloy steels and dissimilar ferrous
metals. The high ferrite, austenitic stainless steel deposit has
excellent resistance to hot cracking, even under dilution by
high carbon, alloy and tool steels. Unicord 312 is a universal
maintenance electrode combining high strength, toughness, wear
and corrosion resistance with compatibility to most ferrous metals.
Unicord 312 is suitable for many repair and maintenance
applications on steels of unknown composition. It is an ideal
electrode for welding medium to high carbon steels, low alloy
steels and dissimilar ferrous metal combinations. Unicord 312
is also suitable as a buffer or intermediate layer prior to the
application of hard surfacing.
OPERATIONAL DATA
2.5 300 50-75 22
3.2 350 75-110 26
*Recommended for DC +/- or AV (minimum 45 OCV) operation.
24 Arc voltage shown is typical and is only to be used as a guide.
CONTENTS
2G 3G

4G 1F 4F
1G 2F

C Mn Si Cr Ni Fe
0.04 0.9 0.85 30.0 9.0 Bal

Elongation 45%
Deposit Hardness 28-35 HRc
PACKAGING DATA
PACKAGING APPROX
2.5 2.5 12.5 52 UC31225
3.2 2.5 12.5 27 UC31232
25
CONTENTS
SUPERCAST Ni
SUMMARY
• Pure Nickel Core Wire/Basic, Graphite Coating
• Soft Machineable Nickel Deposit for the Lower Strength
Welding of Cast Irons
IDENTIFICATION
Coating - Black Tip - Plain Imprint - WIA SC Ni
CLASSIFICATION
• AWS A5.15: ENi-Cl

Supercast Ni is a basic, graphite coated AC/DC electrode for the
lower strength welding of cast irons. It is characterised by a soft,
smooth arc with low penetration and spatter levels on both AC
and DC power sources. Ease of striking is a feature of Supercast
Ni and it also has a particularly good wetting action resulting in
well bonded welds of regular contour and attractive appearance.
This electrode is made from a pure nickel core wire and

produces a ductile, fully machineable weld deposit. Supercast
Ni may be used for the repair and reclamation of all standard
grades of grey cast iron, malleable iron, austenitic cast iron
and some grades of mechanite cast iron.
OPERATIONAL DATA
3.2 350 50-100 23

26
CONTENTS
2G 3G
ELECTRODES - CAST IRON ELECTRODES

1F 4G
1G

Mn Ni S Fe
0.3 97.0 0.006 Bal

Deposit Hardness 150-170 HV (30)
PACKAGING DATA
PACKAGING APPROX
3.2 2.5 12.5 37 SNI32
27
CONTENTS
SUPERCAST Ni/Fe
SUMMARY
• Nickel -Iron Core Wire/Basic, Graphite Coating
• Machineable Nickel-Iron Deposit for the Higher Strength
Welding of Cast Irons, Particularly SG Irons
IDENTIFICATION
Coating - Black Tip - Green Imprint - WIA SC NiFe
CLASSIFICATION
• AWS A5.15: ENiFe-Cl

Supercast Ni/Fe is a basic, graphite coated AC/DC electrode
for the higher strength welding of cast irons. It is characterised
by a soft, smooth arc with low penetration and spatter levels on
both AC and DC power sources. Ease of striking is a feature of
Supercast Ni/Fe.
This electrode is made from a Nickel-Iron core wire and

produces a ductile, machineable weld deposit with the extra
strength required for welding SG (Spheroidal Graphite) irons.
Supercast Ni/Fe may also be used for the repair and reclamation
of all standard grades of grey cast iron, malleable iron, austenitic
cast iron and some grades of mechanite cast iron. It is ideally
suited to the dissimilar welding of these irons to steels.
OPERATIONAL DATA
3.2 350 50-100 23

28
CONTENTS
2G 3G
ELECTRODES - CAST IRON ELECTRODES

1F 4G
1G

Mn Ni S Fe
0.85 57.8 0.007 Bal

Deposit Hardness 200-220 HV (30)
PACKAGING DATA
PACKAGING APPROX
3.2 2.5 12.5 39 SNIFE32
29
CONTENTS
AUSTARC C&G
SUMMARY
• Heavy Coated Manual Electrode for Cutting, Gouging
or Piercing Steels
IDENTIFICATION
Coating - Black End Tip - Plain

Austarc C&G is a heavy coated electrode providing a highly
mobile means of cutting, gouging and piercing most steels,
using standard AC or DC arc welding equipment. Austarc C&G
produces a very high arc force and can be used for general
cutting and grooving in joint preparation, removing defective
welds and reclaiming scrap metal, etc.
Oxy-acetylene and carbon arc-air cutting and gouging are two
processes available to industry capable of giving high quality,
smooth preparations. Austarc C&G will not replace these
processes but rather provide a convenient, easy to use and
mobile tool for the arc gouging and cutting of most metals.
It is particularly useful to the maintenance welder operating in
awkward locations to remove welds, open up joints and trim
off bolt or rivet heads, etc. Similarly, the rural welder will find
C&G handy in repairing or preparing joints when operating
away from (or without) oxy-acetylene equipment.
Cutting - Direct the electrode into the work in the desired cutting
direction, working from the outside edge. Use an up and down
sawing motion, the “up” arc length being increased to increase
heating, the “down” arc length being decreased to contact point
to force the molten metal out of the groove. Angle of electrode
should be approx 70° to the horizontal.
30
CONTENTS
ELECTRODES - GOUGING AND CUTTING ELECTRODES
Gouging - Point the electrode in the direction of gouging at
approx 10-20° to the plate surface. Strike the arc and move
forward rapidly. If slag and molten metal start to clog the groove
bring the electrode up to clear and, without breaking the arc, circle
backwards and move forward again. This latter technique may
prove more necessary than straight forward motion on lower
amps or as the electrode becomes hotter. If amps are excessive,
C&G will tend to “cut out” on AC and overheat, causing premature
charring of the coating and reduced arc force.
Piercing - For holes, plunge the electrode into the plate at slightly
off right angles. With a small circular motion to the holder, force
the electrode into the plate until full penetration is achieved.
Once the hole has been made it may be trimmed with an up
and down sawing motion.
OPERATIONAL DATA
ELECTRODE ELECTRODE PACKAGING (KG) WELDING CURRENT

SIZE (mm) LENGTH (mm) RANGE *(A)
Packet Carton
3.2 380 4 12 170-250
4.0 380 4 12 220-350
31
CONTENTS
32
CONTENTS
WIRES
solid mig wires
Austmig ES6....................................................................... 34-35
solid mig wires - low alloy steel
Austmig ESD2 ........................................................ 36-37
Austmig NiCrMo ...................................................... 38-39
solid mig wires - Aluminium

Austmig 5183........................................................... 40-41
Austmig 5356 .......................................................... 42-43
METAL CORED GAS SHIELDED WIRES

Austfil 70C-6M......................................................... 44-45
flux cored gas shielded wires

Austfil 71T................................................................ 46-47
Austfil 71T-1M.......................................................... 48-49
Hobart XL-525......................................................... 50-51
TM-71HYD............................................................... 52-53
TM-811N2................................................................ 54-55
flux cored SELF shielded wires

Fabshield 4.............................................................. 56-57
Fabshield 23............................................................ 58-59
Fabshield 21B.......................................................... 60-61
Fabshield XLR-8...................................................... 62-63
33
CONTENTS
AUSTMIG ES6
SUMMARY
• Electrostatically Copper Coated Gas Metal Arc (MIG) Wire
• All Positional Welding of Mild and Medium Strength Steels
• Precision Layer Wound, Very Low Diffusable Hydrogen
• Suitable for all Transfer Modes
• Designed for use with Argon/CO₂ and CO₂ Shielding Gases
CLASSIFICATION
• AS/NZS 2717.1: ES6-GC-W503AH
• AS/NZS 2717.1: ES6-GM-W503AH
• AWS A5.18: ER70S-6

Austmig ES6 is a copper coated, low carbon steel GMAW wire,
formulated for optimum performance under Argon/CO₂ mixed
gases and welding grade CO₂. Arc transfer characteristics are
excellent with Argon based gas mixtures, particularly in spray
and pulsed transfer modes. Austmig ES6 is an electrostatically
copper coated wire providing excellent wire feeding and electrical
conductivity and reducing contact tip wear. The higher manganese
and silicon content of Austmig ES6 provides effective weld metal
deoxidation for resistance to porosity.
Austmig ES6 is suitable for a wide range of welding applications
on mild and medium strength steels providing consistently very
low “H5” weld metal diffusible hydrogen levels when used with
suitable shielding gases.
OPERATIONAL DATA
WIRE WELDING CURRENT ARC VOLTAGE
SIZE (mm) RANGE (A) RANGE *(V)
0.6 40-100 12-16
0.8 60-180 14-22
0.9 70-230 15-26
1.0 100-290 16-29
1.2 120-350 18-32
1.6 160-390 18.34
Welding Current DC +
*Voltage is determined by arc current and electrode arc length.
34 Welding currents and voltage shown are operational guides only.
CONTENTS
2G 3G
WIRES - SOLID MIG WIRES - MILD STEEL

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR 3S, 3YS

C Mn Si S P Fe
0.1 1.45 0.88 0.02 0.022 Bal

Gas Type CO₂ Ar+18% CO₂
Yield Stress 460 MPa 480 MPa
Tensile Stress 560 MPa 580 MPa
Elongation 28% 26%
CVN Impact Values 80J @ -20ºC 70J @ -30ºC
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
5kg spool ES606M5KG
0.6
15kg spool ES606S
5kg spool ES608M5KG
0.8
15kg spool ES608S
5kg spool ES609M5KG
0.9
15kg spool ES609S
1.0 15kg spool ES610S
35
CONTENTS
AUSTMIG ESD2
SUMMARY
• Copper Coated, High Manganese-Molybdenum Gas Metal
Arc (MIG) Welding Wire
• For the all Positional Welding of Medium to Higher
Strength Steels
CLASSIFICATION
• AS/NZS 2717.1: ESD2-GC-W559AH
• AS/NZS 2717.1: ESD2-GM-W559AH
• AWS A5.18: ER80S-D2

Austmig ESD2 is a copper coated, low alloy steel wire used
for welding medium to higher strength steels, particularly where
service temperatures up to 500°C are encountered. ESD2 gives
excellent resistance to porosity using CO₂ or Argon based gas
mixtures (i.e. Ar/CO₂, Ar/O₂, Ar/CO₂/O₂). When porosity is a
potential problem due to dirty or rusty surfaces or higher than
normal sulphur contents, Austmig ESD2 will provide a
consistently sound weld deposit.
Austmig ESD2 is also suitable for out-of-position welding due
to its quick freezing weld pool. ESD2 produces high quality
welds on plain carbon and C-Mn steels, low alloy steels and
higher strength used in pressure vessels and boilers, such as
petrochemical and power generation industries, operating at
elevated temperatures. Austmig ESD2 may also be used for the
fillet welding of higher tensile, quenched and tempered steels,
such as Bisalloy 70 and 80 where the lower strength weld metal
may be compensated by larger fillet sizes.
When used with suitable shielding gases, Austmig ESD2
will consistently produce very low “H5”, weld metal diffusible
hydrogen levels, for excellent resistance to HAZ or hydrogen
induced cracking.
36
CONTENTS
2G 3G
WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

4G 1F 4F
1G 2F
OPERATIONAL DATA
0.9 70-230 15-26
1.2 120-350 18-32
Welding currents and voltage shown are operational guides only.

C Mn Si Mo Fe
0.1 1.95 0.75 0.5 Bal

Gas Type CO₂ Ar+18% CO₂
Elongation 19% 20%
CVN Impact Values 35J @ -20ºC 50J @ -30ºC
NOTE: The use of less oxidizing Argon based gas mixtures will result
in higher manganese and silicon weld metal recovery, leading to higher
tensile properties, particularly in heavy multi pass butt welds.
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
0.9 15kg spool ESD209S
1.2 15kg spool ESD209S
37
CONTENTS
AUSTMIG NiCrMo
SUMMARY
• Copper Coated, Low Allloy Gas Metal Arc (MIG) Welding Wire
• All Positional Welding of Medium and High Strength Steels
• Welded Strength 760 MPa Tensile Class
CLASSIFICATION
• AS/NZS 2717.1: ESMG-GM-W769AH-G
• AWS A5.28: ER110S-G

Austmig NiCrMo is a copper coated, low alloy solid wire
suitable for the all positional welding of high strength steels
using Argon + CO₂ gas mixtures.
Austmig NiCrMo is ideal for the full strength welding of

quenched and tempered structural steels, of the 760 MPa
tensile class, such as USS-T1, CcMo Pipe, Welten 80,
Weldox 700, X80, N-A-XTRA and Bisplate 80.
OPERATIONAL DATA
0.9 70-230 15-26
1.2 120-350 18-32
NOTE: Austmig NiCrMo is NOT to be used in weldments which

are to be stress relieved.
38
CONTENTS
2G 3G
WIRES - SOLID MIG WIRES - LOW ALLOY STEEL

4G 1F 4F
1G 2F

C Mn Si Ni Cr Mo V Fe
0.07 1.22 0.37 1.42 0.29 0.24 0.07 Bal

Gas Type Ar+18% CO₂
Tensile Stress 799 MPa
Elongation 18%
CVN Impact Values 78J @ -30ºC
NOTE: The use of less oxidizing argon based gas mixtures

(ie Ar/O₂, Ar/CO₂, Ar/CO₂/O₂), will result in higher alloy recovery
in the weld metal, leading to higher tensile properties.
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
0.9 15kg spool MNICRMO09S
1.2 15kg spool MNICRMO12S
39
CONTENTS
AUSTMIG 5183
SUMMARY
• Aluminium-Magnesium-Manganese, Metal Inert
Gas (MIG) Welding Wire
• Precision Layer Wound and Double Shaved for
Superb Feedability
• For Welding of Alloys of the same Composition
CLASSIFICATION
• AS/NZS ISO 18273 - S AI 5183
• AWS A5.10: E5183

Austmig 5183 is a precision layer wound aluminium wire
alloyed with Mg, Mn and Cr.
It is recommended for welding Al/Mg material of the 5083 type

in the annealed condition, particularly for low temperature
applications where good ductility and toughness are required, ie
cryogenic plant. It may also be used for welding medium strength
Al/Zn/Mg alloys of the 7020 type and joining 5083 alloy to 5456 alloy.
Welding grade Argon or Argon/Helium shielding gas combinations

are recommended with flow rates of 10-20 litres/minute.
OPERATIONAL DATA
1.2 150-250 20-27
1.6 200-350 23-30
40
CONTENTS
2G 3G
WIRES - SOLID MIG WIRES - ALUMINIUM

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR WC/1-1S ABS AWS A5. 10-92/ER5183
DNV 5183

Si Fe Cu Mn Mg Cr Zn Ti AI
0.4 0.4 0.1 0.5-1.0 4.3-5.2 0.05-0.25 0.25 0.15 Bal

Gas Type Ar
Elongation 17%
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 6kg spool M518312S
41
CONTENTS
AUSTMIG 5356
SUMMARY
• Aluminium - 5% Magnesium Alloy, Metal Inert Gas
(MIG) Welding Wire
• Double Shaved and Precision Layer Wound for
Superb Feedability
• For Welding Cast and Wrought Aluminium Alloys
Containing Magnesium
CLASSIFICATION
• AS/NZS ISO 18273 - S AI 5356
• AWS A5.10: ER5356

Austmig 5356 is a precision layer wound Aluminium - 5%
Magnesium wire suitable for a wide range of gas metal arc
welding applications on wrought or cast aluminium alloys
containing magnesium as a major alloying element. Some
grades of wrought aluminium - magnesium alloys which can
be welded with Austmig 5356 are, 5083, 5086, 5454 and 5456.
OPERATIONAL DATA
0.9 80-190 16-22
1.0 100-230 18-22
1.2 150-250 20-27
1.6 200-330 23-30
42
CONTENTS
2G 3G
WIRES - SOLID MIG WIRES - ALUMINIUM

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR WC/I-1,S; ABS AWS A5. 10-92/ER 5356; DNV 5356

Zn Mg Mn Cr Si Fe Ti AI
0.1 5.2 0.15 0.1 0.25 0.4 0.15 Bal

Gas Type Ar
Elongation 17%
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
2kg spool M5356092KG
0.9
6kg spool M535609S
1.0
6kg spool M535610S
1.2
6kg spool M535612S
43
CONTENTS
AUSTFIL 70C-6M
SUMMARY
• Gas Shielded, Metal-Cored Wire
• Slag-Free Weld Bead
• Higher Deposition Rates
• Low Spatter/Smooth Appearance
• Better Fusion Profile
CLASSIFICATION
• AS/NZS ISO 17632-B - T 492T15 0MA-UH5
• AWS A5.18: E70C-6M

Austfil 70C-6M is a metal-cored wire designed for high speed
fillet and butt welding in the downhand position using Argon
+ 18-25% CO₂ shielding gas mixture. Weld beads are almost
completely slag free with only minimal silicon islands, reducing
the time and effort spent between runs and on cleanup prior to
surface finishing.
Austfil 70C-6M is recommended for single and multi pass

welding in both flat and horizontal positions for mild steel,
carbon and maganese carbon steels with minimum clean up
and where high deposition rates and efficiencies are required
in high productivity, semi automatic and fully automatic welding
installations. Suitable applications include mining buckets,
structural fabrication and tank construction where high speed
welding is required.
OPERATIONAL DATA
1.2 200-350 29-35
1.6 300-450 27-34
*Voltage is determined by arc current and wire arc length.
44
CONTENTS
2G
WIRES - METAL CORED GAS SHIELDED WIRES

1F
1G 2F
SHIPPING APPROVALS
LR 3S, 3YS

C Mn Si S P Cu Fe
0.038 1.46 0.68 0.009 0.012 0.02 Bal

Gas Type Ar+25%CO₂
Elongation 29%
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg spool 70C6M12S
1.6 15kg spool 70C6M16S
1.2 250kg drum 70C6M12D
45
CONTENTS
AUSTFIL 71T
SUMMARY
• All Purpose Rutile Flux Cored Wire
• For Both Single or Multiple Pass Welds
• All Positional Wire
• Formulated Exclusively For CO₂ Gas
CLASSIFICATION
• AS/NZS ISO 17632-B - T492T1-1CA-UH10
• AWS A5.20: E71T-1 H8

Austfil 71T is a rutile flux cored wire designed for excellent
performance in all positional fillet and butt-welding applications.
Austfil 71T is formulated exclusively for use with cost effective
CO₂ shielding gas.
Austfil 71T is recommended for general purpose all positional

welding of mild, carbon and carbon-manganese steels where
excellent weld profile and penetration is required. Suitable for
applications such as storage tanks, structural fabrication, bridge
construction, machinery and earthmoving equipment. Suitable
for AS/NZS 1554.5 of the structural code; Part 5: Welding of
the steel structures subject to high levels of fatigue loading.
OPERATIONAL DATA
1.2 130-230 25-32
1.6 200-350 25-32
Welding parameters shown above are for DC electrode positive
using 100% CO₂ shielding gas at a flow rate of 15-20 litres/minute.
46
CONTENTS
2G 3G
WIRES - FLUX CORED GAS SHIELDED WIRES

4G 1F 4F
1G 2F
SHIPPING APPROVALS
LR 3S, 3YS

C Mn Si S P Fe
0.03 1.28 0.44 0.01 0.013 Bal

Gas Type CO₂
Elongation 26%
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg spool 71T112S
1.6 15kg spool 71T116S
47
CONTENTS
AUSTFIL 71T-1M
SUMMARY
• Rutile Type Flux Cored Joining Wire, Micro Alloyed
• Formulated Exclusively for use with Ar/CO₂
Shielding Gas Mixtures
• Excellent Operator Appeal “Smooth Spray Arc Transfer”
• Versatile all Positional Capabilities
• Grade 3 Weld Metal Impact Properties
CLASSIFICATION
• AS/NZS ISO 17632-B - T492T1-1MA-UH10
• AWS A5.20: E71T-1M

An all positional rutile micro alloyed type flux cored welding
wire specifically formulated for optimum performance using
Ar/CO₂ shielding gas mixtures.
The exceptionally smooth arc performance produces a

superb weld for single or multipass welding with low spatter
losses in all positions and applications (except vertical down).
Austfil 71T-1M is recommended for the welding of mild,
carbon and carbon-manganese medium steels where good
impact properties at -20°C are required.
This high deposition wire offers excellent operator appeal for

general steel fabrications and constructions such as plate
sections, beams, girders, truck chassis/bodies, shipbuilding,
earth moving equipment, storage tanks, bridge construction etc.
Recommended shielding gases are: Argon + 18-25%CO₂
48
CONTENTS
2G 3G

4G 1F 4F
1G 2F
OPERATIONAL DATA
WIRE WELD WELDING CURRENT ARC VOLTAGE
SIZE (mm) POSITION RANGE (A) RANGE *(V)
Flat 250-300 29-35
1.2 Flat Fillet 230-280 28-30
Vertical - up 170-220 24-28
Flat 300-350 28-34
1.6 Flat Fillet 200-350 24-34
Vertical - up 200-250 26-28
Recommended electrical stick out is 15-20mm.

SHIPPING APPROVALS
LR 3S, 3YS

C Mn Si S P B Fe
0.04 1.20 0.42 0.012 0.013 0.001 Bal

Elongation 25%
PACKAGING DATA
WIRE PACK SIZE PALLET SIZE
PART NUMBER
SIZE (mm) AND TYPE (KG)
1.2 15kg spool 1080 71T1M12S
1.6 15kg spool 1080 71T1M16S
49
CONTENTS
HOBART XL-525
SUMMARY
• Low Diffusible Hydrogen
• Excellent Toughness at Low Temperatures
• Outstanding Weldability
• Exceeds 27J CVN @ -40℃
CLASSIFICATION
• AS/NZS ISO 17632-B - T494T1-1MA-UH5
• AWS A5.20: E71T-1M, E71T-12MJ H8

A rutile flux cored all position wire designed for welding mild
and carbon steels, especially when good impact toughness
is required at sub zero temperatures. Ideal for single and
multi-pass applications, it delivers outstanding welding
performance and produces high quality X-ray clear weld
deposit with a bead contour that is flat to slightly convex.
It can be used over rust, mill scale and some primers with
no pre-cleaning of the steel necessary. Formula XL-525 has
outstanding mechanical properties that resemble those of
E7018 MMAW (SMAW) electrodes, plus high operator
appeal with low fume levels, low spatter and easy slag removal.
Recommended for ship building, storage vessels, off-shore

structures, earth moving equipment and pipe welding.
50
CONTENTS
2G 3G

4G 1F 4F
1G 2F
OPERATIONAL DATA
1.2 150-300 24-31
1.6 200-350 24-34

SHIPPING APPROVALS
LR 3S, 3YS; ABS 3SA, 3YSA Impact @ -40̊C 34 ft, lbs
DNV Y40MS BV 3YM; CWB E491T-12MJ-H4;

C Mn Si Ni Fe
0.04 1.24 0.29 0.37 Bal

Elongation 29%
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg spool S283212-029
1.6 15kg spool S283219-029
51
CONTENTS
TM- 71HYD
SUMMARY
• Low Diffusible Hydrogen
• Exceeds 27J CVN @ -40℃
• Outstanding Weldability in all Positions
• Actual Certification to AWS A5.01 Lot Class: T3
CLASSIFICATION
• AS/NZS ISO 17632-B - T494T1-1CA-UH5
• 1.2mm, AWS E71T-1C, E71T-12CJ H4
• 1.6mm, AWS E71T-1C, E71T-12CJ H8

Formulated to provide extremely low hydrogen levels. This
outstanding all positional wire produces a high quality X-ray
clear weld deposit with high impact values at low temperature.
Every batch of the TM-71HYD is actual tested to certify the
quoted mechanical property, and the vacuum sealed packaging
further ensures the product integrity upon delivery.
Applications include ship building and repair, earth moving

equipment, structures, pressure vessel and storage vessels.
OPERATIONAL DATA
1.2 100-350 22-34
1.6 200-350 24-34

52
CONTENTS
2G 3G

4G 1F 4F
1G 2F
SHIPPING APPROVALS
MIL-71T-1-HYD

C Mn Si S P Ni Fe
0.05 1.17 0.25 0.014 0.12 0.5 Bal

Gas Type 100% CO₂
Elongation 26.6%
137J @ -40ºC
Aged 48 hours @ 104ºC
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg spool S245112-K53
1.6 15kg spool S245019-K53
53
CONTENTS
TM-811N2
SUMMARY
• Fast-Freezing Slag
• Low Spatter
• Excellent Arc Characteristics
• High Impact Strengths at Low Temperatures
CLASSIFICATION
• AS/NZS ISO 17632-B - T555T1-1C/MA-2Ni-UH5
• AWS A5.29: E81T1-Ni2C/MJ H8

Offers excellent arc stability and low spatter using either
CO₂ or Ar/CO₂ mixtures with up to 80% Argon. These weldability
features, combined with low diffusible hydrogen levels and good
impact values makes the wire a good choice for single and
multiple pass welding in all positions.
Applications include ship building, offshore drilling rigs, HSLA

steels and weathering steels with no colour match requirement..
OPERATIONAL DATA
1.2 100-350 22.34

54
CONTENTS
2G 3G

4G 1F 4F
1G 2F
SHIPPING APPROVALS
ABS 3YSA; DNV Y40MS; LR 3Ys

Shielding Gas C Mn Si P S Ni
100% CO₂ 0.04 1.02 0.29 0.010 0.007 2.09
75% Ar/25% CO₂ 0.05 1.26 0.44 0.010 0.007 2.07

Gas Type 100% CO₂ 75% Ar/25% CO₂
Elongation 27.5% 26%
CVN Impact Values 126J @ -40˚C 104J @ -40˚C
95J @ -51˚C 71J @ -51˚C
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg spool S283712-K29
55
CONTENTS
FABSHIELD 4
SUMMARY
• Self Shielded or “Gasless” Flux Cored Joining Wires
• For Fast Downhand Fillet and Butt Welding Applications
• Excellent Bead Appearance/Low Spatter Levels
• Crack Resistant Weld Deposits/Tolerant to Poor Joint Fit-up
CLASSIFICATION
• AS/NZS ISO 17632-B - T49ZT4-0NA-H15
• AWS A5.20: E70T-4

Fabshield 4 is an outstanding, high deposition rate, (up to 12.7kg/
hr using 2.4mm size wire) self-shielded or “gasless” flux cored
wire for downhand single or multi-pass welding applications.
It is specifically designed to de-sulphurise the weld deposit and
thereby resist cracking. Fabshield 4 is particularly suited to the
fast fillet welding of mild and medium strength steels.
Typical applications include the welding of structural members

and machinery. Due to its self shielding arc, Fabshield 4 is ideal
for “on site” field construction and repair applications.
OPERATIONAL DATA
2.4 250-500 28-34
3.0 450-680 28-37
Welding Current DC -
56
CONTENTS
WIRES - FLUX CORED SELF SHIELDED WIRES
1F
1G 2F

C Mn Si P S AI Fe
0.27 0.73 0.30 0.11 0.005 1.42 Bal

Elongation 25%
CVN Impact Values Not Required
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
2.4 22.7kg spool S224529-014
3.0 22.7kg spool S224541-014
57
CONTENTS
FABSHIELD 23
SUMMARY
• All Positional Welding Capabilities
• Suitable for Single-Pass Applications only
• Ideal for Mild and Galvanized Steels
CLASSIFICATION
• AS/NZS ISO 17632-B - T49ZTG-1SNA
• AWS A5.20: E70T-GS

Fabshield 23 is a general-purpose self-shielded tubular wire
that is designed for welding thin gauge mild or galvanized steel.
Suitable for single-pass applications, especially for fillet lap
welds, you will get outstanding welding performance as
Fabshield 23 produces a smooth spray arc type of transfer
with goods wetting action.
Great for welding outdoors in draughty conditions, this

all-positional wire also provides very low splatter levels,
resulting in a weld bead that is excellent in appearance.
Perfect for on site applications such as welding mild steel/
galvanized gates, fences, frames, sheds, prefab building
fabrications, ornamental ironwork, general fabrication, etc.
OPERATIONAL DATA
TYPICAL
STICKOUT
(mm)
0.8 25-125 14-16 12
0.9 55-120 17-20 12
58
CONTENTS
2G 3G

4G 1F 4F
1G 2F

C Mn Si S P AI Fe
0.18 0.65 0.40 0.01 0.01 1.30 Bal

NOTE: Yield Stress and impact values not applicable.
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
0.8 4.5kg spool S222306-022
0.9 4.5kg spool S222308-022
0.9 15kg spool S222308-029
59
CONTENTS
FABSHIELD 21B
SUMMARY
• All Positional Welding Capabilities
• Suitable For Single Pass/Multi-pass Applications
• Suitable for Mild/Galvanised Steels
CLASSIFICATION
• AS/NZS ISO 17632-B - T49ZT11-1NA-H15
• AWS A5.20: E71T-11

Fabshield 21B is a general purpose self-shielded tubular wire
that is designed for single and multi-pass welding of thin gauge
to 20mm thick mild or galvanized steels. Great for welding fillet or
lap welds, you will find that this all-position wire has high operator
appeal, producing a smooth spray-like transfer with low spatter
levels, excellent weld appearance and easy to remove slag.
Perfect for on-site applications such as the welding of machine

parts, galvanized steels tanks, gates, frames, sheds, prefab
construction, light structures, general fabrication etc.
OPERATIONAL DATA
Welding parameters shown below are for
DC Electrode negative only.
TYPICAL
STICKOUT
(mm)
0.9 55-120 17-20 12
1.2 130-160 15-18 12
1.6 150-250 18-20 19
2.0 200-300 16-23 19
60
CONTENTS
2G 3G

4G 1F
1G 2F

C Mn Si S P AI Fe
0.28 0.34 0.15 0.008 0.003 1.04 Bal

Elongation 22%
CVN Impact Values Not Required
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
0.9 4.5kg spool S222108-022
1.2 4.5kg spool S222112-022
1.2 15kg spool S222112-029
1.6 15kg spool S222119-029
2.0 15kg spool S222125-029
61
CONTENTS
HOBART XLR-8
SUMMARY
• Welds Out of Position at High Currents
• Low Hydrogen Weld Deposit
• Excellent Slag Removal
• No Shielding Gas Required
• High Impact Strength at Low Temperatures
• Excellent Mechanical Properties Under a
Wide Range of Heat Input
CLASSIFICATION
• AS/NZS ISO 17632-B - T494T8-1NP-H10
• AWS A5.20: E71T-8JD H8

Low hydrogen T-8 self-shielded, all positional flux cored wire,
producing a stable arc and flat bead profile, especially suited
for vertical-up welds at high currents with excellent mechanical
properties and a tensile strength of 490 MPa. Capable of
depositing X-ray quality welds, making it highly suitable for critical
welding applications requiring a high degree of crack resistance
due to its low diffusible hydrogen levels, less than 6.7ml per
100g of weld metal deposited. XLR-8 has been designed for
single and multi-pass welding applications with improved
productivity in out-of-position welding, offering high impact
strength of (42J) at sub zero temperatures to -40˚C.
Specifically designed for increased productivity and high
deposition rates on challenging structural steel erection, heavy
equipment repair, mining equipment, bucket repairs, storage
tanks, pipe spooling, ship construction and site work applications.
OPERATIONAL DATA
1.6 180-300 18-25
1.8 170-330 18-25
2.0 200-360 18-26
Recommended electrical stick out is 25-35mm. Welding Current DC -
62 Welding currents and voltage shown are operational guides only.
CONTENTS
2G 3G
WIRES - FLUX CORED SELF SHIELDED WIRES

4G 1F 4F
1G 2F
SHIPPING APPROVALS
ABS 3YSA; AWS D1.8 Conformance

C Mn Si P S AI Fe
0.19 0.51 0.17 0.009 0.006 1.51 Bal

Elongation 25%
CVN Impact Values 42J @ -40˚C
Diffusible Hydrogen 6.7ml/100g of weld deposited
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.6 15kg spool S225719-053
1.8 15kg spool S225724-053
2.0 15kg spool S225725-053
2.0 22.7kg coil S225725-014
63
CONTENTS
64
CONTENTS
HARDFACING PRODUCTS
hardfacing electrodes
Abrasocord 43......................................................... 66-67
Abrasocord 350....................................................... 68-69
Abrasocord 700....................................................... 70-71
Tubecord D - 2355................................................... 72-73
Tubecord E - 2460................................................... 74-75
Hardfacing Solid mig wires

Austmig TD-600 ...................................................... 76-77
Hardfacing self shielded flux cored wires

Mckay Tube-Alloy 240-0.......................................... 78-79
Mckay Tube-Alloy 258-0.......................................... 80-81
Mckay Tube-Alloy A43-0.......................................... 82-83
Hardfacing GAS shielded flux cored wires

Mckay Vertiwear-600............................................... 84-85
65
CONTENTS
ABRASOCORD 43
SUMMARY
• Tough, Wear Resistant Complex Carbide Type Deposit
• For Hard Surfacing Components Subjected to Extreme
Abrasion and Moderate to Heavy Impact
• Similar Deposit Type to Tubecord E-2460
IDENTIFICATION
Coating - Black Tip - Plain Imprint - WIA AC 43
CLASSIFICATION
• AS/NZS 2576: 2465-A4

Abrasocord 43 is a heavy coated, hard surfacing electrode
depositing extremely hard, abrasion resistant Chromium/
Niobium carbides in an austenitic matrix. It is ideal for hard
surfacing applications where resistance to extreme abrasion
(in particular sliding abrasion) and moderate to heavy impact
are required. Due to the nodular shape of the complex
carbides, Abrasocord 43 deposits are capable of withstanding
heavier impact levels than standard chromium carbide grades.
Typical applications include bucket teeth/lips, grizzlies, press
screws, crusher hammers and ripper teeth to name but a few.
Abrasocord 43 deposits are non-machineable, grindable, prone

to fine relief checking and should be restricted to 3 layers high.
While two layers of Abrasocord 43 may be required for maximum
wear resistance, this complex carbide alloy has lower dilution
sensitivity than straight chromium carbide deposits.
OPERATIONAL DATA
3.2 380 115-140 19
4.0 380 140-185 22
5.0 450 190-255 24

66 Arc voltage shown is typical and is only to be used as a guide.
CONTENTS
2G
HARDFACING PRODUCTS - HARDFACING ELECTRODES

1G

C Mn Cr Nb Fe
5.0 0.7 22.0 7.0 Bal

Single Layer onto Mild Steel Typical Hardness 60-65 HRc
Multi-Layer Typical Hardness 64-69 HRc
Single layer deposit hardness may vary depending
on base metal type and degree of dilution
PACKAGING DATA
PACKAGING APPROX
3.2 5 15 16 AC4332
4.0 5 15 11 AC4340
5.0 5 15 6 AC4350
67
CONTENTS
ABRASOCORD 350
SUMMARY
• Tough, Machineable, Wear Resistant Martensitic Steel Deposit
• For Hard Surfacing Steels Subjected to Metal-to-Metal Wear
Under Compressive Loading
IDENTIFICATION
Coating - Brown Tip - Yellow Imprint - WIA AC 350
CLASSIFICATION
• AS/NZS 2576: 1435-A4

Abrasocord 350 is a smooth running, AC/DC electrode which
deposits a tough wear resistant low carbon martensitic steel
alloy. It is suitable for the heavy build-up and surfacing of steel
components subjected to metal-to-metal wear and compressive
loading such as, track components, gears and shafts, etc.
Abrasocord 350 deposits an air hardening C-Mn-Cr steel alloy

which is machineable and can be readily hot forged. It offers
high compressive strength and excellent resistance to impact
for all types of metal-to-metal wear.
OPERATIONAL DATA
3.2 380 100-140 19
4.0 380 150-200 22
5.0 450 190-240 24

68
CONTENTS
2G

1G

C Mn Si Cr Fe
0.2 0.4 0.3 2.8 Bal

PACKAGING DATA
PACKAGING APPROX
3.2 5 15 24 HF35032
4.0 5 15 16 HF35040
5.0 5 15 9 HF35050
69
CONTENTS
ABRASOCORD 700
SUMMARY
• Wear Resistant, High Carbon Martensitic Steel Deposit
• For a Wide Range of General Hard Surfacing Applications,
Such as Points, Tynes, Lips, Blades and Augers, ect.
IDENTIFICATION
Coating - Grey Tip - Orange Imprint - WIA AC 700
CLASSIFICATION
• AS/NZS 2576: 1855-A4

Abrasocord 700 is a smooth running, AC/DC electrode
which deposits an air hardening martensitic Cr-Mo-V steel
alloy. Abrasocord 700 deposits one of the hardest steel alloys
available and is free from relief checks. Applications include
the surfacing of post hole augers, agricultural points, shares
and tynes, grader and cultivator blades and other components
subject to fatigue or flexing during service.
Abrasocord 700 deposits an air hardening steel alloy which

can be readily hot forged and offers good resistance to all
types of abrasion under low to moderate impact conditions.
In the “as welded” condition Abrasocord 700 weld metal

cannot be machined without prior heat treatment.
OPERATIONAL DATA
3.2 380 90-130 19
4.0 380 140-180 22
5.0 450 160-240 24

70
CONTENTS
2G

1G

C Mn Si Cr Mo V Fe
0.7 0.3 0.5 8.5 0.3 0.5 Bal

PACKAGING DATA
PACKAGING APPROX
3.2 5 15 27 HF70032
4.0 5 15 18 HF70040
5.0 5 15 10 HF70050
71
CONTENTS
TUBECORD D - 2355
SUMMARY
• High Chrome Carbide
• Improved Abrasion Resistance
• Welds can be Shaped by Grinding
IDENTIFICATION
Coating - Black Tip - Light Green
CLASSIFICATION
• AS/NZS 2576: 2355-A1*
* Nearest Classification
DESCRIPTION
Tubecord D - 2355 deposits are high in carbon and chromium
resulting in improved abrasion resistance. Tubecord D - 2355
is ideal for hard surfacing components subjected to heavy
abrasion and moderate impact loading.
No preheat is required for direct application onto grey cast

iron, low carbon or manganese steels.
Applications include the hard surfacing of dredge bucket lips,

shovel buckets, scraper and dozer sides, cone crushers and
mill hammers, etc. Deposits are grindable, subject to relief
checking and may be multi-layered up to 3 layers. Features
include, controlled fume levels, minimal spatter, easy bead
deposition and low penetration.
Tubecord D - 2355 is suitable for AC or DC applications.
OPERATIONAL DATA
SIZE (mm) LENGTH (mm) RANGE (A) RANGE *(V)
6.3 450 85-135 25

72
CONTENTS
2G 3G

4G
1G

C Mn Cr Fe
5.5 1.5 40.0 Bal

Single Layer Typical Hardness 55-60 HRc
PACKAGING DATA
PACKAGING
ELECTRODE (KG) PART
SIZE (mm) NUMBER
Packet Carton
6.3 5 15 TUBD60
APPLICATIONS
• Dredge Bucket Lips
• Shovel Buckets
• Cone Crusher
73
CONTENTS
TUBECORD E - 2460
SUMMARY
• All Tubecord Electrodes are 450mm Long.
• 6.3mm Tubecord E - 2460 is also Suitable for Vertical Up
and Overhead Welding Positions.
• All Tubecore Electrodes are Coated with a Moisture
Resistant, Non Alloying, Black Flux Coating, Resulting
in Infinate Storage life!
IDENTIFICATION
Coating - Black Tip - Blue
CLASSIFICATION
• AS/NZS 2576: 2460-A1
DESCRIPTION
Tubecord E - 2460 deposits contain carbon, chromium,
niobium and molybdenum alloys for good resistance to
both impact and abrasion:
Tubecord E - 2460 produces a similar complex carbide

iron deposit to the popular Abrasocord 43 electrode.
No preheat is required for direct application onto grey
cast iron, low carbon or manganese steels.
Applications include the hard surfacing of grizzly bars,
bucket teeth, crusher hammers, rail ballast tampers,
dredger and ripper teeth, etc. Deposits are grindable, subject
to relief checking and should be restricted to 3 layers high.
Features include, controlled fume levels, minimal spatter,
easy bead deposition and low penetration.
Tubecord E - 2460 is suitable for AC or DC applications.
74
CONTENTS
** **
3G 2G

4G 1F
OPERATIONAL DATA
ELECTRODE WELDING CURRENT ARC VOLTAGE
6.3 90-130 25
8.0 135-185 29

**6.3mm only

C Cr Mo Nb V Mn Si Fe
4.0 26.5 0.9 7.9 0.4 0.8 1.5 Bal

Single Layer Typical Hardness 58-61 HRc
PACKAGING DATA
PACKAGING
ELECTRODE (KG) PART
SIZE (mm) NUMBER
Packet Carton
6.3 5 15 TUBE60
8.0 5 15 TUBE80
TYPICAL APPLICATIONS
Grily Bars
Bucket Teeth
Crusher Hammers
75
CONTENTS
AUSTMIG TD - 600
SUMMARY
• Copper Coated, Chromium Alloy Gas Metal Arc
(MIG) Welding Wire
• For Hard Surfacing Components Subjected
to Severe Abrasion and Heavy Impact

CLASSIFICATION
• AS/NZS 2576: 1855-B6
DESCRIPTION
Austmig TD - 600 is a copper coated, chromium alloy welding wire
depositing weld metal with a hardness of 55-60 HRc which
has a high resistance against severe abrasion and impact.
The deposit is non-machineable but can be shaped by grinding
Typical applications include: excavator blades, bucket lips,

bucket teeth, screw conveyors, crushing mills, shear blades.
OPERATIONAL DATA
1.2 120-340 18-32
76
CONTENTS
2G 3G
HARDFACING PRODUCTS - HARDFACING SOLID MIG WIRES

4G
1G

C Si Mn P S Cr Fe
0.45 3.00 0.40 0.025 0.020 9.00 Bal

As Welded - Two Layers 55-60 HRc
Recommended Shielding Gases:
Argon/18 - 25% CO₂, Ar/CO₂ or 100% CO₂
APPLICATIONS
• Excavator Blades • Bucket Teeth
• Screw Conveyors • Crushing Mills
• Sheer Blades
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) AND TYPE
1.2 15kg MTD60012S
77
CONTENTS
McKAY TUBE-ALLOY 240-O
SUMMARY
• Self Shielded Hard Surfacing Flux Cored Wire
• General Purpose Alloy with Good Abrasion
and Impact Resistance
• Chromium Carbide - Alloy Steel
• Non Machinable, Difficult to Grind
CLASSIFICATION
• AS/NZS 2576: 2155-B7
DESCRIPTION
McKAY Tube-Alloy 240-O is a self shielded, flux cored hard
surfacing wire that deposits a chromium carbide alloy steel.
It is an “excellent general purpose alloy due to a combination
of good abrasion and impact resistance.
McKAY Tube-Alloy 240-O is designed for overlaying carbon,

low alloy or austenitic manganese base metals. The smooth
globular type arc transfer gives minimal spatter and the
minimum slag cover allows the wire to operate well without
de-slagging between weld passes in automatic applications.
Some relief check cracking will occur however it is not

detrimental to the wear properties of the deposit and
provides some degree of stress relief for the weld metal.
OPERATIONAL DATA
The recommended operating parameters are for DC positive

with an electrode stick out of 16-25mm for the 1.2mm size,
25-35mm for 1.6mm. Out-of-position welding is limited to a
horizontal shelf technique.

1.2 120-275 19-27
1.6 275-400 24-29
78
CONTENTS
HARDFACING PRODUCTS - HARDFACING SELF SHIELDED FLUX CORED WIRES
1G

C Mn Si Cr Fe
3.20 1.80 1.90 15.50 Bal
TYPICAL MECHANICAL PROPERTIES (AS WELDED):
Number of As-deposited on
Layers
1020 Steel Mn Steel
1 40 Rc 35 Rc
Hardness 2 48 Rc 42 Rc
3-5 52 Rc 50 Rc
Abrasion Resistance: Very Good

Impact Resistance: Fair
Non-Machinable: Grinding is difficult
Cannot be Flame Cut
Deposit will Relief check Cracks
Thickness should be Limited to Five Layers Maximum
APPLICATIONS
• Ammonia Knives • Hammer Mill Hammers
• Augers • Impactor Crusher Bars
• Bucket Teeth and Lips • Manganese Pump Shells
• Bulldozer End Bits & Blades • Mill Guides
• Conveyer Screws • Muller Tires
• Crusher Jaws and Cones • Pipeline Ball Joints
• Crusher Rolls • Pulverizer Hammers
• Cultivator Chisels & Sweeps • Scraper Blades
• Dragline Buckets • Screw Conveyors
• Sheepsfoot Tampers • Sizing Screens
• Dredge Pump Impellers
and Side Plates
PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) (KG)
1.2 11.3 S604012-029
1.6 11.3 S604019-029 79
CONTENTS
McKAY TUBE-ALLOY 258-O
SUMMARY
• Self Shielded or Open Arc Hard Surfacing Flux Cored Wire
• Hard Wearing Martensitic Steel Alloy Deposit
• Tough, Hard Tool Steel Weld Metal Composition
• Good Impact and Abrasion Resistance
• Excellent Resistance to Metal-to-Metal Wear
• Weld Deposits Grindable Only
CLASSIFICATION
• AS/NZS 2576: 1550-B7*
*Nearest Classification
DESCRIPTION
McKAY Tubealloy 258-O is a fabricated type, open arc tubular
flux cored wire depositing a Cr-Mo-W Martensitic steel alloy.
It is designed for surfacing mild and low alloy steel components
subject to moderate abrasive wear and impact under high
compressive stresses and/or at temperatures up to 530°C.
Crack free deposits can be obtained by controlled heat input

or the use of preheat.
OPERATIONAL DATA
Welding parameters shown below are for DC electrode positive.
An electrode stick out length of 12-25mm is recommended for
1.2mm size, 25-35mm for 1.6mm.

1.2 120-230 24-27
1.6 225-350 30-34*
80
CONTENTS
1G

C Mn Si Cr Mo W Fe
0.45 1.40 0.80 6.00 1.50 1.50 Bal
Layers
1020 Steel Mn Steel
1 49 Rc 51 Rc
Hardness 2 53 Rc 54 Rc
3 57 Rc 57 Rc
Abrasion Resistance: Good

Impact Resistance: Good
Non-Machinable: Grinding only
Flame Cutting: Difficult
Deposit will Relief Check Cracks
APPLICATIONS
• Coupling Boxes • Dragline Chains
• Kiln Trunnions • Mill Guides
• Spindles • Wobbler Ends

PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) (KG)
1.2 11.3 S605812-029
1.6 11.3 S605819-029
81
CONTENTS
McKAY TUBE-ALLOY A43-O
SUMMARY
• Self Shielded or Open Arc Hard Surfacing
• Flux Cored Wire
• Niobium-Chromium Carbide Iron Weld Deposit
• Resistant to Severe High and Low Stress Abrasion
• Low to Moderate Impact Loading
• Weld deposits are to be Shaped by Grinding Only
CLASSIFICATION
• AS/NZS 2576: 2460-B7
DESCRIPTION
McKAY Tube-Alloy A43-O is a fabricated type, self shielding
tubular flux cored wire depositing a high chromium-niobium
surfacing alloy which resists severe high and low stress abrasion
and low to moderate impact.
The weld deposit will check crack readily and out performs
straight C-Cr hard surfacing alloys. It can also be used where
high temperature (650°C) wear resistance is required. Spatter
level is low, slag cover is minimal and is easily removed.
OPERATIONAL DATA
The recommended operating parameters are for DC positive
with an electrode stick out length of 20-35mm.

1.6 300-350 30-34
Other wire sizes and spool weights are available on indent only.
82
CONTENTS
1G

C Mn Si Cr Nb Fe
5.50 0.20 1.0 22.00 6.50 Bal
Layers
1020 Steel Mn Steel
1 56-60 Rc 45-50 Rc
Hardness
2-3 60-64 Rc 54-58 Rc
Abrasion Resistance: Excellent

Impact Resistance: Poor
Non-Machinable: Grinding only
Deposit will Relief Check Cracks
APPLICATIONS
• Augers • Bucket Lips and Teeth
• Coal Feeder Screws • Coal Pulverizer Rolls & Tables
• Coke Chutes • Coke Pusher Shoes
• Conveyer Screws • Fan Blades
• Grizzly Bars and Fingers • Pipeline Ball Joints
• Muller Tires • Paving Agitator Screws
• Pipeline Ball Joints • Pub Mill Paddles
• Scraper Blades • Sheepsfoot Tampers
• Sizing Screws
• Dredge Cutter Heads & Teeth
• Dredge Pump Inlet Nozzle
and Side Plates

PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) (KG)
1.6 11.3 S607719-029
83
CONTENTS
McKAY VERTIWEAR-600
SUMMARY
• Suites Out-of Position Applications
• Multi-Purpose Martensitic Steel
• Moderate Abrasive Wear and Medium to High Impact
• Weld Deposits - Machineable
CLASSIFICATION
• AS/NZS 2576: 1855-B5*
*Nearest Classification
DESCRIPTION
McKAY Vertiwear 600 is a gas shielded, all position, hard
surfacing fluxcored wire designed to operate in a smooth
semi-spray arc transfer. The weld metal control is superior to
competitive gas shielded hard surfacing wires allowing higher
deposition and greater productivity in out-of-position applications.
Excellent operator appeal in all positions.
McKAY Vertiwear 600 deposits a multi-purpose martensitic steel

alloy and can be used to hard surface mild and low alloy steel
components subject to moderate abrasion coupled with medium
to high impact. It also exhibits excellent compressive strength
and metal-to-metal wear resistance.
The recommended shielding gas for Vertiwear 600 is

75% Argon - 25% CO₂.
OPERATIONAL DATA
The recommended operating parameters are for DC positive with
an electrode stick out length of 20-35mm.

1.2 165-185 24-28
84
CONTENTS
2G 3G
HARDFACING PRODUCTS - HARDFACING GAS SHIELDED FLUX CORED WIRES

4G
1G

C Mn Si Cr Mo Fe
0.40 0.75 0.60 6.50 1.00 Bal
TYPICAL MECHANICAL PROPERTIES (AS WELDED)
As-deposited
Number of
on
Layers
1020 Steel
1 52 Rc
Hardness 2 56 Rc
3-8 57 Rc
Hardness as- Hardness after Tempering
Time at Temp
deposited 535C° 620C°
55 10 Hours 54 46
20 Hours 49 40
80 Hours 47 40
Abrasion Resistance: Good

Impact Resistance: Good
Machinability Good
Magnetic
APPLICATIONS
• Coupling Boxes • Dragline Chain
• Dredge Ladder Rolls • Kiln Trunnions
• Mill Guides • Sliding Metal Parts
• Wobber Ends

PACKAGING DATA
WIRE PACK SIZE
PART NUMBER
SIZE (mm) (KG)
1.2 15 S607112-029
85
CONTENTS
CONTENTS
TECHNICAL INFORMATION
The following pages cover a range of technical
information and data tables pertaining to the field of
welded fabrication and general engineering.
This section is designed to provide a ready reference
guide for welding engineers, design costing personnel,
workshop supervisors and welding operators, and to
foster higher quality, higher productivity welding.
GLOSSARY........................................................... 88-105
OXY-ACETYLENE FLAME ADJUSTMENT..........106-107
WELDING SYMBOLS..........................................108-115
ELECTRODE CLASSIFICATIONS
Manual Metal Arc Welding Electrodes.....................116-123
Gas Metal Arc Welding Ferritic Steel Electrodes....... 124-126
Flux Cored Arc Welding Electrodes........................ 127-129
Manual Metal Arc and Gas Metal Arc Welding
for Aluminium and Stainless Steel Electrodes........... 130-131
Repair and Hardfacing .......................................... 132-133
Submerged Arc Welding Electrodes and Fluxes.... 134-135
Weld deposition and costing data
Users Guide........................................................... 136-147
Mass of Weld Metal in Joint.................................... 148-153
Quantity of Consumables Required....................... 154-157
Deposition Rates.................................................... 158-165
Duty Cycles............................................................ 166-167
Electrode Consumption for Typical Butt Joints....... 168-169
CONTENTS
CONTENTS
TECHNICAL INFORMATION
Weldability guide for steels..................170-193
Common weld TROUBLES ............................194-199
SI units and conversion data...................200-203

Table 1.
Conversion from Inches to Millimetres...........................204
Table 2.
Travel and Wire Feed Speeds........................................205
Table 3
°C - °F Temperature Conversions.......................... 206-209
Table 4.
Comparison of Hardness Scales....................................210
Table 5.
Stress and Energy Conversions..................................... 211
Table 6.
Wire and Sheet Sizes............................................. 212-213
Symbols for elements and
geometric formulae......................................... 214
87
CONTENTS
GLOSSARY
The following is a selection of some of the more common welding
terms and abbreviations in current Australian usage. Please refer
to Australian Standard AS2812 (Welding, Brazing and Cutting of
Metals - Glossary of Terms) for a more comprehensive list.
AMPERAGE - The measurement of the amount of electricity
flowing past a given point in a conductor per second.
Current is another name for amperage.
ANGLE OF BEVEL - The angle at which the edge of a joint is
prepared for making a weld, refer to FIG 1. (A) - (F) for typical
examples
ARC BLOW - An uncontrolled deflection of a welding arc caused
by an uneven distribution of magnetic field around the arc.
ARC LENGTH - The distance from the end of the electrode
to the parent material.
ARC VOLTAGE - The voltage across the welding arc.
ARC WELDING (AW) - Fusion welding in which heat for
welding is obtained from an electric arc or arcs.
ARC WELDING GUN - A device used in semi-automatic and
automatic arc welding to transfer current, guide the consumable
electrode and direct shielding gas when used.
AS-WELDED - The condition of weld metal, welded joints or
weldments after welding prior to any subsequent thermal or
mechanical treatment.
BACKING - A weld backing maybe incorporated in welded joint
design to simplify the root pass. Backing of suitable material
can be incorporated in the weldment, or alternativley removable
temporary backing material can be used. e.g. ceramic tiles
BACK-STEP WELDING - A welding technique wherein the
increments of weld metal are deposited in a direction opposite to
that of progression.
BARE ELECTRODE - A filler metal electrode consisting of a
single metal or alloy that has been produced into a wire, strip or
bar form which has no flux coating or covering applied to it.
88
CONTENTS
GLOSSARY
BASE (PARENT) METAL - The metal to be welded or joined other
than the filler metal.
BASIC ELECTRODE - A flux coated electrode in which the
covering contains a high proportion of basic materials, such as
limestone and flurospar etc.
BRAZE WELDING (BW) - The joining of metals using similar joint
designs as for fusion welding. However, the parent metal is not
melted as in fusion welding. A non-ferrous alloy with a melting
point above approx. 500°C and below that of the parent metal is
normally used as the filler metal and is deposited without the aid
of capillary action, as in brazing.
BRAZING - A joining process in which, during heating, molten
filler metal is made to flow by capillary action between a narrow
joint preparation. In general, the melting point of the filler metal is
above approx. 450°C, but is always below the melting temperature
of the parent metal. A fluxing agent is usually used to promote the
flow of filler metal along and around the joint.
BRONZE WELDING - Term used to describe Braze Welding using
a Copper rich filler metal.
BUTTERING - A material preparation process in which one or
two layers of weld metal are deposited on the surfaces to be
joined. The buttering provides a suitable transition weld deposit for
subsequent completion of the joint.
BUTT WELD - A weld in which the weld lies substantially within
the extension of the planes of the surfaces of one or more of the
pads joined, see Fig 1 for typical examples.
CDT - Controlled Droplet Transfer
CELLULOSE ELECTRODE - A flux coated electrode in which
the covering contains at least 15 percent cellulose and up to 30
percent titania as rutile or titanium white.
CO₂ WELDING - Gas Metal-Arc welding using CO₂ as the
shielding gas, see preferred term - Gas Metal Arc Welding.
CONSTANT VOLTAGE POWER SOURCE - An arc welding power
source whose terminal voltage remains substantially constant
between full load and no load conditions.
89
CONTENTS
GLOSSARY
CONSUMABLES - Materials directly consumed in the making
of a weld, including electrodes, flux heating and shielding gas
and filler wire etc.
CORED ELECTRODE - A consumable electrode having a
core of flux and/or alloying ingredients.
COVERED ELECTRODE - A filler metal electrode, used in
arc welding, consisting of a metal core wire with a relatively
thick covering of flux which provides protection for the molten
metal from the atmosphere, improves the properties of the
weld metal and stabilises the arc.
CRATER - A depression left in the weld where the arc is broken.
CONSUMABLE GUIDE WELDING - see Electroslag Welding.
DEFECT - One or more discontinuities that cause non
compliance of a weld.
DEPTH OF FUSION - The distance from the fusion face
to that point within the joint at which fusion ceases, see
Fig 2.(a) and (b).
DEPOSITION EFFICIENCY -
(a) For manual metal arc welding electrodes, the ratio of the
mass of deposited metal to the mass of the core wire consumed
(excluding stubs); expressed as a percentage.
(b) For continuous electrodes, the ratio of the mass of
deposited metal to the mass of electrode consumed; expressed
as a percentage. For 85% deposition efficiency means 85kg
of weld metal was produced from 100kg of electrode metal.
DEPOSITION RATE - The mass of metal deposited
(excluding spatter) in a unit of time.
DILUTION - The alteration of composition of the weld metal
deposited from a filler metal or electrode due to mixing with
the melted parent metal. It is expressed as a percentage of
melted parent metal to the weld metal.
DIP TRANSFER - see Short Circuiting Arc Transfer.
DISCOUNTINUITY - a flaw in the weld which complies or may
comply with the acceptance standard
90
CONTENTS
GLOSSARY
DROOPING CHARACTERISTIC POWER SOURCE - An arc
welding power source whose terminal voltage drops to a value
appreciably below the open circuit voltage (O.C.V.) after the
arc has been initiated.
DUTY CYCLE - (a) Power Source Duty Cycle is the amount
of time a welding machine can be used at a given amperage,
generally expressed as a percentage of a 5 min. period, eg.
60% at 300amps means the machine can be used at 300
amps for 3 mins in every 5 mins
(b) Operator Duty Cycle is the ratio of welding or cutting time
to the total work time expressed as a percentage.
ELECTRODE - A component of the welding circuit through
which current is immediately conducted to the arc, molten
slag, or base metal.
(a) Non-consumable electrode - an electrode which does
not provide metal eg. a Tungsten electrode.
(b) Consumable electrode - an electrode which provides
filler metal.
ELECTRODE NEGATIVE - Arc welding using direct current
in which the electrode is connected to the negative pole of the
welding power source. Also referred to as, “straight polarity”.
ELECTRODE POSITIVE - Arc welding using direct current
in which the electrode is connected to the positive pole of the
welding power source. Also referred to as, “reverse polarity”.
ELECTRODE STICKOUT - In automatic and semi-automatic
arc welding, the length of the electrode projecting beyond the
region of current pick-up / contact tip during welding.
ELECTROSLAG WELDING (ESW) - A continuous wire
electrode, vertical fusion welding process in which the molten
pool of metal and covering slag are confined to the joint by
copper shoes. The wire feeding nozzle progresses automatically
up the joint or in the case of the consumable guide variant, is
melted as the weld level rises. The heat for fusion is generated
by the electrical resistance of the slag bath.
91
CONTENTS
GLOSSARY
FILLET WELD - A weld or series of welds of approximately
triangular cross-section joining two surfaces approximately
at right angles to each other in a lap joint, tee joint or corner
joint. Note. The bulk of the weld metal is outside the planes
made by the surfaces of the base metals, see Fig 2, (b)
and (d) for typical examples.
FLAT POSITION - The position in which welding is
performed from the upper side of the joint and the weld
face is approximately horizontal (Sometimes called downhand
welding), see Fig 3, 1F and 1G positions.
FLUID SLAG - A slag which flows freely during whilst molten
during welding.
FLUX - A substantially non-metallic material used during welding,
brazing, braze welding or soldering to clean the surfaces of the
joint chemically, to prevent atmospheric oxidation and to reduce
impurities or float them to the surface in the form of a slag.
FRIABLE SLAG - A slag that crumbles easily to aid removal.
FUSION FACE - The portion of a surface, or an edge, which is to
be fused (melted) in making a fusion weld, see Fig 2(a) and (b).
FUSION ZONE - The area of parent metal melted as determined
on the cross section of a weld, see Fig 2(a) and (b).
FLUX CORED ARC WELDING (FCAW) - Arc welding using
a continuous, consumable, flux cored wire (electrode) which
provides the filler metal. Gas shielding, alloying addlions and
slag coverage may be provided by the flux contained within the
electrode. Gas shielding may or may not be required.
FUSION WELDING - Welding in which similar parent metals are
fused (melted) together with or without the use of a filler metal of
similar composition.
GAS METAL ARC WELDING (GMAW) - The preferred
terminology for the process of arc welding using a continuous,
consumable, solid wire (electrode) which provides the filler metal
and in which shielding is obtained entirely from an externally
supplied gas or gas mixture. The process is similar to and also
known as MIG, MAG AND CO₂ welding.
92
CONTENTS
GLOSSARY
GAS PORE - A weld cavity caused by entrapped gas.
GAS TUNGSTEN ARC WELDING (GTAW) - The preferred
terminology for the process of arc welding, with or without added
filler metal, using a non-consumable electrode of pure or activated
tungsten, shielded by an externally supplied gas or gas mixture.
The process is similar to and also known as TIG, Heliarc or
Argonarc welding.
GAS WELDING - Welding in which the heat for welding is
produced by the combustion of a gas mixture. Filler metal may or
may not be used. The most popular gas combination is oxygen
/ acetylene however oxygen / LP gas, air / acetylene or air / LP
gas are mixtures which may be used, depending on the joining
process adopted.
GLOBULAR TRANSFER - Metal transfer which takes place
as globules of diameter substantially larger than that of the
consumable electrode from which they are transferred.
HARD SURFACING - Surfacing with a wear resistant material.
The preferred term to hardfacing.
HEAT AFFECTED ZONE (HAZ) - The portion of parent
metal which has not been fused but has nevertheless been
metallurgically affected by the heat of welding, brazing or cutting,
Refer to Fig 2(a) and (b) for clarification.
HERTZ - Hertz is often referred to as “cycles per second”.
In Australia, the frequency or directional change of alternating
current is usually 50 hertz.
HIGH FREQUENCY - Covers the entire frequency
spectrum above 50,000 Hz. Used in GTA welding for arc
ignition and stabilization.
HORIZONTAL POSITION - The position of welding wherein
the line of the weld root is approximately horizontal, see Fig 3,
2F and 2G positions.
93
CONTENTS
GLOSSARY
HYDROGEN CONTROLLED ELECTRODE - An electrode
depositing weld metal containing not more than a specified
quantify of diffusible hydrogen in the deposited weld metal
when assessed in accordance with the appropriate standard.
The category of such electrodes may be sub-divided into
classifications of medium hydrogen, low hydrogen and “very low”
hydrogen, each having successively lower allowable levels of
diffusible hydrogen.
INCLUDED ANGLE - The angle between the planes of the fusion
faces of the parts to be welded, see Fig 1 for typical examples.
INDUCTANCE - Inductance comes from an inductor (stabilizer).
The inductor slows down the changes in current, changing
the machine’s rate of response and number of short circuits
per second. An inductor helps limit the amount of spatter, and
generally improves the wetting out of the weld puddle.
INTERMITTENT WELD - A series of welds at specified intervals
along a joint, see Fig 7 (c).
INTERRUN TEMPERATURE - In a multi run weld, the
temperature of the weld and adjacent parent metal immediately
prior to the deposition of the next weld run.
Also called INTERPASS TEMPERATURE.
INVERTER - Power source which increases the frequency of the
incoming primary power, thus providing for a smaller size machine
and improved electrical characteristics for welding,
such as faster response time and more control for pulse welding.
IRON POWDER ELECTRODE - A flux coated electrode in which
the covering contains a high percentage of iron in the form of
powder to improve deposition efficiency typically 110-130%.
JOINT PENETRATION - The minimum depth of fusion into
a joint, excluding reinforcement.
JOINT PREPARATION - Details of the edge preparations
and set up of workpieces for welding.
Refer to Fig 1, (A)-(F) for examples.
Ksi - (kips) kilo (1000) pounds per square inch.
94
CONTENTS
GLOSSARY
LAND - The straight portion of a fusion face between the edge
of the root face and: (a) the sloping face of a bevel preparation,
or (b) the curved part of a J edge preparation, see Fig 1, (F).
LANDING - See root face
LAP JOINT - A joint between two overlapping members
approximately in the same plane, see Fig 9, (C).
LEG LENGTH - The distance between the root and the toe of a
fillet weld. Leg length is the dimension used to size a fillet weld to
AS1101.3. Leg length is known as the ‘z’ dimension in ISO 2553,
see Fig 2(d) and weld symbols section.
LOW HYDROGEN ELECTRODE - see Hydrogen
Controlled Electrode.
MAG WELDING - “Metal Active Gas”, see Gas Metal Arc Welding.
MANUAL METAL ARC WELDING (MMAW) - Arc welding with
a flux covered electrode manually applied by the welder without
automatic or semi-automatic replacement of the electrode.
Shielding is provided only by decomposition of the electrode
covering. In American terminology, known as, Shielded Metal
Arc Welding (SMAW).
MECHANISED WELDING - Welding with equipment which
performs the welding operation under preset conditions under
the constant control of a welding operator.
MIG WELDING - “Metal Inert Gas”, see Gas Metal Arc Welding.
MITRE FILLET WELD - A fillet weld of equal leg lengths in which
the face of the weld is essentially flat.
MULTIPLE ARC WELDING - Welding wherein a single
process runs with more than one electrode from a single
power source eg. twin arc, or a single process operates with
more than one electrode from separate power sources and
separate nozzles eg. tandem arc. Essentially a single weld
pool is maintained throughout.
95
CONTENTS
GLOSSARY
NARROW GAP WELDING - A modification of conventional
automatic arc Welding of thick sections where square
preparations or ‘V’ preparations with small included angles
and narrow gaps are used.
NON-TRANSFERRED ARC - A plasma arc struck between the
tungsten electrode and the torch nozzle.
OPEN-CIRCUIT VOLTAGE (OCV) - The voltage between
the live output terminals of a welding power source when no
current is flowing/no arc.
OVERHEAD POSITION - The position in which welding
is performed from the underside of the joint, see Fig 3, 4F
and 4G positions.
OVERLAP - Weld metal at the toe of a weld which covers the
parent metal surface but is not fused to it.
OXYGEN-ACETYLENE WELDING - Gas welding in which the
heat for welding is produced by the combustion of an oxygen-
acetylene gas mixture.
PARTIAL PENETRATION - A butt weld where, by design, fusion
does not extend the full depth of the joint.
PASS - see Weld Run.
PEENING - The mechanical working of weld metal by means of
hammer blows or bombardment with shot or pellets to reduce
residual stress or distortion.
PENETRATION BEAD - Weld metal protruding through the root of
a fusion weld made from one side only.
PLASMA ARC WELDING (PAW) - A process in which the electric
arc generates a hot ionised gas stream that both shields and
transfers heat to the joint.
POROSITY - Clustered/grouped gas pores or voids in weld metal.
POROUS SLAG - A slag that has a honeycomb structure.
POSITIONER - A mechanical device manually or power operated
to hold, tilt or rotate the work to the desired position for welding.
96
CONTENTS
GLOSSARY
POST WELD HEAT TREATMENT (PWHT) - Any thermal
treatment carried out after welding.
PREHEAT - The application of heat to the parent metal
immediately prior to welding or cutting.
PULSED ARC WELDING - Welding in which pulses of current are
superimposed on a constant background current. In continuous
electrode processes the pulses control metal transfer across
the arc. Ideally, one pulse produces one droplet of molten metal
across the arc.
PULSING - Sequencing and controlling the amount of current,
the polarity, and the duration of the welding arc.
REINFORCEMENT - Weld metal lying outside the plane joining
the weld toes.
RESIDUAL WELDING STRESS - Stress remaining in a metal part
of structure as a result of welding.
RESISTANCE WELDING - A process in which two pieces of
metal are joined by placing pressure on electrodes which are
on opposite sides of the joint to be welded, maybe a spot or a
continuous weld. There is no arc with this process, the resistance
of the metal to the current flow is what causes fusion.
RMS - Root Mean Square. The “effective” values of measured AC
voltage or amperage. RMS equals 0.707 times the maximum, or
peak value.
ROOT FACE - The portion of a fusion face at the root which is not
bevelled or grooved, Refer to Fig 1 for examples.
ROOT GAP - The minimum distance at any cross-section
between edges, ends or surfaces to be joined, Refer to
Fig 1 for examples.
ROOT OF WELD - The points as shown in cross-section, at
which the back of the weld intersects the base metal surfaces,
see Fig 2 (a) and (b) for examples.
97
CONTENTS
GLOSSARY
SHORT CIRCUITING ARC TRANSFER - Metal transfer in which
fused parts of a consumable electrode are detached in rapid
succession during repeated short circuiting contacts with the
molten weld pool. Also called short arc or dip transfer.
SILVER BRAZING - Brazing in which a silver alloy is used as
the filler metal.
SILVER SOLDERING - See Silver Brazing.
SIZE OF WELD - (a) Equal leg fillet weld - the length of the
equal sides of the largest isoceles triangle which can be inscribed
within the fillet cross-section, see leg length.
(b) Unequal leg fillet weld - the lengths of the sides containing
the angle of the largest triangle which can be inscribed within
the fillet cross section.
(c) Butt weld - the minimum depth which a butt weld extends
into a joint, exclusive of reinforcement.
SLAG INCLUSION - Slag entrapped in weld metal or between
weld metal and base metal. Only present with welding
processes that use a flux eg. MMA and SAW.
SOFT SOLDERING - see Soldering.
SOLDERING - A low strength joining process in which, during
heating, a molten Lead-Tin filler alloy is made to flow onto and
around the joint preparation. In general, the melting point of the
filler metal is less than 450°C, but always below the melting
temperature of the parent metal. A fluxing agent is often used
to promote the flow of filler metal around the joint.
SPATTER - Globules of weld metal which are expelled during
welding and which do not form part of the weld.
SUBMERGED ARC WELDING (SAW) - Arc welding in which
a continuous, consumable, wire electrode (flux cored or solid) is
used and the arc is submerged under a granular flux cover, some
of which fuses to form a slag. Single or multiple electrodes in the
form of solid or tubular wires or strip may be employed, attached
to one or more power sources and feeding devices.
98
CONTENTS
GLOSSARY
TIG WELDING - “Tungsten Inert Gas”, see Gas Tungsten
Arc Welding.
SPRAY TRANSFER - Metal transfer which takes pace as a
rapid projected stream of droplets of diameter not larger than
that of the consumable electrode from which they are transferred.
STRESS RELIEF HEAT TREATMENT - Heating to, and if
necessary holding at, some temperature generally below the
transformation range, usually followed by slow cooling, for the
purpose of reducing internal stresses.
STRINGER BEAD RUN - A bead or run made without intentional
weaving motion.
TACK WELD - A weld (generally short) made to hold parts of
a weldment in alignment until final welds are deposited.
THROAT THICKNESS - (a) Actual throat thickness -
the perpendicular distance between two lines (each parallel to
a line joining the outer toes) one being a tangent at the weld
face and the other being through the further most point of fusion
penetration. Measured from the root to the weld face. Known as
the ‘a’ dimension in ISO 2553.
(b) Design throat thickness - the minimum dimension of
throat thickness used for design purposes, refer to Fig 4,
(a) and (b) for examples.
TINNING - The term as applied to brazing and braze welding
defines the deposition of a thin layer of fluxed filler metal onto joint
surfaces in order to provide a sound and strong interface between
parent metal and weld deposit.
T-JOINT - A joint between the end or edge of one part and the
face of the other part, The parts making an angle to one another
of more Than 5 degrees up to and including 90 degrees in the
region of the joint, see Fig 1, (E) and (F) for examples.
TOE - The junction between a weld face and the base metal
or between weld faces, refer to Fig 2, (C) and (d) for examples.
99
CONTENTS
GLOSSARY
TOUCH OR SCRATCH START - An arc starting procedure
for TIG (GTAW). The tungsten is touched or scratched on
the workpiece; when the tungsten is lifted from the workpiece
an arc is established
TOUCH WELDING - Metal arc welding using a coated electrode,
where, as a result of a characteristic of the coating, it can be
kept in contact with the base metal during welding to facilitate
control of arc length.
TRANSFERRED ARC - A plasma arc which is struck between
a tungsten electrode and the workpiece.
UNDERCUT - A sharp groove at the toe of a weld flaw which is
a run between the weld and the parent metal or in previously
deposited weld metal caused by wastage of the underlying
material, see Common Weld Defects section.
VERTICAL POSITION - The position of welding wherein the
line of the weld root is approximately vertical, see Fig 3, 3F
and 3G positions.
VISCOUS SLAG - A slag with characteristics which restrict the
flow of molten slag into the weldpool during welding.
VOLTAGE - The pressure or force that pushes the electrons
through a conductor. Voltage does not flow, but causes amperage
or current to flow. Voltage is sometimes termed electromotive
force (EMP) or difference in potential.
VOLTAGE REDUCTION DEVICE (VRD) - a device used to reduce
the OCV of welding machines to lower and safer levels
WEAVING - Transverse movement of the end of an electrode
during deposition of weld metal.
WELDING PROCEDURE - The detailed methods and practices
involved in the making of a weld eg. amps, volts, travel speed,
material and consumable type etc.
WELD FACE - The exposed surface of a weld on the side from
which welding was performed, refer to Fig 2, (C) and (d) for
examples.
100
CONTENTS
GLOSSARY
WELD JUNCTION - The boundary between the fusion zone and
the heat affected zone (HAZ) of a weld, see Fig 2, (a) and (b).
WELD METAL - All metal melted during the making of a weld and
retained in the weld, see Fig 2, (a) and (b).
WELD RUN - The weld metal resulting from one passage of an
electrode, torch or blowpipe, also called weld pass.
WIRE FEED SPEED - Expressed in in/min or mm/s, and refers
to the speed and amount of filler metal fed into a weld. Generally
speaking the higher the wire feed speed, the higher the amperage.
WORK - The material or object on which welding, brazing,
soldering or cutting is carried out. Also called workpiece..
101
CONTENTS
GLOSSARY
Included Included
angle angle
Angle Angle
of bevel of bevel
Root
face
Root Root
Root Root radius
gap face gap
(A) SINGLE-V BUTT JOINT (B) SINGLE-U BUTT JOINT
Included Included
angle angle
Angle Angle
of bevel of bevel
Root
face
Root
Root radius
face
Root gap Root gap

(C) DOUBLE-V BUTT JOINT (D) DOUBLE-U BUTT JOINT
Included Included
angle & angle &
angle of angle of
bevel bevel
Root
face
Root Root
face radius
Root
Root gap gap Land
(E) SIBGLE BEVEL-T BUTT JOINT (F) SIBGLE-J T-BUTT JOINT
102
CONTENTS
GLOSSARY
Weld zone
Weld
Parent zone
Heat- Weld metal
affected metal
Zone
Depth of Weld
fusion metal
Fusion
face
Fusion
zone Weld
junction
Root of Root of
weld weld Fusion zone
Heat affected
zone
(A) BUTT WELD (B) FILLET WELD
Weld width
Toe
Weld face
Toes Toe
Weld
width
Weld
face
Leg Toes
(length)
Toe
Weld
face Leg
(length)
(C) BUTT WELD (D) FILLET WELD
103
CONTENTS
GLOSSARY
FILLET WELDS
FLAT POSITION HORIZONTAL VERTICAL OVERHEAD
1F POSITION POSITION POSITION
2F 3F 4F
Axis of Weld Axis of Weld Axis of Weld Axis of Weld

Horizontal Horizontal Vertical Horizontal
PIPE BUTT WELDS
FLAT HORIZONTAL POSITION POSITION

1G 2G 5G 6G
45º± 5º
L
Pipe shall be Pipe shall NOT be

turned or rolled turned or rolled while
while welding, Axis welding, Axis of Pipe
of Pipe Horizontal Horizontal
Axis of pipe Inclined Axis with
Vertical Pipe Stationary
BUTT WELDS
FLAT HORIZONTAL VERTICAL OVERHEAD
POSITION POSITION POSITION POSITION
1G 2G 3G 4G
104 Plates Horizontal Plates Vertical Plates Vertical Plates Horizontal
CONTENTS
GLOSSARY
Design throat thickness
Actual
throat
thickness
(A)
Actual
throat
thickness
Design throat thickness

(B)
FIGURE 4 ACTUAL AND DESIGN

THROAT THICKNESS OF TYPICAL WELDS
D₁
D₂
D₁ + 0.85 D₂
FIGURE 4A DEEP PENETRATION WELD AND

DESIGN THROAT THICKNESS TO AS 1554.1
105
CONTENTS
ADD
106
CONTENTS
OXY-ACETYLENE
OXY-ACETYLENE FLAME ADJUSTMENT

FLAME ADJUSTMENT
FLAME ADJUSTMENTS FOR OXYGEN — ACETYLENE WELDING
For oxy-acetylene welding there are essentially four main types of
flame adjustments used for welding a wide variety of base metals.
A neutral flame is the most common setting used for the majority of
fusion welding and braze welding applications. The following diagrams
are intended as a guide to the easy identification of these flame types
and their use with specific base metals.
(A) OXIDISING FLAME

For welding Copper and
certain Copper based alloys
Small inner cone
(B) NEUTRAL FLAME

For welding Steel, Stainless
Steel, Cast Iron, Aluminium
and Copper etc.
Bright inner cone
(C) REDUCING FLAME
For welding Aluminium

and Low Alloy Steel etc.
Small pale green feather
(D) CARBURIZING FLAME

Suitable for silver brazing,
soldering and many hard
surfacing applications.
Bright acetylene feather
107
CONTENTS
WELDING SYMBOLS
Welding symbols are the shorthand of welding, they provide a
concise means of relaying information on engineering drawings.
Detailed information such as the type, size, orientation and
finishing requirements of the weld joint can be communicated.
Welding symbols do not always contain all the information
required for welding. Reference is often given on the welding
symbol, to a specification, process, procedure or other document
which provides the necessary data to complete the welding
operation.
The use of welding symbols result in the following benefits:
1.The complete translation of specific design requirements to the
workshop; regarding such parameters as weld sizes, processes
to be used, joint preparations etc thus allowing the welding task
to be complete as per instruction.
2.The elimination of unnecessary and incomprehensible
details on drawings-when such details specify weld type, size,
length, pitch etc.
3.The establishment of a common understanding of design intent
and welding prerequisites between designers, workshop welder/
inspectors, welding engineers, Q.A./Q.C personnel and code
authorities etc.
4.Standardisation, within and across the welding, fabrication
and construction industries.
BASIC SYMBOLS
There are different standards for welding symbols. The following
pages are set out using the International Standard ISO2553
(Welded, brazed and soldered joints - Symbolic representation
on drawings) and the Australian Standard AS1101.3 (Graphical
Symbols for General Engineering - Welding and Non-Destructive
Examination) which is based on the American Welding Society
Standard. AWS A2.4 In AS1101.3, a clear distinction is made
between the terms weld symbol and welding symbol. The term,
weld symbol describes the type of weld to be deposited — see
FIGURE 6A for the basic weld symbols in common use. The
welding symbol is a method of representing the weld symbol on
drawings and includes all the relevant information and references
necessary to complete the welded joint.
108
CONTENTS
WELDING SYMBOLS
ELEMENTS OF A WELDING SYMBOL TO AS1101.3
The major elements are:
(a) Reference line (shown horizontally)
(b) Arrow
(c) Basic weld symbols
(d) Dimensions and other data
(e) Supplementary symbols
(f) Finish symbol
(g) Tail
(h) Specification, process, or other references
Refer to Figure 5 for the standard location of these

elements on a welding symbol.
109
CONTENTS
110
CONTENTS
Finish symbol
Contour symbol
Preparation angle; included angle
Root gap; depth of filling of countersink for plug welds
for plug and slot welds
Length of weld
Design throat thickness F Pitch (centre-to-centre
Depth of preparation; size spacing) of welds
)
A
or strength for certain welds
)
R Site weld symbol
Specification, process,
SIDE
OTHER
procedure or other reference S (D) L P Arrow connecting reference line
to arrow side member of joint
)(
T
Tail (Tail omitted when
reference is not used)
(BOTH SIDES
SIDE
Weld-all-around symbol
ARROW
(
(N) Reference line
Basic weld symbol Number of spot, seam, stud,
WELDING SYMBOLS
or detail reference plug or protection welds
Elements in this area remain NOTE: Reproduced with permission from

as shown when tail and SAI Global under Licence 1110-c075
arrow are reversed
FIGURE 4: LOCATION OF ELEMENTS ON A WELDING SYMBOL

WELDING SYMBOLS
BUTT WELD
Flare
Square Scarf V Bevel U J Flare V
Bevel
Plug Backing
Spot Weld
Fillet Weld Seam Run Or Edge Stud
Or Projection Surfacing
Weld Or Slot Weld Backing Weld Weld
Weld
Weld Weld
FIGURE 6A BASIC WELD SYMBOLS
Complete
Backing
Weld All Penetration
Site Weld Or Spacer Surfacing Convex Concave
Around From One
Material
Side
FIGURE 6B SUPPLEMENTARY SYMBOLS
111
CONTENTS
WELDING SYMBOLS
(A) SINGLE-FILLET WELD
8
8
8 Symbol
Desired weld
(B) UNEQUAL DOUBLE-FILLET WELDS.

6
6
12 12
6
12
Desired weld Symbol
(C) STAGGERED INTERMITTENT FILLET WELDS.

75 75 75 75
75-250
75-250
125 125
250
C Weld C Weld C Weld C Weld
Desired welds
(D) COMBINED FILLET AND BUTT WELD IN T-JOINT

WITH SPECIFIED ROOT GAP.
(3)
3 (3) 2
2 5
5
Desired weld 5 Symbol
112
CONTENTS
WELDING SYMBOLS
(A) PARTIAL PENETRATION, SINGLE-V BUTT WELD
90°
6 (10) 90°
6
Desired Weld (D=10) Symbol
(B) FULL PENETRATION

90° 5 (12) 90° See
(D=12) 5 (12) Note
90°
5
22
5
90° (D=12) Symbol
Note Note: The total design throat
overlap Desired Weld
thickness (D)=22mm
(C) SINGLE BEVEL BUTT WELD WITH ROOT OPENING

10
(4) (4) 2 See
(7) Note
60°
60° Symbol
2 Note: The total design throat
thickness cannot be greater than
(7) plate thickness (10mm)
Desired
Weld
(D) COMBINED FILLET AND BUTT WELDS
25
14 9
14
6 (14) 70°
Note
overlap 6 (14) 70°
70° 70° 9
Symbol
6 6
9 9
Desired Weld
113
CONTENTS
WELDING SYMBOLS
(A) SURFACE WELD
Desired weld 3
3
Symbol
(B) PLUG WELD
45° See
12 12 Note
45°
Symbol
Section of desired weld
NOTE: See drawing for
dimensions and orientation
114
CONTENTS
WELDING SYMBOLS
(C) SPOT WELD
A (5)
6 24
24 24 24 24 RSW
12 12 12
+ + + + + 6
A Symbol
Desired weld Section A-A RSW - Resistance spot welding
(D) SEAM WELD
Min acceptable shear

₂
strength 35 N/mm EBW
A ₂
35 N/mm
A Symbol
Desired weld Section A-A
EBW - Electron-
beam welding
115
CONTENTS
A GUIDE TO INTERPRETING THE AUSTRALIAN / NEW
ZEALAND STANDARD CLASSIFICATION FOR LOW
CARBON STEEL MMAW ELECTRODES
The Australian/New Zealand Standard 4855 for Manual Metal Arc
Welding of non-alloy and fine grain steel is identical to ISO 2560
standard, and is to supersede AS/NZS 1553.1.
Under the new AS/NZS 4855 standard, covered electrode can be
classified based upon either yield strength and 47J minimum impact
energy known as method -A, or tensile strength and 27J minimum
impact energy known as method -B, which the second method is
widely accepted in Australian market. For details of the complete
range of classifications, please consult AS/NZS 4855.
Compulsory
clalssification designators
Specification number
Classification by tensile
strength and 27J CVN
requirement
Covered electrode
Deposit metal tensile strength.
“49” indicates minimum ₂
tensile strength of 490 N/mm ,
other designator like “43, 55
or 57” is often used
Type of flux coating
Condition of heat treatment.
The symbols “A” and/or
“P” are used to indicate
the as-welded and/or heat
treated condition/s
AS/NZS 4855-B - E49 16 A U H10
Optional supplemental
designators
Optional supplemental
designators Diffusible hydrogen. “H5,
H10,H15” is used to indicate
47J impact energy a maximum diffusible
at the normal hydrogen content of “5,10,
27J test temperature and 15 ml/100g of deposited
has also been met. metal, respectively
116
CONTENTS
ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC WELDING ELECTRODES
A GUIDE TO INTERPRETING THE AMERICAN ANSI / AWS
SPECIFICATION FOR CARBON STEEL ELECTRODES FOR
SHIELDED METAL ARC WELDING
The ANSI/AWS A5.1 Specification for Shielded Metal Arc Welding
details classifications covering general purpose, iron powder and
low hydrogen electrodes. The classification system consists of
an alphanumeric group followed by a group of optional designators.
Please consult ANSI/AWS A5.1 for further details on the range.
1ST GROUP 2ND GROUP 3RD GROUP

Minimum Weld Metal Welding Position, Optional Designator for
Strength Welding Current Improved Impact Toughness
and Coating Type E7016-1=20 ft.lb
Tensile Yield Elongation ie EXX12, EXX24 @ -50°F av.min.
ksi ksi % and EXX18
E7018-1=20 ft.lb
60 48 22 For details refer @ -50°F av.min.
to the Usability
Digits of Major E7024-1=20 ft.lb
70 58 22 @ -0°F av.min.
Classifications
on next page.
ELECTRODE
E XX XX XHXR 3RD GROUP
Optional designators
3RD GROUP 3RD GROUP

Optional Diffusible Hydrogen Optional Coating Absorbed
Designator indicates that the low MoistureDesignator indicates
hydrogen electrode meets the that the coating of a low hydrogen
requirements of the diffusible electrode is moisture resistant after
hydrogen test. being exposed to an environment
of 80°F and 80% relative humidity
H4 <4mL/100g) for a period of not less than 9
of deposited weld metal hours. Maximum specified
H8 <8mL/100g) moisturecontents are detailed in
of deposited weld metal Table 10 of thespecifications.
H16 <16mL/100g)
of deposited weld metal
117
CONTENTS
USABILITY DIGITS OF MAJOR CLASSIFICATIONS INDICATING
TYPE OF POSITIONS AND CURRENT TYPE REQUIREMENTS
TYPE OF
USABILITY WELDING TYPE OF CURRENT
COVERING AND
CLASSIFICATION POSITIONS AND POLARITY
SLAG
10 F,V,OH,H D.C. electrode High cellulose

positive
11 F,V,OH,H A.C. or D.C. High cellulose

electrode positive
A.C. or D.C High titania
12 F,V,OH,H electrode positive viscous slag
or negative
A.C. or D.C High titania viscous
13 F,V,OH,H electrode positive slag
or negative
A.C. or D.C
14 F,V,OH,H electrode positive Low iron powder
or negative
15 F,V,OH,H D.C. electrode *Hydrogen
positive controlled
16 F,V,OH,H A.C. or D.C. *Hydrogen

electrode positive controlled
A.C. or D.C. *Hydrogen
18 F,V,OH,H electrode positive controlled basic,
low iron powder
A.C. or D.C
19 F,V,OH,H electrode positive Limenite
or negative
20 F,H, Fillet A.C. or D.C. High iron oxide
electrode positive
A.C. or D.C High iron
24 F,H, Fillet electrode oxide titania
positive or negative
A.C. or D.C *Hydrogen
27 F,H, Fillet electrode positive controlled powder
or negative iron oxide
A.C. or D.C. *Hydrogen
28 F,H, Fillet electrode positive controlled low iron
powder basic
46 F,V-down A.C. or D.C. *Hydrogen
OH, H electrode positive controlled basic
F,V-down A.C. or D.C. *Hydrogen
48 OH, H electrode positive controlled basic,
low iron powder
99 As As Specified by As Specified by
specified manufacturer
NOTE: The abbreviations, F, V, V-Down, OH, H, and H-FiIIet indicate the following welding positions:
F-Flat, V-Vertical, V-down - Vertical down, OH-Overhead, H-Horizontal, H-fillet-Horizontal fillet. *Unless
otherwise indicated the classification digits have wide usage amongst the Australian AS, USA (AWS),
Canadian (CSA), Japanese (JIS) and the new draft ISO Standards. European Economic Community
118 Standards (CEN). As national standards are subject to regular revision these situations could alter.
CONTENTS
A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD
CLASSIFICATION FOR HIGH STRENGTH STEEL MMAW
The Australian/New Zealand Standard 4857 for Manual Metal Arc
Welding of high-strength steesl is identical to ISO 18275 standard,
and is to supersede AS/NZS 1553.2.
Under the new AS/NZS 4857 standard, covered electrode can be
classified based upon either yield strength and 47J minimum impact
energy known as method -A, or tensile strength and 27J minimum
impact energy known as method -B, which the second method is
widely accepted in Australian market. For details of the complete
range of classifications, please consult AS/NZS 4857.
Compulsory
clalssification designators
Specification number
requirement
Covered electrode
Deposit metal tensile strength.
“62” indicates minimum ₂
tensile strength of 620 N/mm ,
other designator like “59, 69,
76, 78 or 83” is often used
Type of flux coating
Any other agreed chemical
composition
Condition of heat treatment.
The symbols “A” and/or
“P” are used to indicate
AS/NZS 4857-B - E62 18-G A U H10 the as-welded and/or heat
treated condition/s
Optional supplemental Optional supplemental
designators designators
47J impact energy Diffusible hydrogen. “H5,
at the normal H10,H15” is used to indicate
27J test temperature a maximum diffusible
has also been met. hydrogen content of “5,10,
and 15 ml/100g of deposited
metal, respectively
119
CONTENTS
A selection of designators for nominal alloy weld metal
compositions widely used in ISO, Australian (AS) European
and American (AWS) systems of classification for electrodes
and weld metal. See the appropriate Standard for the fully
specified composition requirements and the location(s) of the
designator in the classification.
NOMINAL COMPOSITION
ALLOY GROUP DESIGNATOR
REQUIREMENTS
Carbon -
A1 0.40 - 0.65Mo
Molybdenum
B1 0.50Cr 0.5Mo
B2 or B2L• 1.25Cr 0.5Mo
Chromium - B3 or B3L 2.25Cr 0.5Mo
Molybdenum Steels B6 (5Cr)# 5Cr 1Mo
B7, B7L (7Cr)# 7Cr 5Mo
B8, B8L (9Cr)# 9Cr 1Mo
Ni1, Ni3L or C3 1 Ni
Ni2, Ni2L or C1, C1L 2.5 Ni
Nickel Steels
Ni3, Ni3L or C2, C2L 3.5 Ni
NM 1 Ni 0.5Mo
Manganese D1 1.5 Mn 0.35 Mo
Molybdenum Steels D2 1.8 Mn 0.35 Mo
Mil. Spec. Type Low
M (eg. E7618-M) A series of Mn-Ni-Cr-Mo
Alloy High Tensile
M1, M2, M3, M4 specified compositions
Series, AS 1553.2
eg. F9A2- for various strength levels
and AWS A5.23
ECM1-M12) Refer to standards
Examples
Other Low Alloy
SAW Electrodes•
Steels of specified EF1-EF6 series
SAW Weld metals•
composition (SAW F1-F6 series
FCAW Weld metals•
and FCAW K1-K7 series
Refer to AWS Standards
standards
Weathering Steels
Ni-Cr-Cu steels
(Corten - Austen W, W1, W2
typically 0.5Ni-0.5Cr 0.5Cu
etc.)
Composition exceeds
Alloy unspecified G, GS minimum requirements in at
least one specified element.
• L variants are a low carbon version (usually 0.05 % max) of

the standard alloy carbon range
# Alternative designators in some AWS standards.
120
CONTENTS
DESCRIPTION OF MMAW ELECTRODE TYPES AS CLASSIFIED
BY NATIONAL AND INTERNATIONAL STANDARDS
EXX10 AND EXX11 TYPES (AUSTARC 11)
Electrodes of these classifications have thin coatings which
contain at least 15% cellulose and up to 30% titania as rutile or
titanium white. The group is characterised by a forceful, deeply
penetrating, spray type arc with fairly high spatter. A voluminous
gas shield is produced, as a result of decomposition of the
cellulose materials in the arc region, which protects the weld
metal from atmospheric contamination. High weld metal quality
(including radiographic soundness) is achieved in all welding
positions and the electrodes operate satisfactorily from AC or DC
(electrode positive) power sources for EXX11 types and from DC
(electrode positive) only for EXX10 types.
EXX12 TYPE (AUSTARC 12P)
Electrodes of this classification have thin coatings which contain a
high proportion of titania as rutile, ilmenite or titanium white. The
group is characterised by a quiet, medium penetrating arc with
low spatter. The slag is viscous, full covering and easily removed
when cool. General ease of handling in all welding positions and
an ability to bridge gaps in work having poor fit-up are features
common to this electrode type. Due to the viscous slag, many of
these electrodes are suitable for use in the vertical down position.
In Europe, rutile-cellulose is a common designation, while in the
AWS classification sodium binders are specified.
EXX13 TYPE (AUSTARC 13S)
Electrodes of this classification are similar in formulation to the
EXX12 group. However, basic materials are added to increase
the fluidity of the slag. Similar to EXX12 electrodes, they operate
with a quiet medium-penetrating arc with low spatter. The slag is
fluid, full covering and easily removed when cool. The fluid slag
makes this electrode ideal for fillet welding in the flat or horizontal,
vertical-up and overhead welding positions. Potassium binders
give improved arc stability and are specified for the
AWS classification. (cont. over)
121
CONTENTS
EXX14 TYPE
Electrodes of the EXX14 type have medium thick coatings,
containing a high proportion of titania and sufficient iron powder to
ensure a deposition efficiency of 105 - 130%. They operate with
a smooth, medium penetrating arc with low spatter. The slag is
fairly viscous, full covering and easily removed when cool. These
electrodes are suitable for both single-run and multiple-run welds
in all positions and can be used to bridge gaps in work having
poor fit-up. Due to the viscous slag, many of these electrodes are
suitable for use in the vertical down position.
EXX15 TYPE
The original basic low hydrogen type is suitable for use on
DC electrode positive only. Similar characteristics and
application to EXX16 and EXX18.
EXX16 TYPE (AUSTARC 16TC)
These electrodes have a chemically basic slag, generally of
the limestone-fluoride type similar to the EXX15 group but with
the ability to run on AC as well as DCEP Higher arc stability
is provided by the use of potassium silicate binders and other
potassium bearing materials in the coating. Coating materials are
inorganic, selected for minimal combined moisture and coverings
are baked at a high temperature to provide low hydrogen in the
arc atmosphere.
Basic coated electrodes are noted for their tough low oxygen weld
metals and suitability for welding a wide range of carbon and low
alloy steels. The fluid full covering slag gives slight convex beads
and excellent all position welding capabilities.
EXX18 TYPE (AUSTARC 18TC AND AUSTARC 77)
Similar coating type and operational characteristics to the EXX16,
but the somewhat heavier coating contains sufficient iron powder
to give increased deposition efficiency to 105-130%. This still
permits all position welding on AC or DCEP but the presence of
the iron powder also improves metal transfer and operational
characteristics. The EXX18 group are widely used in a range of
steels and critical applications where weld quality is the main
requirement, particularly in all position welding. The group also
serves as the major basic group for a wide range of low alloy high
tensile electrodes.
122
CONTENTS
EXX19 TYPE
The slag type is based on the titanium oxide-iron oxide mineral,
ilmenite, and therefore has similarities to the EXX12 & 13 types
but with some distinct differences. Characterised by fluid slag and
forceful arc it gives Grade 1 radiographic standards, good ductility
and toughness down to -20°C.
EXX20 TYPE
A high iron oxide-manganese oxide/silicate type slag giving a
spray type arc and smooth flat to concave welds. Easily removed
honeycomb type brittle slag.
EXX24 TYPE (AUSTARC 24)
Similar slag type to EXXl2, 13 & 14 but with larger proportion of
iron powder and heavier coating, approximating some 50% of
electrode weight. High deposition rate, high speed runs and high
efficiency in the 130 to 150% class.
EXX27 TYPE
Electrodes of this type have thick, heavy coatings which contain
a high proportion of iron and manganese oxides and/or silicates,
and sufficient iron powder to ensure a deposition efficiency
greater than 130%. They operate with a vigorous, spray type arc
with medium to deep penetration. The slag is fluid, voluminous,
full covering and when cool well honeycombed on the underside,
friable and easily removed. Electrodes of this type are suitable
for high speed welding applications in the flat and horizontal-fillet
positions where good penetration and easy deslagging
are essential.
EXX28 TYPE
A heavy coated high iron powder version of the basic coated
lime fluorspar EXX18 electrode. The coating usually contains
approximately 50% of the weight of the electrode, restricting its
use to the flat and horizontal fillet positions.
EXX46 AND EXX48 TYPES
Electrodes of the EXX46 and EXX48 classifications have
respectively the same usability, composition and design
characteristics as EXX18, except for excellent vertical-down
performance.
123
CONTENTS
CLASSIFICATION FOR FERRITIC STEEL GMAW ELECTRODES
The standard AS/NZS 2717.1 for Gas Metal Arc Welding Ferritic
Electrodes is the only AS/NZS standard for semi-automatic welding
process that has not been superseded by ISO standards. Previous
FCAW stand AS 2203.1 has been supersended by AN/NZS ISO
17632, 17634 and 18276. The system of classification consists of
three alphanumeric groups separated by the hyphens, which may
be summarised as follows. For full details of the complete range of
classifications, testing, chemical, mechanical, radiographic and other
requirements of the standard, please consult AS/NZS 2717.1.
2ND GROUP AS WELDED TENSILE PROPERTIES*

Type of external Min.
Weld Metal Min. Tensile Min.Yield
shielding gas First Elongation
Classification Strength Strength
digit is G for gas. on 5d
C = shielding with W50XH 500 MPa 360 MPa 22%
welding grade
carbon dioxide W559H 550 MPa 470 MPa 19%
M = shielding with For complete details refer to AS / NZS 2717.1
mixed gases.
I = shielding with 3RD GROUP
inert gas.
Weld metal properties.
A indicates as-welded
AS 2717.1 ES6 - GC - W 50 3 A H condition, or
P after post weld
heat treatment
H indicates hydrogen
FIRST GROUP - ES = Electrodes, Solid,
followed by a numerical or alphanumerical controlled weld metal.
code which define the chemical composition of
the wire. For example The third digit, for carbon
steel electrodes, indicates
Wire the Impact energy grade
C Mn Si Other number as specified below.
Class.
For low alloy, ferritic steel
ES3 .06-.15 .90-1.40 .45-.75
- electrodes, the third digit is
ES4 .07-.15 1.00-1.50 .60-.85
- 9 and the minimum average
ES5 .06-.19 .90-1.40 .30-.60
.50-90AI- CVN impact values are as
ES6 .06-.15 1.40-1.85 .80-1.15
- stated in AS / NZS 2717.1.
ES7 .07-.15 1.50-2.00 .50-.80
Impact Min. Avrge
ESB2L
Low carbon Cr-Mo Alloy
Energy Charpy ‘V’ notch
ESNi2
2.5 Ni Alloy
Grade # impact value
ESD2 Z Not required
Mn-Mo-Alloy
ESM3
Mn-Ni-Cr-Mil Spec Alloy A 47J at +20°
ESMG
o specified composition
ER70S-G 0 47J at 0°
Refer AS / NZ 2717 for full range of 2 47J at -20°
classifications and compositions. 4 47J at -40°
124 6 47J at -60°
CONTENTS
A GUIDE TO INTERPRETING THE ANSI /AWS GAS SHIELDED
ELECTRODE CLASSIFICATIONS - GAS METAL ARC WELDING FERRITIC STEEL ELECTRODES

ARC WELDING FILLER METAL SPECIFICATION
The ANSI / AWS A5.18 specification for Carbon Steel Electrodes
and Rods for Gas Shielded Arc Welding includes Metal Cored
electrodes formerly classified in ANSI / AWS A5.20 and an example
is illustrated to acquaint the user with information provided by the
specification.While the full range of classifications can be employed
with GMAW only solid rods should by used for GTAW (TIG) and
PAW processes. For full details of all test requirements, radiographic
standards, manufacturing tolerances, packaging etc refer to the
latest edition of the standard.
LETTER AS WELDED TENSILE PROPERTIES*

DESIGNATORS Min. Tensile Min. Yield Min.
E = Electrode Weld Metal Strength Strength Elongation
R = Rod Classification
psi MPa psi MPa %
S = Solid Wire
C = Composite Metal ER 70-X 70,000 480 58,000 400 22
Cored Wire
M = Mixed Shielding ER 70-XX 70,000 480 58,000 400 22
Gas *Properties as detailed are appliccable for all classifications
C = Cabon Dioxide
Shielding Gas
OPTIONAL
DESIGNATORS
ER70S - 6 H4 Indicate diffusible

weld metal
ER70C - 6M H4 hydrogen content
H4 = <4mL/100g)
H8 = <8mL/100g)
H16 = <16mL/100g)
DEPOSITION PROCESS
Class C Mn Si Other
ER70S-2 0.07 0.90-1.40 0.40-0.70 Ti, Zr, AI DEPOSITION PROCESS
ER70S-3 0.06-0.15 0.90-1.40 0.45-0.75 0.50 Cu
ER70S-4 0.07-0.15 1.00-1.50 0.60-0.85 0.50 Cu Class Ftlb J
ER70S-5 0.07-0.19 0.90-1.40 0.30-0.60 Cu, Al
ER70S-2
ER70S-6 0.06-0.15 1.40-1.85 0.80-1.15 0.50 Cu
ER70S-7 0.07-0.15 1.50-2.00 0.50-0.80 0.50 Cu ER70S-3 20 @ -20°F 27 @ -29°F
ER70S-4 20 @ 0°F 27 @ -18°F
ER70S-G Agreed between the supplier & customer ER70S-5 N/A N/A
ER70S-6 N/A N/A
WELD METAL ANALYSIS ER70S-7 20 @ -20°F 27 @ -29°F
ER70S-G 20 @ -20°F 27 @ -29°F
E70C-3X 0.12 1.75 0.90 0.50 Cu ER70S-3X As Agreed As Agreed
E70C-6X 0.12 1.75 0.90 0.50 Cu ER70S-6X 20 @ 0°F 27 @ -18°F
ER70S- 20 @ -20°F 27 @ -29°F
E70C-G Agreed between the suppler & customer G(X) As Agreed As Agreed
E70C-GS(X) Agreed between the suppler & customer ER70S- N/A N/A
Single figures are maximum GS(X)
G- general, GS = general, single pass only
125
CONTENTS
EXAMPLES:
1. AWS A5.18: ER70S-6
Indicates a solid wire electrode and filler rod. Mechanical testing
of an all weld metal test plate, deposited under CO₂ shieldng will
give min. 72 ksi (500 MPa) tensile strength, 60 ksi (420 MPa) yield
strength, min. 22% elongation on 4D and a charpy impact strength
of 27J at - 29°C. The weld will meet radiographic requirements. The
wire meets a specffied chemical analysis, dimensional requirement
and some additional testing where supplied as a filler rod only.
2. AWS AS.28: ER80S-B2
Indicates a solid wire electrode and filler rod. Mechanical testing of
an all weld metal deposit, welded under Argon+1-5% O₂ gas
shielding is carried out after PWHT at 620°C. The requirements are a
min. tensile strength of 80 ksi (550 MPa) yield strength at 0.2% offset
of 68 ksi (470 MPa) and an elongation 19% min. on 4D. It has to
meet radiographic soundness but no impact properties are specified
for this alloy. The wire, a nominal 1.25% Cr/0.5% Mo alloy must meet
a specific composition analysis, dimensional requirements and some
addtional requirements for supply as a filler rod only.
3. AWS A5.28: E80C-B2
A cored or composite electrode the dropping of the R indicates
it meets the specification for an electrode only. It meets all the
weld metal soundness and mechanical requirements specified in
example 2 above but the B2 alloy specific composition is confirmed
by anaysis of the deposited weld metal.
126
CONTENTS
A GUIDE TO INTERPRETING THE AS/NSZ ISO SPECIFICATIONS
ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODES

FOR FLUX CORED ARC WELDING
The new AS/NZS ISO 17632 standard is a series of adopted ISO
standards to cover Flux Cored Arc Welding (FCAW) electrodes
for Non-alloy and fine grain steels. The following provides a brief
introduction into the classification systems, and the standard series
cover different electrode range. For full classification details, please
consult the latest standards.
AS/NZS ISO 18276: high strength Steels
AS/NZS ISO 17634: creep resisting steels
AS/NZS ISO 17633: Stainless steels.
Compulsory clalssification designators
requirement
Tubular cored electrode
Minimum tensile strength
meets 550MPa
Tested temperature @
-40°C meets the minimum
impact properties of 27J
Usability designator. T5
indicates Lime-flouride
flux, and generally referes
to Basic flux system
Welding position. 1
indicates all positional;
and 0 - downhand only.
Shielding gas M
indicates mixed gases
Indicates tested in the
as welded condition
chemical composition
designator, N2 indicate
AS/NZS ISO 17632-B - T 55 4 T5-1 M A-N2-U H5 2%Nil in deposited weld
Optional supplemental designators metal
47J impact energy at the normal 27J
test temperature has also been met.
Diffusible hydrogen. “H5,H10,H15”
is used to indicate a maximum
diffusible hydrogen content of “5, 10
and 15 ml/100g of deposited metal,
respectively. 127
CONTENTS
A GUIDE TO INTERPRETING THE ANSI / AWS SPECIFICATIONS
FOR FLUX CORED ARC WELDING
The ANSI / AWS A5.20 (Plain Carbon) and A5.29 (Low AlIoy)
Electrode specifications have similar classification systems. They are
shown in a combined form to acquaint the user with the information
provided by the classification. For full details of all test requirements,
radiographic standards, manufacturing tolerances, packaging, weld
metal compositions etc., please consult the latest edition of the
appropriate specification
WELD METAL WELD METAL
STRENGTH DIGITS COMPOSITION
The strength digits ‘6’ and ‘7’ in Electrodes to A5.20 have a weld metal
A5.20 and ‘6’, ‘7’, ‘8’, ‘9’, ‘10’, composition requirement that ensures they
‘11’ and ‘12’ in A5.29 represent are plain carbon steels and do not employ
0.1 of the min. tensile strength in an alloy suffix. Electrodes to A5.29 have
ksi, eg. ‘8’=80ksi (550MPa) specific compositions and employ the
‘11’=110ksi (760MPa) designations as shown in Table 4 of this
Each strength group has a min. section (Page 126). These include the
yield strength, 12ksi (10ksi for A1, B2, B3, Ni1, Ni2, D1, D2, D3, K1 to
‘6’ in A5.29) below the min. K7: W types.
tensile strength and a min.
elongation requirement. For full details of the chemical
compositions, refer to Table 1 of A5.29
TUBULAR
Flux Cored Electrode
AWS A5.20 E X X T - X
ELECTRODE AWS A5.29 E X X T X - X
POSITIONAL
CAPABILITIES
“0” = Flat and Horizontal
“1” = All Positions
IMPACT STRENGTH
The A5.20 classification EXXT-1, T-5,
T-6 & T-8 have min. impact requirements
USABILITY AND shown in the usability table. In A5.29
PERFORMANCE the requirement for impact testing on
Note: A5.20 as-welded or PWHT specimens and the
Classifications shown test temperature for min. 20ft-lb (27J) is
here are T-X, A5.29 as specified in Table 4 against the complete
TX. For details of usability classification eg.
and performance refer to E81T1-Ni2 AW-40°F (40°C)
Page 135.
E80T5-Ni2 PWHT - 75°F (-60°C)
128
CONTENTS
ELECTRODE CLASSIFICATIONS - FLUX CORED ARC WELDING ELECTRODES
USABILITY AND PERFORMANCE CAPABILITIES
CLASSIFICATION
T-1, T1 - Almost invariably a Rutile (Titania) based flux imparting
smooth running, spray transfer, low spatter using CO₂ shielding,
electrode positive. Some designed for out of positioning welding
when Argon/CO₂ mixtures may be preferred. Most popular group.
E7XT-1 - Has impact requirement of 20ft-lb (27J) at 0°F. (-18°C).
T-2 - Essentially similar to T-1 but higher Mn and Si for improved
single pass welding over mill scale, rust or on rimmed steel in the
flat and horizontal fillet positions.
T-3 - Self shielded, high speed single pass welds on sheet metal
up to 5mm thick using DCEP.
T-4, T4 - Self shielded, very high deposition rate with globular
transfer on DCEP. Low penetration, desulphurised welds, resistant
to cracking, can be used on poor fit up. Suitable single or multiple
run in flat and horizontal positions.
T-5, 15 - Lime Fluoride basic flux for high toughness and
crack resistance using DCEP and CO₂ shielding. Argon/CO₂
mixtures may be preferred for some applications.Globular
transfer, convex beads (similar E7016-18 electrodes) for critical
flat and horizontal fillet welds. Impact requirement for EXXXT-5
is 20ft-lb. (27J) at -20°F (-29°C).
T-6 - Self shielded, DCEP, spray type transfer for single or multiple
pass welding in flat or horizontal positions. Provides good low
temperature impact properties 20ft-lb (27J) at -20°F (-29°C) and
root penetration, easy slag removal in flat and horizontal positions.
Single or multipass welds,
T-7 - Self shielded, DCEN, single and multipass pass welds with
desulphurising slag giving crack resistant welds. Larger sizes give
high deposition rates, small sizes provide all position welding.
T-8, T8 - Self shielded, DCEN, all position welding, single and
multipass. The slag system produces good impact properties
(T8 min. 20ft-lb (27J) at -20°F (-29°C). and a desulphurised weld
metal resistant to weld cracking.
T-10 - Self shielded, DCEN, single pass welding at high travel
speeds in the flat, horizontal, down slopes (to 20°).
T-11 - Self shielded, DCEN, with a smooth spray arc, General
Purpose electrodes for single and multipass welding in all
positions and high travel speed welding.
T-G, TX-G - A classification for new multipass electrodes not
covered by any of the above.
T-GS - A classification for new single pass electrodes not
covered by any of the presently defined classifications.
129
CONTENTS
STANDARDS AUSTRALIA AND THE ANSI/AWS
SPECIFICATION STANDARDS FOR STAINLESS STEEL
AND ALUMINIUM ALLOY ELECTRODES
The new AS/NZS standards offer two classification systems, which
are according to nominal composition (-A) and alloy type (-B)
respectively. In Australia market, the B system is widely accepted
and substantially the same to AWS standards.The following provides
a brief introduction into the classification systems employed and the
information they provide to the user. These are:
ANSI/AWS A5.4 - Stainless Steel MMAW ELECTRODES - AS/NZS 4854
ANSI/AWS A5.9 - Stainless Steel GMAW ELECT. - AS/NZS ISO 14343
ANSI/AWS A5.10 - Al./Al. Alloy GMAW - AS/NZS ISO 18273
For full details of the manufacturing tolerances, testing
requirements, packaging, chemical composition and other
aspects of the standard specifications, please consult the latest
edition of the appropriate above standard.
1. CORROSION-RESISTING CHROMIUM AND CHROMIUM-
NICKEL STEEL ELECTRODES (a) MMAW COVERED
ELECTRODES - AS/NZS 4854-B and ANSI/AWS A5.4
The basis of these classifications is the chemical composition
and mechanical properties of the deposited metal, the coating type
and current.The system of designation is as follows:
ELECTRODE ALLOY DESIGNATION

E X X X - X
An alphanumeric system COATING TIME
of alloy designation almost -15 DC Electrode Positive Lime Type
universally employed. eg. -16 AC or DCEP Lime or Rutile Type
308, 316L, 309Mo, 310 etc.
-17 AC or DCEP Acid Rutile Type•
-25 DC EP Heavy Coated Lime Type•
-26 AC or DCEP Heavy Coated Rutile Type •
The -17, -25, and -26 suffixes are recent additions to the
classifications. The -17 is a more siliceous version of the -16.
The -25 and -26 coatings are designed for flat and horizontal
welding and are generally “synthetic” versions using lower alloyed or
plain carbon core wires. (b) GMAW ELECTRODES The Standards
Australia AS/NZS ISO 14343 for gas metal arc electrodes bases its
classification of the electrode range on the composition of the solid
wire. This is followed by the commonly employed alphanumeric
designation of the chromium nickel steel, the actual composition of
130 which is specified in the standard.
CONTENTS
No mechanical properties are specified. The ANSI/AWS A5.9
ELECTRODE CLASSIFICATIONS - MANUAL METAL ARC & GAS METAL ARC WELDING
Specification covers solid wires, and metal cored, stranded or
composite wires and again bases its classification on the chemical
composition of the solid wires or a fused sample of the cored
or composite wires. This specification covers electrodes or filler
metals for GMAW, GTAW or SAW processes. For this reason, no
mechanical testing requirements are specified. The designations
in the classifications differ slightly.
2. ALUMINIUM AND ITS ALLOYS — GMAW ELECTRODES
The AS/NZS ISO 18273 and ANSI / AWS A5.10 standards
specifications for Aluminium and Aluminium alloys GMAW
electrodes (and in the case of A5.10, filler rods) both base their
classification on the chemical composition of the solid wire. The
alloy is designated by an internationally accepted system involving
a four digit number, the first indicating the aluminium content or
the main alloying element, Of these, the following are employed in
welding as electrodes or filler rods, viz.
1XXX = Aluminium content 99% min.
2XXX = Copper is main alloying element
4XXX = Silicon is main alloying element.
5XXX = Magnesium is main alloying element.
The second digit indicates modifications to the basic alloy
or impurity limits while the third and fourth digits identity the
aluminium alloy or indicate the aluminium purity.
A prefix of E indicates an electrode wire in the Australian Standard
and ER indicates Electrode/Filler Rod in the ANSI / AWS System.
Example:- E5356 and ER5356 are classifications for a popular
4.5-5.5% Mg aluminium alloy with minor additions of Mn, Cr and Ti
and limits on Si,Fe,Cu,Zn and others.
Modifying the alloy designation to 5556 indicates mainly a rise in
Mn level from approximately 0.1 to 0.5-1.0% and marginally higher
“aim” value for Mg and Zn (0.1 max to 0.25 max.), which results in
a higher tensile strength deposit.
Alloy E5183 and ER5183 has become a popular filler metal used
in the fabrication of marine passenger, car ferry and pleasure
craft. It is a modification of the 5356 alloy with increases in Si, Mn
and Zn and is particularly suitable for welding 5083 alloy in marine
applications because of the higher tensile strength weld metal.
The composition of the wires in both standards are almost identical
with slightly narrow tolerance on Beryllium content from AWS
standard and an electrode fully meeting the requirements of AWS
A5.10 will be deemed to be qualiﬁed to the AS/NZS ISO 18273.
131
CONTENTS
132
CONTENTS
ELECTRODE CLASSIFICATIONS - REPAIR AND HARDFACING

A GUIDE TO INTERPRETING THE AUSTRALIAN
ANDNEW ZEALAND SPECIFICATION FOR REPAIR
AND HARDFACING CONSUMABLE
The AS/NZS 2576 Welding Consumable for Build-Up and Wear
Resistance is based on the Welding Technology Institute of
Australia (WTIA) Technical Note 4.
The standard classifies consumables by alloy type, deposit
hardness, welding process and consumable type. For complete
details of the consumable classifications please refer to the latest
edition of AS/NZS 2576.
1ST = ALLOY GROUP 2ND DIGIT =

1 = Steels ALLOY TYPE
2 = Chromium white irons In combination with the first
digit it indicates the specific
3 = Tungsten carbide composites
type of alloy whithin a group.
4 = Cobolt alloys
23XX = Austenitic
5 = Nickel alloys chromium-carbide iron
6 = Copper alloys
3RD & 4TH DIGIT = DEPOSIT HARDNESS

2360 - A4 Indicates mean undiluted deposit hardness
prior to any heat treatment or work in service.
Hardness is expressed in Rockwell C (HRC) units.
ie. XX60 = 60-65 HRC
DEPOSITION PROCESS 5TH DIGIT = CONSUMABLE TYPE

The letter indicates the A1 = Tubular electrode no alloy
welding process. contribution from the flux coating.
A = Manual Metal Arc Welding A4 = Low carbon steel core wire alloy
B = Submerged Arc Welding and additive flux coating.
Flux Cored Arc Welding B1 = Tubular wire no alloy. contribution
C = Gas Welding from the flux coating.
B5 = Gas shielded tubular flux core wire.
B7 = Self shielded tubular flux core wire.
C1 = Filler Rod.
C3 = Powder.
133
CONTENTS
CLASSIFICATION FOR SUBMERGED ARC WELDING
ELECTRODES AND FLUXES
The Australian Standard for electrodes and fluxes for SAW, AS
1858.1 (C and C-Mn Steels) published by Standards Australia
and its classification system has strong similarities with the ANSI /
AWS SAW specifications, particularly in relation to electrode and
alloy weld metal designations and compositions. The following
provides a guide to the designations and layout of the classification
systems (shown in combined form) to acquaint the user with the
information provided by the classifications. For full details of the
complete range of classification testing requirements, chemical,
mechanical, radiographic and other requirements of the standard,
consult AS 1858.1.
EXAMPLE: AS1858.1
EL12-FMM-W404 is a complete designation. It refers to a flux
and wire combination that will produce weld metal which in the
as-welded condition, will have a tensile strength no lower than
430 MPa and Charpy V-notch impact strength of a minimum of
35J at -40°C when deposited with an EMK12 electrode under the
conditions called for in this specification.
134
CONTENTS
ELECTRODE CLASSIFICATIONS - SUBMERGED ARC WELDING ELECTRODES AND FLUXES
CLASSIFICATION FOR SUBMERGED ARC WELDING
ELECTRODES AND FLUXES
ELECTRODE AND WELD METAL FLUX HYDROGEN

DESIGNATIONS AND COMPOSITIONS APPLICATION
S = Single Run A suffix
Electrode C Mn Si M = Multi Run indicating
B = Basic Flux hydrogen
EL8 0.10max 0.25/0.60 .0.07max G = General controlled weld
EL12 0.05-0.15 0.25/0.60 0.07max Purpose metal may be
EM12K 0.05-0.15 0.80/1.25 0.10/0.35 added when
max. H2 level
Note: A small selection only of carbon is established.
steel electrodes. For full list and details
refer tothe appropriate part of the (AS 3752 - 1996)
standard H15 <15mL/100g
H10 <10mL/100g
FLUX CONTRIBUTION TO WELD ANALYSIS H5 <5mL/100g
L = Low Mn & Si A = Alloys other than of deposits of
metal
M = Medium Mn & Si Mn & Si and added to L,
H = High Mn & Si M or H eg.LA, MA or HA
E or EC XXX - F X X - W XX X X X HX
ELECTRODE (SOLID) FLUX WELD METAL HEAT TREATMENT

A+ Tested “As Welded”
P=Tested “Post Weld
heat treated”
ELECTRODE COMPOSITE (CORED)
WELD METAL STRENGTH DIGITS IMPACT ENERGY NUMBER

The strength digits ‘40’ and ‘50 in ‘0’ = No impact required
part 1 of AS 1858 represent one-tenth ‘1’-‘5’ = test temperature of +20°C
of the approximate min. tensile strength to -60°C in 20° intervals.
in MPa of the tensile range. Each Energy Requirement
strength level also has a min. Proof
Stress (0.2% Offset) and Elongation W40X = 35J
requirements specified by this standard. W50X = 40J
WXXX = 27J
135
CONTENTS
WELD DEPOSITION
AND COSTING DATA
Weld costing systems differ throughout the world and between
companies in similar operations but with different methods of cost
accounting. Some variations in systems are due to variations
in methods of selling consumables. For example, MMAW
consumables may be sold by the number, length or mass of
the electrodes. However, all systems invariably rely on a basic
philosophy of determining the quantity (in kg.lb, m etc) of consumable
required to produce a given volume of joint. From this, the labour
time for joint completion, based on the deposition rate and duty
cycle estimates for the welding consumables/processes, welding
positions and workshop/site situations, in question, can be determined.
The costs of joint preparation and finishing must also be considered,
and like the other factors mentioned can be substantially influenced
at the design stage. The lowest welding costs are achieved when
full use is made of the high productivity welding processes and
when joints are designed specifically for these processes.
Australia sells all major solid (and some gas) welding consumables
by mass (kg), and all requirements can be related back to the
mass of added weld metal required to produce a unit length of joint.
Most well equipped welding shops have a range of processes,
particularly MMAW, GMAW and SAW machines, and the following
approach to weld costing is based on a system which can integrate
the various methods and allow for substitution as desired.
THE WIA APPROACH TO WELD COSTS DETERMINATIONS
TO ASSIST YOU IN ESTIMATING WELDING COSTS WE
HAVE PUT TOGETHER THE FOLLOWING GUIDE IN FOUR
SECTIONS. A COMPREHENSIVE GUIDE TO USING
SECTIONS 1-4
The mass of weld metal in a length of joint is a product of its
volume (cross-sectional area x length) and its density. Most weld
joint cross-sections can be broken up into basic shapes as detailed
below and illustrated in Figure 10
136
CONTENTS
WELD DEPOSITION AND COSTING DATA - USERS GUIDE
Major area of the square,
RECTANGULAR
vee and U joints and roof TABLE 1.0
CROSS SECTIONS
gap components.
TRIANGULAR Major areas of vee and
TABLE 1.1
CROSS-SECTIONS bevel joints, fillet sections
1 Semi-elliptical shapes of
REINFORCMENT predictable or measurable
TABLE 1.2
CROSS-SECTIONS heights and widths
reinforcing the weld face.
Part circle segments
RADIUS
associated with U and J TABLE 1.3
CROSS-SECTIONS
joints
The carbon arc electrode
selected Or gas nozzle)
determines the width, while
BACK GOUGED
the rate of travel and angle TABLE 1.4
CROSS-SECTIONS
determines the depth of
gouge. Areas of predicable
contours are covered.
A range of fillet sizes and
FILLET WELD
shapes including convexity TABLE 1.5
SECTIONS
and concavity allowances.
137
CONTENTS
WELD DEPOSITION
AND COSTING DATA
fA hA
Side A
1/2 L
d
T
W=2r
r
hB
d2
Side b fB
Figure 10
TABLES 1.0-1.5 of SECTION 1 are a convenient means of
determining the mass of weld metal per unit length of joint for
each of the simple joint cross-sections described. Simply look up
the appropriate dimensions of the shape in question, and the weld
metal mass, in kilograms per metre (kg/m), is calculated for you.
By referring to GUIDE 1, shown in the following pages, a practical
example is given illustrating the correct usage of TABLES 1.0-1.5
Where ready made tables are not available or greater accuracy
is required you can calculate the area. Given the length of the
required weld, the volume of weld metal can be calculated and
converted to the mass of weld metal, using an appropriate
density figure. For example, 1 mm² cross-sectional area of steel
weld metal by 1000 mm (1 metre) long has a mass of .00785
kg. Therefore, finding the cross-sectional area, in mm², and
multiplying by .00785 will give the mass of weld metal per metre
of joint, in kg/m.
138
CONTENTS
A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 CONT.
“Quantity of consumables” data, tabled in section 2, allows
the quantity of consumable(s) required to weld a given joint,
to be calculated. Further to this, the “DEPOSITION RATE” and
“Duty Cycle” data of sections 3 & 4 enable realistic estimates
of actual welding speeds and times to be determined for
specific consumables/welding processes, welding positions and
workshop/site situations. Detailed practical examples, illustrating
the use of information contained in Sections 2-4
are featured respectively in Guides 2-4.
BY FOLLOWING THE GUIDES THROUGH FROM 1-4 THE USER
IS GIVEN A STEP-BY-STEP METHOD FOR DETERMINING:
1. the mass of weld metal required per metre of joint
2. the quantity of consumable(s) required per metre of joint
3. the continuous (100% duty cycle) welding speed/time for one
metre of joint
4. a realistic estimate of the actual welding speed/time to
complete one metre of joint.
GUIDE 1 - DETERMINE MASS OF WELD PER METRE USING
TABLES 1.0 - 1.5 OF SECTION 1
(a) Fillet Welds
For fillet welds the user is directed to TABLE 1.5. Select the
desired leg length (L) with the likely degree of convexity (h) given
the electrode size/type used, the welding position and process
etc., and read off the mass of weld metal per metre of joint (kg/m).
For acute angle or obtuse angle fillets or fillets of unequal leg
length treat as for a butt weld and refer to (b).
(b) Butt Welds
For butt welds, first sketch the joint cross-section under
consideration, breaking it down into fundamental shapes such
as rectangles, triangles and reinforcement and radius sections as
shown in figure 10.
Dimension the shapes, from available information, by calculation or
by “intelligent guessing”. Using these dimensions, the mass of weld
metal per metre of joint can be arrived at for each shape segment
using the data from TABLES 1.0-1.4. From here, the total mass of
weld metal required per metre of joint can be simply calculated by
adding the figures obtained for each shape segment.
139
CONTENTS
WELD DEPOSITION
AND COSTING DATA
PRACTICAL EXAMPLE 1
For the U-joint illustrated in FIGURE 10, assume the
following dimensions:
T (plate thickness) = 60 mm
Ø = 10° (therefore, included angle is 20°)
r (root radius) = 10 mm
d₂ (root face) = 8 mm
Side A Rectangular, Triangular and Radius Cross-Sections
With a root face (d₂) of 8 mm and a root radius (r) of 10 mm, the
depth of the rectangular and triangular sections (d) will be, d =
T - (d₂ + r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of
course equal to 2r = 20 mm.
From table 1.0, the mass of weld metal per metre of joint required
for a rectangle of area, 20 x 42 mm = 840 mm2, is approximately.
6.59 kg/m (A).
From table 1.1, two triangles with an included angle of 20° and a
depth of 42 mm will need a mass of weld metal per meter of joint
of approximately .....................................................2.50 kg/m (B).
From table 1.3, a semi-circular section of radius 10 mm will
require a mass of weld metal per metre of joint of approximately..
................................................................................1.23 kg/m (D).
GUIDE 1 CONT.
SIDE A REINFORCEMENT CROSS-SECTION
The reinforcement width of Side A (fA ) will be the addition of 2r
(20mm) and L (15mm, taken from TABLE 1.1) plus whatever
overlap onto the parent metal is considered desirable practice.
For this example, assume an average overlap of 3mm on each
side of the joint which gives fA = 6 + 20 + 15 = 41 mm. Also let us
assume a reinforcement height on Side A (hA ) of 3 mm.
From table 1.2, the mass of weld metal required per metre of joint
for the reinforcement section of Side A of f = 41 mm and h = 3 mm
is approximately ...................................................0.75 kg/m (C1).
140
CONTENTS
SIDE B BACK GOUGED CROSS-SECTION
Here the user will be guided by such factors as, the welding
process used for the root pass, to determine resultant root
penetration, the fracture toughness requirements of the root and
established workshop practices, etc. to determine the extent of
back gouging required.
For this example, we will assume a carbon-arc gouge carried out
with a 10 mm carbon electrode to produce a groove 14 mm wide
and 10 mm deep. From TABLE 1.4, the mass of weld metal
required per metre of joint to fill a groove of these dimensions is
approximately ..........................................................0.86kg/m (E).
Side B Reinforcement Cross-Section
With a gouge width of 14 mm (allow a little more for uneven
gouging) and estimating a 3 mm overlap onto each side of the
joint gives a reinforcement width for Side B (f8) of 21 mm.
From TABLE 1.2, the mass of weld metal required per metre of
joint for a reinforcement section of f = 21 mm and an assumed
height of h = 1.5 mm is approximately................... 0.19 kg/m (C2).
Therefore, A + B + D + C1 + E + C2 gives the total mass of
weld metal required per metre of joint: 6.59 + 2.50 + 1.23 +
0.75 + 0.86 + 0.19 = 12.12 Kg/m
GUIDE 2 - DETERMINE QUANTITY OF CONSUMABLES
REQUIRED PER METRE USING TABLES 2.0 - 2.3 OF SECTION 2
Given the mass of weld metal required to “Fill” a metre of joint,
the next step is to determine the mass of consumable(s) initially
required. The weld metal yield achieved from welding with
a consumable electrode or filler wire largely depends on the
efficiency of the welding process / consumable in question. This
efficiency is influenced by such inherent wastage factors as, weld
metal spatter, slag coverage and gas plume production. The
“Quantity of consumables” figures listed in tables 2.0-2.3 are
for a weld metal yield of 1 kg and take account of these inherent
losses. An additional percentage (listed in the ‘EXTRA FOR
WASTAGE” column) is usually added to allow for typical shop
wastage such as stub ends & wire snips etc.
141
CONTENTS
WELD DEPOSITION
AND COSTING DATA
PRACTICAL EXAMPLE 1 CONTINUED
For the U-joint discussed in EXAMPLE 1 of GUIDE 1 let us
assume that 1.6 mm Austfil 71T with CO₂ shielding gas is used
for the single root pass weld on Side A and for welding the entire
back gouged section on Side B; and a SAW process using 4.0mm
wire is used for the remainder of the joint.
AUSTFIL 71T REQUIREMENTS (NOT INCLUDING
ALLOWANCE FOR SHOP WASTAGE)
Side A. Allow .25 kg of weld metal/metre of joint for the root pass
deposit (assuming that a single pass with a 1.6 mm Austfil 71T is
comparable in size to an 8 mm fillet weld).
Side B. From Guide 1, the mass of weld metal per metre of joint
for the back gouged cross-section (including reinforcement) is
1.05 kg/m. (0.86 +0.19)Therefore, the total weld metal required
from Austfil 71T is 1.05 + 0.25 = 1.30 kg/m.
From table 2.2 type A, 1.20 kg of Austfil 71T will produce 1 kg
of weld metal. Therefore, 1.20 x 1.30 = 1.56kg of Austfil 71T will
produce 1.30 kg of weld metal per metre of joint.
CO₂ Shielding Gas Consumption
To estimate CO₂ gas consumption let us assume, the 1.6mm
Austfil 71T is deposited at 350 Amps and 29 Volts, which will
produce a weld metal deposition rate of approx 5.4 kg/hr
(see table 3.2 part B of section 3).
GUIDE 2 CONT.
For a CO₂ flow rate of 12 L/min approximately 0.13m₃ (or .24kg)
of CO₂ gas will be consumed per kg of weld metal deposited (see
table 2.2). Therefore, 1.30 x 0.13 = 0.17 m3 (or .32 kg) of CO₂
will be used to deposit 1.30 kg of weld metal per metre of joint.
SAW FILLER METAL AND FLUX REQUIREMENTS (NOT
INCLUDING ALLOWANCE FOR SHOP WASTAGE)
The wire/flux submerged arc combination is required to produce
12.12 - 1.30 = 10.82 kg of weld metal per metre of joint. From
table 2.3 approximately 1.02 kg of wire will produce 1 kg of weld
metal. Therefore, 1.02 x 10.82 = 11.04 kg of wire will produce
10.82 kg of weld metal per metre of joint. Also from table 2.3
approximately 1.1 kg of flux is required to produce 1 kg of weld
metal. Therefore, 1.1 x 10.82 11.90 kg of flux will be consumed
to produce 10.82 kg of weld metal per metre of joint.In the
summary, the quantity of consumables required to complete
142 one metre of joint are:
CONTENTS
• 1.6 kg of 1.6 mm Austfil 71T wire
• 0.2 m₃ (0.3 kg) of CO₂ shielding gas
• 11.0kg of wire
• 11.9 kg flux not including allowances for shop wastage.
GUIDE 3 - DETERMINE 100% DUTY CYCLE WELDING SPEED
TIME USING TABLES 3.0 - 3.6 of SECTION 3
From the “Deposition Rate” data in tables 3.0 - 3.6 of section 3
for the selected consumables and arc processes, the continuous
welding speed (in m/hr) and welding time (in hr/m) can be
determined. Where deposition conditions are substantially varied
for different sections of a joint - for example narrow root passes
versus wide weave capping passes, the welding speed should be
calculated separately rather than an average taken.
PRACTICAL EXAMPLE 1 — CONTINUED
For the U-joint discussed in example 1 of guides 1 and 2 let us
assume the 1.6 mm Austfil 71T (used for the single root pass weld
on Side A and for welding the entire back gouged section on Side
B) is deposited at 350 amps and 29 volts under CO₂ shielding gas
with an electrode stickout of 25 mm. From table 3.2, part B, the
typical deposition rate is 5.4 kg/hr.
As calculated in guide 2, the wire requirements is 1.30 kg of weld
metal per metre of joint. Therefore the welding speed for Austfil
71T will be 5.4 ÷ 1.30 = 4.15 metres of joint/hour or the welding
time will be 0.24 hours/metre of joint.
For welding the remainder of the joint with SAW process, assume
a welding current of 700 amps and voltage of 34 volts for the 4
mm wire nominated. From table 3.3 the typical deposition rate is
approximately 8.3 kg/hr.
As determined in guide 2, the wire/flux combination is required to
produce 10.82 kg of weld metal per metre of joint. Therefore, the
welding speed will be:
8.3 ÷ 10.82 = 0.77 metres of joint/hour or the welding time will be
1.30 hours/metre of joint. 10.82From the calculated welding time
for continuous welding of the Austfil 71T /CO₂ and SAW process
combinations, the total welding time is .24 + 1.30 = 1.54 hours/
metre of joint.
In summary, given a duty cycle of 100%, (that is continuous,
uninterrupted, welding of the consumables detailed in this
example) one metre of joint will be completed in 1.54 hours.
143
CONTENTS
WELD DEPOSITION
AND COSTING DATA
GUIDE 4— DETERMINE REALISTIC ESTIMATE OF WELDING
SPEED/TIME USING THE DUTY CYCLE DATA OF SECTION 4
The continuous welding speeds and welding times, (That is for
a Duty Cycle of 100%) calculated in practical example 1 of
guide 3 serve as a starting point for determining realistic welding
speeds and welding times for joint completion.
As stated in section 4, Duty Cycle is a measure of the “arc on”
time as a percentage of the total time elapsed. The total elapsed
time must take into account all additional “non-arc” operations,
such as materials handling, weld deslagging, electrode changes
overs etc and personal allowances, as well as the total “arc-on” time.
In order to arrive at realistic welding speeds and times which
will approach the actual figures achieved, it is important to use
duty cycle estimates which are realistic for the consumable/arc
process combinations and workshop/site in question.
The choice of a satisfactory duty cycle may be determined
by referring to past records for workshop or site projects
undertaken using similar welding consumables and arc
processes under similar working conditions. Since detailed
information of this nature is often unavailable, a suitable duty
cycle figure may be arrived at by using “published data” and/or
by “educated guessing”.
section 4 entitled “Duty Cycles” details a range of achievable
duty cycles for the main arc welding processes used. The duty
cycles given under each heading are generally accepted as
‘maintainable’ by most reasonably equipped workshops or
welding sites.
To continue practical example 1 from guide 3, let us assume
from the information in parts (b) and (c) of SECTION 4;
• a duty cycle of 30% for the FCAW process
• a duty cycle of 40% for the SAW process
Therefore, a realistic estimate of the welding speed for Austfil
71T/CO₂ is 4.15 x .30 = 1.25 metres of joint/hour, and the welding
time is 0.80 hours/metre of joint; and a realistic estimate of the
welding speed for SAW process is 0.77 x .40 = 0.31 metres of
joint/hour, and the welding time is 3.25 hours/metre of joint.
144
CONTENTS
FROM THE CALCULATED WELDING TIMES FOR THE FCAW
AND SAW COMBINATIONS THE TOTAL WELDING TIME TO
COMPLETE ONE METRE OF JOINT IS 0.80 + 3.25 = 4.05 HRS.
This welding time will be a good approximation of the actual time
to complete one metre of join given that the duty cycle estimates
used are realistic for the welding task involved.
PRACTICAL EXAMPLE 2
If, for the joint described in example 1, the initial two passes on
Side A and all of Side B is welded with MMAW electrodes, Austarc
77 and Austarc 24 -instead of Austarc 71T; and the remainder
of the joint is welded with SAW process, the following variations
could take place.
Side A. The initial two passes with 4 mm Austarc 18TC will deposit
2 x .14 = .28 kg of weld metal per metre of joint (assuming, a
single pass with 4 mm Austarc 18TC is comparable to a 5 mm
fillet, see section 1, Table1.5). The remainder of Side A is to be
welded with SAW process.
Side. The first pass welded with 4 mm Austarc 18TC will deposit
.14 kg of weld metal per metre of joint. The remainder of Side B is
to be complete with 5 mm Austarc 24.
GUIDE 4 CONT.
4 MM AUSTARC 18TC REQUIREMENT
The total mass of weld metal required from 4 mm Austarc 18TC is
.28 + .14 = .42 kg per metre of joint.
At a typical current setting of 170 amps, the deposition rate (at
100% duty cycle) is 170 x .01 = 1.70 kg/hr (see section 3 table
3.0) Therefore, the continuous welding time to deposit .45 kg of
weld metal with 4 mm Austarc 18TC is.
.42 = 0.25 hours/metre of joint
170
Assuming a duty cycle of 25% (see section 4), a realistic estimate
of the actual welding time is
.25 = 1,00 hours/metre of joint
.25
145
CONTENTS
WELD DEPOSITION
AND COSTING DATA
5 MM AUSTARC 24 REQUIREMENT
The remainder of Side B requires 1.05 - 0.14 = 0.91 kg of weld
metal per metre of joint, deposited with 5 mm Austarc 24.
At a typical current setting of 300 amps, the deposition rate (at
100% duty cycle) is 300 x 0.135 =
4.05 kg/hr (see section 3, table 3.0) Therefore, the continuous
welding time to deposit 0.92 kg of weld metal with 5 mm
Austarc 24 is
0.91 = 0.22 hours/metre of joint
4.05
Assuming a duty cycle of 30% (see section 4), a realistic
estimate of the actual welding time is
.22 = 0.73 hours/metre of joint
.30
SAW CONSUMABLE
The remainder of Side A requires 11.07 - .28 = 10.79 kg of weld
metal per metre of joint.
A typical current and voltage setting of 700 amps and 34 volts,
for the 5 mm SAW wire nominated will produce a
typical deposition rate (at 100% duty cycle) of 8.3 kg/hr
(see section 3, table 3.3)
Therefore, the continuous welding time to deposit 10.72 kg
of weld metal with 5 mm wire is
8.3
Assuming a duty cycle of 40% (see SECTION 4), a realistic
estimate of the actual time is
.40
For Example 2, The Total Welding Time To Complete
One Metre Of Joint May Be Summarised As Follows:
4mm Austarc 18TC (at 25% duty cycle) - 1.00 hrs/metre of joint
5mm Austarc 24 (at 30% duty cycle) - 0.73 hrs/metre of joint
5mm wire/flux combination (at 40% duty cycle) - 3.25 hrs/metre of joint
Estimate of actual welding time to complete joint -
4.98 hrs/metre of joint
146
CONTENTS
₂
SIMPLY, MULTIPLY “D X W” FOR CROSS-SECTIONAL AREA (MM ) AND READ DIRECTLY
FROM THE TABLE. WHERE A SECTIONAL OR TOTAL ₂ JOINT AREA IS ALREADY KNOWN
IN SQUARE INCHES, MULTIPLY BY 645.2 FOR MM AND USE THIS TABLE.
This table provides the mass of steel weld metal per metre of joint (kg/in) for
known₂ cross-sectional areas.Simply, multiply “d x w” for cross-sectional area
(mm ) and read directly from the table. Where a sectional ₂or total joint area is w
already known in square inches, multiply by 645.2 for mm and use this table.
AREA
₂ d
0 10 20 30 40 50 60 70 80 90
(mm )
0 - 0.08 0.16 0.24 0.31 0.39 0.47 0.55 0.63 0.71
100 0.79 0.86 0.94 1.02 1.10 1.18 1.26 1.33 1.41 1.49
200 1.57 1.65 1.73 1.81 1.88 1.96 2.04 2.12 2.20 2.28
300 2.36 4.43 2.51 2.59 2.67 2.75 2.83 2.90 2.98 3.06
400 3.14 3.22 3.30 3.38 3.45 3.53 3.61 3.69 3.77 3.85 d
w
500 3.93 4.00 4.08 4.16 4.24 4.32 4.40 4.47 4.55 4.63
600 4.71 4.79 4.87 4.95 5.02 5.10 5.18 5.26 5.34 5.42
RECTANGULAR WELD
700 5.50 5.57 5.65 5.73 5.81 5.89 5.97 6.04 6.12 6.20
w
800 6.28 6.36 6.44 6.52 6.59 6.67 6.75 6.83 6.91 6.99
d
CROSS-SECTIONS TABLE
900 7.07 7.14 7.22 7.30 7.38 7.46 7.54 7.61 7.69 7.77
1000 7.85 7.93 8.01 8.09 8.16 8.24 8.32 8.40 8.48 8.56
d w
₂
Where increments of less than 10 mm are considered necessary,
₂
add to the above, on the basis of .008 kg/in for every 1 mm .
147
CONTENTS
MASS OF WELD
METAL IN JOINT
TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS
SECTION SHAPES AND ANGLES

30˚ 45˚ 20˚ 30˚
L L L L
d
d
MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m)

Depth Width Width Width Width
d L kg/m L kg/m L kg/m L kg/m
(mm) (mm) (mm) (mm) (mm)
6 3.5 008 6.0 0.14 2.1 005 3.2 0.08
8 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.14
10 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.21
12 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.30
14 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.41
16 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.54
20 11.5 0.90 20.0 1.57 7.1 0056 10.7 0.84
22 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.02
24 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.22
26 15.0 1.53 26.0 2.65 9.5 0.94 13.9 1.42
28 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.65
30 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.90
35 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.58
40 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.36
45 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.26
50 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.26
55 31.8 6.86 55.0 11.87 9.4 4.19 29.5 6.37
60 34.6 8.15 60.0 14.13 21.2 5.99 32.2 7.58
70 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.30
75 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.83
80 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47
148
CONTENTS
WELD DEPOSITION & COSTING DATA - MASS OF WELD METAL IN JOINT
TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS CONT.
SECTION SHAPES AND ANGLES

50˚ 60˚ 70˚ 90˚
L L L L
d
d
d

Depth Width Width Width Width
d L kg/m L kg/m L kg/m L kg/m
(mm) (mm) (mm) (mm) (mm)
6 5.6 0.13 6.9 0.16 8.4 0.20 12.0 0.28
7.5 7.5 0.24 9.2 0.29 11.2 0.35 16.0 0.50
10 9.3 0.37 11.5 0.45 14.0 0.55 20.0 0.79
12 11.2 0.53 13.9 0.65 16.8 0.79 24.0 1.13
14 13.1 0.72 16.2 0.89 19.6 1.08 28.0 1.54
16 14.9 0.94 18.5 1.16 22.4 1.41 32.0 2.01
20 18.7 1.47 23.1 1.81 28.0 2.20 40.0 3.14
22 20.5 1.77 25.4 2.19 30.8 2.66 44.0 3.80
24 22.4 2.11 27.7 2.61 33.6 3.17 48.0 5.42
26 24.2 2.47 30.0 3.06 36.4 3.71 52.0 5.31
28 26.1 2.87 32.3 3.55 39.2 4.31 56.0 6.15
30 28.0 3.30 34.6 4.07 42.0 4.95 60.0 7.07
35 32.6 4.48 40.4 5.55 49.0 6.73 70.0 9.62
40 37.3 5.86 46.2 7.25 56.0 8.79 80.0 12.56
45 42.0 7.42 52.0 9.18 63.0 11.13 90.0 15.90
50 46.6 9.15 57.7 11.32 70.0 13.74 100.0 19.63
55 51.3 11.07 63.5 13.71 77.0 16.62 110.0 23.75
60 56.0 13.19 69.3 16.32 84.0 19.78 120.0 28.26
70 65.3 17.94 80.8 22.20 98.0 26.93 140.0 38.47
75 69.9 20.58 86.6 25.49 105.0 30.91 150.0 44.16
80 74.6 23.42 92.4 29.01 112.0 35.7 160.0 50.24
149
CONTENTS
MASS OF WELD
METAL IN JOINT
TABLE 1.2 WELD REINFORCEMENT CROSS-SECTIONS
h
F
Depth, REINFORCEMENT HEIGHT, h.
d
(mm)
h=1.0mm h=1.5mm h=3.0mm h=4.5mm h=6.0mm
6 0.04 0.06
8 0.05 0.07
10 0.06 0.09 0.18 0.28
12 0.07 0.11 0.22 0.33
14 0.09 0.13 0.26 0.39
16 0.10 0.15 0.30 0.44
20 0.12 0.18 0.37 0.55 0.74
22 0.14 0.20 0.41 0.61 0.81
24 0.15 0.22 0.44 0.67 0.89
26 0.16 0.24 0.48 0.72 0.96
28 0.17 0.26 0.52 0.78 1.04
30 0.18 0.28 0.55 0.83 1.11
35 0.22 0.32 0.65 0.97 1.29
40 0.25 0.37 0.74 1.11 1.48
45 0.28 0.42 0.83 1.25 1.66
50 0.31 0.46 0.92 1.39 1.85
Note. For face widths in excess of 50 mm, estimate average height of

reinforcement and calculate as for a rectangle, referring to table 1.0
150
CONTENTS
MASS OF WELD

METAL IN JOINT
TABLE 1.3 RADIUS WELD CROSS-SECTIONS
MASS OF WELD METAL PER

Radius
r METRE OF JOINT (kg/m)
(mm)
“U” “J” r
3 0.11 0.06 U
4 0.20 0.10
5 0.31 0.15
r
6 0.44 0.22
J
7 0.60 0.30
8 0.79 0.39
9 1.00 0.50
10 1.23 0.62
11 1.49 0.75
12 1.18 0.89
13 2.08 1.04
14 2.42 1.21
15 2.77 1.39
MASS OF
Depth WELD
Width Area
r METLEL PER
(mm) (mm) (mm²)
METRE OF 1/2 width
JOINT (kg/m)
1.5 6 7.07 0.06
2.5 8 15.71 0.12
depth
3.5 7 19.24 0.15

4 12 37.70 0.30
5 10 37.27 0.31
7 12 65.97 0.52
8 19 119.38 0.94
10 14 109.96 0.96
L
10 22 172.79 1.36
12 20 188.50 1.48
15 30 353.43 2.77
Note. Note: Appropriate reinforcement additions, selected from

table 1.2, will generally be required to be added to the above figures.
151
CONTENTS
TABLE 1.5 FILLET WELDS
The table shows the mass of steel weld metal per metre of
joint (kg/m) for fillet welds of varying degrees of convexity and a
typical concave profile. The figures are based on actual leg length
being maintained. Note that the leg lengths shown are
not applicable to the concave welds which are designated in
this table by throat thickness.
WELD SIZE
Leg Length, L Cross- sectional
Throat Thickness Area (mm²)
(mm) (inch) T (mm)
3.2 1/8 2.3 5.1

3.5 2.5 6.1
4.0 5/32 2.8 8.0
4.8 3/16 3.4 11.5
5.0 3.5 12.5
5.6 7/32 4.0 15.7
6.0 4.2 18.0
6.4 1/4 4.5 20.5
7.0 4.9 24.5
8.0 ~5/16 5.7 32.0
9.5 3/8 6.7 45.1
10.0 7.1 65.0
12.7 7.1 50.0
15.9 5/8 11.2 126.4
19.0 ~3/4 13.4 180.5
22.2 7/8 15.7 246.4
24.4 1.0 18.0 322.6
152
CONTENTS
T
h
L
MASS OF WELD METAL PER METRE (kg/m)

Flat and Convex Welds Convex Welds
h=0 Throat Typical

h=1.0mm h=1.5mm h=2.5mm Thickness Concave
(There.) T (mm) Weld
.04 .07 .08 - 2.3 0.05
.05 .08 .10 - 2.5 0.06
. 06 .09 .11 - 2.8 0.07
.09 .13 .15 - 3.4 0.10
.10 .14 .17 - 3.5 0.11
.12 .17 .19 - 4.0 0.13
.14 .19 .22 - 4.2 0.15
.16 .22 .24 - 4.5 0.17
.19 .25 .28 - 4.9 0.21
.25 .32 .35 - 5.7 0.27
.36 .44 .48 .57 7.7 0.39
.39 .48 .52 .61 7.1 0.42
.63 .74 .80 .91 9.0 0.68
.99 1.13 1.20 1.34 11.2 1.06
1.42 1.59 1.67 1.84 13.4 1.52
1.93 2.13 2.23 2.42 15.7 20.6
2.53 2.75 2.86 3.08 18.0 2.70
153
CONTENTS
QUANTITY OF
CONSUMABLES REQUIRED
The “QUANTITY OF CONSUMABLE”
figures listed in TABLES 2.0 - 2.3 are for a weld metal production
of 1kg and to take into account inherent wastage losses such as
weld metal spatter, slag coverage, and gas plume production.
An additional percentage (listed in the “EXTRA FOR WASTAGE”
column) is usually added to allow for typical shop wastage
such as stub ends and wire snips etc.To obtain the quantity of
consumable required to produce 1kg of weld metal read directly
from tables 2.0 - 2.3 for the appropriate consumable, shielding
gas, arc transfer mode etc.
TABLE 2.0 MANUAL METAL-ARC WELDING (MMAW)
QUANTITY OF
ELECTRODE CONSUMABLES EXTRA
CONSUMABLES TYPE LENGTH 50mm 75mm FOR
(mm) Stub Stub WASTAGE
Length Length
High Efficiency (150%),
450 1.60 1.66 10%
Iron Type Electrodes
EXX24, 27 & 28 to
AS/NZS 4855 380 1.63 1.75 10%
Conventional, Low Iron
Powder or Hydrogen 450 1.63 1.73 10%
Controlled Electrodes
EXX12, 13, 14, 16 &18 380 1.66 1.73 10%
Types to AS/NZS 4855
Cellulose Type
Electrodes
380 1.73 1.87 10%
(EXX10 & 11 Types
to AS/NZS 4855)
TABLE 2.3 SUBMERGED-ARC WELDING (SAW)

QUANTITY EXTRA
CONSUMABLES TYPE,
OF FOR
CONDITIONS ECT.
CONSUMABLE WASTAGE
Mild and Low Alloy Steel Welding Wire 1.02 2%
Flux Consumption - For any given wire
size under the following conditions
Low Voltage, Normal Amperage 0.8 kg 15%
Low Amperage, Normal Voltage 1.6 kg 15%
Normal Voltage, Normal Amperage 1.1 kg 15%
High Voltage, Normal Amerpage 1.6 kg 15%
Hight Amperage, Normal Voltage 0.8 kg 15%
154 Note. For Aluminium weld metal divide the steel weld metal mass per metre by 2.9
CONTENTS
WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED
TABLE 2.1 GAS METAL-ARC WELDING (GMAW)
AND PULSED ARC WELDING
QUANTITY EXTRA
CONSUMABLES TYPE, SHIELDING
OF FOR
GAS, ARC TRANSFER MODE ECT.
CONSUMABLE WASTAGE
TYPE A MILD ALLOY STEEL WELDING WIRES
(AUSTMIG ES6, ESD2 ECT)
USED WITH
(i) CO₂ SHIELDING GAS 1.05 kg 2%
• Short Arc Transfer (95%)
• Globular Transfer (90%) 1.11 kg 2%
• Globular ‘Free Flight’ Transfer (93%) 1.08 kg 2%
(ii) Ar + 15 - 25% CO₂ SHIELDING GAS
1.03 kg 2%
• Short Arc Transfer (97%)
• Globular Transfer (94%) 1.06 kg 2%
“Streaming Spray Transfer (96%) 1.04 kg 2%
(iii) Pulsed Arc Transfer (:Syncro-Pulse
CDT”) and Programmed Shielding Gas 1.02 kg
(98%)
TYPE B STAINLESS STEEL WELDING WIRES
(eg. AUSTMIG 308LSI, 316SI ect):
USED WITH Ar or Ar/He Based Shielding
Gases and all Arc Transfer Modes, 1.02 kg
including Pulsed Arc Transfer (98%)
SHIELDING GAS CONSUMPTION FOR MILD, LOW ALLOY

AND STAINLESS STEEL WIRES
EXTRA
TYPICAL DEPOSITION CONSUMPTION PER
FOR
CONDITIONS RATE OF: KG OF WELD METAL
WASTAGE
₃
Short Arc Transfer or .90m (1.68kg of
1.0 kg/hr; 10%
Pulsed Arc Transfer CO₂+)
with a Typical Gas ₃
Flow rate of 15L/min 2.8 kg/hr .32m (.60kg of CO₂+) 10%
₃
Globular, “FreeFlight” .40m (.75kg of
3.0 kg/hr 10%
or “Streaming” CO₂+)
Spray Transfer with
a typical Gas Flow ₃
7.0 kg/hr .17m (32kg of CO₂+) 10%
Rate of 20L/min
(%) Typical Electrode Efficiency for wire type, shielding gas and transfer mode
₃
Indicated. + Where appropriate, the mass of CO₂ shielding gas required.NB. 1m
₃
of CO₂ at 15.6°C and 1 atmosphere has a mass of 1.87 kg. 1m = 1000 Litres.
155
CONTENTS
QUANTITY OF
CONSUMABLES REQUIRED
TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND
PULSED ARC WELDING
EXTRA
CONSUMABLES TYPE, SHIELDING GAS, QUANTITY OF
FOR
ARC TRANSFER MODE ECT. CONSUMABLE
WASTAGE
TYPE D ALUMINIUM WELDING WIRES
(eg. AUSTMIG 5356, 4043, 5183 etc.)
Spray Arc Transfer (95%) 1.05 kg 1%
Pulsed Arc Transfer (Syncro-Pulse CDT) (98%) 1.02 kg 1%
SHIELDING GAS CONSUMPTION FOR FOR ALUMINIUM WIRES:
EXTRA
DEPOSITION QUANTITY OF
TYPICAL CONDITIONS FOR
RATE OF: CONSUMABLE
WASTAGE
Spray Arc Transfer with a
1.0kg/hr 1.68m3 10%
Inert Gas Flow Rate
of 28L/min 2.0kg/hr 0.84m3 10%
Pulsed Arc Transfer with a
0.5kg/hr 2.16m3 10%
Inert Gas Flow Rate
of 18L/min 2.0kg/hr 0.54m3 10%
(%) Typical Electrode Efficiency for arc transfer mode Indicated.
156
CONTENTS
WELD DEPOSITION & COSTING DATA - QUANTITY OF CONSUMABLES REQUIRED
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)
EXTRA
CONSUMABLES TYPE, TYPICAL QUANTITY OF
FOR
DEPOSITION EFFICIENCY ECT. CONSUMABLE
WASTAGE
TYPE A GAS SHIELDED, DOWNHAND
AND POSITIONAL, DCEP WIRES
1.20 kg 2%
OF 83% EFFICIENCY:
(E70T-1, E71T-5 TYPES TO AWS A5.20)
TYPE B SELF SHIELDED, DOWNHAND
DCEP WIRES OF 83% EFFICIENCY: 1.20 kg 2%
TYPE C GAS SHIELDED,
DOWNHAND METAL CORED WIRES 1.05 kg 2%
OF 95% EFFICIENCY:
TYPE D SELF SHIELDED, POSITIONAL
DCEN WIRES OF 75% EFFICIENCY: 1.20 kg 2%
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)

EXTRA
CONSUMPTION PER
FOR
KG OF WELD METAL
WASTAGE
Assuming a gas flow
rate of 12 L/minfor a 2 kg/hr; .36m₃ (.67kg of CO₂*) 10%
weld deposition rate of: 4 kg/hr; .32m₃ (.18kg of CO₂*) 10%
6 kg/hr; .40m₃ (.12kg of CO₂*) 10%
8 kg/hr; .17m₃ (.09kg of CO₂*) 10%
* Where appropriate, the mass of CO₂ shielding gas required.

NB. 1 m3 of CO₂ at 15.6°C and 1 atmosphere has a mass of 1.87 kg.
1 m3 = 1000 Litres.
157
CONTENTS
DEPOSITION RATES
TABLES 3.0-3.5 provide a comprehensive range of typical
deposition rates for the continuous operation of various arc
welding consumables and arc processes. The tables are
designed as an easy-to-read guide to show typical deposition
rates achievable tor the electrode/wire types, sizes, welding
parameters and shielding gases shown. The tables also give
useful information on suitable welding parameters such as
welding current, voltage and modes of operation. It should be
emphasised that the deposition rates tabulated are for continuous
operation (100% duty cycle) of the consumable/arc process in
question. Refer to SECTION 4 for further information on typical
duty cycle estimates for the welding task involved. The typical
deposition rates given for each current setting may vary with
changes in arc voltage, electrode stickout and shielding gas
composition - refer to the information given below each Table.
For accurate deposition rate calculations for continuous wires,
measure wire feed speed (in m/min) during welding and use the
appropriate “Mass/Length” figures from table 3.6 and “Quantity
of Consumables” data from tables 2.1-2.3.
TABLE 3.0 TYPICAL DEPOSITION RATES USING MMAW
TYPICAL
₁
ELECTRODE
WIA (F)
TYPE, DEPOSITION F X A = kg/hr
ELECT- FACTOR
CLALSSIFICATION TYPICAL CURRENT, A( )
RODES kg/amp/
TO AS/NZS 4855
hr
5mm 4mm 3.2mm
E4110/11 11 .009 1.7(190) 1.4(150) 1.0(110)
12P,
E4112/13 .008 1.8(220) 1.4(170) 1.0(130)
13S
E4814 - .01 2.4(240) 1.9(190) 1.4(135)
E4824 24 .0135 4.1(300) 2.7(200) 2.0(150)
E4127 .0135 4.1(300) 2.8(210) 2.0(150)
E4816 16TC .009 2.0(220) 1.5(170) 1.2(130)
18TC,
E4818 / E4846 .01 2.0(200) 1.6(160) 1.2(115)
77
The factors (F) are typical for those low carbon steel electrodes, as classified
to AS/NZS 4855 in popular use throughout Australia. Multiplying the FACTOR
(F) by the CURRENT (A) selected for the electrode size (within its normal
current range) will provide typical deposition rates (kg/hr) at 100% duty cycle.
158
CONTENTS
WELD DEPOSITION & COSTING DATA - DEPOSITION RATES
TABLE 3.1A TYPICAL DEPOSITION RATES USING GMAW
WITH LOW CARBON AND LOW ALLOY STEEL WIRES
(EG AUSTMIG ES6, ESD2 OR SIMILAR WIRES)
WIRE WELDING ARC WIRE FEED
DEPOSITION
SIZE CURRENT VOLTAGE SPEED (M/
RATE (kg/hr)
(mm) (AMPS) (VOLTS) MIN)
0.8 60+ 16+ 3.3 0.7
0.8 80+ 17+ 4.4 1.0
0.8 100+ 18.5+ 5.9 1.3
0.8 120+ 20+ 7.0 1.6
0.8 140+ 20+ 9.9 2.2
0.8 160+ 22+ 12.4 2.8
0.8 180 30 14.3 3.2
0.9 70+ 15+ 3.7 1.1
0.9 100+ 19+ 6.0 1.7
0.9 120+ 19+ 6.9 2.0
0.9 150+ 20+ 8.7 2.5
0.9 180+ 21+ 11.5 3.3
0.9 180 29 12.0 3.4
0.9 200 31 14.0 4.0
1.0 90+ 19+ 3.3 1.2
1.0 100+ 19+ 3.6 1.3
1.0 150+ 20+ 5.6 2.0
1.0 100+ 20+ 7.0 2.5
1.0 220 28 14.6 5.2
1.0 250 32 15.7 5.6
1.0 280 34 16.8 6.0
1.2 120+ 18+ 2.7 1.4
1.2 150+ 18+ 3.5 1.8
1.2 170+ 19+ 3.9 2.0
1.2 220 30 6.2 3.2
1.2 250 32 9.1 4.7
1.2 310 34 11.3 5.8
1.2 340 36 12.9 6.6
1.6 140+ 19+ 1.7 1.6
1.6 200+ 19+ 1.7 1.6
1.6 250+ 21+ 3.1 2.8
1.6 300 30 4.9 4.5
1.6 350 34 6.2 6.7
1.6 400 34 7.5 6.8
+ Short arc transfer conditions. Note: Deposition rate data determined using:
• DC+ (reverse polarity) with a conventional constant power source.
• Ar - 16/18% CO2 shielding gas
• An electrode stickout length at 8-10 mm for short arc transfer conditions
and 15 mm for spray arc transfer conditions.
• Deposition efficiency at 96% for both short arc transfer & spray arc transtor conditions 159
CONTENTS
DEPOSITION RATES
TABLES 3.1B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH LOW CARBON AND LOW ALLOY
STEEL WIRES (EG AUSTMIG ES6)
DEPOSITION
SIZE CURRENT VOLTAGE SPEED
RATE (kg/hr)
(mm) (AMPS) (VOLTS) (M/MIN)
0.8 35 17.0 2.0 0.5
0.8 70 20.0 5.3 1.2
0.8 105 23.0 8.6 2.9
0.8 140 25.0 11.9 2.7
0.8 175 28.0 15.2 3.5
0.9 40 18.0 2.5 0.7
0.9 45 17.0 1.9 0.7
0.9 90 21.0 6.1 1.8
0.9 135 24.0 9.3 2.7
0.9 180 27.0 12.5 3.7
0.9 230 30.0 16.0 4.7
1.0 110 21.0 5.3 1.9
1.0 170 24.0 8.4 3.1
1.0 230 28.0 11.5 4.2
1.0 290 31.0 14.6 5.3
1.2 40 19.0 1.5 0.8
1.2 100 21.5 3.5 1.8
1.2 160 24.0 5.5 2.9
1.2 220 26.5 7.4 3.9
1.2 280 29.0 94 4.9
1.2 350 32.0 11.7 6.1
1.6 70 20.0 1.3 1.2
1.6 165 24.0 2.8 2.6
1.6 260 28.0 4.4 4.1
1.6 355 31.0 5.9 5.5
1.6 450 35.0 7.5 7.0
Note: Deposition rate data obtained using: • Ar + 16-18% CO2 shielding gas
• A deposition efficiency of 98% for pulsed arc transfer
TABLE 3.3 TYPICAL DEPOSITION RATES USING SUBMERGED-ARC
WELDING (SAW) WITH LOW CARBON AND LOW ALLOY STEEL WIRES
WIRE DEPOSITION RATE •(kg/hr) - WELDING CURRENT (AMPS)
SIZE
(mm) 300 400 500 600 700 800 900
2.0 3.1 4.8 - - - - -
2.4 2.9 4.1 5.5 7.5 - - -
3.2 2.6 3.9 5.3 6.8 8.7 10.1 -
4.0 - 3.6 5.1 6.7 8.3 10.0 11.9
4.8 - - - 5.0 7.4 8.9 10.4
• Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage
settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire
sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC-
(Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout
longer than 25mm with the same welding current increases deposition rate significantly.
160
CONTENTS
TABLE 3.2A TYPICAL DEPOSITION RATES USING FCAW
DEPOSITION
RATE (kg/hr)
(mm) (AMPS) •••(VOLTS) (M/MIN)
PART A. T1 TYPE OF CORED WIRE
1.2 130 23 3.4 1.4
1.2 150 24 5.3 2.2
1.2 200 26 7.4 3.3
1.2 250 28 9.8 4.5
1.6 200 26 3.7 2.4
1.6 250 28 5.1 3.4
1.6 300 30 6.7 4.4
1.6 350 32 8.2 5.4
1.6 400 34 10.8 7.1
1.6 425 36 11.5 7.6
2.4 300 27 2.4 3.4
2.4 350 28 3.0 4.3
2.4 400 32 3.7 5.2
2.4 450 32 4.3 6.1
2.4 500 34 5.0 7.1
2.4 525 35 5.5 7.8
PART B. T5 TYPE OF CORED WIRE
1.2 130 22 3.4 1.4
1.2 150 23 5.3 2.2
1.2 200 24 7.4 3.3
1.2 250 26 9.8 4.5
1.6 200 25 3.7 2.4
1.6 250 27 5.1 3.4
1.6 300 28 6.7 4.4
1.6 350 29 8.2 5.4
1.6 375 30 9.4 6.1
2.4 300 25 2.4 3.4
2.4 350 26 3.0 4.3
2.4 400 28 3.7 5.2
2.4 450 29 4.3 6.1
2.4 475 30 4.7 6.6
Note. Deposition rate data determined using:

• DC+ (reverse polarity) with a conventional Constant Potential power source
• Welding grade CO₂ shielding gas
• An electrode stickout length of, 15mm for 1.2mm, 25mm for 1.6mm
& 2.4mm wire sizes
• A deposition efficiency of 84% for globular transfer
•••Voltage figures are typical machine meter readings-actual arc voltage will
be 1-3 volts lower than meter reading due to voltage drop across welding leads.
Reduce arc voltage by 2-3 volts when using mixed gas.
161
CONTENTS
DEPOSITION RATES
TABLES 3.4A TYPICAL DEPOSITION RATES USING GMAW
WITH “300” SERIES STAINLESS STEEL SOLID WIRES
DEPOSITION
RATE (kg/hr)
(mm) (AMPS) (VOLTS) (m/min)
0.9 80+ 17+ 4.2 .3
0.9 100+ 18+ 5.1 1.5
0.9 150 20 8.4 2.5
0.9 200 23 12.5 3.7
1.2 125+ 18+ 3.1 1.6
1.2 200 20 5.9 3.1
1.2 250 27 8.1 4.3
1.2 300 29 10.9 5.8
+ Short arc transfer conditions Note: Deposition rate data determined using:
• DC+ (reverse polarity) with a conventional constant potential power source
• Ar+ 1-2% O2 shielding gas • An electrode stickout length of, 8-10mm for
short arc transfer conditions and 15mm for spray arc transfer conditions
• A deposition efficiency of 98% for both short arc transfer and spray arc
transfer conditions
TABLE 3.4B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH “300” SERIES STAINLESS STEEL
SOLID WIRES
DEPOSITION
RATE (kg/hr)
(mm) (AMPS) • (VOLTS) (m/min)
0.8 30 17.0 2.4 0.6
0.8 60 19.0 5.8 1.4
0.8 90 21.0 9.2 22
0.8 120 230 12.6 3.0
0.8 150 25.0 16.0 3.9
0.9 35 17.0 2.5 0.8
0.9 75 20.0 5.6 1.7
0.9 120 235 9.1 2.7
0.9 165 26.5 12.5 3.8
0.9 210 30.0 16.0 4.8
1.0 35 16.0 1.5 0.6
1.0 80 18.0 4.2 1.6
1.0 130 21.0 7.1 2.6
1.0 180 24.0 10.1 3.7
1.0 225 26.0 12.7 4.7
1.2 50 17.0 1.5 0.8
1.2 100 19.5 2.8 1.5
1.2 150 22.0 4.1 2.2
1.2 200 24.5 5.3 2.8
1.2 250 27.0 6.6 3.5
1.2 300 295 7.9 4.2
1.2 350 32.0 9.1 4.8
Note: Deposition rate data obtained using:
162 • A deposition efficiency of 98% for pulsed arc transfer • Ar + He + 1.5% CO₂
CONTENTS
TABLES 3.5A TYPICAL DEPOSITION RATES USING GMAW
WITH AUSTMIG ALUMINIUM ALLOY WIRES (EG. AUSTMIG 5183)
DEPOSITION
RATE (kg/hr)
(mm) (AMPS) (VOLTS) (m/min)
0.9 100 17 9.2 0.9
0.9 125 18 10.9 1.1
0.9 175 21 15.0 1.5
0.9 200 22 18.0 1.7
1.2 150 22 7.8 1.4
1.2 175 23 9.0 1.6
1.2 225 05 13.8 2.4
1.2 250 25 13.8 2.4
Note: Deposition rate data determined using:
• DC+ (reverse polarity) with a conventional constant potential power source.
• Welding grade Ar shielding gas
• An electrode stickout length of 20mm
• A deposition efficiency of 95%
TABLE 3.5B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH AUSTMIG ALUMINIUM ALLOY WIRES
(EG. AUSTMIG 5183)
DEPOSITION
RATE (kg/hr)
(mm) (AMPS) • (VOLTS) (m/min)
0.9 25 14.0 2.8 0.3
0.9 50 16.0 5.6 0.6
0.9 70 17.0 7.9 0.8
0.9 90 18.0 10.1 1.0
0.9 115 20.0 13.0 1.3
1.0 35 15.0 3.6 0.5
1.0 70 17.0 6.5 0.8
1.0 110 19.0 10.0 1.3
1.0 140 21.0 12.6 1.6
1.0 180 23.0 16.0 2.1
1.2 35 15.0 2.8 0.5
1.2 85 18.0 6.1 1.1
1.2 135 21.0 9.4 1.7
1.2 185 24.0 12.7 2.3
1.2 235 27.0 16.0 2.9
1.6 80 15.0 2.5 0.8
1.6 140 17.5 4.6 1.5
1.6 200 20.0 6.7 2.1
1.6 265 22.5 8.8 2.8
1.6 325 25.0 10.9 3.5
Note: Deposition rate data determined using:
• Welding grade Ar shielding gas
• A deposition efficiency of 98% for pulsed arc transfer 163
CONTENTS
164
CONTENTS
DEPOSITION RATES

TABLES 3.6 MASS / LENGTH TABLES
PART A. LOW CARBON AND LOW ALLOY STEEL GMAW WIRES
WIRE SIZE (mm) 0.6 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER

2.2 3.9 5.0 6.2 8.9 15.8
METRE
METRES OF WIRE
450.5 253.7 200.4 161.3 112.7 63.4
PER KG
PART B. FCAW WIRES

WIRE SIZE (mm) 1.2 1.6 2.0 2.4 3.2
GRAM OF WIRE PER

7.6 13.0 20.0 28.0 50.1
METRE
METRES OF WIRE
131.6 76.9 50.0 34.7 20.0
PER KG
PART C. LOW CARBON AND LOW ALLOY STEEL SAW WIRES

WIRE SIZE (mm) 2.0 2.4 3.2 4.0 4.8
GRAM OF WIRE PER

24.6 35.5 63.1 98.6 141.0
METRE
METRES OF WIRE
40.6 28.2 15.9 10.1 7.0
PER KG
PART D. STAINLESS STEEL WELDING WIRES

WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER

4.1 5.1 6.3 9.0 16.0
METRE
METRES OF WIRE
245 197.7 158 111.2 62.6
PER KG
PART E. ALUMINIUM WELDING WIRES

WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER

1.4 1.7 2.2 3.1 5.4
METRE
METRES OF WIRE
712 528.2 455 327.5 184.2
PER KG
165
CONTENTS
DUTY CYCLES
The deposition rates tabled in SECTION 3, are for a duty
cycle of 100% - that is continuous (uninterrupted) welding
of the consumable/arc process in question.
DUTY CYCLE IS, BY DEFINITION, A MEASURE OF THE “ARC
ON” TIME EXPRESSED AS A PERCENTAGE OF THE TOTAL
ELAPSED TIME, IE
arc time x 100
Duty Cycle = (%)
total elapsed time
This parameter indicates the proportion of the operating
time during which weld metal is actually being deposited. The
duty cycle can vary considerably according to a number
of factors including:
• the welding process
• the type of consumable
• operating conditions
• the application involved
• the degree of mechanisation
• general workshop efficiency
• a variety of human factors or personal allowances such
as putting gloves and helmet on, putting aside and
picking up electrode holder etc.
Figure 4.0 summarizes the potential range of duty cycles for
various arc welding processes and modes of operation.
100
Surfacing Operations
80
Duty Cycle %
Automatic Welding
SAW
60
GMAW
FCAW
Machine or
RW
Mechanised Welding
40
MMAW
20
GW Manual Welding
0
Figure 4.0
166
CONTENTS
WELD DEPOSITION & COSTING DATA - DUTY CYCLES
(a) Manual Metal-Arc Welding (MMAW)
The maximum obtainable duty cycle for MMAW is of the order of
65% but most applications will not permit a duty cycle greater than
50% to be achieved over a day’s production. The duty cycle for
MMAW operations varies widely with the type of application and
operating conditions. Electrode changes, slag removal, intermittent
welding and changing positions etc all play a part in reducing
the actual “arc on” time. With added delays, such as personal
allowances and materials handling, most welding workshops are
capable of maintaining duty cycles of 15-30%
(b) Gas Metal-Arc Welding (GMAW) and Flux Cored Arc
Welding (FCAW) —Semi-automatic Arc Processes
For semi-automatic surfacing operations a duty cycle approaching
80% is possible. However, most GMAW and FCAW operates
between 30-60%; with mechanised semi-automatic welding yielding
duty cycles of 45-60% and conventional (or manual) semi-automatic
processes producing duty cycles of typically 30-40%.
(c) Submerged-Arc Welding (SAW)
For fully automatic hard surfacing operations, a 95% duty cycle
is possible with the submerged-arc process; however most
submerged-arc welding operates between 40-60% duty cycle due
to essential setting up, deslagging, loading / positioning and other
handling operations.
167
CONTENTS
ELECTRODE CONSUMPTION
FOR TYPICAL BUTT JOINTS
ELECTRODE CONSUMPTION FOR SOME COMMON BUTT
JOINTS
The following Tables provide useful data on the mass of weld
metal and MMAW electrodes required to complete some common
butt joints. Electrode consumption is calculated using the following
simple equation:
D
M=
1-P
where M = Mass of electrodes required per metre of joint.
D = Mass of weld metal deposited per metre of joint.
P** = Proportion of electrode lost, due to spatter, slag
loss, stub end etc.
OPEN SQUARE GROOVE BUTT JOINT - WELDED BOTH SIDES

Reinforcement height, r = 2 mm.
W
r
T
JOINT DIMENSIONS Mass of steel weld Mass of MMAW**

(MM) metal per metre. electrodes required
T R W (D) (kg/m) per metre (M) (kg/m)
3 0 7 0.17 0.28
3 1 7 0.20 0.33
6 1.5 10 0.32 0.53
6 3 10 0.39 0.64
168
CONTENTS
WELD DEPOSITION & COSTING DATA - ELECTRODE CONSUMPTION FOR BUTT JOINTS
60°
W
r
SINGLE V BUT JOINT
Reinforcement height, r = 2mm T
L
R
JOINT Mass of steel weld Mass of MMAW**

DIMENSIONS (MM) metal per metre. electrodes required
T R L W (D) (kg/m) per metre (M) (kg/m)
6 3.5 1.5 10.0 0.26 0.43
8 3.5 1.5 13.0 0.57 0.95
10 3.5 1.5 15.0 0.79 1.31
12 3.0 3.0 15.0 0.83 1.39
16 3.0 3.0 19.0 1.38 2.29
20 3.0 3.0 23.0 2.06 3.43
60°
W
r
Single V But Joint

Reinforcement height, r = 2mm L T
JOINT Mass of steel weld Mass of MMAW**

DIMENSIONS (MM) metal per metre. electrodes required
T R L W (D) (kg/m) per metre (M) (kg/m)
12 3.0 3.0 10.0 0.71 1.18
16 3.0 3.0 12.0 1.06 1.75
20 3.0 3.0 15.0 1.50 2.48
25 3.0 3.0 18.0 2.13 3.53
50 3.0 3.0 32.0 6.97 11.58
• For 380mm long EXX12, 13, 14, 16 & 18 type MMAW electrodes to AS/NZS
4855, P is typically 0.4. This figure assumes a stub end length of 50mm.
(See table 2.0 for further details.) 169
CONTENTS
WELDABILITY GUIDE
FOR STEELS
The majority of steels in general use are considered “Weldable”
using most arc welding processes. The degree to which they are
rated as weldable is indicated by an imprecise term, “Weldability”
which is (as yet) not fully assessable by a laboratory test or series
of tests. We have included two different weldability guides to
assist you in determining preheat of materials. The first guide is
the same as that used in Australian Standards and WTIA technical
notes the second guide is a method adopted by WIA and known
as the “WIA Welability Guide”
Furthermore, what is considered to be a satisfactory joint for one
set of service conditions, possibly, steel sections embedded in
concrete under static loading, may not be acceptable for another
set of service conditions, such as in the tension member of a
flexing structure or under corrosive conditions. For this reason,
no economically acceptable hard and fast rules can be
provided in a Guide such as this and the recommendations
should always be tempered in their translation into practice
with a knowledge of the intended application and other
factors relevant to the situation.
Arc welding is a process of intense localised heating and rapid
cooling, providing a sudden heating-quenching heat treatment
effect on both the weld metal and the adjacent parent metal
(HAZ). As a general rule the tendency of a steel to strengthen and
harden, following this heat treatment, increases as the carbon and
alloy content increases. Its composition is therefore an important
factor in assessing weldability.
CARBON EQUIVALENT
Carbon is the most effective of the commonly used alloying
elements in achieving increased strength and hardness (increased
hardenability) and is present in all steels. Over many years,
researchers have established numerous rating systems to
compare the hardening potential of other common elements such
as manganese and chromium against that of carbon. This has
led to the concept of calculating “Carbon Equivalent” (CE) from
the chemical composition of the steel as a means of assessing its
weldability. The following is the IIW formula used for determining
Carbon Equivalent from the percentage of elements present:
Mn Cr + Mo + V Ni + Cu
CE = C + + +
170 6 5 15
CONTENTS
WELDABILITY GUIDE FOR STEELS
The Weldability Reference Numbers used in this guide, relate to
the following carbon equivalents:
REFERENCE REFERENCE
CE CE
NUMBER NUMBER
below 0.30 1 0.55 to below 0.60 7
0.30 to below 0.35 2 0.60 to below 0.65 8
0.35 to below 0.40 3 0.65 to below 0.70 9
0.40 to below 0.45 4 0.70 to below 0.75 10
0.45 to below 0.50 5 0.75 to below 0.80 11
0.50 to below 0.55 6 0.80 and above 12
NOTE: Reference numbers above 12 are not related to CE. In instances

where the ladle analysis is given for a steel, the maximum specification limits
have been used to calculate CE. For steels containing multiple alloy additions,
the use of maximum specification limits to calculate CE give conservative
results; because the possibility of all alloying elements simultaneously
achieving their maximum limit is remote. In these circumstances, it is
recommended that the CE be calculated using 80-85% of the ladle analysis
maximum specification limits.
OTHER FACTORS INFLUENCING WELDABILITY
Composition, although important, is not the only criterion used to assess the
weldability, of a given steel, in a given joint situation. Other influences can
be broadly related either to their effect on the “heat treatment” or the “stress
level” of the joint.
171
CONTENTS
WELDABILITY GUIDE
FOR STEELS
OTHER FACTORS INFLUENCING WELDABILITY
Factors which can have an effect on the “heat treatment and
hence (with composition) the microstructure include; the mass
of the section, its initial temperature, the heat input per unit
length and the interpass temperature in multipass welds. Factors
which relate generally to the “stress level” include; the degree
of restraint imposed on the joint by its own mass and from
external sources, base metal strength (rigidity, hardness) and
geometry, uneven heating and cooling conditions and geometrical
considerations such as joint preparation and alignment, notches
due to weld contour, weld nugget shape and the presence of
non-metallic inclusions, etc. The tendency towards weld and
base metal cracking is further influenced by the inherent
toughness and strength of the weld metal, the effect of base
metal dilution on these properties and the presence of hydroge
in the arc atmosphere.
NOTES ON USING THE GUIDE
The following pages list recommendations for welding some of
the more commonly available steels in Australia. Based primarily
on the steel composition, they assume moderate conditions of
restraint and joint complexity. Where low hydrogen or hydrogen
controlled conditions are nominated, electrodes should be dried
accordingly to meet the required level. For MMAW, the use of
4mm electrodes (minimum size) has been assumed, although the
user is expected to use the largest size practicable. The use of
higher and lower heat inputs by other electrode sizes or
processes can respectively lower and raise the recommended
preheat temperature.
Silicon levels are not listed for steels unless their content,
within a particular group, exceeds the normal maximum limit
of .35%, for other steels, typical Silicon figures have been
quoted for interest sake. For further details regarding the
Sulphur, Phosphorus and Silicon levels in a particular steel,
refer to the manufacturers specification.
172
CONTENTS
The term “Combined Joint Thickness” (CJT) is used in many
instances in conjunction with recommended preheat temperatures
as a measure of the quenching severity of the joint. For simple
butt and corner joints the CJT is the sum of each plate thickness,
whilst for more complex joints, such as T joints, the CJT can be
calculated as shown in figure 11.
t₁
t₂ t₂
CJT = t₁ + 2t₂
t₃
t₁ t₁ = average
thickness
75mm over 75mm
CJT = t₁ + t₃
t₁
If t₃ is already
t₂ t₂ welded to t₂ then:
CJT = t₁ + 2t₂ + t₃
t₃
t₁
t₃ If t₃ is already welded
t₂ to t₂ as shown then:
CJT = t₃ + t₂ + t₁
FIGURE 11 Combined Joint Thickness

(CJT) calculations for welds shown in black.
173
CONTENTS
WELDABILITY GUIDE
FOR STEELS
HYDROGEN CONTROL
The term “low hydrogen” or “hydrogen controlled” is not indicative
of no hydrogen, but of products and processes which have
controlled limits on moisture or hydrogen producing materials. The
fact that a product can meet the specified requirements of a code
is not necessarily indicative of its ability to meet requirements in
more critical situations. Some codes have maximum permissible
moisture levels for lower strength electrodes and more stringent
requirements for higher strength. As a general rule, as the
retainability of the base material and weld metal increase, the
allowable maximum limit for hydrogen is reduced. This situation
is further complicated when restrictions are placed on preheat
temperature and heat input - which normally help to increase the
diffusion rate of hydrogen; such as for the welding of quenched
and tempered steels.
Flux coated “hydrogen controlled” electrodes when used in critical
applications should be thoroughly dry prior to use. If any doubt
exists, electrodes should be rebaked and used from a hot box.
WIA WELDABILITY REFERENCE NUMBERS AND
RECOMMENDATIONS
1&2 Readily weldable with any low carbon steel electrodes (for
example, Austarc 11, 12P, 13S, 24) or arc welding process
without special precautions.
1A Rimmed steels welded with the GTAW Process (TIG)
without added filler metal will give porous welds, due
to gas evolution, caused by resumption of the rimming
process. Use double deoxidised filler wire for sound joints.
2A The sulphur or lead content of these steels can lead to
“hot shortness” during welding and sulphur can also cause
porosity. Welding is therefore not generally recommended
except for non-critical applications. Basic coated,
MMAW electrodes such as Austarc 16TC, 18TC, 77
should be used or specially formulated electrodes for
welding sulphurised steels. The use of an intermediate
buffer pad is recommended in extreme cases and
through thickness joints are preferred to fillet welds.
174 No preheat required.
CONTENTS
3&4 Readily weldable with any low carbon steel electrode,
such as Austarc, 11, 12P, 13S, 24. For CJT’s of 50mm or
greater a preheat temperature of 50-75°C is recommended,
depending on the degree of restraint. Alternatively
hydrogen controlled electrode such as Austarc 16TC, 18TC
or 77 may be used with a preheat
temperature of only 25°C.
3A As for 2A, but use 50°C preheat on heavy sections.
3B Check if Shipping Society approval and specific CVN
impact gradings are required for electrode,then as for 3
4B Check if Shipping Society approval and specific CVN
gradings are required for electrode, then as for 4.
5 Conventional low carbon electrodes, such as Austarc
13S & 24 are still acceptable however,special notch
toughness requirements etc. may dictate a preference
for basic electrodes, particularly for butt welding
applications. The use of “hydrogen controlled”
basic electrodes, such as Austarc 16TC, 18TC & 77,
reduce the preheat temperature necessaryto prevent
HAZ weld metal cracking in highly restrained, heavy
sections. No preheat is generally required for CJTs up
to 40mm, welded with “hydrogen controlled” electrodes or
CJTs up to 30mm, welded with conventional low carbon
electrodes. When using conventional low carbon
electrodes, preheat joint to 50°C for CJT’s of 40mm,
and 125°C for CJT’s of 80mm. Using “hydrogen controlled”
electrodes, preheat joint to 50°C for CJT’s of 55mm and
100°C for CJT’s of 80mm and above. For welding with
semi automatic solid or flux cored wire like the Formula
XL-525, Austmig ES6 or Austmig 70C-6M etc. at a
heat input of 2.2kJ/mm, use a preheat temperature of
50°C for CJTs of 80mm and above.
175
CONTENTS
WELDABILITY GUIDE
FOR STEELS
WIA WELDABILITY REFERENCE NUMBERS
AND RECOMMENDATIONS
6A As for 5, except when matching colour and corrosion
resistance are required, an electrode
depositing a Ni-Cu weld metal is recommended.
6B “Hydrogen controlled” electrodes of matching weld metal
analysis and strength are normally recommended.
For minimum preheat temperatures, refer to 5.
6 “Hydrogen controlled” electrodes are generally considered
essential for the deposition of sound welds — use a
preheat temperature of 70°C for CJT’s of 40mm. 100°C
preheat for CJT’s of 60mm and 150°C preheat for CJT’s
of 110 mm and above. When using semi automatic solid
or flux cored wire like the Formula XL-525, Austmig ES6
or Austmig 70C-6M etc., at approximately 2.2kJ/mm, a
preheat temperature of 50°C is recommended for CJT’s of
60mm and 125°C for CJT’s of 110mm and above.
7 “Hydrogen controlled” electrodes must be used with a
preheat temperature of 70°C for CJT’s of 28mm, 100°C
for CJT’s of 40mm and 170°C for CJT’s of 110mm and
above. For welding with appropriate solid or flux cored
wires, at approximately 2.2kJ/mm, a minimum preheat of
70°C is required for CJT’s of 45mm and 125°C for CJT’s
of 80mm. Slow cooling from interpass temperature is
required and critical weldments should be stress relieved.
7A Follow the general advice of 2A The welding of sulphur
bearing steels is not generally recommended, except for
non-critical applications. For general preheat requirements
refer to 7.
7B “Hydrogen controlled” electrodes of matching chemical
analysis and strength are recommended. The service
requirements of weldments employing this type of alloy
demand high integrity welding. A minimum preheat
temperature of 150°C is generally recommended, for
CJT’s of 30-60mm, followed by slow cooling. A stress
relieving heat treatment to 650°C is common practice,
176 following welding.
CONTENTS
8 Use “hydrogen controlled” electrodes with a preheat
temperature of 75°C for CJT’s of 20mm. 120°C for CJT’s
of 40mm and 170°C for CJT’s of 80mm. For semi-
automatic welding with appropriate solid or flux cored
wires, at approximately 2.2kJ/mm, use a preheat of
100°C for CJTs of 40mm, and 200°C for CJT’s of 100mm.
Slow cooling is essential, followed by a stress relieving
heat treatment for critical joints.
9 Use “hydrogen controlled” electrodes such as Austarc
16TC, 18TC or 77 with a minimum preheat of 90°C for
CJT’s of 20mm, 150°C for CJT’s of 40mm and 200°C for
CJT’s of 80mm. For semi-automatic welding with
appropriate solid or flux cored wires, at approximately
2.2kJ/mm, a minimum preheat of 50°C is recommended
or CJT’s of 20mm, 120°C for CJTs of 40mm and 180°C for
CJT’s of 80mm.
9A Follow the general advice of 2A. The welding of sulphur
bearing steels is not generally recommended, except for
non-critical applications. For general preheat
requirements, refer to 9.
10&11 Use “hydrogen controlled” electrodes such as Austarc
16TC, 18TC or 77 which have been thoroughly dried,
with the following minimum preheat temperatures.
CJT WIA WELDABILITY
20 mm 40 mm 80mm REF: NUMBER
120°C 170°C 220°C 10

140°C 190°C 230°C 11
Alternatively use austenitic, stainless steel electrodes such as

Unicord 312 with preheat temperatures approximately 50°C
less than those recommended above for “hydrogen controlled”
electrodes. The use of dry electrodes is essential, as is slow
cooling after welding. A post weld heat treatment is considered
good welding practice.
177
CONTENTS
WELDABILITY GUIDE
FOR STEELS
RECOMMENDATIONS
11A Following the general advice of 2A. The welding of
higher carbon, sulphur bearing steels is not generally
recommended, except for non-critical applications For
general preheating requirements, refer to 11.
9C, 11C For high strength butt and filet welding of these steels,
use “Hydrogen controlled” electrode & 12C
of matching chemical analysis or strength. Refer to the
minimum preheat temperatures and welding details
described in 9,11 and 12 respectively. When welding
these steels in the heat treated (hardened and
tempered) condition check that the post weld heat
treatment temperature chosen does not exceed the
tempering temperature of the base material.
10B, 11B The welding of alloy spring steels in the heat treated
(hardened and tempered) condition
& 12B can be carried out using preheat and interpass
temperatures of 200-300°C, with extra slow cooling in
insulating powder, a lime bath or a thermal blanket
etc. Austarc 16TC, 18TC and 77 is recommended for
root pass welding whilst subsequent higher strength
passes may be made with high strength electrode eg.
AWS A5.5: E110XX. Thoroughly dried electrodes
are essential and post weld heat treatment is generally
not recommended.
12 Use hydrogen controlled electrodes’-in thoroughly dry
condition, with the following minimum preheat temperatures:
CJT WIA WELDABILITY
20 mm 40 mm 80mm REF: NUMBER
170°C 220°C 260°C 12
178
CONTENTS
Welding on these steels is preferred in the annealed condition
and low dilution techniques should be employed. Under higher
degrees of restraint a further 50°C of preheat is recommended to
avoid cracking. In some applications, the use of Unicord 312 is
acceptable, especially where high preheats are difficult to achieve.
Dry electrodes and clean joints are essential. Slow cooling followed
by a PWHT immediately after welding is a compulsory practice.
13 Arc welding of these steels should be avoided if
possible. Welding is best carried out on tool steels in
the annealed condition, however, repair work on heat
treated (hardened and tempered) material or minor
attachments can be welded with Unicord 312. A preheat
temperature of 150-500°C is required as is a Post Weld
Heat Treatment (PWHT) of 150-650°C — for exact heat
treatment details refer to manufacturers data on the tool
steel being welded. It is important that the “PWHT”
temperature chosen does not exceed the tempering
temperature of the tool or mould steel being welded.
“Hydrogen controlled” ferritic electrodes, such as Austarc
16TC, 18TC and 77, should only be used on annealed
tool steels, with accordingly higher preheat temperatures.
14 Should be welded with “hydrogen controlled” electrodes
or wires of matching chemical analysis and strength.
Low hydrogen conditions are essential. Preheat
and interpass temperatures of the order of 250°C-300°C
are recommended followed by retarded cooling and a
stress relieving heat treatment of 650-700°C.
14A As for 14, except that a matching 5% Cr - 1/2 Mo
“hydrogen controlled” electrode is essential for matching
strength and corrosion. An alternative approach of using
Unicord 312 is acceptable for joints not subject to
thermal fatigue conditions and allows the use of lower
preheat temperatures and higher interpass temperatures.
179
CONTENTS
WELDABILITY GUIDE
FOR STEELS
RECOMMENDATIONS
15 Should be welded with a type 420 filler metal for
matching chemical analysis and mechanical properties.
However, Staincord 309Mo-16, Unicord 312 are suitable
austenitic, stainless steel electrodes for repair welds.
A preheat and interpass temperature of 200°C is
recommended, immediately followed by a post weld
heat treatment of 370°C. Allow component to cool to
40°C and post heat a second time, to ensure
optimum properties.
16 This class of alloy is best treated by water quenching
during welding and remains a tough austenitic structure,
unless reheated above 400°C. Use 1220-A4 type electrode,
for build-up or reclamation and Unicord 312 for butt and
fillet welds. The base metal should be kept cool during
welding by intermittent quenching, skip welding etc.
17 The use of “hydrogen controlled” consumables is compulsory
for welding Quenched and Tempered (Q & T) steels.
Electrodes and wires providing matching strength to
the structural grades are recommended for butt welding,
however, consumables of under-matching strength such as
Austarc 18TC, 77 may be suitable for fillet welding
applications on both structural and abrasion resistant grades.
Because of the risk of stress relief cracking, post weld heat
treatment of Q & T steels should not be undertaken, unless
absolutely necessary. If so stress relieving temperatures should
not exceed the tempering temperature of the Q & T steel being
welded. Refer to WTIA Technical Note 15 for complete details
on the welding of Q & T steels. The following minimum pre-heat
temperatures, maximum interpass temperatures and maximum
arc heat input energies should be used as a guide for welding
both structural and abrasion resistant grades of Q & T steels.
180
CONTENTS
GRADE OF Q & T STEEL <13 13 ~15 25 ~50 <50
MINIMUM PREHEAT TEMPERATURES
(°C) (HIGH RESISTANT)
HIGH STRENGTH GRADES
450 MPa min. Yield Stress 10 25 75 10
ABRASION RESISTANT GRADES
320 HB (3000/10) 50 100 125 150
360 HB (3000/10) 50 100 125 15
500 HB (3000/10) 100 100 150 -
MAXIMUM INTERPASS
ALL GRADES TEMPERATURES (°C)
150 175 200 220
MAXIMUN ARC HEAT INPUT (kj/mm)
ALL GRADES
2.5 3.5 4.5 5.0
181
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
CHEMICAL ANALYSIS (%) WIA

STEEL
WELDABILITY
DESIGNATION
C Mn REF: NUMBER
LOW CARBON AND MILD STEELS

1008 .10 max .20-.50 1,1A
1020 .18-23 .30.60 3
1022 .18-23 .70-1.00 4
1025 .22-28 .30-60 4
MEDIUM CARBON STEELS
1030 .28-.34 .60-.90 5
1035 .32-.38 .60-.90 6
X 1038 .35-.42 .70-1.00 8
1040 .37-.44 .60-.90 7
1045 .43-.50 .60-.90 7
HIGH CARBON STEELS
1050 .48-55 .60-.90 10
1055 .50-.60 .60-.90 11
1060 .55-.60 .60-.90 11
1070 .65-.75 .60-.90 12
FREE MACHINING STEELS

STEEL WELDABILITY
DESIGNATION REF:
C Mn S Pd NUMBER
RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES
1110 .06-.11 .30-.60 .05-1.0 - 2A
X1112 .08-.15 1.10-1.40 .20-.30 - 3A
1214 .15 max .80-1.20 .25-.35 - 3A
1137 .32-.39 1.35-1.65 .08-.13 - 9A
1144 .40-.48 1.35-1.65 .08-.13 - 11A
1146 .42-.49 .701-.00 0.089-.13 - 9A
X1147 .40-.47 1.60-1.90 .10-.35 - 11A
RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES
.15
12L14 .15 max .80-1.20 .25-.35 2A
-.35
182
CONTENTS
STEEL TYPES

STEEL
WELDABILITY
DESIGNATION
C Mn REF: NUMBER
CARBON-MANGANESE STEELS
X1320 .18-.23 1.40-1.70 5
X1325 .23-.28 1.40-1.70 6
X1330 .28-.33 1.40-1.70 8
X1340 .38-.43 1.40-1.70 10

STEEL WELDABILITY
DESIGNATION REF:
C Mn Si Cr NUMBER
SPRING STEELS
XK 55S .50-.60 .70-1.00 .10-.35 .70-.90 11B
XK 5160S .50-.65 .70-1.00 .10-.35 .70-.90 12B
XK 9258S .50-.65 .70-1.05 1.60-2.20 - 12B
XK 9261S .50-.65 .70-1.00 1.80-2.20 1 12B
ALLOY STEELS (FOR OTHER THAN SPRING APPLICATIONS)
5155 .50-.60 .70-1.00 .10-.35 .70-.90 11
5160 .55-.65 .70-1.00 .10-.35 .70-.90 12
9255 .50-.60 .70-1.05 1.60-2.20 - 12
9261 .50-.65 .70-1.00 1.80-2.20 .10-.25 12

STEEL WELDABILITY
DESIGNATION REF:
C Mn Si Ni Cr Mo Other NUMBER
ALLOY CONSTRUCTION STEELS
4140 .40 .60 .25 - .90 .20 - 12C
XK 4150 .50 1.30 .25 - .65 .18 5.08 12C
4340 .40 .60 .25 1.50 1.0 .25 - 12C
XX9931(en 26) .30 .60 .25 2.50 .50 .20 - 11C
XX9940 (en 26) .40 .60 .25 2.50 .50 .20 - 12C
183
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
CHEMICAL ANALYSIS (%) WIA WELD-

STEEL ABILITY
DESIGNATION REF:
C Mn Si Ni Cr Mo Other NUMBER
CASE HARDENING STEELS

4620 .20 .50 .25 1.75 - .25 - 6
8620 .20 .80 .25 .50 .50 .20 - 5
En 36A .12 .50 .25 3.20 .90 - - 9C
XK9315 (en 398) .15 .50 .25 4.20 1.20 .20 - 12

STEEL
WELDABILITY
DESIGNATION
C Mn SI Cr REF: NUMBER
FERRITIC CREEP RESISTANT STEELS

Mn-Mo .20 1.40 - .45 7B
1/2Cr - 1/2Mo .15 .50 .50 .50 7B
1Cr - 1/2Mo .12 .50 1.10 .50 7B
2 1/4Cr - 1Mo .12 .50 2.30 1.0 14
5Cr - 1/2Mo .12 .50 5.00 .60 14A
184
CONTENTS
CHEMICAL ANALYSIS (%)
STEEL WIA WELDABILITY
DESIGNATION REF: NUMBER
C Mn Si Cr Ni Mo S Other
PLASTIC MOULD STEEL

ASSAB
718 .33 .80 .30 1.80 .90 .20 .07 - 12 STEEL TYPES
STAVAX .38 .50 .80 13.60 - - - V.30 15
IMPAX SUPREME .33 1.40 .30 1.80 .80 .20 .008 - 12
BOHLER STEEL
M200 .40 1..50 .40 1.90 - .20 - - 12
COMMONWEALTH STEEL
CSM2 .30 .75 - 1.70 - .40 - - 12C
MAXEL
HOLDER BLOCK .50 1.0 .0 13.0 - - - - 12
STEEL MARK - EAGLE GLOBE
CSM2 .30 .80 .50 1.65 .40 - - 12C
MAXEL H.B .50 1.25 - .65 - .18 .08 12
420 MFQ .35 1.0 1.0 13.0 - - - - 15
THYSSEN
THYRODUR 2767 .45 - - 1.40 4.0 .30 - - 12C
THYROPLAST 2311 .40 1.50 - 1.90 - .20 - - 12C
THYROPLAST 2312 .40 1.50 - 1.90 - .20 - - 12C
THYROPLAST 2162 .21 1.30 - 1.20 - - - - 11
THYROPLAST 2399S .40 1.30 1.65 .15 .08 12C
THYROPLAST 2083 .42 - - 1.30 - - - - 15
CONTENTS
185
186
CONTENTS
HOT WORK TOOL STEELS

ASSAB
STEEL TYPES
8407 SUPREME .37 1.0 .40 1.40 5.30 1.0 - - 13

QRO 90 .04 .75 - 2.60 - 2.25 - - 13
BOHLER STEEL
VEW W302 .39 - 1.0 5.0 - 1.30 - V1.0 13
FOR STEELS
VEW W320 .31 0 0 2.90 - 2.80 - V.5 13

VEW W321 .39 - - 2.90 - 2.80 V5.CO₂ 13
COMMONWEALTH STEEL
NU - DIE V .40 .40 - 5.0 - 1.30 - V.50 13
ADIC .40 - 1.0 5.0 - 1.30 - V1.0 13
THYSSENN
THYROTHERM 2344 .40 - 1.0 5.30 - 1.40 - V1.0 13
WELDABILITY GUIDE
THYROTHERM 2885 .32 - - .30 2.80 - - CO₃ V.5 13

THYROTHERM 2713 .55 - - .70 1.70 .30 - V1.0 12C
COLD WORK TOOL STEELS

ASSAB
XW10 1.0 .60 .20 5.30 - 1.0 - V.20 13 STEEL TYPES
XW41 1.55 .30 .30 12.0 - .80 V.80 13
XW5 +W 2.50 .80 .30 12.50 - - - W1.3 13
DF2 .90 1.20 - .50 - - - W.51V.1 13
BOHLER STEEL
K100 2.0 - - 11.50 - - - - 13
K105 1.60 - - 11.50 - .60 - V.2 W.5 13
K107 2.10 - - 11.50 - - - W.70 13
K110 1.55 - - 11.50 - .70 - W.10 13
K245 .63 1.10 1.10 .60 - - - - 13
K305 .98 - - 5.10 - 1.0 - W.20 13
K450 .48 - .90 1.0 - - - V.2 W2 13
K455 .63 - - 1.10 - - - V.2 W2 13
K460 .95 1.10 - .50 - - - V.1 W.5 13
K510 1.18 .30 .25 .70 - - - V.10 13
K605 .52 - - 1.0 3.10 .20 - - 13
K630 .85 - - - .80 - - V.10 3
K720 .90 .20 - .40 - - - V.10 13
187
CONTENTS
188
CONTENTS
COLD WORK TOOL STEELS - CONT.

STEEL TYPES
SC 23 2.0 2.0 .30 12.0 - - - - 13

SC 25 1.50 .20 .30 12.0 - .75 Z.25 13
TOH .93 1.20 .20 .50 - - - W.5 V.1 13
NSS6 .70 1.90 .30 1.0 - 1.35 - - 13
FOR STEELS
SRS .60 .80 1.60 .35 - .40 - V.15 13

THYSSEN
THYRODUR 2379 1.55 - - 12.0 - .70 - V1.0 13
THYRODUR 2842 .90 2.0 - .40 - - - V1.0 13
THYRODUR 2250 .60 - .60 1.10 - - - W.2 V.2 13
THYRODUR 2767 .45 - - 1.40 4.0 .30 - - 3
THYRODUR 2101 .65 .80 - .90 - - - - 13
WELDABILITY GUIDE
STEEL
WELDABILITY
DESIGNATION
C Mn Si Ni Cr Mo Cu REF: NUMBER
AS 3678, STRUCTURAL STEELS - ORDINARY WELDABLE GRADE

200 .15 .60 .35 - - - - 1
250 or L15 .22 1.70 .55 - - - - 4 STEEL TYPES
350 or L15 .22 1.70 .55 - - - - 5
AS 3678, STRUCTURAL STEELS - WEATHET RESISTANT WELDABLE GRADES
WR350/1 or L0 .14 1.70 .55 - - - - 5
AS 1548, STEEL PLATES FOR BOILERS AND PRESSURE VESSELS
7-460 R,N,A,T .20 .90-1.70 .60 .30• .25• .10• .30• 5
5-490 N or A .24 .90-1.70 .60 .30• .25• .10• .20• 5
7-490 R,N,A,T .24 .90-1.70 .60 .30• .25• .10• .30• 6
AS 1085.1, RAIL STEELS
31kg or 41kg .53-.69 .60-.95 .15-.35 - - - - 12
50kg or 60kg .66-.82 .70-1.00 .15-.15 - - - - 12
CONTENTS
189
WELDABILITY GUIDE
FOR STEELS
STEELS TO SHIPPING CLASSIFICATION SOCIETY RULES
CHEMICAL ANALYSIS (5) WIA

STEEL
WELDABILITY
DESIGNATION
C Mn REF: NUMBER
LLOYDS REGISTER OF SHIPPING

GRADE A .23 - 3B
GRADE B .21 .80 min 3B
GRADE D .21 .60 min 4B
GRADE E .18 .70 min 4B
AMERICAN BUREAU OF SHIPPING
CLASS A .23 - 3B
CLASS B .21 .80-1.10 4B
CLASS CS .16 1.00-1.35 3B
CLASS DS .16 1.00-1.35 3B
CLASS D .21 .70-1.35 4B
CLASS E .18 .70-1.35 4B
DET NORSKE VERITAS
GRADE NVA .23 - 3B
GRADE NVD .21 .60 min 4B
GRADE NVE .18 .70 min 4B
BUREAU VERTITAS
GRADE A - - 3B
GRADE B .21 .80-1.40 3B
GRADE D .21 .60-1.40 4B
GRADE E .18 .70-1.50 4B
Single values unless otherwise stated are maxima.
190
CONTENTS
MIN CHEMICAL ANALYSIS (%) WIA
STEEL YIELD (DEPENDING ON PLATEN THICKNESS) WELDABILITY
DESIGNATION STRESs REF:
(MPa) C Mn Si Ni Cr S Mo Ti Other NUMBER
BISPLATE 60 500 0.16 1.10 - - 0.20 - - - - 17
BISPLATE 70 600 to to 0.20 - to 0.003 0.20 0.02 B. 0010 17
620-
80 & 80PV 0.18 1.40 - - 0.90 - - - - 17
690•
HY 80 550 .14 .30 .25 2.80 1.60 - .40 - - 17
HY 100 690 .14 .30 .25 2.80 1.60 - .40 - - 17
WEL-TEN 60 450 .11 1.22 .45 - .17 - .40 - V. 04 14
WEL-TEN 80C 690 .10 .85 .22 - .79 - .45 B. 001 -
V. 04 17
Cu. 28
V. 03
WEL-TEN 80E 686 .18 .18 .90 .23 .10 .40 B. 004
USS T1 690 .16 .85 .30 .90 .57 - .50 - B. 004

V. 04 17
(A) (A) HIGH STRENGTH STRUCTURAL STEELS
Cu .30
USS T1
690 .18 .90 .30 - .55 - .20 .02 B. 001 17
TYPE A
STEEL TYPES - QUENCHED AND TEMPERED STEELS
V 04
CONTENTS
191
192
CONTENTS
BRINDAL TYPICAL CHEMICAL ANALYSIS RANGE (%) WIA
STEEL HARD- (DEPENDING ON PLATEN THICKNESS) WELDABILITY
DESIGNATION NESS REF:
(HB) C Mn Si Ni Cr S Mo Ti Other NUMBER
BISPLATE 320 320-360 .18 1.15 .40 - .85 .20 .03 .002 - 17
BISPLATE 360 360-400 .28 1.15 .40 - .85 .20 .03 .002 - 17
BISPLATE 400 400-460 .18 .50 .35 - .95 .15 .04 .002 - 17
WEL-TEN
321 min .18 1.10 .25 - .70 .35 - .002 - 17
AR 320
17
WEL-TEN Cu
FOR STEELS
361 min .18 1.10 .25 - .90 .35 . .002 17

AR 360C .35
WEL-TEN
361 min .18 1.10 .25 - .40 - - .002 B .001 17
AR 360E
WEL-TEN
477 min .18 1.20 .40 - .60 .10 .002 Cu .28 7
(B) ABRASION RESISTANT GRADES
AR 500E
B .003
WELDABILITY GUIDE
STEEL TYPES - QUENCHED AND TEMPERED STEELS
193
CONTENTS
COMMON WELDING
TROUBLES
1 UNDERCUTTING
2 CRACKED
WELDS
3 POROUS
WELDS
4 POOR
PENETRATION
194
CONTENTS
COMMON WELDING TROUBLES
8 SPATTER
7 OVERLAPPING
6 INCLUSIONS
5 LACK OF
FUSION
195
CONTENTS
COMMON WELDING
TROUBLES
1 UNDERCUTTING
WHY WHAT TO DO
1. Faulty electrode 1. Pause at each side of the
manipulation weld bead when using a
2. Welding current too high weaving technique
3. Too long an arc length 2. Use proper electrode angles
3. Use proper welding current
4. Too fast travel speed
for electrode size and
5. Arc blow welding position
4. Reduce arc length
5. Reduce travel speed
6. Reduce effects of arc blow
2 CRACKED WELDS
WHY WHAT TO DO
1. Insufficient weld size 1. Adjust weld size to
2. Excessive joint restraint part thickness
3. Poor joint design 2. Reduce joint restraint
and/or preparation through proper design
4. Filler metal does not 3. Select the proper
match base metal joint design
5. Rapid cooling rate 4. Use more ductile filler
6. Base metal surface covered 5. Reduce cooling rate
with oil, grease, moisture, through preheat
rust, dirt or mill scale 6. Properly clean base
metal prior to welding
196
CONTENTS
3 POROUS WELDS
WHY WHAT TO DO
1. Excessively long or 1. Maintain proper arc length
short arc length 2. Use proper welding current
2. Welding current too high 3. Increase gas flowrate and
3. Insufficient or damp check gas purity
shielding gas 4. Reduce travel speed
4. Too fast travel speed 5. Properly clean base metal
5. Base metal surface prior to welding
covered with oil, grease, 6. Properly maintain and
moisture, rust, mill store electrode
scale, etc
4 POOR PENETRATION
WHY WHAT TO DO
1. Travel speed too fast 1. Decrease travel speed
2. Welding current too low 2. Increase welding current
3. Poor joint design 3. Increase root opening or
and/or preparation decrease root face
4. Electrode diameter too large 4. Use smaller electrode
5. Wrong type of electrode 5. Use electrode with deeper
6. Excessively long arc length penetration characteristics
6. Reduce arc length
197
CONTENTS
COMMON WELDING
TROUBLES
5 LACK OF FUSION
WHY WHAT TO DO
1. Improper travel speed 1. Reduce travel speed
2. Welding current too low 2. Increase welding current
3. Faulty joint preparation 3. Weld design should allow
4. Too large an electrode electrode accessibility to all
diameter surfaces within the joint
5. Magnetic arc blow 4. Reduce electrode diameter
6. Wrong electrode angle 5. Reduce effects of magnetic
arc blow
6. Use proper electrode angles
6 INCLUSIONS
WHY WHAT TO DO
1. Incomplete slag removal 1. Completely remove slag
between passes between passes
2. Erratic travel speed 2. Use a uniform travel speed
3. Too wide a weaving motion 3. Reduce width of weaving
4. Too large an electrode technique
5. Letting slag run ahead 4. Use a smaller electrode size
of arc for better access to joint
6. Tungsten spitting or sticking 5. Increase travel speed or
change electrode angle or
reduce arc length
6. Properly prepare tungsten
and use proper current
198
CONTENTS
7 OVERLAPPING
WHY WHAT TO DO
1. Too slow travel speed 1. Increase travel speed
2. Incorrect electrode angle 2. Use proper electrode
3. Too large an electrode angles
3. Use a smaller electrode
size
8 SPATTER
WHY WHAT TO DO
1. Arc blow 1. Attempt to reduce the
2. Welding current too high effect of arc blow
3. Too long an arch length 2. Reduce welding current
4. Wet, unclean or damaged 3. Reduce arc length
electrode 4. Properly maintain and
store electrodes
199
CONTENTS
SI UNITS AND
CONVERSION DATA
AUSTRALIAN INDUSTRY IS NOW FULLY CONVERTED TO
THE S.I. (SYSTEME INTERNATIONAL) SYSTEM OF UNITS.
In the S.I. system there are seven base units, from which other
units are derived:
QUANTITY NAME SYMBOL
length metre m
mass kilogram kg
time second s
electric current ampere A
Thermodynamic temperature kelvin K
luminous intensity candela cd
amount of substance mole mol
₃
In the S.I. system the use of factor notations, such as 10⁶ or 10 ,
are avoided by the use of S.I. prefixes to indicate submultiples and
multiples. The prefixes used to denote these, together with their
appropriate symbols are shown as follows:
PREFIX X SYMBOL PREFIX X SYMBOL

₁
deca 10 da deci 10⁻ d
₂ ₂
hecto 10 h cent 10⁻ c
₃ ₃
kilo 10 k milli 10⁻ m
₆
mega 10⁶ M micra 10⁻ u
₉ ₉
giga 10 G nano 10⁻ n
Therefore, for example, one millionth of a metre of .000001 m is

expressed as one micrometre or 1 um. Some countries employ
different unit systems, such as the U.S.A. which uses the imperial
system. The following data is provided to assist the user in
converting to locally accepted units.
LENGTH: 1mm = .03937 in = 39 thousandths of an inch

1 m = 39.3701 in 1 in = 25.4mm
1 m = 3.2808 ft 1 ft = 0.3048m
1 m = 1.0936 yd 1 yd = 0.9144 m
1 km = 49.7097 chain 1 chain = 20.1168 m
1 km = 0.6214 mile 1 mile = 1.6093 km
200
CONTENTS
SI UNITS AND CONVERSION DATA
₂ ₂ ₂ ₂
AREA: 1 mm =. 00155 in 1 in = 645.16 mm
₂ ₂
1 m = 1,550 in
₂ ₂ ₂ ₂
1 m = 10.7639 ft 1 ft = .0929 m
₂ ₂ ₂ ₂
1 m = 1.19599 yd 1 yd = .8361 m
1 ha = 2.4710 acre 1 acre = .4047 ha
₃ ₂
1 km = .3861 sq mile 1 sq mile = 2.5899 km
₃ ₃ ₃ ₃
VOLUME: 1 cm = .06102 in 1 in = 16.3871 cm
₃ ₃ ₂ ₃
1 m = 35.3147 ft 1 ft = .0282 m
₃ ₃ ₃ ₃
1 m = 1.3080 yd 1 yd = .7646 m
₃ ₃ ₃
1 dm = 1 litre = 61.0237 in 1000 litres = 1m
₃ ₃
1 dm = .2200 gal 1 gal = 4.5461 dm
₃ ₃
1 dm = 0.8799 qt 1 qt = 1.1365 dm
₃ ₃
1 dm = 1.7598 pt 1 pt = 0.5683 dm
₃ ₃
1 dm = 0.2642 US gal 1 US gal = 3.7854 dm
MASS: 1 kg = 35.2740 oz 1 oz = 28.3495 g

1 kg = 2.2046 lb 1 lb = 0.4536 kg
1 kg = 0.1575 stone 1 stone = 6.3503 kg
1,000 kg = 1t = 19.6841 cwt 1 cwt = 50.8023 kg
1t = 0.9842 ton 1 ton = 1.01605 t
1t = 2204.6 lb 1 ton = 22040 lb
SPEED: 1 in/min = 25.4 mm/min

1 rn/hr = 16.7 mm/min
1 mm/min = 0.20 ft/hr
1 in/min = 5.0 ft/hr
see table 2 tor Travel and Wire Speed Conversion Tables
₃ ₃
FLOW 1 L/min = 2.119 ft /hr 1 ft /hr = 0.472 L/min
RATE: 1 L/min = 0.264 gal/min 1 US gal/min = 3.785 L/min
₃ ₃
1 ft /hr = 0.125 US gal/min 1 US gal/min = 8.021 ft /hr
201
CONTENTS
SI UNITS AND
CONVERSION DATA
TEMPERATURE
The S.I. units of temperature is strictly speaking the Kelvin, K. The
temperature unit used widely in Australia and recognised for use
in the S.I. system, is however, the degree Celsius - °C. Degree
Celsius (°C) is related to Kelvin (K) by the following formula:
Temperature in Kelvin (K) = Temperature in degrees Celsius (°C)
+ 273.15. Therefore, the zero point for Celsius temperature, 0°C,
is exactly equal to 273.15K. Another temperature unit still used in
some countries is the degree Fahrenheit. °F - refer to table 3 for
0°C — °F Temperature Conversions.
HARDNESS
Refer to table 4 for a comparison of Hardness Scales
STRESS
In the S.I. system, the unit of stress is the newton per square metre,
₂
N/m , more popularly known as the “pascal” (symbol Pa). One
pascal represents only a very small unit of stress, so the multiples,
₂
kN/m2 or kPa and MN/m or MPa, are frequently used. In the metric
₂
system the unit of stress is the kgf/mm whilst the imperial system
₂ ₂
uses both ton f/in (TSI) and lbf/in (psi) to define stress.
₂ ₂
NB. 1 MPa = 1 MN/m = 1 N/mm -1,000 kPa
₂
1 MPa = 0.0647 ton f/in (TSI) 1TSI = 15.456 MPa
₂
1 MPa = 145.038 lb f/in (psi) 1 psi = .0069 MPa
N.B. (70 MPa equivalent
to 10,000 psi)
₂ ₂
1 MPa = 0.1020 kgf/ mm 1 kgf/ mm = 9.804 MPa
Refer to table 5 for conversion to various Stress units.
202
CONTENTS
PRESSURE
The units of Stress and Pressure are, of course, interchangeable
however some of the more popular units used for defining gas and
atmospheric pressure are:
₂
1 lbft/in (psi) = 6,895 Pa
N.B. (14.5 psi equivalent to 100 kPa) 1 ksi = 1000 psi
1 kPa = 10-2 b (bar) lb = 105 Pa
1 kPa = 9.869 x 10-3atm 1 atm = 1.013 x l05 Pa
1 kPa = 7.501 mmHg 1 mm Hg - 133.3 Pa
IMPACT ENERGY
In the S.I. system the unit of energy is the joule, J. In the widely
employed Charpy-Vee Notch Impact Test the joule is the unit
used. One joule, J, is equivalent to 1 newton (force) x 1 metre
(distance) in the S.I. system.In metric countries the energy figure
commonly quoted is the kilogram metre, kgfm, whilst the imperial
system commonly uses the foot pound, ft lbf.
1 J = 0.7376 ft lbf 1 ft lbf = 1.3558J
1 J = 0.1020 kgfm 1 kgfm = 9.8066
Refer to the Impact Energy Conversion table 5
DENSITY
₃
The S.I. unit of density is the kilogram per cubic metre, kg/in .
In the metric system the unit of density is the gram per cubic
₃ ₃
centimetre, g/cm . The pound per cubic inch, lb/in , and the pound
₃
per cubic foot, lb/ft are units frequently used in the imperial system.
₃ ₃ ₃ ₃
1 kg/m = 10-3 g/cm 1 g/cm = 1,000 kg/m
₃ ₃ ₃ ₃
1 kg/m = 36.1273 x 10-6 lb/in 1 lb/in = 27,679.9 kg/m
₃ ₃ ₃ ₃
1 kg/m = .0624 lb/ft 1 lb/ft = 16.0185 kg/m
Some weld metal densities worth noting are:
₃ ₃
Mild Steel 7.85 x 10 kg/m
₃ ₃
Stainless Steel 7.95 x 10 kg/m
₃ ₃
Aluminium 2.7 x lO kg/m
₃ ₃
Tin Bronze 8.9 x 10 kg/m
203
CONTENTS
204
CONTENTS
INCH INCH INCH INCH INCH INCH
MM MM MM
(Fraction) (Decimal) (Fraction) (Decimal) (Fraction) (Decimal)
1/64 0.0158 0.3969 11/32 0.3437 8.7312 43/64 0.6719 17.0656
1/32 0.0312 0.7937 23/64 0.3594 9.1281 11/16 0.6875 17.4625
3/64 0.0469 1.1906 3/8 0.375 9.525 45/64 0.7031 17.8594
1/16 0.0625 1.5875 25/64 0.3906 9.9219 23/32 0.7187 18.2562
5/64 0.0781 1.9844 13/32 0.4062 10.3187 47/64 0.7344 18.6532
3/32 0.0937 2.3812 27/64 0.4219 10.7156 3/4 0.750 19.050
7/64 0.1094 2.7781 7/16 0.4375 11.1125 49/64 0.7656 19.4469
1/8 0.125 3.175 29/64 0.4531 11.5094 25/32 0.7812 19.8433
9/64 0.1406 3.5719 15/32 0.4687 11.9062 51/64 0.7969 20.2402
5/32 0.1562 3.9687 31/62 0.4844 12.331 13/16 0.8125 20.6375
11/64 0.1719 4.3656 1/2 0.500 12.700 53/64 0.8281 21.0344
INCHES TO MM
3/16 0.1875 4.7625 33/64 0.5156 13.0968 27/32 0.8437 21.4312

13/64 0.2031 5.1594 17/32 0.5312 13.4937 55/64 0.8594 21.8281
7/32 0.2187 5.5562 35/64 0.5469 13.8906 7/8 0.875 22.2250
CONVERSION FROM
15/64 0.2344 5.9531 9/16 0.5625 14.2875 57/64 0.8906 22.6219

1/4 0.25 6.35 37/64 0.5781 14.6844 29/32 0.9062 23.0187
17/64 0.2656 6.7469 19/32 0.5937 15.0812 59/64 0.9219 23.4156
9/32 0.2812 7.1437 39/64 0.6094 15.4781 15/16 0.9375 23.8125
19/64 0.2969 7.5406 5/8 0.625 15.875 61/64 0.9531 24.2094
5/16 0.3125 7.9375 41/64 0.6406 16.2719 31/32 0.9687 24.6062
21/64 0.3281 8.3344 21/32 0.6562 16.6687 63/64 0.9844 25.0031
TRAVEL AND WIRE

FEED SPEEDS
INCHES FEET MM CM M M
PER MIN PER HR PER MIN PER MIN PER MIN PER HR
3 15 76 7.6 .08 4.6
4 20 102 10.2 .10 6.1
5 25 127 12.7 .13 7.6
6 30 152 15.2 .15 9.1
8 40 203 20.3 .20 12.2
10 50 254 25.4 .25 15.2
12 60 305 30.5 .30 18.3
14 70 356 35.6 .36 21.3
16 80 406 40.6 .41 24.4
18 90 457 45.7 .46 27.4
20 100 508 50.8 0.51 30.5
22 110 559 55.9 .56 33.5
24 120 610 61.0 .61 36.6
26 130 660 66.0 .66 39.6
28 140 711 71.1 .71 42.7
30 150 762 76.2 .76 45.7
32 160 813 81.3 .81 48.8
34 170 864 86.4 .86 51.8
36 180 914 91.4 .91 54.9
38 190 965 96.5 .97 57.9
40 200 1016 101.6 1.02 61.0
45 225 1143 114.3 1.14 68.6
50 250 1270 127.0 1.27 76.2
55 275 1397 139.7 1.40 83.8
60 300 1524 152.4 1.52 91.4
65 325 1651 165.1 1.65 99.1
70 350 1778 177.8 1.78 106.7
75 375 1905 190.5 1.91 114.3
80 400 2032 203.2 2.03 121.9
85 425 2159 215.9 2.16 129.5
90 450 2286 228.6 2.29 137.2
95 475 2413 241.3 2.41 144.8
100 500 2540 254.0 2.54 152.4
INCHES/ INCHES/ INCHES/
M/MIN M/MIN M/MIN
MIN MIN MIN
110 2.79 200 5.08 425 10.80
120 3.05 225 5.72 450 11.43
130 3.30 250 6.35 475 12.07
140 3.56 275 6.99 500 12.70
150 3.81 300 7.62 525 13.34
160 4.06 325 8.26 550 13.97
170 4.32 350 8.89 575 14.61
180 4.57 375 9.53 600 15.24
190 4.83 400 10.16 625 15.88 205
CONTENTS
°C - °F TEMPERATURE
CONVERSIONS
The numbers in bold face type refer to the temperatures, either
in degrees Celsius (°C) or degrees Fahrenheit (°F). For example,
reading from centre to left, -150°F is equivalent to -101°C or from
centre to right -150°C is equivalent to -238°F and so on.
°C °F °C °F
°C °F °C °F
-101 -150 -238 5.00 41 105.8
-95.6 -140 -220 5.56 42 107.6
-90.0 -130 -202 6.11 43 109.4
-84.4 -120 -184 6.67 44 111.2
-78.9 -110 -166 7.22 45 113.0
-73.3 -100 -148 7.78 46 114.8
-67.8 -90 -130 8.33 47 116.6
-62.2 -80 -112 8.89 48 118.4
-56.7 .70 -94 9.44 49 120.2
-51.1 -60 -76 10.0 50 122.0
-45.6 -50 -58 10.6 51 123.8
-40.0 -40 -40 11.1 52 125.6
-34.4 -30 -22 11.7 53 127.4
-28.9 -20 -4 12.2 54 129.2
-23.3 -10 14 12.8 55 131.0
-17.8 0 32 13.3 56 132.8
-17.2 1 33.8 13.9 57 134.6
-16.7 2 35.6 14.4 58 136.4
-16.1 3 37.4 15.0 59 138.2
-15.6 4 39.2 15.6 60 140.0
-15.0 5 41.0 16.1 61 141.8
-14.4 6 42.8 16.7 62 143.6
-13.9 7 44.6 17.2 63 145.4
-13.3 8 46.4 17.8 64 147.2
-12.8 9 48.2 18.3 65 149.0
-12.2 10 50.0 18.9 66 150.8
-11.7 11 51.8 19.4 67 152.6
-11.1 12 53.6 20.0 68 154.4
-10.6 13 55.4 20.6 69 156.2
-10.0 14 57.2 21.1 70 158.0
-9.44 15 59.0 21.7 71 159.8
-8.89 16 60.8 22.2 72 161.6
-8.33 17 62.6 22.8 73 163.4
-7.78 18 64.4 23.3 74 165.2
206
CONTENTS
°C °F °C °F
°C °F °C °F
-7.22 19 66.2 23.9 75 167.0
-6.67 20 68.0 24.4 76 168.8
-6.11 21 69.8 25.0 77 170.6
-5.56 22 71.6 25.6 78 170.4
-5.00 23 73.4 26.1 79 174.2
-4.44 24 75.2 26.7 80 176.0
-3.89 25 77.0 27.2 81 177.8
-3.33 26 78.8 27.8 82 179.6
-2.78 27 80.6 28.3 83 181.4
-2.22 28 82.4 29.4 84 183.2
-1.67 29 84.2 29.4 85 185.0
-1.11 30 86.0 30.0 86 186.8
-0.56 31 87.8 30.6 87 188.6
0 32 89.6 31.1 88 190.4
0.56 33 91.4 31.7 89 192.2
1.11 34 93.2 32.2 90 194.0
1.67 35 95.0 32.8 91 195.8
2.22 36 69.8 33.3 92 197.6
2.78 37 98.6 33.9 93 199.4
3.33 38 100.4 34.4 94 201.2
3.89 39 102.2 35.0 95 203.0
4.44 40 104.0 35.6 96 204.8
TEMPERATURE CONVERSION FORMULAE:

°C = 5 x (°F - 32) °F = 9 x °C + 32
9 5
207
CONTENTS
°C - °F TEMPERATURE
CONVERSIONS
The numbers in bold face type refer to the temperatures, either
in degrees Celsius (°C) or degrees Fahrenheit (°F). For example,
reading from centre to left, -100°F is equivalent to -38°C or from
centre to right -100°C is equivalent to -212°F and so on.
°C °F °C °F
°C °F °C °F
36.1 97 206.6 277 530 986
36.7 98 208.4 382 540 1004
37.2 99 210.2 288 550 1022
38 100 212 293 560 1040
43 110 230 299 570 1058
49 120 248 304 580 1076
54 130 266 310 590 1094
60 140 284 316 600 1112
66 150 302 321 610 1130
71 160 320 327 620 1148
77 170 338 332 630 1166
82 180 356 338 640 1184
88 190 374 343 650 1202
93 200 392 349 660 1220
99 210 410 354 670 1238
100 212 413 360 680 1256
104 220 428 366 690 1274
110 230 446 371 700 1292
116 240 464 377 710 1310
121 250 482 382 720 1328
127 260 500 388 730 1346
132 270 518 393 740 1364
138 280 536 399 750 1382
143 290 554 404 760 1400
149 300 572 410 770 1418
154 310 590 416 760 1436
160 320 608 421 790 1454
166 330 626 427 800 1472
171 340 644 432 810 1490
177 350 662 438 820 1508
182 380 680 443 830 1526
188 370 698 449 840 1544
193 380 716 454 850 1562
199 390 734 460 860 1580
208
CONTENTS
°C °F °C °F
°C °F °C °F
204 400 752 466 870 1598
210 410 770 471 880 1616
216 420 788 477 890 1634
221 430 806 482 900 1652
227 440 824 488 910 1670
232 450 842 493 920 1688
238 460 860 499 930 1706
243 470 878 504 940 1424
249 480 896 510 950 1742
254 490 914 516 960 1760
260 500 932 521 970 1778
266 510 950 527 980 1796
271 520 968 532 990 1814
538 1000 1832
TEMPERATURE CONVERSION FORMULAE:

°C = 5 x (°F - 32) °F = 9 x °C + 32
9 5
209
CONTENTS
COMPARISON OF
HARDNESS SCALES
Figures are approx. Actual values to be substantiated by measurement.
VICKERS MM
ROCKWELL
Hardness No. PER MIN APPROXIMATE
Hardness No.
(Diamond Hardness No. TENSILE
C Scale
Pyramid) (3000kg/10mm STRENGTH (MPa)
(HRc)
(HV 30) WC ball) (HB)
68.0 940 - -
66.4 880 767 -
64.0 800 722 -
62.5 760 698 -
60.0 697 653 -
58.8 670 630 2,239
57.3 640 601 2,131
55.6 607 570 2,020
53.5 569 534 1,887
52.1 547 541 1,813
50.3 516 485 1,703
49.6 508 477 1,675
47.1 472 444 1,544
45.7 455 429 1,496
44.5 440 415 1,447
41.8 410 388 1,351
40.4 396 375 1,294
37.9 372 352 1,214
36.6 360 341 1,172
35.5 350 331 1,144
34.3 339 321 1,102
33.1 328 311 1,068
32.1 319 302 1,034
30.9 309 293 999
29.9 301 285 971
28.8 292 277 945
26.6 276 262 889
24.2 261 248 841
22.8 253 241 814
20.5 241 229 766
(18.8) 234 223 745
(15.2) 218 207 689
(10.0) 196 187 621
(6.4) 182 174 585
(0.9) 163 156 523
- 143 137 462
- 122 116 400
- 117 111 386
210 Value in brackets are beyond normal range.
CONTENTS
STRESS AND ENERGY

CONVERSIONS IMPACT ENERGY
STRESS CONVERSIONS
CONVERSIONS
₂ ₂ ₂
MPa tonf/in lbf/in kgf/mm kgfm Joules ft lb
(x 1000) 17
1400 90 120
200 140 160
1350 16
85 190 135
1300
130 150 110
1250 15
80 180
125
1200 140
75 170 120 14
1150 100
115
1100 160 130
70 110 13
1050 90
150 105 120
1000 65 12
100
140
950 110
60 95 11 80
900 130
90
850 55 100
120 85 10
800 70
50 80
110 9 90
750
75
700 45 100 60
70 80
8
650 65
40 90
600 60 7 70
50
550 35 80 55
500 6 60
70 50
30 40
450 45
60 5 50
400 25 40
350 50 35 40 30
4
300 20
30
40
250 25 3 30
15 20
200 30 20
10 2 20
150 15
20
10
100 10
5 1 10
10
50 5
0 0 0 0 0 0 0 211
CONTENTS
212
CONTENTS
THICKNESS OF DIAMETER, X IMPERIAL
SHEET OR WIRE
STANDARD
BIRMINGHAM PLATE OF OR ROD
OF WIRE
INCHES INCHES GAUGE (B/G.) THICKNESS, DIAMETER, X
MM GAUGE
(Decimal) (Fractions) X. kg/in₂ Kg/50m
(SWG)
0.015625 1/64 0.397 28 3.1 - .049
0.0196 - 0.498 26 3.9 - .076
0.0220 - 0.559 25 4.4 24 .096
0.0247 - 0.628 24 4.9 - .122
0.028 - 0.711 - 5.6 22 .156
0.03125 1/32 0.794 22 6.2 - .194
0.036 - 0.914 - 7.2 20 .258
0.0392 - 0.996 20 7.8 - .302
0.03937 - 1.0 - 7.9 - .308
0.046875 3/64 1.191 - 9.3 - .437
0.048 - 1.22 - 9.6 18 .459
0.495 - 1.26 18 9.9 - .489
0.059 - 1.5 - 11.8 - .694
0.0625 1/6 1.588 16 12.5 - .777
0.064 - 1.63 - 12.8 16 .819
0.0785 - 1.99 14 15.6 - 1.22
0.0787 - 2.0 - 15.7 - 1.23
0.080 - 2.03 - 15.9 14 1.27
0.0984 - 2.5 - 19.6 - 1.93
0.0991 - 2.52 12 19.8 - 1.96
WIRE AND SHEET SIZES
0.104 - 2.64 - 20.7 12 2.15

0.118 - 3.0 - 23.6 - 2.77
0.1250 1/8 3.175 10 24.9 - 3.11
0.128 - 3.25 - 25.5 10 3.26
0.138 - 3.5 - 27.5 - 3.78
Figures are approx. Actual values to be substantiated by measurement.
THICKNESS OF DIAMETER, X IMPERIAL
SHEET OR WIRE
STANDARD
BIRMINGHAM PLATE OF OR ROD
OF WIRE
INCHES INCHES GAUGE (B/G.) THICKNESS, DIAMETER, X
MM GAUGE
(Decimal) (Fractions) X. kg/in₂ Kg/50m
(SWG)
0.157 5/32 4.0 8 31.4 - 4.93
0.160 - 4.07 - 31.9 8 5.11
0.177 - 4.5 - 35.3 - 6.24
0.1875 3/16 4.762 - 37.4 - 6.99
0.192 - 4.88 - 38.3 6 7.34
0.1969 - 5.0 - 39.3 - 7.71
0.232 - 5.89 - 46.2 4 10.69
0.2362 - 6.0 - 47.1 - 11.10
0.25 1/4 6.35 - 49.8 - 12.43
0.2756 - 7.0 - 55.0 2 15.11
0.300 - 7.62 - 59.8 1 17.90
0.3125 5/16 7.938 - 62.3 - 19.42
0.3150 - 8.0 - 62.3 - 19.42
0.324 - 8.23 - 64.6 0 20.88
0.3543 - 9.0 - 70.7 - 24.97
0.375 3/8 9.525 - 74.8 - 27.97
0.3937 - 10.0 - 78.5 - 30.83
0.5 1/2 12.700 - 99.7 - 49.72
0.625 5/8 15.875 - 124.6 - 77.69
0.75 3/4 19.050 - 149.5 - 111.87
0.875 7/8 22.230 - 174.5 - 152.34
1.0 - 25.400 - 199.4 - 198.88
NOTE: The Birmingham Gauge is generally employed for uncoated plain carbon steel sheet. The Imperial
Standard Wire Gauge (SWG) is commonly used for all steel (inc. stainless) & aluminium wires. It is also used
for stainless steel, aluminium and other non ferrous sheets and tubes.
213
CONTENTS
SYMBOLS FOR ELEMENTS
AND GEOMETRIC FORMULAE
SYMBOL FOR ELEMENTS
Al Aluminium H Hydrogen O Oxygen
B Boron Fe Iron P Phosphorus
C Carbon Mg Magnesium Pb Lead
Cb Columbium• Mn Manganese S Sulphur
Cd Cadmium Mo Molybdenum Si Silicon
Co Cobalt N Nitrogen Ti Titanium
Cr Chromium Ta Tantalum Zn Zinc
Sn Tin W Tungsten
V Vanadium Nb Niobium•
Cu Copper Ni Nickel
•Columbium (Cb) is commonly know as Niobium (Nb).
GEOMETRIC FORMULAE
LENGTHS:
Circumference of a circle = π x diameter of circle
Arc of a circle = .01745 x angle of arc, in degrees.
AREAS:
Triangle = 1/2 base x perpendicular height
Circle = .7854 x square of diameter = π x square of radius
Ellipse = .7854 x long axis x short axis
Parabola = 2/3 base x height
Square = square of the side
Rhomboid or Rhombus = base x height
Parallelogram = base x height
Sector of a circle = 1/2 radius x length of arc
Polygon (regular) = 1/2 radius of inscribed circle x length of
one side x number of sides
VOLUMES:Cone = 1/3 area of circle x perpendicular height

Cylinder = area of circle x height
Prism = area of base x height
Pyramid = 1/3 area of base x perpendicular height
Sphere = 4.1783 x radius cubed
214
CONTENTS
SYMBOLS FOR ELEMENTS AND GEOMETRIC FORMULAE
215
CONTENTS
NOTES
NOTES
216
CONTENTS
217
CONTENTS
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WIA offers an extensive range of consumables for various

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DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products,

Hydrogen Controlled Electrodes

Iron Powder Electrodes

Stainless Steel Electrodes

Cast Iron Electrodes

GOUGING AND CUTTING ELECTRODES

DESCRIPTION AND APPLICATION

A stiff fast freezing slag for all positional (especially vertical

*Recommended for DC +/- or AC (minimum 45 OCV) operation.

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

Austarc 13S is formulated primarily for fillet welding in all

*Recommended for DC +/- or AC (minimum 45 OCV) operation.

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

Typical applications include oil and gas, pipe welding, structural

*Please note, the recommended welding polarity for

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

AS/NZS 3679.1 250, 300, 350, 400

AS/NZS 3678.1 200, 250, 300, 350, 400, 450,

DESCRIPTION AND APPLICATION

*Recommended for DC +/- or AC (minimum 70 OCV) operation.

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

Austarc 24 is suited to long, heavy fillet and butt welding

*Recommended for DC +/- or AC (minimum 55 OCV) operation.

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

Features include: Forceful, deep penetrating arc with

Austarc 11 is recommended for specific applications including

*Recommended for DC +/- or AC (minimum 70 OCV) operation.

ELECTRODES - CELLULOSE ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

Staincord 309Mo-16 is a Molybdenum bearing, highly alloyed

*Recommended for DC +/- or AC (minimum 70 OCV) operation.

ELECTRODES - STAINLESS STEEL ELECTRODES

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

DESCRIPTION AND APPLICATION

ELECTRODES - STAINLESS STEEL ELECTRODES

*Recommended for DC +/- or AC (minimum 45 OCV) operation.