SS FCAW TO RESCUE OF ASPRIN MAKER’S HEAD ACHE

• SS Half Coil Reactor Found Leaking.

• Leak Spots Identified as likely restart points in OH Position.

• Small Dia. SS FCAW made it possible to reduce restart points & also better approach made improved Fusion.

HALF COIL

ONE MINUTE WELD VERTICAL UP POSITION-6MM FILLET

• One Minute Welds made using SMAW 3.2mm –70mm, GMAW-0.9mm –105 mm FCAW 1.2mm –300 mm

• Cost aspect based on above productivity.

FCAW SMAWGMAW

9001300

2900

DEP. COST PER KG

CO

ST

IN

RS

. LABOUR &OVERHEAD-RS.500

SMAW

FCAW

GMAW

FCAW CONSUMABLES AVILABILITY

• E70T-1 FOR• E71T-1 BOILER • E70T5 QUALITY• E81T1-W WHEATHERING

• E80T1-A1 FOR• E80T1-B2 LOW ALLOY• E8-T1-B3 STEEL• E80T5-G FOR• E90T5-K2 HSLA• E100T5K3 STEELS • E110T5-K4

• E308TX-X FOR SS

• E316TX-X POSITIONAL

• E312TX-X WELDING

• E309TX-X

• E308.T0-3 FOR

• E309T0-3 CLADDING

CORED STAINLESS STEEL WIRES

• Metal Cored - Mostly metallic Powders in the Core.Welding Characteristics similar to solid wire

• Self Shielded -Generates its Own Protective Gas .Used in Flat & Horizontal Position only

• Down Hand Gas Shielded - For Flat & Horizontal Positions

• All -Position Gas Shielded -Newest Type for Welding in all-position

TYPICAL APPLICATIONS

• For Joining Similar Material• For Cladding & Overlay Welding• For Corrosion Resistance Application• For Cryogenic Application• For Dissimilar Metal Welding

METAL CORED

• Deposition Efficiencies : 98%• Shielding Gases : 98% Ar 2% O2

95% Ar 5% CO2• Higher Deposition Rates Than Solid Wire

Types Commonly Available: 409 Ti

410

430

439

SELF- SHIELDED CSS AWS 5.22

• Application :Joining & Cladding

• Deposition Efficiencies : 75 - 85 %

Increasing the Voltage Increase N2 Level

at a Constant Current Decrease Ferrite

Increasing Electrode Extension Decreases N2 Level

at a Constant Current Increases Ferrite

Types Generally available

E 307T-3 E309T-3

E308MoT-3 E316LT-3

E308LT-3 E 347T-3

DOWNHAND GAS SHIELDED CSS AWS 5.22

• Deposition Efficiency : 87 - 92%• Shielding Gases : 100 % CO2 75% Ar & 25% CO2 ADVANTAGES• Faster Travel Speeds Than Solid Wire • Spray Arc Transfer• Low Spatter• Fine Rippled Bead• Self Releasing Slag

ALL-POSITION GAS SHIELDED CSS

• Deposition Efficiencies : 86 -90%

• Shielding Gases : 75% Ar & 25% Co2

100% CO2

• Fast Freezing Slag System

• High Current Levels For Welding in the Vertical & Overhead Position

Types Available

E 308Lt-1 E317LT-1

E309LT-1 E309MoLT-1

E316LT-1 E347LT-1

MMAW ELECTRODE -CONSTITUENTS & THEIR FUNCTIONS```

CONSTITUENTS

IRON OXIDETITANIUM DIOXIDEMAGNESIUM OXIDECAL. FLOURIDEPOT. SILICATEOTHER SILICATES

CAL. CORBONATEOTHER ORBONATESCELLULOSEFERRO MANGANESEFERRO CHROMEFERRO SILICON

PRIMARY FUNCTION

SLAG FORMERSLAG FORMERFLUXING AGENTSLAG FORMERARC STABILISERSLAG FORMER &BINDERGAS FORMERGAS FORMERGAS FORMERALLOYINGALLOYINGDE-OXIDISING

SECONDARY FUNCTION

ARC STABILISERARC STABILISERNILFLUXING AGENTBINDERFLUXING AGENT

ARC STABILISERNILNILDEOXIDISERNILNIL

SHIELDED METAL ARC WELDING-SMAWSTICK/MANUAL/MMAW

Advantages• Variety of Electrodes with Different features• Most versatile -All Positional Joints /Joints with Limited

Access• Suitable for most Alloys• Equipment Simple ,Portable & Inexpensive Disadvantages• Finite Length• High dependence on Welders Skill• Not Amenable to Automation

TYPES OF SLAG SYSTEM

• Acid

• Basic

• Metal cored

• Rutile Basic (Semi- Basic)

FCAW CONSUMABLES AVILABILITYWITH AWS SPECIFICATION

E70T-1 FOR E71T-1 BOILER

E70T5 QUALITY E81T1-W WHEATHERING

E80T1-A1 FOR E80T1-B2 LOW ALLOY E8-T1-B3 STEEL E80T5-G FOR E90T5-K2 HSLA E100T5K3 STEELS E110T5-K4

E308TX-X FOR SS E316TX-X POSITIONAL E312TX-X WELDING E309TX-X E308.T0-3 FOR E309T0-3 CLADDING

CLASSIFICATION OF FLUX CORED ELECTRODES AWS 5.20

Electrodes Min. Tensile Strength x 10,000 psi Position : 1 - All Position 0 - Flat & Horizontal

Usability E X X T- XMJ HZDesignates Spl. Impact Prop. At -40Deg C -27 J

Meeting Diffusible H2 Content 4/8/16 ml per 100 gms as indicated by “Z”

-

CLASSIFICATION OF METAL CORED WELDING AWS 5.18

Electrode

UTS X1000 psi

Indicates Composit Rod

E 70 C - X Y N HZ Diffusible Hydrogen

Higher Impact &Lower Impurities

(N Application)

Type of Gas C / M

Impact Properties

FLUX CORED ARC WELDINGAWS A 5.22

Electrode

Alloy Composition

Alloy addition

L-Low Corbon

Tubular or Flux Cored

External Gas Shielding

E XXX XX X T - X

SELECTING A WELDING PROCESS

• Available Forms of Filler Metal Needed• Available Welding Equipments• Dimension of the Weldments• Number of Pieces to be Welded

SOURCE OF HYDROGEN IN WELDWelding Consumables Moisure in Flux (SAW)

Excess Lubricant on Electrodes (FCAW &GMAW)Moisure / Hydrogen in Shielding Gas (FCAW

&GMAW)Moister in Coating (SMAW)

Moister in Fluxing Ingredients (FCAW)

Work PieceMoisture ,Oils .Rust . Paint

Ambient Conditions

EFFECTS OF

HYDROGEN ON STEEL

• Porosity /Worm Tracking

• Loss of Ductility

• Hydrogen Cracking

SELECTION OF PROPER GAS• Material Types

-Carbon ,Stainless , Aluminium ,Etc

• Material Condition

- Rusty ,Oily , Primed , Etc

• Types Of Metal Transfer

- Short Circuit ,Spray , Pulse , Etc

• Weld Metal Mechanical Properties

• Job Requirements

- Fit- Up

- Penetration

- Spatter Levels

DEVELOPMENT OF WELDING

• 1 Forge Welding BC Tubal Cain -Middle East

• 2 Electric Arc 1801 Sir Humphrey Davy,UK

• 3 CorbonArc Welding 1881 De Meritens -French

• 4 CorbonArc Welding 1885 N.V.Bernardo -Russian

• 5 Electric Resistance 1886 Elihu Thompson -USA

• 6 Metal Arc Welding 1888 Slavianoff -Russian

• 7 Thermit Welding 1897 H. Goldschmidt -Germany

• 8 Oxyacetylene Welding 1906 Eugene Davis -USA

• A.Bournonvile -French

• 9 Metal Arc Welding 1910 Oscar Kjellberg -Swede

PROPER SELECTION OF CONSUMABLES

Base Material StrengthBase Material Composition

Welding Position Joint Design &Fit-Up

Thickness & Shape of MaterialService Condition & /or Specification

Production Efficiency & Job Condition