Flux Cored Wire

8/10/2019 Flux Cored Wire

1/38

Flux cored wireIdeal combination of high quality and high

efficiency

Dipl.-Ing. IWE Michael Reimann

Product Manager OERLIKON Switzerland

Welding conference Lima, Peru 25.11.2005


2/38

2

Arrangement of flux cored wires

Seamless flux cored wire

Metal cored wire

Rutil flux cored wire

Basic flux cored wire


3/38


4/38

4

Welding project with Fluxofil 14 HD


5/38

5

Welding project with Fluxofil 14 HD

WPS Fluxofil 14 HD with weldycar


6/38

6


Root pass on ceramic backing


7/38

7


Front view on round ceramic backing


8/38

8


Fixation the weldycar


9/38

9


Root pass on ceramic backing


10/38

10


CurrentI=225AVoltageU=24VWelding speedVs=13cm/minWire speed8,0m/minWeld deposit3,5 Kg/h

Cap welding


11/38

11


Nahtvorbereitung Lagenaufbau

Schweiparameter

Joint preparation

Welding parameters

Layers set up


12/38

12


Weldycar fixed in transver position


13/38

13


Transver welding on ceramic in action


14/38

14

WPS Fluxofil 14 HD with weldycar Nahtvorbereitung Lagenaufbau

Schweiparameter

Joint preparation

Welding parameters in transver position

Layers set up


15/38

15

Fluxofil 14 HD in project operation


16/38

16



17/38

17



18/38

18



19/38

19

Flux cored wire application tank building


20/38

20

Flux cored wire application tank building

Joint preparation

Vessel


21/38

21

Fluxofil 14 HD Application pipe junction


22/38

22

Flux cored wire application hall truss


23/38

23

Flux cored wire application exhibition hall


24/38

24

Fluxofil 14 HD in all welding position


25/38

25

Calculation comparison between solid and flux coredwire

Schweiverfahren MAG- FlldrahtMAG- MassivdrahtSchweizusatz Fluxofil 14 HD

Ausfhrungen HalbmechanisiertNahtvorbereitungLagenaufbau

Lagenzahl/RaupenzahlSchweipositionDrahtdurchmesser (mm)Schweistrom I (mm)Schweispannung U (V)Schweigeschwindigkeit Vs (cm/min)

Abschmelzleistung SG (Kg/h)Schweizeitfaktor ED (%)

Lohnsatz LS (Euro/h)Schweizusatzpreis SZP (Euro/KgSchutzgaspreis SP (Euro/l)Schutzgasmenge SM (l/min)Gemeinkostenfaktor GKF (%)

Carbofil 1

1,545

Halbmechanisiert

PF1,2140

300

3L/3R

130,930.0115

1813

3L/3RPF1,221023263,045

133,3

0.0115300

12 90


26/38

26

Calculation comparison between solid and flux coredwire

Schweiverfahren MAG- FlldrahtMAG- MassivdrahtSchweizusatz Fluxofil 14 HD

Ausfhrungen Halbmechanisiert

NahtvorbereitungLagenaufbau

Lagenzahl/RaupenzahlSchweinahtgewicht SNG (Kg/m)

Hauptzeit Th ( min/m )Hauptzeit + Nebenzeit T ( min / m )

Schweizusatzkosten KZ (Euro/m)Schutzgaskosten KS(Euro/m)

Lohnkosten KL (Euro/m)Gemeinkosten KG (Euro/m)Fertigungskosten KF (Euro/m)

Gesamtkosten KGe (Euro/m)

Ersparnis Euro/m

Ersparnis %

Carbofil 1halbmechanisiert

3L/3R1,20

48,00106,67

1,12

94,43

0,87

23,1169,3392,44

3L/3R1,20

24,0053,33

3,96

0,87

11,56

45,94

34,6746,22

51,05

43,38

12 90


27/38

27

Fluxofil 14 HD - Data sheet -

Standards: DIN EN 758 T 46 2 P C 1 H5 / T 46 2 P M 1 H5 AWS/ASME SFA-5.20 E71T-1 H4 / E71T-1M H4

Applications and properties:The higher filling degree of FLUXOFIL 14 HD results in higher current carrying capacity and deposition rate. Weldingspeed is thereby essentially increased which leads to a saving of time and reduction of costs. It can be used in allpositions with only one setting of welding parameters (24 volts, wire feed = 9m/min, wire dia. 1,2 mm). FLUXOFIL 14HD is employed in manual welding, as well as in fully mechanized welding by means of the orbital welding unit CI-TOTRACK OSG-O1 or the vertical welding set CITOTRACK VSG-O1. It is preferably used under mixed shielding gasand is characterized by low spatter loss, good slag removal and finely rippled, pore-free welds without undercuttinginto the base metal.Materials:

EN-Designation DIN-Designation EN-Designation DIN-/AWS-DesignationS185 St 33 S235 to S355 St 37.0 to St 52.0S235 to S355 St 37-2 to St 52-3 P235 to P35 5 St 37.4 to St 52.4P235 St 35.8 P265 St 45.8L210 to L415 StE 210.7 to StE 415.7 L360 to L 485 StE 360.7 T M-StE 480.7 TML290, L320 StE 290.7TM, StE 320.7TM P235GH, P265GH HI, HII X42 to X65 P295GH 17 Mn 4 StE 255 S(P)275 to S(P)460 StE 285to StE 460 A, B, D, E AH 32 to EH 36 GS-38 GP240R GS-45

Please observe admissible operating temperature for welding consumable and base material.

Qualification tests: TVApprovals: DB, ABS, DNV, GL, LRSIndications as to approvals, see appendix.

Analysis of all-weld metal (typical values in %):C Si Mn

0,05 0,55 1,2

Mechanical properties of all-weld metal (single values are typical values):Impact energy ISO-V [Joule]

Heat treatment Yield strength[N/mm]Tensile strength

[N/mm]Elongation

A5 [%] -20 C AW >460 550 650 >22 >80

AW = as-weldedChemical composition and mechanical properties apply to the use of shielding gas:

DIN EN 439 - M21 (82 Vol. % Ar + 18 Vol. % CO2)Shielding gas as to DIN EN 439: M21 (ARCAL 21), C1 (carbon dioxide)Consumption: 12 15 l/min for 1,6 mmWelding parameters and deposition rate, see: B 131

Form of delivery:Wire cage reel K300 (16 kg)

Wire diameters [mm] 1,0 1,2 1,6Further forms of delivery on request.

Type of current/Polarity/Welding positions:

Rutile tubular cored electrode for MAG-welding, with fast-freezing slag

FLUXOFIL 14 HD


28/38

28

Fluxofil 14 HD - advantages -

Easy handling in all welding position

- High deposition rate in all welding position

- To use in fully mechanized welding processes

- One side welding on ceramic backing

- Less spatter during the welding process- Easy slag removal

- Very good penetration

- Seamless wire

- Less fume and less hydrogen content

- High efficiency


29/38

29

Application Metal cored wire Fluxofil M8


30/38

30

Metal cored wire Fluxofil M8 - advantages -

- Easy handling in H and F welding position

- Seamless wire

- Less fume and less hydrogen content

- High deposition rate in H and F welding position

- To use in fully mechanized welding processes

- One side welding on ceramic backing

- Less spatter during the welding process

- Very good penetration

- High efficiency

- Very good ristriking


31/38

31



32/38

32



33/38

33



34/38

34



35/38

35



36/38

36

Variable applications with flux cored wires


37/38

37



38/38

38


Documents

Flux Cored Wire