Newsletter - Metrode Welding Consumables: Home … Lincoln Electric® Company Newsletter Summer 2010 In this issue: - Superoot 316L application story Power generation MT304H Essen

A Lincoln Electric® Company NewsletterSummer 2010

In this issue: -

Superoot 316L application story

Power generation MT304H

Essen worldwide

Storage & Handling

Submerged arc flux

New packaging

USA symposium’s

New people

New RCC-M range

Exhibition News

Sports News

Local MP visits

A Lincoln Electric® Company

Burj Khalifa (Arabic:_ “Khalifa Tower”), formerlyknown as Burj Dubai prior to its inauguration, is askyscraper in Dubai, United Arab Emirates, and thetallest man-made structure ever built, at 828 m(2,717 ft) Construction began on 21 September2004, with the exterior of the structure completedon 1 October 2009. The building officially opened on4 January 2010 and just over a week later somespectacular storms gave the buildings lightingarrestor a pretty stern test!

The building has a central water pipeline (supplyingdrinking water for various purposes) that runs thecomplete length of the tower which ends up as thelightning arrestor. Originally, this pipeline was fullyflanged & bolted without realizing the fact that tall

structures are designedto be flexible in order towithstand earthquakes& tremors. Burj Khalifahas been estimated tosway by about 11⁄2 mtrs(the top floors) in alldirections due to theambient atmosphere atthat height. This wouldeventually, withoutdoubt, rip off the boltsand tear the pipeline,which would havecaused major damage &property loss.

It was subsequently decided to replace the flangingby welding & this is where Metrode Superoot camein. We were approached among a few other brandsto offer a safe & reliable solution. As a prerequisitegoverned by SAMSUNG (the main EPC contractor),the primary concern was to keep up to a minimaltimescale & hence, the basic idea was to avoidcarrying purging gas cylinders up in the tower.Superoot 316L is designed specifically forsituations where it is impractical to apply back-purge for the TIG root run, or to gain the economicbenefit of eliminating back-purge. We suppliedsamples which proved to be ideal for the task and atotal of 200kgs was eventually used to complete theproject.

The wire was supplied via our distributor TechnicalParts who are based in Dubai.

Superoot 316L | AWS A5.22 R316LT1-5Specifications | BS EN ISO 17633-B TS316L-RI1

2 Metrode Products Limited - 2010 Newsletter

Power Generation - MT304H

Metrode Superoot Flux Cored TIG -

A tall story

Metrode continues to build on thisalready well established position in thepower generation market by introducinga new solid wire, Metrode MT304H, forwelding Super 304H tube. The super304H alloy is designed for use as asuperheater and reheater boiler tubing inthe latest generation of Ultra SuperCritical (USC) cool fired power plant. Thealloy already appears in European(EN10216-5: X10CrNiCuNb 18 9 3) andUSA (ASTM A213: S30432) specifications

but there is not yet any specifications forthe welding wire.

The alloy has Cu, Nb and N additions toimprove creep performance at servicetemperatures of approximately 600°C,although the relevant ASME code casespecifies allowable stresses up to 815°C.The wire is currently available at 2.4 mmdiameter manual TIG wire and willshortly be available as small diameterwire for orbital tube welding.


Last year Metrode took part in the ‘Olympic Games’of the welding industry at Essen in Germany and forthe first time it was a team event! We joined LincolnElectric and were part of their stand. The new ‘team’performed well and we both reported an excellentshow with plenty of new leads to follow up after theevent.

In February this year we tookpart in our first Essen India.

Raghav Srivastava representedus at the show and reported thatsome useful new leads weregained and existing customers

also visited to discuss current business.

And to complete the set we exhibited for the 11thtime at Beijing Essen Welding & Cutting Fair in May.Together with its mother show “Schweissen &Schneiden” in Essen, Germany it now ranks in the toptwo professional welding and cutting shows aroundthe world.

Metrode Products Limited - 2010 Newsletter 3

Essen - Germany, India & China!


To ensure that welding consumables aremaintained in an optimum condition it is importantthat they are stored and handled correctly. Thisdocument summarises the requirements for thedifferent consumables and processes.

General storage recommendations for allconsumable are >18°C and <60% relativehumidity.

MMA ElectrodesAll Metrode MMA electrodes are supplied inhermetically sealed metal tins. The metal tinshave a ring pull and provide an excellent andefficient form of packaging for MMA electrodes.Packaging waste is minimal and the steel tin caneasily be recycled with normal steel scrap.

The tins are hermetically sealed and meet therequirements of AWS A5.5 paragraph 22.2 forhermetically sealed containers. If unopened, andappropriately stored, this packaging will maintainthe electrodes in the as-packed condition for anindefinite period of time.

Once opened the tins can be closed using theplastic lid supplied and should be stored at >18°Cand <60% relative humidity.

Low Alloy Low HydrogenMMA electrodes can be used direct from the tinand for most applications will provide satisfactoryperformance. For critical applications, and forelectrodes that have been exposed, the electrodesshould be redried as follows: 250-300°C for 1-2hours to ensure hydrogen less than 10ml/100g,and at 300-350°C to ensure hydrogen less than5ml/100g. A maximum of three redrying cyclesand/or ten hours total time at temperature isrecommended to avoid permanent flux damage.Temperatures during redrying should not exceed420°C.

Stainless SteelElectrodes can be used directly from freshlyopened tins, without need for redrying treatment.Storage of electrodes on the shopfloor, duringusage, should be in the tins or a suitablecontainer, eg heated quiver (~50°C). Electrodesare capable of being stored in this manner forperiods substantially longer than a typical eighthour working shift, without risk of flux coatingmoisture regain to a level where there is a risk ofweld porosity.

At the end of a working shift, tins should beresealed using the plastic lid and returned to

storage under recommended conditions of 18°Cminimum ambient temperature and 60% relativehumidity.

Excessive exposure of electrodes to humidconditions, will promote moisture pick-up and riskof weld porosity. In situations where this issuspected, or weld porosity is encountered,electrodes can be restored to the as-packedcondition by redrying for 1-2 hours at 200-300°C.

A maximum of three redrying cycles and/or tenhours total time at temperature is recommendedto avoid permanent flux damage. Temperaturesduring redrying should not exceed 400°C.

SOLID WIRESSolid TIG wires are supplied in 2.5kg or 5kg tubes,and MIG wires are supplied on 12.5kg or 15kgspools (either plastic or metal baskets). The solidwires that may be susceptible to rusting (mildsteel and low alloy) are copper coated. Underappropriate storage conditions solid wires do notpresent any handling difficulties.

MIG wires supplied on 15kg wire baskets need tobe properly handled because if they are lifted byone rim it can bend the basket and lead to feedingproblems.

FLUX CORED WIRESFlux cored wires need to be stored correctly toprevent moisture pick-up, which may lead toporosity. As supplied the wires are adequatelyprotected for moisture pick-up to not present aproblem, but once opened part-used spools needto be correctly stored. It is recommended thatspools are removed from machines overnight andput in a controlled store. If a part spool is to bestored for any period of time it should beadequately protected (in a plastic bag withdesiccant) and held in a controlled store.

Care is required when handling mild steel and lowalloy wires because handling of the wire surfacecan result in rust marks if the wire is then storedfor a prolonged period. If the wire is to be usedimmediately handling the wire surface presents noproblems but if a part spool is to be stored for anyperiod of time avoid touching the wire surfacewith bare hands.

SUBMERGED ARC FLUXSubmerged arc fluxes are supplied in metaldrums, but for most applications it isrecommended that the flux should be dried priorto use.


Storage & Handling - AN UPDATE


LA436 FluxThis is a new flux that has recently been introducedinto the range. It is intended for general purpose usewith 1CrMo, 2CrMo and 1NiMo low alloy wires wherethere is no requirement for low temperature impactproperties.

LA491 FluxThis flux has been used extensively for welding P91creep resisting steel using 9CrMoV-N wire. This fluxis still available for customers who have been usingthis flux in conjunction with the 9CrMoV-N wire.

The flux also has a secondary use which is forwelding with the ER308LCF and ER316LCF wires forLNG projects and other applications requiringcryogenic properties.

LA492 FluxThis new flux has been introduced for welding P91and P92 steels using the 9CrMoV-N and 9CrWV wiresrespectively. LA492 provides similar mechanical

properties to the LA491 flux but has better slagrelease and is the flux we would offer for newcustomers and projects wishing to weld P91 and P92steel.

LA424 FluxThis is a specialist flux for high speed fillet welding,mainly with CrMo alloys.

SSB FluxThis is a long standing Metrode flux and one that isstill recommended for use with duplex, ER329N, andsuperduplex, Zeron 100X, wires. It can also be usedfor a wide range of other stainless steel wiresalthough there is now an alternative flux availablewhich we would recommend for applicationsinvolving the standard 300 series stainless steelwires, see Metrode SS300 flux.

SS300 FluxThis is a new flux that has been introduced for usewith the standard 300 series stainless steel wires:


Metrode’s Submerged Arc Welding FluxesThere have been a number ofchanges to the submerged arcwelding fluxes that are currentlyavailable from Metrode.

The following is a list of thecurrently available fluxes and theirmain applications. There are alsoindividual data sheets on all of thefluxes which provide more detailedinformation about the fluxes but ifyou wish to discuss specificapplications please contact theTechnical Department.

Examples of applicationsinvolving SSB flux.


308S92, 316S92 and 309S92. This is the flux wewould now recommend for use with all of thestandard stainless steel wires.

The flux also has other potential applicationsincluding duplex, superduplex and possibly nickelbase wires. These uses will be investigated further inthe future.

NiCr FluxThis is the standard flux we recommend for use withnickel base wires for joining applications. It is veryhigh basicity, producing excellent metallurgicalintegrity but this does mean that it does not havesuch good slag release as some other fluxes,particularly when welding with the 62-50 wire. Thelimitation in slag release is compensated for by thehigh integrity of the deposit and the minimal risk of

hot cracking, even in highlyrestrained joints.

NiCu FluxThis is a flux that only haslimited use because it is onlyused with the 65NiCu wire.

Cladding with 62-50 wire and L2N flux.

L2N FluxL2N is the only fused flux in Metrode’s range, whichhas advantages with respect to the resistance tomoisture pick-up. The flux can be used with low alloyand stainless steel wires, and also with nickel basewires for cladding applications.


New Decade - new packagingMetrode will be introducing some exciting newpackaging over the next few months. Our TIG wireswill gradually start to be delivered in new Reflex Blue,rectangular shaped section, two piece tubes. Thepack weights will not change from our popular 2.5and 5.0 kg tubes.

This will be a phased introduction over the comingmonths and wires will continue to be supplied in black.

We also have a new innercarton for our limited rangeof low alloy MMA electrodessupplied in cardboard packs.


Metrode in the guise of John Stoll, recently teamedup with Bill Newell of Euroweld to hold 3 educationalsymposium’s on a range of subjects. They took placeat Beaumont, Corpus Christi and Houston at the endof February.

• The Challenges of Welding Chrome-Molys...Why Technique & Workmanship Matter!

• Altering Welding Consumables to MeetSpecialized Needs!

• Dispelling Myths Associated with CurrentWelding & Consumable Technology!

• Welding P91 - An Update!

A total of 91 of the top QA/QC welding people alongthe Gulf Coast attended the events and they were alldecision makers and WPS qualifiers and writers.

All three events were universally well received, thisis a typical comment: -

“Just wanted to let you know I thought the classsubject and presentation was excellent. Theseminar covered actual welding applications we dealwith from day to day. I have a couple of youngengineers that need to attend this course or maybeattend the next class. Thanks for the invite.”


The American Way

New People

The customer care team has been joinedby Ritu Srivastava and we would like towelcome her to the Metrode team.

Sports NewsWe have been sponsoring the under 8 football teamat Abbey Rangers, based in Chertsey, this season andhaving the logo on the shirts seems to have worked- they won two end of season tournaments!


Stainless steel, RCC-M tested and certified “nucleargrade” MMA and TIG welding consumables deliveredfrom stock

Available Upon Request

SAW 308S92(N) S 19 9 L S 2940

SAW 316S92(N) S 19 12 3 L S 2945

SAW 309S92(N) S 23 12 L S 2950

Flux SS300(N) S A AF 2 64 AC

Table 1 Overview of available RCC-M consumables (*No relevantRCC-M data sheet).

Stick electrodes.Ultramet stick electrodes have all the benefits of anadvanced rutile flux design. This includes optimumversatility; downhand welding with high cosmetic finishand weld metal integrity; and all-positional weldingwith the 2.5/3.2mm electrodes including fixed pipework. Recovery is about 110% with respect to corewire, 65% with respect to whole electrode.

All Ultramet electrodes have a moisture resistantcoating ensuring porosity-free welds, even under lessfavourable (moisture) exposure conditions. As perMetrode’s standard, all electrodes have the batchnumber imprinted on the coating for optimumtraceability.

Solid wiresAll 3XXS92(N) wires, for both TIG - and SA Weldinghave low carbon and low silicon content. TIG wiresare cleaned to prevent weld pool contamination.

All TIG wires have the batch number stamped on bothends of the TIG wire providing optimum traceability,even when the welder cuts the wire in half.

Figure 1 Sizewell I Nuclear power plant UK.


Metrode Products Ltd Launches RCC-M Welding Consumable Programme

Founded in 1963, Metrode has always been atthe forefront when it comes to manufacturingand supplying high quality weldingconsumables, particularly in those industriesthat require the highest integrity from theirwelding consumables.

The nuclear, (French) RCC-M code drivenindustry, is one of those industries. In order tosatisfy requirements of those fabricators activein the nuclear welding industry, MetrodeProducts launches a new RCC-M consumableprogram.

Not all fabrication work can be scheduled manymonths in advance, allowing for production andtesting of both base materials and weldingconsumables. This is particularly true formaintenance and repair work and general fabricationwork that need quick turn-around time.

That is why Metrode is now launching a new programto deliver, from stock, fully tested and certifiedstainless welding consumables according to RCC-MAdd 2007 Section IV.

Metrode RCC-M Consumable RangeThe consumable range will include historically provenstainless steel products. An overview of the availableproducts is shown in table 1.

All products will be supplied with the requiredproduct traceability and certification. Upon requestspecific RCC-M datasheets can be made available.

Trade name EN Classification RCC-M Data Sheet

Ultramet 308L(N) E 19 9 L R 32 S 2920

TIG 308S92(N) W 19 9 L S 2910

Ultramet 316L(N) E 19 12 3 L R 32 S 2925

TIG 316S92(N) W 19 12 3 L S 2915

Ultramet 309L(N) E 23 12 L R 32 S 2930

TIG 309S92(N) W 23 12 L *


SA welding fluxFor Submerged Arc Welding applications Metroderecommends its agglomerated flux SS300-N. ThisAluminate Fluoride type flux with a basicity index(Boniszewski) of 1.6 provides the right balancebetween mechanical properties and weldability.SS300-N will provide a self-releasing slag and issuitable for DC and AC. Under normal transportationand storage conditions the flux can be used from thetin without the need for redrying.

CertificationMetrode’s Quality System conforms to therequirements imposed by RCC-M. Furthermore, allrequired testing on the consumables has beenperformed in order to satisfy the RCC-M requirements.

Every batch of Metrode’s RCC-M consumables issupplied with a 3.1 certificate with both actual chemicaland mechanical properties meeting the specificrequirements stipulated in RCC-M Add 2007 Section IV.In figure 2 a copy of a certificate is shown.

Figure 2 Certificate of Ultramet 316L(N)

By taking all necessary steps to fulfill the RCC-M coderequirements Metrode can guarantee that itsconsumables meet the full scope of RCC-M.

PackagingMetrode has introduced specific packaging labels forits nuclear certified welding consumable range.Bright orange labels will be exclusively used fornuclear certified material which should allow for easyidentification and avoids mixing with standardconsumables at every stage of the supply chain.

Figure 3 Metrode RCC-M labels

MMA electrodes are supplied in Metrode traditionalmetal tins with ring-pull opening. The tins arehermetically sealed and meet the definition forhermetically sealed containers given in AWS A5.5. Ifunopened, and appropriately stored, this packagingwill maintain the electrodes in the as-packedcondition for an indefinite period of time.

Electrodes can be used directly from the tin withoutthe need for redrying. Once opened, the tins can beclosed using the plastic lid supplied and should bestored at >18°C and <60% relative humidity.Redrying requirements are given on the data sheetsfor individual electrodes.

TIG wires are, as mentioned earlier, individuallymarked with grade and batch number on both endsand conveniently packed in a rugged 2.5kg PE tube.This provides sufficient product protection for bothin-shop and on-site applications.

Submerged Arc Welding flux is supplied in 25 kgrobust metal drums and can, under normalconditions, be used direct from an unopened drum.Submerged Arc wire is supplied on industry standard25kg “stein baskets”.


Figure 4a & 4bSellafieldNuclearReprocessingPlank - UK


30 May - 2 June 2010, Barcelona, SpainENC 2010 was aunique networkingevent for scientists,

nuclear industry representatives and policy makers,who can consider and discuss ideas and innovationsthat will drive the technological developments of thefuture.

Following on froma series of sevensuccessful duplexc o n f e r e n c e sduring the pasttwenty years, the

next Duplex Stainless Steel Conference will be heldat the same venue in Beaune, France, where thelegendary and most famous Duplex Conference ever,was held in 1991. Again the content will be solelydedicated to duplex stainless steels with a strongemphasis on new developments such as lean andhyper duplex stainless steels. Presentations will besourced on the comparison of properties betweenduplex and other alloys. Visitors to this upcoming

conference will therefore benefit from the up-to-date exchange of information on long-termexperiences with duplex stainless steels that havetaken place since the previous Beaune Conferencein 1991. The main topic will be cost saving and life-cycle aspects of nitrogen-containing duplexstainless steels in a variety of applications.

Metrode will be presenting an update of the paperthat they presented at the first Beaune Conference,focused on ‘Corrosion Testingof Duplex & Superduplex WeldMetal’

June 16-17th

The Atlantic Canada PetroleumShow put the spotlight the technology, the people, andthe projects of the East Coast region. Over 100exhibiting companies and 2,000 attendees cametogether in the beautiful setting of St. John’sNewfoundland to source new technologies, discovernew business opportunities, and explore the latestinnovations.


Typical mechanical propertiesProduct Rp0,2 Rm A4 CVN

[MPa] [MPa] [%] [J+20°C]UM308L(N) 465 600 47 65

(+350°C) 305 410 30 —

TIG 308S92(N) 465 605 48 160

(+350°C) 290 400 30 —

UM316L(N) 500 600 38 65

(+350°C) 340 470 33 —

(+360°C) 340 470 30 —

TIG 316S92(N) 465 605 48 110

(+350°C) 280 410 30 —

(+360°C) 280 410 30 —

UM309L(N) 495 595 41 —

TIG 309S92(N) 450 590 43 —

Typical chemical compositionProduct C Mn Si S P Cr Ni Mo Cu Co N FN*Ultramet 308L(N) <0.025 0.7 0.6 0.01 0.02 19.5 9.5 0.1 <0.1 0.04 0.08 8

TIG 308S92(N) 0.01 1.7 0.4 0.01 0.015 20 10 0.1 0.15 0.04 0.04 8

Ultramet 316L(N) <0.025 0.7 0.6 0.01 0.02 19.5 12.5 2.6 <0.1 0.04 0.1 8

TIG 316S92(N) 0.01 1.7 0.4 0.01 0.015 19 12.5 2.6 0.15 0.04 0.04 10

Ultramet 309L(N) 0.025 0.8 0.6 0.01 0.02 23.5 12.5 0.2 <0.1 0.04 0.1 16

TIG 309S92(N) 0.01 1.7 0.5 0.01 0.015 23.5 13 0.1 0.1 0.04 0.04 12

*Ferrite calculated according to DeLong diagram.

Metrode to go - exhibition programme


Coalition is trying to protectBritish jobs, says Tory MP.Philip Hammond Conservative MP for Runnymede andWeybridge, has said it is “more important than ever”to support local business.

The MP, currently Transport Secretary in theConservative Liberal Democrat coalition government,was speaking at a meeting at Metrode Products, inHanworth Lane, Chertsey, on Friday. He was visitingthe welding consumerables manufacturing company todiscuss the impact of overseas contracts on Britishindustry. During his meeting, he met businessmanagers and had a tour of the premises.

He said: “I like to visit a local business each week as Itour my consistuency and I’ve been hoping to comehere since the election. Supporting local business isimportant. We are trying to protect jobs and aid theeconomy while we get through this budget deficit.”

The company has been in Chertsey for the past 37years and is part of US company, Lincoln Electrical.

Mr Hammond was greeted by general manager PeterFrost and Runnymede borough valuer Ian Gifford. MrFrost said: “I wrote to Mr Hammond at the turn of theyear to discuss some contract that, if awarded, wewere concerned could have used overseasemployment.

“We wanted British workers to be employed andgetting Mr Hammond here is a great opportunity to tellhim about manufacturing in Britain.

“It is more important for the future of manufacturingin this country that we not only harness theoreticalbut also practical skills.

For more information on Metrode Products, visitwww.metrode.com.


VIP GuestsArticle from the Surrey Herald

Keith Palmer shows Philip Hammond our new FCW Plant.


Metrode Products LimitedHanworth Lane, Chertsey, Surrey, KT16 9LL UK

www.metrode.comEmail: [email protected]: [email protected]

Documents

Newsletter - Metrode Welding Consumables: Home … Lincoln Electric® Company Newsletter Summer 2010 In this issue: - Superoot 316L application story Power generation MT304H Essen