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    Saw Wire& Flux......

    Uploaded by

    Arul Chinnapillai
    The document discusses submerged arc welding consumables including filler wires, electrode sizes and tolerances, functions of copper coating and flux, flux constituents, welding characteristics, types of fluxes, AWS classifications, impact test requirements, and diffusible hydrogen requirements. It also provides examples of flux and wire combinations and summarizes the characteristics of common flux types used in submerged arc welding.

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    © All Rights Reserved
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    Saw Wire& Flux......

    Uploaded by

    Arul Chinnapillai
    95 views41 pages
    The document discusses submerged arc welding consumables including filler wires, electrode sizes and tolerances, functions of copper coating and flux, flux constituents, welding characteristics, types of fluxes, AWS classifications, impact test requirements, and diffusible hydrogen requirements. It also provides examples of flux and wire combinations and summarizes the characteristics of common flux types used in submerged arc welding.

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    Saw Wire & Flux

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    The document discusses submerged arc welding consumables including filler wires, electrode sizes and tolerances, functions of copper coating and flux, flux constituents, welding characteristics, types of fluxes, AWS classifications, impact test requirements, and diffusible hydrogen requirements. It also provides examples of flux and wire combinations and summarizes the characteristics of common flux types used in submerged arc welding.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    95 views41 pages

    Saw Wire& Flux......

    Uploaded by

    Arul Chinnapillai
    The document discusses submerged arc welding consumables including filler wires, electrode sizes and tolerances, functions of copper coating and flux, flux constituents, welding characteristics, types of fluxes, AWS classifications, impact test requirements, and diffusible hydrogen requirements. It also provides examples of flux and wire combinations and summarizes the characteristics of common flux types used in submerged arc welding.

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    © All Rights Reserved
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    SUBMERGED ARC

    WELDING CONSUMABLES
    FILLER WIRE
    •IRECT CURRENT ELECTRODE POSITIVE
    • SOLID WIRE
    • METAL CORED WIRES
    • STRIPS
    • METAL POWDER
    CURRENT RANGE FOR
    SOLID WIRES
    Wire diameter Current range
    (mm) (amps)
    1.6 150 - 300
    2.0 200 - 400
    2.4 250 - 500
    3.15 300 - 600
    4.0 450 - 750
    5.0 600 - 1000
    6.3 700 - 1200
    ELECTRODE SIZES AND
    TOLERANCES

    TOLERANCE (mm)

    DIAMETER SOLID (E) COMPOSITE


    (EC), mm

    1.6 TO 2.8 + - 0.04 + 0.04, - 0.05


    ______________________________________________

    3 TO 6.4 + - 0.06 + 0.06, - 0.08


    ______________________________________________
    FUNCTIONS OF
    COPPER COATING

    • TO PREVENT RUSTING OF WIRE

    • ENABLE EASY CURRENT TRANSFER

    • REUCE FRICTION IN WIRE GUIDES


    FLUX CONSTITUENTS
    (TYPICAL)
    CaO TiO2
    MnO ZrO2
    K2O Al2O3
    NaO FeO
    SiO2 CaF2
    FUNCTIONS OF FLUX

    • PROVIDE SHIELDING

    • CONTROLWELDMETALCHEMISTRY

    • SCAVENGING OF IMPURITIES
    SCAVENGING ACTION
    SULPHUR

    [FeS]+(Mn) (MnS)+[Fe]

    [FeS]+(Mno) (MnS)+[FeO]

    [FeS,MnS]+(CaO) [FeO,MnO]+(CaS)
    SCAVENGING ACTION
    PHOSPHOROUS

    [2P]+(5FeO) (P2O5)+[5Fe]

    (P2O5)+(4CaO) (Ca4P2O3)
    FUNCTIONS OF FLUX

    • ARC STABILITY
    • GOOD MECHANICAL
    PROPERTIES

    • SELF PEELING SLAG


    FUNCTIONS OF SLAG

    • REDUCE COOLING RATE


    • PROVIDESECONDARY SHIELDING
    • CONTROL BEAD GEOMETRY
    • CRUSHED SLAG AS A SHIELDING
    MEDIUM (SELECTED APPLICATIONS)
    PROPERTIES OF FLUXES

    PROPERTIES AT R T

    • BULK DENSITY

    • PARTICLE SIZE

    • FLOWABILITY
    PROPERTIES OF FLUXES
    PROPERTIES AT ELEVATED
    TEMPERATURE
    • MELTING RANGE
    • SURFACE TENSION
    • VISCOSITY
    • ELECTRICAL CONDUCTIVITY
    PROPERTIES ON COOLING
    • THERMAL CONTRACTION
    WELDING CHARACTERISTICS

    ARC STABILITY

    ABILITY TO GIVE ACCEPTABLE


    WELD BEAD SHAPE

    WELDING SPEED RANGE

    SLAG DETACHABILITY
    WELDING CHARACTERISTICS

    • MOISTURE CONTENT AND


    HIGROSCOPICITY

    • METAL TRANSFER

    • EFFECT ON ELEMENT TRANSFER

    • FLUX CONSUMPTION
    TYPES OF FLUXES

    • FUSED

    • BONDED

    • AGGLOMERATED
    CHARACTERISTICS
    OF FLUXES
    FUSED
    • Crystalline
    • Homogenous
    • Non hygroscopic
    • Sharp edges
    CHARACTERISTICS
    OF FLUXES
    AGGLOMERATED
    • Mixture
    • Non Homogenous
    • Hygroscopic
    • Globules
    FLUX RECYCLING

    • FUSED
    UNLIMITED
    • AGGLOMERATED
    LIMITED
    FLUX DRYING

    • FUSED
    150 C For1 Hr
    • AGGLOMERATED
    300 C For 2 Hr
    CLASSIFICATION OF
    FLUXES

    • ACIDIC
    • NEUTRAL
    • BASIC
    BASICITY INDEX
    It is weight coefficient describing the different affinities of
    various basic oxides to SiO2.

    TYPICAL EXPRESSION FOR BASICITY INDEX


    %CaO+%CaF2 + %MgO+%K2O

    +%Na2O+1/2(%MnO+%FeO)
    B1 = --------------------------------------------------

    %SiO2 + ½(%Al2O3 +%TiO2+ %ZrO2)


    FLUX CLASSIFICATION

    BASICITY CLASSIFICATION
    INDEX

    <1 Acidic flux

    1 to 1.5 Neutral flux

    > 1.5 Basic flux


    AWS CLASSIFICATION
    CARBON STEEL
    AWS 5.17

    ALLOY STEEL
    AWS 5.23
    AWS CLASIFICATION
    Flux - Wire combination
    Alloy steel

    FS XX X X– EC XXX X–XX XH X
    F – Flux E – Electrode H - Hydrogen

    S – Slag C – Cored wire X – H content

    X – Min Ten Strength X – Weld metal composition

    X – Heat treatment X – Test temperature

    X – N Nuclear / R Reduced residual requirements


    X – Wire composition
    AWS CLASIFICATION
    Flux - Wire combination
    Carbon steel

    FS XXX – ECXXX–HX
    F – Flux E – Electrode H - Hydrogen

    S – Slag C – Cored wire X – H content

    X – Min Ten Strength X – Mn Content

    X – Heat treatment X – Carbon content

    X – Test temperature X – Condition of core wire


    IMPACT TEST REQUIREMENTS
    Digit Maximum Test Minimum Average
    Temperature oC Energy Level

    0 0
    2 -20 27 Joules
    3 -30
    4 -40
    5 -50
    6 -60
    Z No Impact requirements
    DIFFUSIBLE HYDROGEN
    REQUIREMENTS
    Diffusible Hydrogen Average Diffusible
    Designator Hydrogen
    (maximum ml/100gr)

    H16 16.0
    H8 8.0
    H4 4.0
    H2 2.0
    EXAMPLE

    CARBON STEEL

    F 48 A2 – E M12K
    EXAMPLE

    ALLOY STEEL

    F 62 P2 – E B3N – B3N

    F 70 A2 – E B2 R – B2 R
    IIW CLASSIFICATION OF
    FLUXES
    _________________________________________________________
    SYMBOL Principal Compounds Common Name

    CS CaO+MgO+SiO2>50% Calcium silicate


    MS MnO+SiO2>50% Manganese Silicate
    AR Al2O3+TiO2>45% Aluminate Rutile
    AB Al2O3+CaO+MgO>45% Aluminate Basic

    BF CaO+MgO+MnO+CaF2 Basic fluoride


    >50%
    CHARACERSTICS OF FLUXES

    Type Calcium Silicate

    Description Strongly acid,


    Bonded type

    Characteristics Tolerates high current,


    Easy slag removal

    Disadvantage High oxygen pick up


    CHARACERSTICS OF FLUXES
    Type Manganese Silicate

    Description Weakly acid,


    Bonded type

    Characteristics Use for fast weld,


    travel speed

    Disadvantage Requires relatively


    clean steel
    CHARACERSTICS OF FLUXES
    Type Aluminate rutile
    Description Neutral aluminate
    basic, Bonded type
    Characteristics Can be used on steel
    with rust, or mill
    scale if formulated
    active
    Disadvantage Use only with
    DC power
    CHARACERSTICS OF FLUXES

    Type Calcium Silicate Neutral

    Description Neutral, Fused type

    Characteristics Helps gain good weld


    metal toughness

    Disadvantage Slag removal more


    difficult
    CHARACERSTICS OF FLUXES

    Type Basic fluoride

    Description Agglomerated type

    Characteristics Helps to gain good


    weld metal toughness

    Disadvantage Slag removal more


    difficult

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