Selection of Welding Consumables
Selection of Welding Consumables
Selection of Welding Consumables
1.0 INTRODUCTION:
The term Welding Consumables refers to the filler metals employed in different forms in
various welding processes. The selection of most appropriate welding consumables is of
paramount importance to achieve good weldments most economically and selection involves
study of metallurgy of base material, service conditions as also ready availability of
consumables.
Globalization and rapid Industrialization has brought about major changes in design and
selection of base materials for fabrication. The emphasis is mainly in cost reduction by using
improved base materials. The advancement in welding technology has made it possible to
meet this challenge by developing new consumables to meet specific requirements.
Advances made by consumable manufacturer in terms of product and process are needed to
be understood by fabricator to achieve quality-welded product at minimum cost.
2.0 CRITERIA FOR SELECTION:
For a given specific application, the filler metal selection with compatible process is to be
done taking following factors into consideration.
2.1. METALLURGICAL
Base Materials
Mechanical Properties
Chemical composition
Corrosion requirements
Physical properties
Soundness & Structural Stability
Heat treatment
2.2. MECHANICAL
Thickness of Material
Dimension & No. of components
2.3. PROCESS
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2.1.1 BASE MATERIAL:
The single important factor determining the selection of filler metal and process is, base
material specification being joined. The base materials are classified as per ASTM
specification.
In general the base metals are broadly classified as Carbon Steel, LAS, SS and High Alloy
Steels. In addition there are other steels for low temperature application, Q & T Steels etc.,
for specific application.
Even though consumable selection steps are same for various materials, in this presentation
consumable selection for CS & SS are highlighted.
2.1.2 MECHNICAL PROPERTIES:
Mechanical property of weld metal basically covers the aspect of
(i)
Soundness
(ii)
Strength
(iii)
Toughness
The welding consumable should be so designed, so as to be compatible metallurgically with
base material and produce sound weld to give radiographic quality deposits.
As the weld metal has a cast structure as compared to the rolled structure of the base metal
and weld zone is likely to contain defects like porosity and slag, the weld metal tensile
strength is required to be higher than base material or atleast equal to it.
The Weld metal should also have adequate toughness at given design temperature taking in
to account fabrication practices.
2.1.3CHEMICAL COMPOSITION:
The Weld Metal chemistry in general matches the composition of base metal for similar
metal joining. In case of dissimilar base metals are being welded, the selection care should
be taken to see that diluted weld metal will not result information of brittle inter metallic of
weld metal chemistry is based on diluted weld metal compatibility.
2.1.4 CORROSION PROPERTIES:
The Weld Metal corrosion properties are to be equal or superior to that of base metal. This
is to avoid preferential attacks on the weld joint.
2.1.5 PHYSICAL PROPERTIES:
The Physical properties of weld metal should be compatible with that of the base metal.
These include properties like the thermal expansion co-efficient, thermal and electrical
conductivities, magnetic permeability etc.
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2.1.6 SOUNDNESS AND STRUCTURAL STABILITY:
The Weld Metal should be capable of resisting some amount of dilution of the base metal
without forming a crack sensitive weld metal and the weld micro structure should be stable
under the expected service conditions.
2.1.7 HEAT TREATMENT:
The Consumables selected for joining should be capable of giving the desired test results in
as welded condition as well as heat-treated condition. When heat treatment is not specified
in design/code, it is very essential to identify various heat-treatment stages during
fabrication and ensure that consumable selected does meet these requirements. The general
heat-treatment cycles encountered during fabrication are normalizing and stress relieving.
2.2.1 THICKNESS OF MATERIAL:
For selection of proper consumable and process, thickness of material plays a vital role.
The selection of semi-automatic and automatic process comes into picture only if base
metal thickness normally exceeds 10mm and joint configurations are adaptable for
automation.
2.2.2 DIMENSION & NO. OF COMPONENTS:
While thickness in principle decide the selection of process, the dimension of job and
number of components to be welded also play an important role. In case of heavy subassembles even though length of the joint may be too small for automation, if the operation
is repetitive in nature, the same can be considered for automation. The automation not only
reduces the cost but also improves the quality of jobs.
2.3.1 AVAILABLE FORMS OF CONSUMABLES:
As you will all agree, this is single most important factor for selection of process. Once the
technical details are worked out and suitable consumable specifications are identified, it is
essential to find out whether consumables are readily available for SMAW, GMAW, FCAW
&/or SAW before process selection could be started. At present, thanks to technological
development, in general for all common materials SMAW, SAW & FCAW consumables are
readily available.
2.3.2 ADAPTABILTY FOR THE JOB:
Before finalization of the type of consumable to be used, it is essential to study whether the
job is being done in the work shop, site or sub-contractors premises, so as to ascertain
availability of suitable equipment and also take into consideration environmental condition.
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3.0 CONSUMABLE SELECTION:
The Welding consumables for welding of CS, LAS & SS are selected based on guidelines
provided in ASME II C. The relevant specification for the same are indicated here below:
SFA 5.1
Carbon Steel Electrodes for Shielded Metal Arc Welding
SFA 5.4
Stainless Steel Electrodes for Shielded Metal Arc Welding
SFA 5.5
Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
SFA 5.9
Bare Stainless Steel Welding Electrodes and Rods
SFA 5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.18 Carbon Steel Electrodes and Rods for Gas Shielding Arc Welding
SFA 5.20 Carbon Steel Electrodes for Flux Cored Arc Welding
SFA 5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux
Cored Rods for Gas Tungsten Arc Welding
SFA 5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.29 Low Alloy Electrodes for Flux Cored Arc Welding
SFA 5.01 Filler Metal Procurement Guidelines
3.1 CONSUMABLE SELECTION FOR CS:
Suggested welding consumables for welding CS are indicated in Table I. For welding of
Carbon the additional metallurgical factors to be taken into consideration are discussed here
below:
(i)
BASE MATERIAL: As per ASTM specification
(ii)
(iii)
(iv)
(v)
(vi)
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(vii)
(ii)
(iii)
(iv)
(v)
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(vi)
(vii)
Disadvantages:
a) Finite length
b) High dependence on welder skill
c) Not amenable to automation
3.3.2
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Disadvantages:
a)
b)
c)
d)
3.3.3
Continuous electrode
Higher current possible
Minimal post-weld cleaning required
Highly amenable to automation
Disadvantages:
a) Equipment more complex and costlier their SMAW
b) Welder skill dependence still high, especially for out-of-position welding
c) Not amenable to customization
3.3.4
Disadvantages:
a)
b)
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As for welding of CS/LAS & SS in most cases as all the process consumable are
readily available, the process limitation is finally dictated by following criteria.
SMAW
SAW
GMAWFCAW
Dep. Rates
Geo. Symmetry
Positional welds
Field joints
Code: (1) Very Good (2) Good (3) Satisfactory (4) Low
3.5 COST OF WELD METAL:
Another important factors to be considered by welding engineer in selecting appropriate
welding consumable is cost of weld deposition.
The cost of weld metal consists of following factors.
i)
ii)
iii)
iv)
v)
vi)
Consumable Cost
Gas cost for GMAW & FCAW
Flux cost for SAW
Power cost
Labour and Overhead
Rework cost
It is well-established fact that cost of labour and overhead will decide the economic level of
operation. Hence reduction in fabrication cost is possible only with increase in productivity.
The fig 1 indicates the productivity of various processes and table IV indicates typical cost
calculation for SMAW & FCAW processes.
From this it is clear that even though unit cost of consumable is high, the deposited weld
metal cost is lower beyond particular labour and over head cost. This factor becomes prime
importance while selecting process for fabrication using available consumables.
4.0 TYPICAL CASE STUDIES
Keeping in view selection of consumables as per guideline given in ASME Sec IIC &
establishing procedure as per Sec IX, some of typical industrial applications where failure
occurred are highlighted here below with analysis of likely cause.
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Petal construction
Hot forming
Spinning
Problem: In petal construction, the weld metal does not undergo any heat-treatment. In case
of hot forming even though normalizing cycle is known, many a times blank made with weld
is not specified in drawing. In case of spinning the fabricator may use intermediate
normalizing for ease of forming.
Hence, in case of Hot forming with welded blank / spinning the weld may undergo
normalizing operation which is not planned.
Analysis: Considering C.S of 515 Gr 70 as base material & E 7018 or E 71T-1 as welding
consumable, the UTS drop of 50-70 N/mm2 is common with normalizing operation. Hence,
the UTS of weld metal will drop to 470 N/mm2-, which is below acceptable level and results
in a failure.
Solution: It is recommended to use E708-A1 or E70-TA1 as welding consumable which does
not show any significant drop in UTS with normalizing heat treatment also.
4.2 316 LF WITH NIL FERRITE
Description: 316 LF consumables with Nil ferrite for butt welds and overlays for used
reactor application.
Problem: These types of consumables were required to be used for fabrication of urea
reactor. During qualification of consumable, no problems were encountered and corrosion
results were excellent.
However, on actual job condition, particularly on C-seams & Nozzle to Shell joints serious
micro fissuring problems were encountered.
Analysis: Even though problem was controlled by grinding of all crater points, still micro
fissuring were noticed at regular interval which shattered confidence of fabricator.
After detailed study, an additional Thomas Schaeffler crack sensivity test was introduced
for evaluation of consumables. The consumables, which gave satisfactory results in this test,
were found to give excellent weld performance or actual job also.
Solution: Use modified 316 LF with crack sensitivity test qualified consumables.
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5.0 CONCLUSION:
1. Even though Selection of Welding Consumables are based on guidelines specified in
ASME Sec II C and procedures have to be established as per ASME Sec IX, in actual
fabrication, the need to consider metallurgical factors affecting the weldment have to be given
due recognition.
2. The process of welding is dictated by availability of suitable consumables. When available,
due importance is to be given for productivity.
3. Whenever weld contour and location makes SAW process not easily adaptable, FCAW plays
an important role as most adaptable process without unduly sacrificing productivity.
4. Quality and Productivity being main tools for minimizing fabrication cost, the
adaptability of processes like SAW & FCAW are to be fully explored and utilized.
TABLE I
SUGGESTED CONSUMABLES FOR WELDING
CARBON STEEL FOR STRUCTURES
Welding process
ASTM Steel
A 242
A 441
A 572 Grade 42
A 588 (4 in and under)
A515 GR 60/70
A 572 Grade 60,65
A 633 Grade E
A 515 GR 70
Shielded
Metal arc
E 7015
E 7016
E 7018
E 7028
E 8015-XX
E 8016-XX
E8018-XX
submerged
arc
Gas metal
arc
F7XX-EXXX
ER 70S-X
F8XX-EXXXb
ER80S-XXb
flux covered
arc
E7XT-1
E7XT-4,5,6,7 or 8
E7XT-11
E7XT-G
E8XTX-XXb
TABLE II
PROPERTIES OF CONSUMABLES WITH TYPICAL
HEAT TREATMENT CYCLE
Sl. No
Consumable
Type
As Welded
SR
Normalized
1.
E 7018
530
525
480
2.
E 7018 A1
540
535
530
3.
E 8018
550
540
500
TABLE III
SUGGESTED CONSUMABLE FOR
AUSTENITIC STAINLESS STEEL
Recommended filler materials for austenitic stainless steels
Base Metal
GMAW/GTAW
Wrought Cast
SMAW
PAW, SAW
AISI
ACI
AWS A 5.4
AWS A 5.9
201
E 209
ER 209
202
E 219
ER 219
E 308
ER 308
301
302
CF-20
E 308
ER 308
304
CF-8
308
304L
CF-3
303
FCAW
AWS A 5.22
E 308T-X
E 308T-X
E 308L
E 347
ER 308L
ER 347
E 308LT-X
E347T-X
E 312
ER 312
E312T-X
309
CH-20
E 309
ER 309
E 309T-X
310
314
CK-20
E 310
ER 310
E 310T-X
316
CF-8M
E 316
ER 316
E 316T-X
316L
CF-3M
E 316L
ER 316L
E 316LT-X
317
E 317
ER 317
E 317T-X
321
E 347
ER 321
E 321T-X
347
E 347
ER 347
E 347T-X
TABLE IV
WELD METAL COST FORMULAS
1. LABOR & OVERHEAD
2. ELECTRODE
OPERATING
FACTOR
= ELECTRODE COST/KG
DEPOSITION EFFICIENCY
3. GAS
4. FLUX
5. POWER
SUM OF 1 5 ABOVE