En and ASME Welding Guide

Fundamentals of Manual Metal Arc (MMA) Welding 295
Fundamentals of Metal Inert Gas (MIG) Welding 304

Fundamentals of Flux and Metal Cored Arc Welding 308
Preheating of Materials 312
Mild Steel 316
Low Alloy 359
Stainless Steel 375
Aluminium 407
Copper 422
Cast Iron 427
Gouge 436
Gas Welding, Brazing and Soldering 438
Hardfacing 462
Consumables
WARNING Welding can give rise to electric shock, excessive noise, eye and skin burns due to the arc rays, and a potential health hazard if you breathe in the emitted fumes and gases.
Read all the manufacturer’s instructions to achieve the correct welding conditions and ask your employer for the Materials Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz
IPRM 2006 : SECTION 8 : CONSUMABLES 293

8 Consumables
Important Safety information
DWARNING
Protect yourself and others.
Alert Symbols - Type of Hazard Hazard Avoidance Symbols -
Precautionary Measure
Read and understand this information.

Electric shock can kill.
Welding can give rise to electric shock, excessive noise, eye
and skin burns due to the arc rays, and a potential health
Electrical Hazard Fire Hazard
hazard if you breathe in the emitted fumes and gases.
Become trained Wear dry, insulated gloves
Over exposure to the fumes and gases can give rise to Hazard Source Symbols
dryness of the nose, throat and eyes, respiratory irritation
and in some cases, longer term health effects such as lung
deposits.
Read all the manufacturer’s instructions to achieve
the correct welding conditions and ask your
employer for the Materials Safety Data Sheets. Refer
to www.boc.com.au or www.boc.co.nz
For eye protection and body protection always wear a Welding electrode causing Fumes and gases coming Insulate yourself from Keep head out of in fumes
welding visor with the correct filter lens, and suitable electric shock from any source work and ground
welding gloves and clothing to prevent injury from burns,
radiation, sparks, molten metal and electric shock. Wear ear
protection when required.
Adequate ventilation to prevent an accumulation of fumes
and gases should be used. Where fume levels cannot be
controlled below the recognised exposure limits, use local
exhaust to reduce fumes and gases; in confined spaces
without adequate ventilation, an air fed breathing system Fumes and gases coming Explosion from Use forced ventilation Wear complete body
should be used; outdoors a respirator may be required. from welding process pressurized gas cylinders or local exhaust to protection
Precautions for working in confined spaces should be remove fumes
observed. Refer to AS/NZS 2865 “Safe working in a confined
space”.
Keep your head out of the fume
Arc rays and fume can affect others in your workplace.
Comply with your employer’s safety practices and
procedures; protect others
Hot work pieces from Loud noise from engine, Use welding helmet with
Refer to WTIA Technical Note 7 “Health and Safety in welding and cutting; hot machinery, and arc correct shade of filter
Welding”. mufflers; hot exhaust pipes
Adherence to recognised occupational exposure standards
(such as the threshold limit values (TLV)) for all fume
constituents should be observed during use. See the
Materials Safety Data Sheets for details.
Flying particles from Welding arc rays

chipping and grinding
Colour Code Explanation

These colour bands appear on BOC consumable packages as an easy reference for indentifing material groups.
Hardfacing Mild Steel Stainless Steel

RED CYAN BLUE LIME
Low Alloy and

Gouge Nickel (Cast FE)
Silver Brazing Alloy
MINT YELLOW
PINK
Aluminium Low Hydrogen Copper

PURPLE GREEN BROWN
294 IPRM 2006 : SECTION 8 : CONSUMABLES

Consumables 8
Fundamentals of
Manual Metal Arc
(MMA) Welding
Welding Technique Electrodes and Typical Applications
Successful MMA welding depends on the following factors:
1 Selection of the correct electrode AWS
Name Classification Application
2 Selection of the correct size of the electrode for the job
BOC Smootharc 13 E6013 A premium quality electrode
3 Correct welding current for general structural and
4 Correct arc length sheet metal work in all
positions including vertical
5 Correct angle of electrode to work down using low carbon steels
6 Correct travel speed
BOC Smootharc 24 E7024 An iron powder electrode
7 Correct preparation of work to be welded. for high speed welding for
H-V fillets and flat butt joints.
Electrode Selection Medium to heavy structural
applications in low carbon
As a general rule the selection of an electrode is straight forward, steels
in that it is only a matter of selecting an electrode of similar
composition to the parent metal. It will be found, however, that for BOC Smootharc 18 E7018-1 A premium quality all
some metals there is a choice of several electrodes, each of which positional hydrogen
has particular properties to suit specific classes of work. Often, one controlled electrode for
electrode in the group will be more suitable for general applications carbon steels in pressure
vessel applications and
due to its all round qualities.
where high integrity welding
The table below shows just a few of the wide range of electrodes is required and for free-
available from BOC with their typical areas of application. machining steels containing
sulphur
For example, the average welder will carry out most fabrication
using mild steel and for this material has a choice of various BOC Smootharc S 308L E308L Rutile basic coated low
standard BOC electrodes, each of which will have qualities carbon electrodes for welding
BOC Smootharc S 316L E316L austenitic stainless steel
suited to particular tasks. For general mild steel work, however,
BOC Smootharc 13 electrodes will handle virtually all applications. BOC Smootharc S 309L E309L Rutile basic coated low
BOC Smootharc 13 is suitable for welding mild steel in all positions carbon electrode for welding
using AC or DC power sources. Its easy striking characteristics and mild steel to stainless steel
the tolerance it has for work where fit-up and plate surfaces are not and difficult to weld material
considered good, make it the most attractive electrode of its class.
Continuous development and improvement of BOC Smootharc
Electrode Size
13 have provided in-built operating qualities which appeal to the
beginner and experienced operator alike. For further advice on the The size of the electrode is generally dependent on the thickness of
selection of electrodes for specific applications, or to obtain a copy the section being welded, and the thicker the section the larger the
of the ‘Welding Consumables: Selection Chart’, contact your local electrode required. In the case of light sheet the electrode size used
BOC representative on 131 262. is generally slightly larger than the work being welded. This means
that if 2.0 mm sheet is being welded, 2.5 mm diameter electrode is
the recommended size.
The following table gives the maximum size of electrodes that may
be used for various thicknesses of section.

8 Fundamentals of Manual Metal Arc (MMA) Welding
Recommended Electrode Sizes Electrode Angle

The angle which the electrode makes with the work is important to
Average Thickness of Plate or Maximum Recommended ensure a smooth, even transfer of metal.
Section Electrode Diameter
The recommended angles for use in the various welding positions
1.5–2.0 mm 2.5 mm are covered later.
2.0–5.0 mm 3.2 mm Correct Travel Speed
5.0–8.0 mm 4.0 mm The electrode should be moved along in the direction of the joint
being welded at a speed that will give the size of run required. At
r8.0 mm 5.0 mm
the same time the electrode is fed downwards to keep the correct
arc length at all times. As a guide for general applications the table
Welding Current below gives recommended run lengths for the downhand position.
Correct current selection for a particular job is an important factor Correct travel speed for normal welding applications varies between
in arc welding. With the current set too low, difficulty is experienced approximately 100–300 mm per minute, depending on electrode
in striking and maintaining a stable arc. The electrode tends to stick size, size of run required and the amperage used.
to the work, penetration is poor and beads with a distinct rounded
profile will be deposited. Excessive travel speeds lead to poor fusion, lack of penetration, etc.,
whilst too slow a rate of travel will frequently lead to arc instability,
Excessive current is accompanied by overheating of the electrode. slag inclusions and poor mechanical properties.
It will cause undercut, burning through of the material, and give
excessive spatter. Normal current for a particular job may be Run Length per Electrode – BOC Smootharc 13
considered as the maximum which can be used without burning
through the work, over-heating the electrode or producing a
Run Length (mm)
rough spattered surface, i.e. the current in the middle of the range
Electrode Size Electrode
specified on the electrode package is considered to be the optimum. (mm) Length (mm) Minimum Maximum
In the case of welding machines with separate terminals for different 4.0 350 175 300
size electrodes, ensure that the welding lead is connected to the
correct terminal for the size electrode being used. When using 3.2 350 125 225
machines with adjustable current, set on the current range specified.
2.5 350 100 225
The limits of this range should not normally be exceeded. The
following table shows the current ranges generally recommended
for BOC Smootharc 13. Correct Work Preparation
The method of preparation of components to be welded will
Generally Recommended Current depend on equipment available and relative costs. Methods may
Range for BOC Smootharc 13 include sawing, punching, shearing, machining, flame cutting and
others.
Electrode Size (mm) Current Range (Amp) In all cases edges should be prepared for the joints that suit the
2.5 60–95 application.The following section describes the various joint types
and areas of application.
3.2 110–130
4.0 140–165 Types of Joints
5.0 170–260 Butt Welds

A butt weld is a weld made between two plates so as to give
Arc Length continuity of section.
To strike the arc, the electrode should be gently scraped on the Close attention must be paid to detail in a butt weld to ensure that
work until the arc is established. There is a simple rule for the the maximum strength of the weld is developed. Failure to properly
proper arc length; it should be the shortest arc that gives a good prepare the edges may lead to the production of faulty welds, as
surface to the weld. An arc too long reduces penetration, produces correct manipulation of the electrode is impeded.
spatter and gives a rough surface finish to the weld. An excessively
short arc will cause sticking of the electrode and rough deposits Butt Welding
that are associated with slag inclusions.
Reinforcement Weld Face
For downhand welding, it will be found that an arc length not
greater than the diameter of the core wire will be most satisfactory.
Overhead welding requires a very short arc, so that a minimum
of metal will be lost. Certain BOC electrodes have been specially
designed for ‘touch’ welding. These electrodes may be dragged along
the work and a perfectly sound weld is produced. Root Face
Root Gap

Two terms relating to the preparation of butt welds require General Notes on Butt Welds
explanation at this stage. They are: The first run in a prepared butt weld should be deposited with an
N Root Face: The proportion of the prepared edge that has not electrode not larger than 4.0 mm. The angle of the electrode for the
been bevelled (Land). various runs in a butt weld is shown below.
N Root Gap: The separation between root faces of the parts to be It is necessary to maintain the root gap by tacking at intervals or by
joined. other means, as it will tend to close during welding.
Various types of butt welds are in common use and their suitability All single ‘V’, single ‘U’ and square butt welds should have a backing
for different thickness of steel are described as follows: run deposited on the underside of the joint, otherwise 50% may be
deducted from the permissible working stress of the joint.
Square Butt Weld Before proceeding with a run on the underside of a weld it is
necessary to backgouge or grind that side of the joint.
The edges are not prepared but are separated
slightly to allow fusion through the full thickness Butt welds should be overfilled to a certain extent by building
of the steel. Suitable for plate up to 6 mm in up the weld until it is above the surface of the plate. Excessive
thickness. reinforcement, however, should be avoided.
In multi-run butt welds it is necessary to remove all slag, and
Single ‘V’ Butt Weld
surplus weld metal before a start is made on additional runs; this is
This is commonly used for plate up to 16 mm particularly important with the first run, which tends to form sharp
in thickness and on metal of greater thickness corners that cannot be penetrated with subsequent runs. Electrodes
where access is available from only one side. larger than 4.0 mm are not generally used for vertical or overhead
butt welds.
Double ‘V’ Butt Weld The diagrams below indicate the correct procedure for welding
Used on plate of 12 mm and over in thickness thick plate when using multiple runs.
when welding can be applied from both sides. It
allows faster welding and greater economy of Bead Sequence for 1st and 2nd Layers
electrodes than a single ‘V’ preparation on the
WELD BEADS
same thickness of steel and also has less of a
tendency to distortion as weld contraction can
be equalised.
Butt Weld with Backing Material

LAYERS
When square butt welds or single ‘V’ welds
cannot be welded from both sides it is desirable
to use a backing bar to ensure complete fusion. Bead Sequence for Subsequent Layers
WELD BEADS
Single ‘U’ Butt Weld
Used on thick plates as an alternative to a single

‘V’ preparation. It has advantages as regards
speed of welding. It takes less weld metal than a
single ‘V’, there is less contraction and therefore
a lessened tendency to distortion. Preparation
is more expensive than in the case of a ‘V’, as LAYERS
machining is required. The type of joint is most
suitable for material over 40 mm in thickness.
Welding Progression Angle
Double ‘U’ Butt Weld
1 Weld Metal
For use on thick plate that is accessible for 2 Workpiece
3
welding from both sides. For a given thickness it 3 Electrode
is faster, needs less weld metal and causes less 4 Slag
distortion than a single ‘U’ preparation. 5 Welding Direction 6
6 70–85° Angle
7 Arc
Horizontal Butt Weld 8 Weld Pool
The lower member in this case is bevelled to

approximately 15° and the upper member 45°,
making an included angle of 60°. This preparation 7
4
provides a ledge on the lower member, which 1
tends to retain the molten metal. 8
2

Fillet Welds Throat Thickness

A fillet weld is approximately triangular in section, joining two A measurement taken through the centre of a weld from the root
surfaces not in the same plane and forming a lap joint, tee joint or to the face, along the line that bisects the angle formed by the
corner joint. Joints made with fillet welds do not require extensive members to be joined. Many countries uses throat thickness rather
edge preparation, as is the case with butt welded joints, since the than leg length.
weld does not necessarily penetrate the full thickness of either Effective throat thickness is a measurement on which the strength
member. It is, however, important that the parts to be joined be of a weld is calculated. The effective throat thickness is based on a
clean, close fitting, and that all the edges on which welding is to be mitre fillet (Concave Fillet Weld), which has a throat thickness equal
carried out are square. On sheared plate it is advisable to entirely to 70% of the leg length. For example, in the case of a 20 mm fillet,
remove any ‘false cut’ on the edges prior to welding. the effective throat thickness will be 14 mm.
Fillet welds are used in the following types of joints:
Convex Fillet Weld
‘T’ Joints A fillet weld in which the contour of the weld metal lies outside
a straight line joining the toes of the weld. A convex fillet weld of
A fillet weld may be placed either on specified leg length has a throat thickness in excess of the effective
one or both sides, depending on the measurement.
requirements of the work. The weld metal
should fuse into or penetrate the corner
Convex Fillet Weld
formed between the two members. Where
possible the joint should be placed in such 1 1 Actual Throat
a position as to form a “Natural ‘V’ fillet” 2 2 Effective Throat
3
since this is the easiest and fastest method 3 Convexity
of fillet welding. 4 Leg
5 Size
4 6 Theoretical Throat
Lap Joints
5
In this case, a fillet weld may be placed
either on one or both sides of the
4 5
joint, depending on accessibility and the
requirements of the joint. However, lap
joints, where only one weld is accessible,
should be avoided where possible and
must never constitute the joints of tanks 6
or other fabrications where corrosion is
likely to occur behind the lapped plates. In
applying fillet welds to lapped joints it is
important that the amount of overlap of
Concave Fillet Weld
the plates be not less than five times the
thickness of the thinner part. Where it is A fillet in which the contour of the weld is below a straight line
required to preserve the outside face or joining the toes of the weld. It should be noted that a concave fillet
contour of a structure, one plate may be weld of a specified leg length has a throat thickness less than the
joggled. effective throat thickness for that size fillet. This means that when
a concave fillet weld is used, the throat thickness must not be less
Corner Joints than the effective measurement. This entails an increase in leg length
beyond the specified measurement.
The members are fitted as shown, leaving a
‘V’-shaped groove in which a fillet weld is
deposited. Fusion should be complete for
Concave Fillet Weld
the full thickness of the metal. In practice
it is generally necessary to have a gap or 1 2 1 Actual Throat
a slight overlap on the corner. The use of 3
2 Effective Throat
a 1.0–2.5 mm gap has the advantage of 5 3 Concavity
assisting penetration at the root, although 4 Leg
4
setting up is a problem. The provision of 5 Size
an overlap largely overcomes the problem 6 Theoretical Throat
of setting up, but prevents complete
penetration at the root and should
therefore be kept to a minimum, i.e. 1.0–2.5
4 5
mm.
The following terms and definitions are important in specifying and

describing fillet welds.
6
Leg Length
A fusion face of a fillet weld, as shown below. In Australia and NZ
specifications for fillet weld sizes are based on leg length.

The size of a fillet weld is affected by the electrode size, welding Multi-run (multi-pass) horizontal fillets have each run made using
speed or run length, welding current and electrode angle. Welding the same run lengths (Run Length per Electrode Table). Each run
speed and run length have an important effect on the size and shape is made in the same direction, and care should be taken with the
of the fillet, and on the tendency to undercut. shape of each, so that it has equal leg lengths and the contour of the
Insufficient speed causes the molten metal to pile up behind the arc completed fillet weld is slightly convex with no hollows in the face.
and eventually to collapse. Conversely, excessive speed will produce Vertical fillet welds can be carried out using the upwards or
a narrow irregular run having poor penetration, and where larger downwards technique. The characteristics of each are: Upwards
electrodes and high currents are used, undercut is likely to occur. – current used is low, penetration is good, surface is slightly convex
and irregular. For multiple run fillets large single pass weaving runs
Fillet Weld Data can be used. Downwards – current used is medium, penetration
is poor, each run is small, concave and smooth (only BOC
Nominal Fillet Min.Throat Plate Thickness Electrode Smootharc 13 is suitable for this position).
Size (mm) Thickness (mm) (mm) Size (mm) The downwards method should be used for making welds on thin
5.0 3.5 5.0–6.3 3.2 material only. Electrodes larger than 4.0 mm are not recommended
for vertical down welding. All strength joints in vertical plates
6.3 4.5 6.3–12 4.0 10.0 mm thick or more should be welded using the upward
8.0 5.5 8.0–12 and over 5.0
technique.This method is used because of its good penetration and
weld metal quality.The first run of a vertical up fillet weld should
10.0 7.0 10 and over 4.0 be a straight sealing run made with 3.2 mm or 4.0 mm diameter
electrode. Subsequent runs for large fillets may be either numerous
Selection of welding current is important. If it is too high the weld straight runs or several wide weaving runs.
surface will be flattened, and undercut accompanied by excessive
Correct selection of electrodes is important for vertical welding.
spatter is likely to occur. Alternatively, a current which is too low
will produce a rounded narrow bead with poor penetration at the In overhead fillet welds, careful attention to technique is necessary
root. The first run in the corner of a joint requires a suitably high to obtain a sound weld of good profile. Medium current is required
current to achieve maximum penetration at the root. A short arc for best results. High current will cause undercutting and bad
length is recommended for fillet welding. The maximum size fillet shape of the weld, while low current will cause slag inclusions. To
which should be attempted with one pass of a large electrode is produce a weld having good penetration and of good profile, a short
8.0 mm. Efforts to obtain larger leg lengths usually result in collapse arc length is necessary. Angle of electrode for overhead fillets is
of the metal at the vertical plate and serious undercutting. For illustrated below.
large leg lengths multiple run fillets are necessary. These are built
up as shown below. The angle of the electrode for various runs in a Recommended Electrode Angles for Overhead Fillet Welds
downhand fillet weld is shown below.
Recommended Electrode Angles For Fillet Welds
1st Run 2nd Run
DE
O
CTR
ELE
40˚ 55˚ - 60˚
15˚ 45˚
3rd Run Multi-run Fillet 30˚
6
20˚ - 30˚ 3 5
1 2 4

Welding Defects and Problems

Manual metal arc welding, like other welding processes, has welding Wagon Tracks
procedure problems that may develop which can cause defects in
the weld. Some defects are caused by problems with the materials.
Other welding problems may not be foreseeable and may require
immediate corrective action. A poor welding technique and
improper choice of welding parameters can cause weld defects.
Defects that can occur when using the shielded metal arc welding
process are slag inclusions, wagon tracks, porosity, wormhole
porosity, undercutting, lack of fusion, overlapping, burn through,
arc strikes, craters, and excessive weld spatter. Many of these
welding technique problems weaken the weld and can cause
cracking. Other problems that can occur which can reduce the
quality of the weld are arc blow, finger nailing, and improper
electrode coating moisture contents.
Defects Caused by Welding Technique

Slag Inclusions Top View Thru Transparent Bead
Wagon tracks are linear slag inclusions that run the longitudinal axis
of the weld. They result from allowing the slag to run ahead of the
weld puddle and by slag left on the previous weld pass. These occur
at the toe lines of the previous weld bead.
Slag inclusions occur when slag particles are trapped inside the weld Porosity
metal which produces a weaker weld. These can be caused by:
N erratic travel speed
N too wide a weaving motion
N slag left on the previous weld pass
N too large an electrode being used Porosity is gas pockets in the weld metal that may be scattered
in small clusters or along the entire length of the weld. Porosity
N letting slag run ahead of the arc.
weakens the weld in approximately the same way that slag
This defect can be prevented by: inclusions do.
N a uniform travel speed Porosity may be caused by:
N a tighter weaving motion N excessive welding current
N complete slag removal before welding N rust, grease, oil or dirt on the surface of the base metal
N using a smaller electrode N excessive moisture in the electrode coatings
N keeping the slag behind the arc, which is done by shortening the N impurities in the base metal, such as sulfur and phosphorous
arc, increasing the travel speed, or changing the electrode angle.
N too short an arc length except when using low-hydrogen or
stainless steel electrodes
N travel speed too high which causes freezing of the weld puddle
before gases can escape.
This problem can be prevented by:
N lowering the welding current
N cleaning the surface of the base metal
N redrying electrodes
N changing to a different base metal with a different composition
N using a slightly longer arc length
N lowering the travel speed to let the gases escape
N preheating the base metal, using. a different type of electrode,
or both.

Wormhole Porosity (Piping Porosity) Lack of Fusion
Wormhole porosity is the name given to elongated gas pockets and Lack of fusion is when the weld metal is not fused to the base metal.
is usually caused by sulfur or moisture trapped in the weld joint. This can occur between the weld metal and the base metal or
The best method of preventing this is to lower the travel speed to between passes in a multiple pass weld. Causes of this defect can be:
permit gases to escape before the weld metal freezes. N excessive travel speed
N electrode size too large
Undercutting
N welding current too low
N poor joint preparation
N letting the weld metal get ahead of the arc.
Lack of fusion can usually be prevented by:
Undercutting is a groove melted in the base metal next N reducing the travel speed
to the toe or root of a weld that is not filled by the N using a smaller diameter electrode
weld metal. Undercutting causes a weaker joint and N increasing the welding current
it can cause cracking. This defect is caused by:
N better joint preparation
N excessive welding current
N using a proper electrode angle
N too long an arc length
N excessive weaving speed Overlapping
N excessive travel speed.
On vertical and horizontal welds, it can also be caused by too large
an electrode size and incorrect electrode angles. This defect can. be
prevented by:
N choosing the proper welding current for the type and size of Overlapping is the protrusion of the weld metal over the edge or
electrode and the welding position toe of the weld bead. This defect can cause an area of lack of fusion
N holding the arc as short as possible and create a notch which can lead to crack initiation. Overlapping is
often produced by:
N pausing at each side of the weld bead when a weaving technique
is used N too slow a travel speed which permits the weld puddle to get
ahead of the electrode
N using a travel speed slow enough so that the weld metal can
completely fill all of the melted out areas of the base metal. N an incorrect electrode angle that allows the

Coating Types
It is the composition of the coating that differentiates one type of Basic-type electrodes for ferritic steels, with low-alloy additions to
electrode from another, and to a degree, what type of application the coatings or the core wire, allow a much wider use, including
it can be used for. MMA electrodes, with a solid wire core, are sub-zero and elevated-temperature application. Basic coatings are
generally categorised by the type of flux coating they employ. also widely used for electrodes for welding stainless steels, nickel
There are three main groups of electrode coating: rutile, basic, and alloys, cast irons, copper and aluminium alloys and for hard-facing
cellulosic, plus a less-widely-used acid type. The name of each group applications.
is a description of the main constituent of the coating. Although not
strictly a coating type, iron-powder electrodes are often considered Cellulosic Electrodes
as a separate group. Cellulosic electrodes contain a high proportion of organic material,
Electrodes for cutting, grooving and gouging, plus those for hard- replacing all or some of the rutile sand. This produces
surfacing, including tubular MMA electrodes, are not classified by a fierce, deep penetrating arc and a faster burn-off rate. Cellulosic
coating type. electrodes are more prone to spatter than rutile types. Only carbon
and some low-alloy steels are made with a cellulosic coating and
Rutile Electrodes most run only on DC+ polarity, but some are made that will also
Rutile electrodes have a coating that contains about 50% rutile sand operate on AC and DC-. They are truly all-positional electrodes
(a pure form of titanium dioxide), plus additions of ferro-manganese, in all sizes and even larger diameters up to 6 mm will operate
mineral carbonates and silicates, held together with approximately vertical-down. Cellulosic electrodes are used for root passes and
15% sodium silicate, also known as waterglass. The rutiles’ pipeline welding.
characteristics include easy striking, stable arc, low spatter, good It should be noted that celullosic electrodes generate high amounts
bead profile and generally, easy slag removal from the electrode. of hydrogen. This presents a risk of hydrogen-induced cracking if
The electrode can operate on both AC and DC currents and correct welding procedures are not followed.
can operate in all positions if the formulation of the coating is so
designed.
Acid Electrodes
Acid electrodes for mild steels have been largely replaced by rutile
One negative aspect of these electrodes is that they produce a high
types but some are still produced by a few manufacturers. These
level of hydrogen, typically greater than 15ml / 100g of deposited
electrodes contain high amounts of iron oxide, are relatively easy to
weld metal. This cannot be avoided because they rely on a certain
use and give a voluminous glassy slag, which detaches easily. They are
amount of moisture being present in the coating to operate properly.
lower-strength products, so are confined to
If the electrodes are dried too much, they will fail to function
use on non-structural components.
properly.
Acid-rutile electrodes for stainless steel are now replacing
Rutile-coated electrodes are manufactured for welding mild and
conventional rutile types. They are higher in silicon, which gives
low-carbon steels. In this context, they are often referred to as
improved operating and wetting characteristics and are much more
general-purpose or GP electrodes. Some low-alloy grades also use
welder-friendly. They strike and re-strike readily and will operate on
rutile coatings. Rutile-type coatings, which are modifications of those
AC and DC current. They produce low spatter levels and an easily
used for ferritic steels, are also used on many austenitic stainless
removed slag. However, they are prone to ‘start porosity’, and need
steel electrodes.
re-drying before use to avoid this.
Basic Electrodes Iron-powder Electrodes
Basic, or low-hydrogen, electrodes contain calcium carbonate and
Iron-powder electrodes are often considered as an independent
calcium fluoride in place of the rutile sand and mineral silicates. This
group of consumables. As their name suggests, these electrodes
makes them less easy to strike and more difficult to re-strike, due
contain high levels of iron powder held within the coating – as
to the very deep cup formed at the tip during operation. They also
the coating melts, the iron powder creates more weld metal. This
have a poorer, more convex bead profile than rutile electrodes. The
effectively improves the productivity from the electrode, allowing
slag is more difficult to remove than the rutile types but they do
either larger or longer welds to be created from a single rod. The
give improved weld metal properties than rutile types, with a higher
amount of iron powder added depends upon the consumable being
metallurgical quality.
produced, but it is not uncommon for 75% of the core weight to
Basic electrodes are capable of being used on AC or DC currents be added.
and can be used in multi-pass welds on materials of all thicknesses.
The addition of the iron powder to the coating has the effect of
Basic electrodes do not rely on moisture to function properly, and increasing the overall diameter of the electrode and reducing the
for the more critical applications should be used completely dry. It amount of fluxing agent present in the coating. With less fluxing
is important to note that basic electrodes are only low-hydrogen agent available, the slag coating tends to be thinner, so many of the
electrodes if they have been correctly dried before use. This MMA electrode’s positional welding characteristics are lost. This
conventionally involves re-drying in ovens on site in accordance means that many of the electrodes can only be used in the flat or
with manufacturers’ recommendations. Drying can reduce weld horizontal-vertical (H-V) positions.
metal hydrogen to less than 5ml / 100g, as can vacuum-packing the
Coatings for iron-powder electrodes may be based on either the
electrodes. These can be used straight from the packs without
rutile or basic systems.
any form of drying being required. BOC Smootharc 16 and 18
electrodes are supplied in hermetically sealed containers which
ensure that they meet the H4 grade.

Care and Conditioning of Consumables

Practical Considerations
Storage and Re-drying
MMA electrodes should be stored in dry, well-ventilated and
preferably heated stores. For critical applications it is also
recommended that they be held in temperature- and humidity-
controlled conditions, maintaining humidity below 60%RH (Relative
Humidity) and a temperature above the dew point, to avoid
moisture condensing onto the electrodes. Electrodes held in dry
conditions will remain in prime condition for several years but if the
coating absorbs moisture, this will lead to a gradual deterioration.
Evidence of deterioration includes the presence of white powdery
areas on the surface of the coating, cracks in the coating or pieces
of coating missing.
Electrodes with rutile or cellulosic coating require some moisture in
the coating to operate properly and should not be re-dried. If rutile
electrodes get wet, re-drying at about 80ºC is all that is needed.
Cellulosic electrodes must not be dried. In some hot environments
they may need wetting to function efficiently.
Basic coated electrodes need to be dry to give low-hydrogen weld
metal. Before use, these electrodes should be re-dried according
to manufacturers’ recommendations, be put in holding ovens
and then transferred to the workstations in heated quivers until
needed.Vacuum-packed basic electrodes can be used straight from
the packet.
Eletrodes for non-ferrous alloys and stainless steel always need to
be completely dry before use and should be treated in accordance
with manufacturers’ requirements.
Welding Parameters
Some electrodes will operate satisfactorily on AC or DC current
and for AC operation, manufacturers will recommend a minimum
OCV (Open Circuit Voltage) in order to initiate a welding arc with
the electrode.

8 Consumables
Fundamentals of
Metal Inert Gas
(MIG) Welding
Welding Technique Common Materials Welded with BOC MIG Wire
Successful welding depends on the following factors:
1 Selection of correct consumables Material BOC MIG Wire
2 Selection of the correct power source AS2074 C1, C2, C3, C4-1, BOC Mild Steel MIG Wire
C4-2, C5, C6
3 Selection of the correct shielding gas
AS/NZS 3678-9 250, 300, 350, 400 BOC Mild Steel MIG Wire
4 Selection of the correct application techniques
AS1548-430, 460,490 BOC Mild Steel MIG Wire
a Correct angle of electrode to work
b Correct electrical stickout ASTM A36, A106, EN8, 8A BOC Mild Steel MIG Wire
c Correct travel speed Stainless Steel
5 Selection of the welding preparation.
Grade 304 BOC Stainless Steel 308LSi
Selection of correct consumable Stainless to Carbon-Mn steels
Chemical composition Grade 316 BOC Stainless Steel 316LSi
As a general rule the selection of a wire is straightforward, in that Aluminium

it is only a matter of selecting an electrode of similar composition 1080 BOC Aluminium MIG 1080
to the parent material. It will be found, however, that there are
6061, 3004 BOC Aluminium MIG 4043
certain applications that electrodes will be selected on the basis
of mechanical properties or level of residual hydrogen in the 5005 BOC Aluminium MIG 5356
weldmetal. Solid MIG wires are all considered to be of the “low
Hydrogen type” consumables. Physical condition
The following table gives a general overview of the selection of Surface condition.
some of the BOC range of MIG wires for the most common
The welding wire must be free from any surface contamination
materials. More detailed selection charts for specific materials can
including mechanical damage such as scratch marks.
be found in the appropriate materials sections
A simple test for checking the surface condition is to run the wire
through a cloth that has been dampened with acetone for 20sec. If
Material Page No a black residue is found on the cloth the surface of the wire is not
Mild and Alloy steel 341 properly cleaned
Quench and tempered steels 343 Cast and Helix.
Ferritic materials 342 The cast and helix of the wire has a major influence on the
Stainless steel 401
feedability of MIG wire
Aluminium 429
Cast
Helix

Cast – Diameter of the circle Different grades of shielding are required for materials such as
Helix – Vertical height stainless steel, aluminium and copper.
If the cast is too small the wire will dip down from the tip. The The following table gives an indication of the most common
result of this is excessive tip wear and increased wear in the liners. shielding gases used for Carbon Manganese and Alloy Steels:
If the helix is too large the wire will leave the tip with a corkscrew
effect and cause feeding problems. Material thickness Recommended shielding gas
1–4 mm (dip transfer) Argoshield Light
Selection of the Correct Power Source
4–12 mm Argoshield Universal
Power sources for MIG / MAG welding is selected on a number of
different criteria, including: >10 mm Argoshield Heavy
?
1 Maximum output of the machine CH ONE
Material thickness WHI Recommended shielding gas
2 Duty cycle
3 Output control (voltage selection,wire feed speed control) 1–8 mm Argoshield Light
4 Portability 5–12 mm Argoshield Universal
The following table gives an indication of the operating amperage >12 mm Argoshield Heavy
for different size wires
More detailed selection charts, including recommendations for
welding parameters (voltage, amperage, electrical stickout, travel
Wire Size Amperage Range (A) speed and gas flow rate) can be found in the following sections:
0.8 mm 60–180
0.9 mm 70–250 Material Page
1.0 mm 90–280 C-Mn and Alloy Steels
1.2 mm 120–340 Argoshield Light 58
Argoshield Universal 59
A BOC power sources selection chart is contained in the arc
equipment section of this manual (see pages 232–233). Argoshield Heavy 60
Argoshield 52 61
Selection of the Correct Shielding Gas
Stainless Steel
The selection of the shielding gas has a direct influence on the
appearance and quality of the weldbead. Stainshield 63
The type and thickness of the material to be welded will determine Stainshield Heavy 63
the type of shielding gas that is selected. As a general rule the Aluminium
thicker the material (C-Mn and Alloy Steels), the higher the
percentage of CO2 in the shielding gas mixture. Argon xxx
Wire Operating Limits

35
Undercutting and burnback

30 Spray Transfer
Optimum Parameters
1.0mm 1.2mm
Burnback and arc instability DipTransfer
25
Optimum Parameters
Voltage (V)
Defect Free Zone

20
0.9mm 1.0mm
Electrode (wire) stubbing and spatter
0.8mm
Defect Zone
15
No working condition
0 1 2 3 4 5
10
Dip Transfer (Steel Thickness (mm))
0 1 2 3 4 5
Spray Transfer (Steel Thickness (mm))

5
0 50 100 150 200 250 300 350 400
Current (A)

8 Fundamentals of Metal Inert Gas (MIG) Welding
0–15°
Material Page
Alushield Light 65 45°
Alushield Heavy 65
Copper 45°
Specshield Copper 68
Correct Application Techniques Torch position for fillet welds
Direction of welding. When welding fillet welds the torch should be positioned at an
angle of 45° from the bottom plate with the wire pointing into the
MIG welding with solid wires takes place normally with a push
fillet corner. Welding is still performed in the push technique
technique. The welding gun is tilted at an angle of 10° towards the
direction of welding. (Push technique) Electrical stickout
10°
1 Gas Nozzle
2 Contact Tube Setback
3 Consumable Electrode
4 Workpiece
5 Standoff Distance
1 6
6 Contact Tube
7 Visible Stickout
2 8 Arc length
9 Electrical Stickout
7 9
3
Torch perpendicular to workpiece Narrow bead width with 5
increased reinforcement 8
The electrical stickout is the distance between the end of the

contact tip and the end of the wire. An increase in the electrical
stickout results in an increase in the electrical resistance. The
resultant increase in temperature has a positive influence in the
melt off rate of the wire that will have an influence on the weldbead
profile
The influence of changing the torch angle and the welding direction
on the weld bead profile can be seen below
10°
Short Normal Long

Influence of the change in electrical stickout length on the weldbead
profile
Torch positioned at a drag angle of 10° Narrow bead with excessive Travel speed
reinforcement
0–15°
Slow Normal Fast
The travel speed will have an influence on the weldbead profile and
the reinforcement height.
90° 90°
If the travel speed is too slow a wide weldbead with excessive
rollover will result. Conversely if the travel speed is too high, a
narrow weldbead with excessive reinforcement will result.
Recommendation about travel speed are contained in the detailed
Torch position for butt welds gases datasheets found in pages 58–68 of this manual.
When welding butt welds the torch should be positioned within the
centre of the groove and tilted at an angle of ±15° from the vertical
plane. Welding is still performed in the push technique

Advantage of BOC Smoothpak

N Improved productivity
N Reduced equipment downtime
N Enhanced weldability and accuracy
N Reduced wear on liners and contact tips
N Drum hood keeps wire free of dust and dirt
The BOC Smoothpak bulk MIG wire system has been designed
specifically to enhance the performance of automated and dedicated
welding systems. Each Smoothpak contains 250 kg of wire – the
equivalent of 16 standard spools – amounting to four hours of
additional production if changeover time is estimated at 15 minutes
a spool.
The secret of the success of the Smoothpak system is the packaging
system. Welding wire is introduced into each Smoothpak drum
using a unique reverse-twist coiling method, ensuring that a
virtually straight wire emerges from the container during welding.
Consequently, the welding wire can be positioned precisely,
enhancing weldability and accuracy, and reducing wear on liners
and contact tips. The negative effects of the cast and / or helix
which can be experienced with conventionally-spooled wire are
also eliminated.

8 Consumables
Fundamentals of
Flux and Metal Cored
Arc Welding
Welding Technique
Material Page No
Successful flux and metal cored arc welding depends on the
following factors: Carbon and Alloy steel castings 341
1 Selection of correct consumables Quench and tempered steels 343

2 Selection of the correct power source Ferritic steels 342
3 Selection of the correct shielding gas
4 Selection of the correct application techniques Common Materials Welded with Flux and Metal Cored Wire
a Correct angle of electrode to work
b Correct electrical stickout Material BOC MIG Wire
c Correct travel speed AS2074 C1, C2, C3, C4-1, C4-2, BOC Smooth-Cor 711,
5 Selection of the welding preparation. C5, C6 Smooth-Cor 70C6, Smooth-Cor 715
AS/NZS 3678-9 250, 300, 350, BOC Smooth-Cor 711,
Selection of correct consumable 400 Smooth-Cor 70C6, Smooth-Cor 715
Chemical composition AS1548-430, 460, 490 BOC Smooth-Cor 711,
As a general rule the selection of a wire is straightforward, in that Smooth-Cor 70C6, Smooth-Cor 715
it is only a matter of selecting an electrode of similar composition ASTM A36, A106, EN8, 8A BOC Smooth-Cor 711,
to the parent material. It will be found, however, that there are Smooth-Cor 70C6, Smooth-Cor 715
certain applications that electrodes will be selected on the basis
of mechanical properties or level of residual hydrogen in the BS970 EN 43A, AS3597-500 BOC Smooth-Cor 811K2
weldmetal. The classification system for flux cored wires will provide BS970 EN24, AS3597-700 BOC Smooth-Cor 115
an indication of the residual Hydrogen level that can be expected in
Stainless Steel
the weldmetal
Grade 304 Cigweld Shieldchrome 308LT
The following table gives a general overview of the selection of
some of the BOC range of Flux and Metal cored wires for the Stainless to mild steel Cigweld Shieldchrome 309LT
most common materials. More detailed selection charts for specific Grade 316 Cigweld Shieldchrome 316LT
materials can be found in the appropriate materials sections
Designates the diffusable

H10 hydrogen-content of deposited weld
ET P – GCP – W50 4 A . CMI H 10 metal-(DWM).
H5 b 5 ml H2 / 100 g of DWM
H10 b 10 ml H2 / 100 g of DWM
H15 b 15 ml H2 / 100 g of DWM

Physical condition The following table gives an indication of the operating amperage
for different size wires
Surface condition
BOC flux and metal cored wires are supplied as an in line baked
Wire Size (mm) Direction Amperage Range (A)
product and therefore has a typical dark surface appearance.
FCAW
The wire must however be free from any surface contamination
including surface rust. Most flux and metal cored wires have a 1.2 Horizontal 200–300
thin film of graphite on the surface of the wire to assist with the 1.2 Vertical up 150–250
feedability.
1.6 Horizontal 300–400
BOC SmoothCor wires are supplied in tough vacuum packs to
ensure performance as manufactured. 1.6 Vertical up 180–250
MCAW
Cast and Helix
1.2 Horizontal 150–350
The AWS standard for Flux cored wires do not specify a cast or
helix other than to stipulate that it should be of such a nature that 1.6 Horizontal 300–500
the wire can be fed uninterrupted.
A BOC power sources selection chart is contained in the arc
Selection of the Correct Power Source equipment section of this manual (see pages 232–233)
Power sources for Flux and Metal cored welding is selected on a Selection Of The Correct Shielding Gas
number of different criteria, including:
The selection of the shielding gas has a direct influence on the
1 Maximum output of the machine appearance and quality of the weldbead.
2 Duty cycle Flux cored wires are manufactured to be welded with either 100%
3 Output control ( voltage selection,wire feed speed control) CO2 or a Argon / CO2 gas mixture. Mostly these mixtures will
4 Portability contain 25% CO2 as is the case with BOC Argoshield 52.
Current / Voltage Envelope for Argoshield 52

40
Undercutting and burnback 1.6 mm

1.2 mm
35 Flat and Horizontal
Optimum Paramaters
Burnback and arc instability Positional Welding

30
Optimum Paramaters
Voltage (V)
Defect Free Zone

25
Electrode stubbing and spatter
Defect Zone
20
No working 0 10 20
15 condition
Plate Thickness (mm) Positional Welding
0 5 10 15 20
Plate Thickness (mm) Flat and Horizontal

10
50 100 150 200 250 300 350 400 450
Current (A)

8 Fundamentals of Flux and Metal Cored Arc Welding
Correct Application Techniques Torch angle for fillet welds

Direction of travel
Flux cored welding are normally performed using a “drag”
technique. The welding gun is tilted to between a 50–60° backhand
angle. If however a flatter bead profile is required the backhand 60–70°
angle can be reduced.
Metal cored wire because of it’s similarity to solid wires (no slag
formers added to the core mainly metallic powders) are normally
30–40°
welded with the “Push” technique
Travel direction (Flux cored)
When welding horizontal – vertical fillet welds the wire tip must
be aimed exactly in the corner of the joint. For the first bead the
welding gun is tilted at an angle of 30–40° from the horizontal
5mm plane. Flux cored welding is still performed with the “drag”
technique and metal cored welding with the “push” technique.
Vertical up
50–60°
2–3mm
Travel direction (Metal cored)

10°
Vertical up welding can be undertaken in a similar way as MMA with

a slight weave motion.
Vertical up welding with metal cored wire can successfully be
undertaken with pulsed MIG welding equipment
Electrical stickout
When welding butt welds with flux or metal cored wires the torch
1 Gas Nozzle
should be positioned within the centre of the groove and tilted 2 Contact Tube Setback
at an angle of ±20°. Flux cored welding is still performed with 3 Consumable Electrode
the “drag” technique and metal cored welding with the “push” 4 Workpiece
technique. 5 Standoff Distance
1 6
6 Contact Tube
7 Visible Stickout
Torch position for butt welds 2 8 Arc length
9 Electrical Stickout
0–15°
7 9
3
5
8
4
90° 90°
The electrical stickout is the distance between the end of the

contact tip and the end of the wire. An increase in the electrical
stickout results in an increase in the electrical resistance. The
resultant increase in temperature has a positive influence in the
melt off rate of the wire that will have an influence on the weldbead
profile
Travel speed
The construction of flux and metal cored wires ensures the highest
current density for a any given current setting compared to all other
welding processes.

High current densities produce high deposition rates.

Amperage
Current Density =
Cross-sectional area of wire
I
or J =
A
Electrode /Wire Dia. (mm) Cross section area (mm2) Current (A) Current Density (A / mm2) Deposition rate (kg / h)
MMA electrode (E7024) 4 12.57 235 18.7 3.0
FCAW wire (E71T-1) 1.2 0.625 235 376 3.8
MIG wire (ER70S-6) 1.2 1.130 235 287.5 3.3
MCAW wire (E70C-6M) 1.2 0.625 300 480 5.2
Consequently, travel speed must be increased proportionately to

maintain control of the weld pool, bead shape and balance the
deposited weld metal versus fusion obtained
Travel speed too slow
Excessive penetration
Excessive weldmetal deposited
Roll over of weldmetal on
horizontal plate
Correct travel speed
Recommended penetration depth

Proper sidewall fusion without roll over
or undercut
Travel speed too fast
Weldbead too small

Inadequate sidewall fusion
Lack of root penetration

8 Consumables
Preheating of Materials
Slow Down the Cooling Rate

What is Preheat? Some alloys (notably high carbon and low alloy steels), if welded
A heating procedure applied to parent metal components and allowed to cool quickly, can develop hard or brittle phases
immediately before welding commences, and considered as an in the heat affected zone (HAZ). These phases can render such
essential part of the welding operation, is called ‘Preheat’. alloys susceptible to cracking under the action of tensile shrinkage
stresses as the weld area cools down, or they can result in low
toughness of the HAZ.
Many steels are susceptible to hydrogen cracking, and fast cooling
rates not only promote the formation of hard, susceptible
microstructures but also lock the hydrogen into the solidifying weld
metal. Because of this trapped hydrogen gas, pressure builds up in
the weld and the heat affected zone which can result in cracking
of the already brittle microstructure. Such cracks are normally
detected by post weld inspection techniques, but should they
escape detection, they may lead to premature failure in service, with
potentially disastrous consequences.
Preheating of components prior to welding in these situations
is designed primarily to slow down the rate of cooling of the
weldment. In reducing the cooling rate, preheat is protecting the
parent metal by helping to prevent hardening of the weld by the
formation of brittle phases. A softer, more ductile structure is more
resistant to cracking. The slower cooling rate also gives more time
Preheating can be applied locally to the areas to be welded, or to for any hydrogen introduced into the weld to diffuse away from the
the whole component. It is usually done to raise the temperature welded joint.
of the weld area so that the weld does not cool too quickly after
welding. This protects the material being welded from the various Reduce Shrinkage Stress and Weld Distortion
adverse effects that can be caused by the normally rapid cooling If welds are made in highly restrained joints, or in materials with
cycle created by the welding process. very low ductility (e.g. cast irons), the welding cycle of heating,
Note that while preheat is applied before welding begins, it is followed by rapid cooling, can result in cracking in the weld or the
essential that the minimum preheat temperature is maintained surrounding area. This is due to the weld metal or adjacent parent
throughout the welding operation. metal not being able to withstand the effects of shrinkage stresses
created by contraction.
What does Preheat do?
Metals and alloys that should not be preheated
Basically, preheat puts the parent metal components in a suitable
condition for the subsequent welding operation. Preheating may be Preheat and high interpass temperatures can have a negative effect
carried out for any of the following reasons; on the mechanical properties or corrosion resistance of some
alloys e.g.
N Slow down the cooling rate
N Austenitic manganese (13% Mn) steel
N Reduce shrinkage stress and weld distortion
N Austenitic stainless steels
N Promote fusion
N Duplex stainless steels
N Remove moisture
N Titanium alloys*
* For futher information, please consult your local BOC Welding Specialist, BOC Technical
Manager or Welding Engineers.

Here preheating is used to balance the thermal cycle and so reduce

the shrinkage stresses in the weld and in the adjacent parent
material.
When welding wrought materials in highly restrained joints, preheat
is normally applied locally in the weld area.
When welding castings, the preheat applied may be ‘local’ (heating
in the area of the weld only), ‘total’ (the whole casting is heated), or
‘indirect’ (heating a part of the casting away from the weld area to
balance the effects of expansion and contraction).
Promote fusion
Some alloy systems (e.g. copper and aluminium) have very high
thermal conductivity, and if a weld is attempted on thick, cold, plate,
the parent material could chill the deposited weld metal so quickly
that it does not fuse with the parent metal. This may be referred
to as a ‘cold start’. The heat conduction away from the joint area
Residual stresses present in a welded joint. can be such that a weld may be impossible using a conventional arc
welding process.
Preheat is used in this case to raise the initial temperature of the
material sufficiently to ensure full weld fusion from the start. This is
particularly important when using a welding process / plate thickness
combination that is likely to produce a cold start.
Remove Moisture
Any metallic components left overnight in a cold workshop or
brought in from outside are likely to be damp or even wet. If they
are welded in that condition, problems can arise in the resultant
welds. For example, if the components are made of steel, then the
moisture will act as a source of hydrogen and the result could be
hydrogen cracking. Aluminium has a porous oxide layer, which will
absorb moisture from the atmosphere, and, if not removed before
welding, this can result in weld metal porosity and subsequent
rejection of the weld.
Whilst not normally the main objective of preheating, its use for
removal of surface moisture prior to welding is not only advisable,
but very often essential.
Carbon Steel and Alloy Steel

These two groups of materials have, quite rightly, been given more
attention regarding estimation of preheat temperature than any
other alloy system, as the penalty for getting it wrong can be severe.
The following list is intended only to give some indication of
the level of preheat required for certain types of steel. In these
examples it is assumed that the weld is a butt weld, and the
thicknesses given are the normally used ‘combined thickness’, where
this is the total thickness of all the parts to be joined.
When calculating the ‘combined thickness’ of parts with varying
thicknesses (such as forgings), the thickness of each part is usually
averaged over a distance of 75 mm from the weld line. However
for some processes and materials, account must be taken of any
difference of thickness beyond the 75 mm point, and it is important
to refer to the specific welding procedures, or relevant standards in
each case.
Distortion due to the presence of residual stress

8 Preheating of Materials
How much Preheat to Apply

Combined
Steel type Thickness (mm) Typical Preheat (°C) The actual preheat temperature required for a specific welding
operation depends not only on the material or materials being
Low C and mild steels <50 b50 welded, but also the combined thickness of the joint, the heat
input from the welding process being used, and the amount of
>50 100–150
restraint imposed upon the components. There are no hard and
Medium C, C-Mn steels <40 100–200 fast rules regarding how much preheat to apply, but there are many
publications available giving helpful guidance. These publications
>40 150–250
include national and international standards or codes of practice,
High C, C-Mn steels All 200–300 guides from steel and aluminium alloy producers, and from
consumable manufacturers. Some guidelines are included here, and
QT steels, HSLA steels All None to 150 (max.) as in the previous section, categorised for convenience by alloy type.
0.5% Mo, 1% Cr-0.5% Mo All 100–250
steels* Preheating of Aluminium and Aluminium alloys
2% Cr-1% Mo, 5% Cr-0.5% Mo All 200–300 When to Preheat
steels*
Preheat is needed when there is a risk that if a welding operation
Direct hardening steels All 150–300 is carried out ‘cold’ an unsound weld could be produced. Whilst
it is not possible here to cover all eventualities, there are certain
Case hardening steels All 150 guidelines that can be followed in making the decision whether
13% Manganese steel All None to preheat or not, and these are outlined here, categorised for
convenience, by alloy type.
*Preheat is usually specified by procedure and tightly monitored and controlled with
these materials.
Aluminium Alloys
It is recommended that more comprehensive documentation be Aluminium Alloys have a high thermal conductivity and preheat
consulted when selecting a temperature for a specific application. is used to provide additional heat to the weld area in order to
Information to assist with calculation of preheat for C-Mn steels help ensure full fusion of the weld. Application of preheat is also
can be found in international standards, for example BS 5135, used to drive off any moisture in the surface oxide. Preheating is
AWS D1.1 and AS / NZS 1554.1. These standards set out minimum not necessary when welding thin sheet, but becomes increasingly
preheat temperatures based on factors such as, the type of steel important as thickness increases. High conductivity aluminium
specification or carbon equivalent, thickness, the welding process or busbars are a prime example.
heat input, and the hydrogen class of the welding consumable. The As a rule, aluminium alloys are only preheated to temperatures
guidelines do not take restraint into consideration, and so highly between 80–120°C. Certain heat treatable aluminium alloys (Al-
restrained joints may need higher levels of preheat than indicated. Si-Mg) are sensitive to HAZ liquation cracking if overheated, and
The information in these standards is often used as a rough guide preheat must be carefully controlled within this range. With less
to determine preheat for low alloy steels; this should be done with sensitive alloys preheat may be increased up to a maximum of 180–
extreme caution as low alloy steels will frequently need much higher 200°C. Remember that aluminium alloys have relatively low melting
preheat than estimated by this means because of their alloy content. points and care must be taken to avoid overheating which can result
in poor weld quality and cracking in some alloys.
When joining or surfacing hardenable steels (steels with high CE) it
is sometimes possible to weld with an austenitic type consumable
and use a lower preheat than would be needed if ferritic
consumables were to be used.
The decision making process when deciding whether to use preheat
with Carbon Steel and Alloy Steel can become quite complicated.
Carbon and carbon-manganese steels and low alloy steels may
require preheating, but this depends on their carbon equivalent,
combined thickness, and proposed welding heat input.
Preheat with these ferritic materials is primarily aimed at reducing
the severity of the “quench” after welding, and helping to prevent
the formation of hard brittle microstructures in the weld and HAZ.
It also allows hydrogen to diffuse away from the weld area, so
reducing the risk of hydrogen cracking. The objective is to keep the
maximum HAZ hardness to below about 350 Hv, although this will
not always be possible, particularly with some low alloy steels with
high hardenability. These low alloy types may, additionally, need a
post-weld heat treatment to restore properties.

Preheating of Stainless Steel

Stainless Steel
Martensitic stainless steels generally require preheating to 200–
300°C, depending on carbon content plus post weld heat treatment
in order to prevent cracking in the weld and/or HAZ. This applies
whether they are welded with matching consumables or, as is quite
common, with austenitic consumables.
Some ferritic stainless steels should be preheated to about 200°C
to prevent embrittlement. They may also need a post weld annealing
treatment, depending on application.
Should it be necessary to preheat duplex stainless steel, it is
normal to keep it fairly low, up to a maximum of 150°C for
‘Duplex’ and 100°C for ‘Super Duplex’. Preheat is invariably
specified by procedure and tightly monitored and controlled with
these materials.
No preheat at all is required when welding austenitic stainless steels.
Preheating of Copper and Copper alloys

Copper and Copper Alloys
High conductivity copper, phosphorus de-oxidised (PDO)
copper and many of the leaner copper alloys have high thermal
conductivities and consequently need a very high preheat to ensure
full fusion of the joint.
Those high conductivity copper alloys requiring to be preheated
before welding are normally heated to temperatures of 600–700°C.
Bronzes and brasses, on the other hand, are normally welded
without preheat. Their thermal conductivity is low enough to allow
full fusion to be readily achieved, and some alloys suffer from ‘hot
shortness’ and so need to cool relatively quickly after welding to
avoid cracking. Any applied preheat would prolong this cooling
period and so render them more liable to crack.

8 Consumables
Mild Steel
Temperate Distribution Across Iron Carbon Equilibrium Diagram

Weldability of Steel Half the Weld
Liquid
Overview d
Weldability is a term used to describe the relative ease or Austenite
difficulty with which a metal or alloy can be welded. The better c
the weldability the easier it is to weld. However, weldability is
b
a complicated property as it encompasses the metallurgical
compatibility of the metal or alloy with a specific welding process, a
its ability to be welded with mechanical soundness, and the capacity Ferrite +
of the resulting weld to perform satisfactorily under the intended Cementile
service conditions.
0.2% Carbon
Before attempting to weld any material it is essential to know
how easy it is to weld and to be aware of any problems that might
arise. One of the main problems likely to be encountered when
welding carbon and alloy steels is hydrogen cracking. For hydrogen
cracking to occur it is necessary to have a supply of hydrogen to Variation in temperature from the centre of the weld to the base material.
the weld and a heat affected zone (HAZ), a susceptible hardened The weldability of steel depends primarily on its hardenability and
microstructure, and tensile stress. If any one of these three this in turn depends largely on its composition, most importantly
components is eliminated then hydrogen cracking will not happen. its carbon content. Steels with carbon content under 0.3% are
Solidification cracking and lamellar tearing are other potential reasonably easy to weld, steels with over 0.5%C are difficult. Other
problems associated with welding of steel. alloying elements having an effect on the hardenability of steel, but
The main problem when welding steel is hardenability. Provided to a much lesser extent than carbon, are manganese, molybdenum,
the steel contains sufficient carbon, when it is cooled rapidly from chromium, vanadium, nickel, and silicon. These, together with carbon,
high temperature a phase transformation takes place. The phase are all generally expressed as a single value, the carbon equivalent.
transformation from austenite to martensite causes the material to The higher the carbon equivalent, the higher the hardenability, the
harden and become brittle. It is then liable to crack on cooling due more difficult the steel is to weld, and the more susceptible the
to restraint or later under the action of hydrogen. microstructure is likely to be to hydrogen cracking.
This effect can be overcome by use of preheat combined with use
of a low hydrogen process or low hydrogen welding consumables.
Calculation of preheat is usually based on carbon equivalent
(derived from steel composition), combined thickness of the
components, and heat input from the welding process. It also
takes account of the amount of hydrogen likely to be introduced
into the weld metal by the welding process. If welding under high
restraint extra preheat may need to be applied. Some high carbon
steels and low alloy steels may also need a post weld stress relief
or tempering.

Mild Steel 8
Hardenability and Hardness After welding, the hardness in the HAZ may range from less
In order to become harder, steel must undergo a phase change. The than 300 Hv to more than 550 Hv, depending on the parent steel
starting point is austenite, so the steel must first be heated into the composition and the other factors described above. As the hardness
austenitic temperature range (see iron-carbon Equilibrium Diagram of the HAZ increases so does its susceptibility to hydrogen cracking.
on previous page). However, as a rule of thumb, it is generally considered that if the
maximum hardness in the HAZ is maintained below 350 Hv then
N Austenite, quenched rapidly, will be transformed into martensite, hydrogen cracking will be avoided.
a hard but brittle phase
N A slower cooling rate will promote formation of bainite and / or Carbon Equivalent
other softer phases Carbon has the greatest effect on hardenability of steel but other
N Cooled even more slowly a soft structure of ferrite plus alloying elements may be added to increase its hardenability.
cementite, called pearlite, results The addition effectively reduces the critical cooling rate and the
temperature at which the austenite to martensite transformation
takes place, making it easier for martensite to form at slower
cooling rates.
Alloying elements having the greatest influence on the hardenability
of steel are manganese, molybdenum, chromium, vanadium, nickel,
copper, and silicon, but they have a much smaller effect than carbon.
The effect of these elements on the tendency to form HAZ
martensite, and hence the likelihood of hydrogen cracking, is
expressed conveniently as a Carbon Equivalent (CE). This basically
Martensite,Tempered Martensite and Heavily Tempered Martensite
describes the influence on hardenability of each element in terms of
the effect that carbon has. There have been many different formulae
Hardenability
derived to express carbon equivalent, but the one quoted here is
Hardenability is the potential for any particular steel to harden on the International Institute of Welding (IIW) equation applicable to
cooling and, as the carbon content of the steel increases towards carbon steel and is widely used:
0.8% so the potential of the steel to harden increases. Increasing the
alloy content of the steel also increases the hardenability. Carbon equivalent (CE) =
While hardness and strength may be desirable in a welded steel %Mn (%Ni + %Cu) (%Cr + %Mo + %V)
structure, martensite can be brittle and susceptible to cracking, and %C + + +
6 15 5
it should be noted that the potential brittleness of the material also
increases as hardenability increases. The equation is only valid for certain maximum percentages of
Hardenability describes the potential of steel to form hard each element and these percentages can be found in the technical
microstructures. What hardness is actually achieved in steel with literature.
known hardenability depends on the maximum temperature to The carbon equivalent is used mainly for estimating preheat. Preheat
which it is heated and the cooling rate from that temperature. is necessary to slow down the cooling rate sufficiently to reduce
During welding parent material close to the weld will be heated to hardening in the HAZ of welds in susceptible carbon and low alloy
temperatures near melting point while further away it will remain at steels. This in turn helps to prevent subsequent HAZ hydrogen
ambient temperature. Cooling rate depends on the mass of material, cracking. The overall effect is to improve the weldability of the steel
its temperature, and the welding heat input. Therefore, when welding being welded, or at least to overcome the weldability problems
any given hardenable steel the hardness in the HAZ depends presented by it.
on the cooling rate, the faster the cooling rate the harder the CE is calculated from the composition of the steel in question and is
microstructure produced and the more susceptible it is to cracking. used, together with welding heat input, potential hydrogen from the
consumable, and combined thickness, or by reference to published
data, to determine the preheat. It is recommended that actual
composition of the steel is used to ensure accuracy of calculation
of CE but nominal or maximum specified compositional data may
be used when this is unavailable. The use of nominal composition
obviously carries some risk that CE will be under-estimated and too
low preheat will be used, with potential cracking problems.

8 Mild Steel
Weldability Structural steels often have limits imposed on maximum carbon

Weldability describes the relative ease or difficulty with which a equivalent to ensure good weldability and ease of welding for
metal or alloy can be welded. the fabricator.
The relative weldability of carbon and low alloy steels are Weldable high strength low alloy (HSLA) steels have weldability
summarised here. similar to the low carbon steels, and so do not usually present
problems.
As has already been stated, weldability varies with the chemistry
of the steel, particularly with reference to its carbon content. Most quenched and tempered steels can be welded, but they rely
on relatively high cooling rates for the strong martensitic structures
The majority of carbon steels are weldable, but some grades to form. Careful control of pre-heat, heat input and interpass
have better weldability and, therefore, are more easily welded temperature is required to achieve the correct structure without
than others. As the carbon content increases, weldability tends to cracking. Welding must be carried out using a low hydrogen process,
decrease as the hardenability increases and the steel becomes more or hydrogen controlled consumables, and welding procedures need
prone to cracking. to be tested and approved.
Low carbon steels containing <0.15% C and manganese <0.6%
generally have good weldability, as the composition is too lean Alloy Steels
to give any significant hardening effect during welding. However, Many low alloy steels are weldable but some grades are easier
steels with <0.12% C and low levels of manganese can be prone to to weld than are others. Weldability again varies with the
porosity but they are not susceptible to hydrogen cracking. chemistry of the steel, particularly with reference to its carbon
Steels with carbon contents between 0.15–0.3% C and manganese content, but also with reference to alloying additions, particularly
up to 0.9%, have good weldability, particularly those with carbon manganese, chromium, molybdenum, vanadium and nickel content.
content below 0.22%. These are mild steels and they rarely The weldability of alloy steels therefore depends on its carbon
present problems provided impurity levels are kept low. They are equivalent.
all weldable without preheat, using any of the common welding Nickel steels with from 1–3% Ni may be welded with suitable
processes. Those at the top end of the composition range, welding procedures, specifying pre-heat and interpass temperature,
above about 0.25% C, may be prone to cracking under certain current levels and heat inputs. As carbon and nickel content
circumstances. They may be welded using any of the common increases, so the weldability of these steels becomes worse. This is
welding processes but are best welded with a low hydrogen process due to an increase in hardenability and is reflected by an increase in
such as MIG or low hydrogen consumables. Thick sections may the carbon equivalent. Nickel steels should always be welded using
require pre-heating to reduce the cooling rate. a low hydrogen process, such as MIG or TIG, or with controlled
Medium carbon steels containing between 0.25–0.5% C, with hydrogen consumables.
manganese generally <1%, are hardenable by heat treatment and so Steels containing 5% Ni or 9% Ni have poor weldability. As they
are prone to cracking when welded. They can be welded but require fall outside the maximum nickel content for which the carbon
suitable welding procedures, specifying pre-heat and interpass equivalent formula is valid, preheat must be estimated by other
temperature control, to account for the carbon content or Carbon means.
Equivalent and the combined thickness of the joint being produced.
All molybdenum, chromium-molybdenum, and chromium-
These steels should always be welded using a low hydrogen welding
molybdenum-vanadium steels are hardenable and their weldability
process or controlled hydrogen consumables.
is not good. They will crack when welded unless attention is paid
Steels with even higher carbon levels, between 0.5–1.0%, with to preheat, interpass temperature, cooling rate, and post weld
manganese <1% are used where their higher hardness and strength stress relief heat treatment. Normally, low hydrogen processes or
can be exploited. However, their high hardenability means that they hydrogen-controlled consumables are used to reduce the likelihood
have poor weldability and are difficult to weld without cracking. of cracking occurring.
They are generally welded in the hardened condition and so
The weldability of direct hardening steels is not good, since, because
require pre-heating, interpass temperature control and post weld
of their medium carbon and alloy content, they are very hardenable,
stress relief to give any chance or avoiding cracking. Low hydrogen
and any welding must be carried out with due attention to
processes, such as MIG and TIG welding or low hydrogen
preheat and maintenance of heat during welding, or they will crack.
consumables, such as low hydrogen MMA electrodes will always be
Consumable selection is important and low hydrogen or austenitic
required when welding these steels.
types may be used.
Carbon-manganese steels have carbon typically between 0.15–0.5%,
Case hardening steels are basically low carbon alloy steels with
and manganese levels between 1.0–1.7%. For structural purposes,
reasonable weldability as long as precautions are taken. Usually this
carbon is normally held below 0.3%, manganese not above 1.2%
means using a moderate preheat and using standard, low hydrogen
and sulphur and phosphorous are required to be below 0.05%.
carbon-manganese consumables. However, welding will destroy the
Generally, they are weldable, although some will require controls
case hardened layer.
on pre-heat and heat input. Those at the higher end of the carbon
range also benefit from use of low hydrogen welding processes or
controlled hydrogen consumables.

Mild Steel 8
Weld and HAZ Cracking N To avoid cold cracking the following point should be noted:
With steel, poor weldability often manifests itself in a reduction of N The lower the carbon equivalent the lower the potential for
the resistance of the steel to cracking after welding cracking
N Limit the hydrogen content of weld metal and HAZ by using a
Base Metal low hydrogen process or low hydrogen consumables
Heat affected Zone N Keep joint restraint to a minimum by careful joint design
Weldmetal
N Reduce cooling rate of weld area by use of pre-heat and suitable
welding heat input
N Eliminate hydrogen after weld is completed by keeping weld
hot - hydrogen release treatment
N Ensure impurities are kept at a low levels
The above guidance is of a very general nature and if in doubt
The main causes of cracking in steel are: seek expert technical advice.
N High levels of carbon and other alloys elements resulting in
brittle zones around the weld Factors Influencing Weldability
N High cooling rates after welding increasing the hardness, which In terms of avoiding weldability problems, particularly hydrogen
increases the susceptibility to cold cracking cracking, when welding carbon or low alloy steels there are several
factors that demand consideration. These include the amount of
N Joint restraint preventing contraction after welding leading to
hydrogen generated by the welding process or consumable, the heat
cracking
input into the weld, the combined thickness (heat sink) of the joint,
N Hydrogen in the weld bead or HAZ leading to hydrogen induced and the level of preheat applied to the components prior to welding.
cold cracking Joint configuration and restraint are also important factors when
N Contaminants like sulphur and phosphorus resulting in considering weldability.
solidification cracking
Process Hydrogen
N Lamellar tearing due to inclusions layering during rolling resulting
in deterioration of the through-thickness properties One of the three key components necessary for hydrogen cracking
is a source of hydrogen. During welding the most likely sources
The most common cause of cracking in steel is the presence of of hydrogen are the welding consumables or contaminants on the
hydrogen. Hydrogen, or cold, cracking is usually considered to be parent material. Here we consider hydrogen from the welding
the most serious potential problem with modern steels. Hydrogen process and consumables only.
cracking is most frequently a HAZ phenomenon, but it can also
occur in weld metal, particularly in high alloy steels. Hydrogen, like The amount of hydrogen put into the weld will vary from one
carbon, is more soluble in austenite than ferrite and can easily be welding process to another and may also vary within a process
picked up by the weld metal. When ferrite is formed as the material from one consumable type to another. The risk of hydrogen
cools, hydrogen solubility decreases, and hydrogen diffuses to the cracking increases as the amount of hydrogen from the process
HAZ where it becomes trapped and can cause crack propagation. or consumable gets larger.
Solid wire processes, such as MIG and TIG, are capable of giving
hydrogen levels below 5ml / 100g of weld metal. These are generally
thought to be low hydrogen processes, provided the MIG wire
is clean.
The manual metal arc process can give a wide range of hydrogen
levels, from well over 15ml / 100g of weld metal, with cellulosic and
rutile coated electrodes, to less than 5ml / 100g of weld metal with
basic coated electrodes given the appropriate baking or re-drying
treatment.
The potential hydrogen levels can vary with product type for cored
wire welding processes too. Basic type flux-cored wires may be
Heat Affected Zone (Cold cracking)
capable of getting below 5ml / 100g of weld metal but rutile-cored
There are published guidelines and standards containing welding and metal-cored wire types may give 10 or 15ml / 100g of weld
procedures to avoid hydrogen cracking. For hydrogen cracking to metal. Some recent developments have enabled metal-cored and
occur it is necessary to have a supply of hydrogen to the weld and rutile-cored wire to achieve hydrogen levels below 10ml / 100g and
HAZ, a susceptible hardened microstructure, and tensile stress. If some even below 5ml / 100g.
any one of these three components is eliminated then hydrogen Submerged arc wires, like MIG wires, should be able to give low
cracking will not happen. levels of hydrogen, but when used in combination with different
fluxes the hydrogen level may vary between <5 to 15ml / 100g of
weld metal.

8 Mild Steel
Welding Heat Input Combined Thickness

The heat input from the welding process plays a major role in the The cooling rate of plate in the region of a weld depends on the
heating and cooling cycles experienced by the weld and parent thickness of the plates in the joint, the number of plates meeting at
plate during welding. For a given plate thickness, a high heat input the joint, the amount of heat put into the weld area, and the initial
is likely to result in a slower cooling rate than a low heat input, and temperature of these plates. Cooling occurs by conduction and so
therefore produce a softer microstructure in the HAZ less prone the greater the heat sink the faster the cooling rate is. Therefore,
to hydrogen cracking. However, that does not mean that welding other factors being constant, the thicker the plate the greater the
should always be carried out with a high heat input because this potential for rapid cooling, and so the greater the likelihood of
brings with it other problems, such as loss of mechanical properties hardening in the HAZ of susceptible steels.
and an increased risk of solidification cracking. So it is necessary to
Estimates of preheat will normally take into account the thickness
select a heat input to give a sound weld with the desired mechanical
of each of the components in the joint to allow for the cooling
properties and to use preheat to exert control of the cooling rate.
effect. The thickness of each component is added together to give
Heat input, ‘Q’ may be calculated as: what is normally referred to as ‘combined thickness’ (CT).
k x V x I x 60 How the combined thickness is derived depends on the joint

Q = kJ / mm configuration and is illustrated below:
S x 1000
CT = T1 +T2 +T3…
where ‘V’ is arc Voltage (V), ‘I’ is welding current, and ‘S’ is welding
speed in mm/min Example of combined thickness calculation for butt joint
The value derived from this formula may be multiplied by a factor
‘k’, the thermal efficiency factor for the welding process, to give an
energy input that takes the efficiency of the welding process into
account. Typical thermal efficiency factors are: T1 T2
N ‘k’ = 1.0 for submerged arc welding
N ‘k’ = 0.8 for MIG / MAG, MMA, flux-cored and metal-cored arc
welding Example of combined thickness calculation for fillet joint
N ‘k’ = 0.6 for TIG and plasma welding
For example, when MIG welding, the welding heat input formula
becomes:
T1 T2
0.8 x V x I x 60
Q = kJ / mm
S x 1000
Welding heat input will vary with process and consumable type and T3
size. With small diameter electrodes, low current, and fast welding
speeds, heat inputs below 1.0kJ / mm are readily attained. With large For butt welds, the CT equals the sum of the thicknesses of the
diameter electrodes, high currents, and slower welding speeds, heat two plates being welded; for fillet welds, the CT equals twice the
inputs in excess of 6.0kJ / mm can be reached. thickness of the base plate plus the thickness of the up-stand.
Therefore, for a given plate thickness a fillet joint has a faster
Note that a weld made using a stringer bead technique will have a cooling rate than a butt joint.
lower heat input than a weld made with the same size electrode, at
the same current, but using a weave bead technique.
For more extensive calculation on heat input and preheat
requirements of steel, refer to the WTIA Technical Note 1 and
AS/NZS 1554.1

Mild Steel 8
Welding Consumables Selection Chart

Carbon and Low Alloy Steel Castings
Material Specification Welding Process
AS 2074 ASTM BS MMAW GMAW FCAW SAW

C1 BS3100 AW1 BOC Smootharc 16 BOC Mild Steel BOC SmoothCor 711 Lincoln L60 + 780
BOC Smootharc 18 BOC SmoothCor 70C6 Lincoln L61 + 860
C2 – BS3100 AM1, BOC Smootharc 13 BOC SmoothCor 715 Lincoln L70 + 860
AM2 BOC Smootharc 16 Lincoln L-S3 + 8500
C3 A27 N-1 BS3100 A1 BOC Smootharc 18
C4-1 A27 65-35 – BOC Smootharc 16
C4-2 A27 70-36 BS3100 A2 BOC Smootharc 18
C5 – BS3100 A3
C6 – BS3100 AW2
C7A-1 A214 WCA BS1504 430
C7A-2 A214 WCB BS1504 480
C7A-3 A214 WCB BS1504 540
L1A – BS3100 A4 BOC Smootharc 16
L1B BS3100 A5, A6 BOC Smootharc 18
L2A – BS3100 BW2, Alloycraft 80-B2 Autocraft CrMo1 W55X.B2H (NA) Lincoln LAC-B2 + 880
L2B BW3 Lincoln SL19G
BS3100 BW4
L3A A352 LC2 BS3100 BL2 E5518-C2 (NA) W559AH-Ni3 (NA) W559.Ni3H (NA) W559.Ni3H (NA)
[Alloycraft 80-C1] [Autocraft Mn-Mo] [BOC SmoothCor [Lincoln LAC-Ni2 + 880]
[Jet-LH 8018-C1 MR] 811K2]
L4A – – Alloycraft 80-C1 Autocraft Mn-Mo BOC SmoothCor 811K2 Lincoln LAC-Ni2 + 880
Jet-LH 8018-C1 MR
L5A-1 A217 WC1 BS3100 B1 E4818-A1 (NA) W501AH-A1 W501.A1H Lincoln LA-90 + 880
L5A-2 A356 - 2 [BOC Smootharc 16] [Autocraft Mn-Mo]
[BOC Smootharc 18]
L5B A217 WC6, BS3100 B2 Alloycraft 80-B2 Autocraft CrMo1 W551.B2H (NA) Lincoln LAC-B2 + 880
W11 Lincoln SL19G
L5C A217 WC9 BS3100 B3 Alloycraft 90-B3 W629AH-B3 (NA) W621.B3H (NA) Lincoln LA-93 + 880M
A356 - 10 Lincoln SL20G
L5D BS3100 B4
L5E – BS3100 B5 E6218-5Cr (NA) W621AH-5Cr (NA) W621.5CrH (NA) W621.5CrH (NA)
L5F – BS3100 B6 Alloycraft 90-B3 W629AH-B3 (NA) W62X.B3H (NA) Lincoln LA-93 + 880M
Lincoln SL20G
L5G – – Alloycraft 80-B2 Autocraft CrMo1 W55X.B2H (NA) Lincoln LAC-B2 + 880
L5H – BS3100 B7 Lincoln SL19G
L6 A148 90-60 – Alloycraft 90 W62XAH-G (NA) BOC SmoothCor 115 Lincoln LA-100 + 880
Lincoln 9018G Autocraft NiCrMo
L6A-1 A148 105-85 BS3100 BT1 Alloycraft 110 Autocraft NiCrMo BOC SmoothCor 115 Lincoln LAC-M2 + 880
L6A-2 Jetweld LH-110M MR
L6B-1 A148 115-95 BS3100 BT2 E8318-M (NA) W831AH-G (NA) W831.GH (NA) W831.GH (NA)
L6B-2 A148 150- BS3100 BT3 {Alloycraft 110} {Autocraft NiCrMo} {BOC SmoothCor 115} {Lincoln LAC-M2 + 880}
L6C 135 {Jetweld LH-110M
MR}
NOTES
(1) NA indicates product not available in Australia / NZ.
(2) Products in [ ] brackets have similar specified minimum tensile strength.
(3) Products in { } brackets have under matching specified minimum tensile strength.
(4) Products in [ ] and { } brackets are not pre-qualified to AS 1988–1989.
(5) WeldingWelding
WARNING procedure
can qualification shouldshock,
give rise to electric be carried out noise,
excessive prior eye
to welding
and skin for structural
burns andarc
due to the matching
rays, andstrength applications.
a potential health hazard if you breathe in the emitted fumes and gases.
(6) Consult
Read you BOC welding
all the manufacturer’s process
instructions specialist
to achieve theor visit BOCs
correct weldingInform website
conditions and (subscription required)
ask your employer for thefor more detailed
Materials information.
Safety Data Sheets. Refer to www.boc.com.au or www.boc.co.nz

8 Mild Steel
Ferritic Steels
Steel Type Grade Welding Process
AS, AISI ASTM or FCAW Gas FCAW

Carbon Steels or SAE BS970 MMAW Electrode GMAW Wire Shielded Gasless SAW Wire and Flux
Mild Steel 200 A36 BOC Smootharc 13 BOC Mild Steel BOC SmoothCor 711 Innershield Lincoln L60 + 780 or
250 A106 BOC SmoothCor NR-211-MP 860
300 EN3A 70C6 NR-232
1006 EN201 NS-3M
1010 NR-311
1015
1016
1020
1022
7-430
7-460
350–500 MPa 350 A105 BOC Smootharc 16 BOC Mild Steel BOC SmoothCor 711 Innershield Lincoln L61 + 860
Yield Strength 400 A106 BOC Smootharc 18 BOC SmoothCor NR-211-MP
Steels 70C6
450 EN5 NR-232
XF500 EN5B BOC SmoothCor 715 NS-3M
7-490 EN8A NR-311
1030 EN8
X1033 EN14A
1035
1040
1045
X1320
8620
Medium Tensile 1050 EN43A Alloycraft 80-C1 Autocraft Mn- BOC SmoothCor Innershield Lincoln LA-90 + 880
Steels 1055 EN33 Jet-LH 8018-C1 MR Mo 811K2 NR-208-H
X1340 EN9
EN15A
High Tensile U1058 EN42 Alloycraft 90 Autocraft BOC SmoothCor 115 Innershield Lincoln LA-100 + 880
Steels 1070 EN19 Lincoln 9018G NiCrMo NR-208-H
4140 EN24
4340 EN18D
K5140 EN25
P20 EN30B
6F7
High Tensile U1058 EN42 Alloycraft 110 Autocraft BOC SmoothCor 115 NA Lincoln LAC-M2 + 880
Steels 1070 EN19 Jetweld LH-110M NiCrMo
4140 EN24 MR
4340 EN18D
K5140 EN25
P20 EN30B
6F7
Spring Steels XK5155S EN48 Alloycraft 110 Autocraft BOC SmoothCor 115 NR NR
XK5160S EN45A Jetweld LH-110M NiCrMo
XK9258S MR
9255
XK9261S
Free Cutting 1137 EN1A BOC Smootharc 18 NR NR NR NR

Steels X1112
1141
1144
1146
X1147
1214
Galvanised – – BOC Smootharc 13 BOC Mild Steel NR NR-211-MP NR

Steels
NOTES
(1) Steels listed on one line are not necessarily equivalent.
(2) Consumables listed against a steel may not achieve matching mechanical properties depending on the condition (heat treatment history) of the steel.
(3) Welding procedure qualification should be carried out prior to welding for structural and matching strength applications.
(4) Consult you BOC welding process specialist or visit BOCs Inform website (subscription required) for more detailed information.
NR = Not Recommended, NA = Not Available

Mild Steel 8
Quenched and Tempered High Strength Steels and Wear Plate
Material
Specification MMAW GMAW (Solid) FCAW SAW
AS / NZS 3597 MS Alloycraft 90 Autocraft Mn-Mo BOC SmoothCor 115 Lincoln LA-100 + 880
Grade 500 Lincoln 9018G
(E.g. Bisplate60, Welten60,
Weldox 420) LS Alloycraft 80-C1 BOC Mild Steel BOC SmoothCor 711 Lincoln LA-90 + 880
Jet-LH 8018-C1 MR BOC SmoothCor 715 Lincoln L61 + 860
BOC Smootharc 16 BOC SmoothCor 70C6 or 880
BOC Smootharc 18
AS / NZS 3597 MS Alloycraft 110 Autocraft NiCrMo BOC SmoothCor 115 Lincoln LAC-M2 + 880
Grade 600 Jetweld LH-110M MR
(E.g. Bisplate 70,
LS Alloycraft 90 Autocraft Mn-Mo BOC SmoothCor 811K2 Lincoln LA-100 + 800
Welten 70, Weldox 500)
Lincoln 9018G BOC Mild Steel BOC SmoothCor 711 Lincoln LA-90 + 880
BOC Smootharc 16 BOC SmoothCor 715 Lincoln L61 + 860
AS / NZS 3597 MS Alloycraft 110 Autocraft NiCrMo BOC SmoothCor 115 Lincoln LAC-M2 + 880
Grade 700 Jetweld LH-110M MR
(E.g. Bisplate 80, 80PV,
Welten 80, Weldox 700) LS Alloycraft 90 Autocraft Mn-Mo BOC SmoothCor 811K2 Lincoln LA-100 + 800
Lincoln 9018G BOC Mild Steel BOC SmoothCor 711 Lincoln LA-90 + 880
BOC Smootharc 16 BOC SmoothCor 715 Lincoln L61 + 860
Wear Plates MS NA NA BOC SmoothCor 115 NR

(E.g Bisplate320, 360, 400,
LS Alloycraft 110 Autocraft NiCrMo BOC SmoothCor 811K2 Lincoln LAC-M2 + 880
500, Welten RE, Hardox
400, 500) Jetweld LH-110M MR Autocraft Mn-Mo BOC SmoothCor 711 Lincoln LA-100 + 800
Alloycraft 90 BOC Mild Steel BOC SmoothCor 715 Lincoln LA-90 + 880
Lincoln 9018G BOC SmoothCor 70C6 Lincoln L61 + 860
BOC Smootharc 16 or 880
BOC Smootharc 18
NOTES
MS = Matching Strength
LS = Lower Strength
NR = Not Recommended
NA = Not Available

8 Mild Steel
MMA Electrodes General Purpose
Specifications
Coating Type Rutile-Cellulosic
™
Smootharc 12 Classification AWS /ASME-SFA A5.1 E6013
AS / NZS 1553.1 E4112-0
Approvals Lloyds Register of Grade 2
Shipping
Det Norske Veritas Grade 2
American Bureau Grade 2
Description Shipping
Smootharc™ 12 is a multi-purpose rutile-cellulosic electrode Welding Current* AC, OCV >50V or DC+-
suitable for a wide range of applications in mild steel. The electrode Metal Recovery 90%
is fully positional, including very good appeal in the vertical down * DC– is recommended for root passes.
position. The electrode welds with a crisp steady arc to produce
a smooth weld bead surface to enhance good slag detachability. Chemical Composition, wt% – All-Weld Metal
Performance can be insensitive to rust, dirt and surface coatings, C Si Mn
and has good ability to bridge gaps or poor fit-up. Typical 0.07 0.4 0.5
Application Mechanical Properties – All-Weld Metal

For the welding of all mild steels, sheet metal, tank work and Typical (as welded)
general fabrication. Combined with the excellent strike / re-strike Yield strength 470 MPa
and a high tolerance to large gaps or poor fit up, this electrode is Tensile strength 540 MPa
easy to use and recommended for all round fabrication work. Elongation 24%
Impact energy, CVN 50J @ 0ºC
Technique
Either the contact or free arc technique can be used. For vertical- Packaging Data
down welding the contact weld technique must be used with a high Dia. (mm) 2.5 3.2 2.5 3.2 4.0
rate of travel. Part No. 184133 184134 184135 184136 184137
Weight packet (kg) 1.0 1.0 5.0 5.0 5.0
Storage
Weight carton (kg) 10.0 10.0 15.0 15.0 15.0
Electrodes, once the seal is broken should be stored in heated Electrodes pkt (approx) 55 33 278 168 109
cabinets at 40–50°C.
Welding Parameters
Re-Drying / Conditioning Dia. (mm) 2.5 3.2 4.0
BOC Smootharc™ 12 electrodes are sealed from moisture during Length (mm) 350 350 350
manufacture, but all fluxes are hydroscopic, and when left in the Current (A) 70–100 90–145 120–195
opened state for a period of time will absorb moisture. Moisture is
Voltage (V) 25 25 25
indicated by a noisy or “digging arc”, high spatter, tight slag, undercut
or excessive “cup” on the end of an electrode. Re-dry damp Deposition Data
electrodes for 2 hours at 80–90°C.
Dia. (mm) 2.5 3.2 4.0
Kg weld metal / kg electrodes 0.7 0.7 0.7
Welding Positions
No. of electrodes / kg weld metal 98 48 33
Kg weld metal / hour arc time 0.8 1.2 1.7
Burn off time / electrode (sec) 48 49 58
Data for Welding Horizontal Fillet Joints

Dia. (mm) 2.5 3.2 4.0
Throat thickness 2.0 3.5 5.0
Leg length 2.8 5.0 7.0
Amps 65 125 165
Arc time (sec) 50 52 59
Bead length / electrode (mm) 201 195 208
Weld speed (m / hr) 15.0 12.4 11.2
Note: Operator technique will influence the values shown

Mild Steel 8
General Purpose MMA Electrodes
Specifications
Coating Type Rutile
™
Smootharc 13 Classification AWS /ASME-SFA A5.1 E6013
AS / NZS 1553.1 E4113-0
Shipping
Smootharc™ 13 is a thicker coated all positional rutile electrode Welding Current* AC, OCV >50V or DC+-
that performs very well in the down hand position, exceptionally Metal Recovery 95%
well in the vertical up and overhead positions and can also be used * DC– is recommended for root passes.
in the vertical down position. The electrode welds with a very
smooth, low spatter arc to produce a finely rippled bead surface Chemical Composition, wt% – All-Weld Metal
with excellent slag detachability. C Si Mn
Typical 0.06 0.4 0.5
Application
For welding mild steels, sheet metal, tank work and general Mechanical Properties Typical All-Weld Metal Analysis
fabrication. Combined with the excellent strike / restrike and a high Yield strength 470 MPa
tolerance to large gaps or poor fit up, this electrode is easy to use Tensile strength 540 MPa
and recommended for all round fabrication work. Especially good Elongation 25%
for the less experienced welder. Impact energy, CVN 70J @ 0ºC
Technique Packaging Data

Either the contact or free arc technique can be used. For vertical- Dia. (mm) 2.5 3.2 2.5 3.2 4.0
down welding the contact weld technique must be used with a high Part No. 187143 187144 187145 187146 187147
rate of travel.
Weight packet (kg) 1.0 1.0 5.0 5.0 5.0
Weight carton (kg) 10.0 10.0 15.0 15.0 15.0
Storage
Electrodes pkt (approx) 46 34 230 170 106
Electrodes, once the seal is broken should be stored in heated
cabinets at 40–50°C. Welding Parameters
Dia. (mm) 2.5 3.2 4.0
Re-Drying / Conditioning
Length (mm) 350 350 350
BOC Smootharc™ 13 electrodes are sealed from moisture during Current (A) 60–95 110–130 140–165
manufacture, but all fluxes are hydroscopic, and when left in the
opened state for a period of time will absorb moisture. Moisture is
indicated by a noisy or “digging arc”, high spatter, tight slag, undercut Deposition Data
or excessive “cup” on the end of an electrode. Re-dry damp
Dia. (mm) 2.5 3.2 4.0
electrodes for 2 hours at 80–90°C.
Welding Positions No. of electrodes / kg weld metal 86 57 38

Dia. (mm) 2.5 3.2 4.0
Amps 65 125 165
Weld speed (m / hr) 15.2 12.4 11.2
Note: Operator technique will influence the values shown.

8 Mild Steel
MMA Electrodes Iron Powder
Specifications
Coating Type Rutile, Iron powder
™
Smootharc 24 Classification AWS /ASME-SFA
AS / NZS 1553.1
A5.1 E7024
E4824-0
Shipping
Smootharc™ 24 is a rutile-coated iron powder electrode with 160% Welding Current AC, OCV >50V or DC+-
recovery designed for high productivity welding in heavier section Metal Recovery 160%
mild steel. Excellent profile mitre fillets are produced having a Chemical Composition, wt% – All-Weld Metal
smooth transition with the base material, ensuring excellent slag C Si Mn
detachability.
Typical 0.07 0.5 0.7
Application Mechanical Properties Typical All-Weld Metal Analysis

Smootharc™ 24 has been designed to produce the highest possible Yield strength 470 MPa
productivity when depositing fillet welds with a leg length in the Tensile strength 560 MPa
4 to 6 mm range in the heavier section construction steels. This
Elongation 24%
electrode performs exceptionally well when welding “inside corner”
Impact energy, CVN 50J @ 0°C
fillets. Fillet welds can also be made in primer treated material
without porosity or fusion defects along the top edge.
Packaging Data
Technique Dia. (mm) 3.2 4.0 5.0
The best results are obtained using the touch welding technique Part No. 186166 186167 186168
with the electrode held at a sufficient angle to prevent the molten Weight packet (kg) 6.0 6.0 5.5
slag from crowding the arc. AC is recommended as it reduces arc Weight carton (kg) 18.0 18.0 16.5
blow, particularly at the high currents required with large diameter Electrodes pkt (approx) 91 60 36
electrodes.
Welding Parameters
Storage Dia. (mm) 3.2 4.0 5.0
Electrodes, once the seal is broken should be stored in heated Length (mm) 450 450 450
cabinets at 40–50°C. Current (A) 130–160 150–235 200–320
BOC Smootharc™ 24 electrodes should be re-dried at 100–120°C Deposition Data
for 2 hours. Dia. (mm) 3.2 4.0 5.0
Welding Positions No. of electrodes / kg weld metal 21 14 9

Dia. (mm) 3.2 4.0 5.0
Amps 135 200 275
Weld speed (m / hr) 14.7 16.6 18.6

Mild Steel 8
Hydrogen Controlled MMA Electrodes
Specifications
Coating Type Basic
™
Smootharc 16 Classification AWS /ASME-SFA A5.1
AS / NZS 1553.1
E7016-1 H4
E4816-4 H5
Approvals Lloyds Register of Grade 3, 3Ym H5
Shipping
Det Norske Veritas Grade 3Y H5
American Bureau Grade 3, 3Y HH
Smootharc™ 16 is a basic coated 105% recovery electrode intended Welding Current* AC, OCV 60V or DC+-
for general welding applications where controlled hydrogen and Metal Recovery 105%
medium tensile properties are required. It has excellent mechanical Hydrogen content / <4ml
and X-ray properties. 100g weld metal
* DC– is recommended for root passes.
Application
Chemical Composition, wt% – All-Weld Metal
For the welding of all section steels, tank work and general C Si Mn P S
fabrication. Suitable for unalloyed, micro alloyed and low alloyed
Typical 0.06 0.5 1.0 0.015 0.005
steels.
Mechanical Properties – All-Weld Metal
Technique Typical (as welded) PWHT Typical*
As with all hydrogen-controlled electrodes, as short an arc as Yield strength 470 MPa 420 MPa
possible should be kept at all times. When starting with a new Tensile strength 560 MPa 515 MPa
electrode the arc should be initiated ahead of the start of the weld Elongation 25% 31%
or crater and worked back over this distance before continuing the Impact energy, CVN 70J @ -46°C 150J @ -40°C
weld in the required direction. On larger size joints several stringer *PWHT 620°C 1 hour
beads should be used in preference to one large weave bead to
ensure optimum mechanical properties. DC– should be used for Packaging Data
root passes where poor fit-up is a factor which should be taken into
Dia. (mm) 2.5 3.2 4.0 5.0
account.
Part No. 184143 184144 186148
Storage Weight packet (kg) 1.0 1.0 5.5
Weight carton (kg) 10.0 10.0 16.5
BOC Smootharc™ 16 electrodes when removed from a freshly
Electrodes pkt (approx) 51 29 54
opened tin will have <4 ml / 100g hydrogen. Once the seal is broken
electrodes should be stored in heated cabinets at 80–120°C. Part No. 186145N 186146N 186147N
Weight packet (kg) 3.5 3.5 3.5
Re-Drying / Conditioning Weight carton (kg) 10.5 10.5 10.5
Basic (Low Hydrogen) type electrodes are redried at temperatures Electrodes pkt (approx) 178 101 66
of 350–400°C for 1–2 hours to achieve a hydrogen level of Welding Parameters
5–10 ml / 100g of weld metal, and restricted to 5 redries. To Dia. (mm) 2.5 3.2 4.0 5.0
achieve extreme low hydrogen levels, <4 ml / 100g, 420–440°C is
Length (mm) 350 350 350 450
recommended for 1–2 hours and restricted to 1 re-dry.
Current (A) 60–90 80–160 110–210 155–290
Welding Positions Voltage (V) 24 26 25 25
Deposition Data
Dia. (mm) 2.5 3.2 4.0 5.0
Kg weld metal / kg electrodes 0.64 0.66 0.66 0.70
No. of electrodes / kg weld metal 80 44 29 14
Kg weld metal / hour arc time 0.9 1.2 1.7 2.4
Burn off time / electrode (sec) 50 65 70 96

Dia. (mm) 2.5 3.2 4.0 5.0
Throat thickness 3.2 4.2 5 6
Leg length 4.5 6 7 8.5
Amps 75 115 170 220
Arc time (sec) 55 67 73 98
Bead length / electrode 135 160 200 270
(mm)
Weld speed (m / hr) 0.64 0.72 0.72 0.76

8 Mild Steel
MMA Electrodes Hydrogen Controlled
Specifications
Coating Type Basic
™
Smootharc 18 Classification AWS /ASME-SFA AS.1
AS / NZS1553.1
E7018-1 H4
E4818-4 H5
Approvals Lloyds Register of Grade 3, 3Y, H5
Shipping
Det Norske Veritas Grade 3YH5
American Bureau Grade 3, H5, 3Y
Smootharc™ 18 is a basic-coated low hydrogen AC / DC electrode Welding Current* AC, OCV 70V or DC+-
for which the outstanding all round operability has been optimised. Metal Recovery 120%
The smooth, soft arc, easy slag control, all positional welding Hydrogen content / 100g <4ml
with low spatter and excellent slag removal provide maximum weld metal
operator appeal. The electrode is suitable for welding mild and * DC– is recommended for root passes.
higher strength steels. It combines strength and toughness and is
particularly suitable for heavily restrained sections where there
C Si Mn P S
can be risk of cracking due to weld stress.
Typical 0.05 0.6 1.4 0.015 0.010
Application
With its excellent general operability and good positional welding
Typical (as welded) PWHT Typical*
characteristics, the Smootharc™ 18 is used for general fabrication
Yield strength 530 MPa 490 MPa
work as well as pipe welding where the fine spray transfer provides
precise weld pool control. The fine arc spray also makes it an ideal Tensile strength 600 MPa 510 MPa
electrode for the experienced welder, and for positional work in Elongation 26% 29%
demanding applications. Impact energy, CVN 60J @ -40°C 130J @ -20°C
40J @ -46°C
The electrode produces a finely rippled bead surface and
*PWHT 620°C 1 hour
smooth transition with the base material. This together with the
exceptionally good slag detachability, even in root runs, gives the Packaging Data
Smootharc™ 18 superior radiographic quality. It is also an ideal
Dia. (mm) 2.5 3.2 4.0 5.0
electrode for use on AC machines with an OCV of 70V.
Part No. 184155 N 184156 N 184157 N 184158
Technique Weight packet (kg) 3.5 3.5 3.5 5.5
Weight carton (kg) 10.5 10.5 10.5 16.5
As with all basic hydrogen-controlled electrodes, as short an arc
as possible should be kept at all times. When starting with a new Electrodes pkt (approx) 148 89 64 55
electrode the arc should be initiated ahead of the start of the weld
Welding Parameters
or crater and worked back over this distance before continuing the
weld in the required direction. On larger size joints several stringer Dia. (mm) 2.5 3.2 4.0 5.0
beads should be used in preference to one large weaved bead to Length (mm) 350 350 350 450
ensure optimum mechanical properties. Current (A) 80–110 110–155 140–205 200–285
Voltage (V) 23 24 25 25
DC– should be used for root passes where poor fit-up is a factor
which should be taken into account.
Deposition Data
Storage Dia. (mm) 2.5 3.2 4.0 5.0
Kg weld metal / kg electrodes 0.71 0.72 0.74 0.75
BOC Smootharc™ 18 electrodes when removed from a freshly
No. of electrodes / kg weld metal 60 35 25 13
opened tin will have <4 ml / 100g weld metal hydrogen. Once the seal is
broken, electrodes should be stored in heated cabinets at 80–120°C. Kg weld metal / hour arc time 1.0 1.6 2.1 2.9
Burn off time / electrode (sec) 54 57 73 91
Basic (Low Hydrogen) type electrodes are re-dried at temperatures
Dia. (mm) 2.5 3.2 4.0 5.0
of 350–400°C for 1–2 hours to achieve a hydrogen level of
5–10 ml / 100g of weld metal, and restricted to 5 re-dries. To Throat thickness 3.0 4.2 5.0 6.0
achieve extreme low hydrogen levels, <4 ml / 100g, 420–440°C is Leg length 4.3 6.0 7.0 8.5
recommended for 1–2 hours and restricted to 1 re-dry. Amps 85 125 175 225
Arc time (sec) 61 74 81 104
Welding Positions Bead length / electrode (mm) 163 215 226 287
Weld speed (m / hr) 9.6 10.6 10.1 9.7

Mild Steel 8
Cellulosic MMA Electrodes
Ferrocraft 11 Classifications Typical all weld metal analysis (%)

N Cellulose pipe welding electrode AS / NZS 1553.1: E4111-2 C Mn Si S P
AWS /ASME-SFA A5.1: E6011 0.12% 0.47% 0.10% 0.01% 0.01%
N All positional, AC / DC capabilities
N High penetration, root pass applications Typical all weld metal mechanical properties Approvals
N White flux colour for easy identification Yield stress 415 MPa Lloyds Register of Shipping Grade 3, 3Y
N Recommended for root pass welding Tensile strength 500 MPa American Bureau of Shipping Grade 3
where the “stovepipe” or “flick” Elongation 28% Det Norske Veritas Grade 3
techniques can be used to achieve full CVN impact values 90J av @ -20°C American Bureau of Shipping AWS A5.1
root penetration E6011
N The root, hot fill and capping pass
welding of-pipelines, pressure vessels, Packaging and operating data AC (minimum 65 OCV) DC+ or DC- polarity
storage tanks, workshop and field
Electrode Approx no. Current
construction
Size (mm) Length (mm) rods / kg Range (A) Packet (kg) Carton (kg) Part No.
2.5 300 62 65–85 5 15 (3 x 5) 611132
3.2 380 33 95–125 5 15 (3 x 5) 611133
4.0 380 22 130–160 5 15 (3 x 5) 611134
PipeArc 6010P Classifications Typical all weld metal analysis (%)

N User friendly pipe welding electrode AS / NZS 1553.1: E4110-2 C Mn Si S P
AWS /ASME-SFA A5.1: E6010 0.11% 0.46% 0.15% 0.011% 0.012%
N Lower spatter levels and easy slag
removal
Typical all weld metal mechanical properties Approvals
N Excellent reverse bead formation Yield stress 400 MPa Lloyds Register of Shipping Grade 3
on butts Tensile strength 510 MPa American Bureau of Shipping AWS A5.1
N Versatile “out-of-position” capabilities Elongation 30% E6010
N Batch numbered for on-the-job CVN impact values 65J av @ -20°C Det Norske Veritas Grade 3
traceability 40J av @ -30°C American Bureau of Shipping Grade 3
N Used to weld out (root, fill and cap)
steel pipes such as API 5L, 5LX grades Packaging and operating data DC+ (Direct Current Electrode Positive) polarity
X42 to-X52
Electrode Approx no. Current
N Welding of ‘V’ butt (groove weld) Size (mm) Length (mm) (rods / kg) Range (A) Packet (kg) Carton (kg) Part No.
joints in higher strength steels, 2.5 300 66 45–85 5 15 (3 x 5) 615602
including 5LX grades X60, X65 and 3.2 350 39 70–125 5 15 (3 x 5) 615603
X70. Recommended for root pass
4.0 350 25 120–190 5 15 (3 x 5) 615604
welding only
4.8 350 18 160–250 5 15 (3 x 5) 615605
The results quoted in this data sheet are obtained from the listed Shipping Societies (ABS, DNV, LRS) Conformance Tests
and Procedures. Actual weld metal mechanical properties achieved with PipeArc 6010P are influenced by many factors
including, base metal analysis, welding parameters / heat input used, number of weld passes and run placement etc. On
the job mechanical tests may produce different results. Please consult your nearest BOC branch for welding procedure
recommendations.

8 Mild Steel
MMA Electrodes General Purpose
GP 6012 Classifications Typical all weld metal analysis (%)

N Versatile general purpose electrode AS / NZS 1553.1: E4112-0 C Mn Si
AWS /ASME-SFA A5.1: E6013 0.07% 0.45% 0.30%
N All positional welding capabilities
N Ideal for the vertical-down welding Typical all weld metal mechanical properties Approvals
of thin steel sections
Yield stress 430 MPa Lloyds Register of Shipping Grade 2
N Wrought iron furniture Tensile strength 490 MPa American Bureau of Shipping Grade 2
N Suitable for welding mild steel plate, Elongation 29% Det Norske Veritas Grade 2
sheet metal and galvanised iron sheet, CVN impact values 80J av @ 0°C
ducting, hoppers, tanks, pipes and low
pressure pipelines
Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity
N Excellent for welding joints with
Electrode Approx No. Current
poor fit-up
Size (mm) Length (mm) (rods / kg) Range (A) Packet (kg) Carton (kg) Part No.
2.5 300 55 55–80 5 15 (3 x 5) 611142
3.2 380 30 90–130 5 15 (3 x 5) 611143
4.0 380 19 130–180 5 15 (3 x 5) 611144
Ferrocraft 12XP Classifications Typical all weld metal analysis (%)

N General purpose “XP series” electrode AS / NZS 1553.1: E4112-0 C Mn Si
AWS /ASME-SFA A5.1: E6013 0.07 0.60 0.50
N Easy striking – hot or cold
N Xtra smooth performance (XP) Typical all weld metal mechanical properties Approvals
N Versatile – all positional capabilities Yield stress 460 MPa Lloyds Register of Shipping Grade 2, 2Y
N Ideal for vertical-down fillet welding Tensile strength 500 MPa American Bureau of Shipping Grade 2, 2Y
Elongation 27% Det Norske Veritas Grade 2
N All positional fillet welding of steel
CVN impact values 75J av @ 0°C American Bureau of Shipping AWS A5.1
furniture, plates, fences, gates, pipes
E6013
and-tanks etc
N Red flux colour for easy identification Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity
Electrode Approx
Size Length No. Current Easyweld
(mm) (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Handipack Part No.
2.0 300 95 40–70 half pack 2.5 15 (6 x 2.5) – 612231
2.0 300 95 40–70 – – 90 rods 322128
2.5 300 55 60–100 5 15 (3 x 5) – 611232
2.5 300 55 60–100 half pack 2.5 15 (6 x 2.5) – 612232
2.5 300 55 60–100 – – 50 rods 322129
3.2 380 30 90–130 5 15 (3 x 5) – 611233
3.2 380 30 90–130 half pack 2.5 15 (6 x 2.5) – 612233
3.2 380 30 90–130 – – 25 rods 322138
4.0 380 19 130–180 5 15 (3 x 5) – 611234
Easyweld Blister pack
10 x 2.5 mm, 5 x 3.2 mm Rod Blister Pack 322213

Mild Steel 8
General Purpose MMA Electrodes
Satincraft 13 Classifications Typical all weld metal analysis (%)

N General purpose, rutile type electrode AS / NZS 1553.1: E4113-0 C Mn Si
AWS /ASME-SFA A5.1: E6013 0.07% 0.60% 0.50%
N Outstanding operator appeal
N Versatile – all positional capabilities Typical all weld metal mechanical properties Approvals
N Smooth mitre fillet welds with low Yield stress 460 MPa Lloyds Register of Shipping Grade 2
spatter Tensile strength 520 MPa American Bureau of Shipping Grade 2
N Developed and manufactured in Australia Elongation 28% Det Norske Veritas Grade 2
CVN impact values 60J av @ 0°C American Bureau of Shipping AWS A5.1
N Blue flux colour for instant identification
E6013
N General workshop, field and structural
welding of mild or galvanised steel
components such as pipes, tanks, frames, Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity.
fences and gates etc Electrode Approx no. Current Easyweld
Size (mm) Length (mm) (rods / kg) Range (A) Packet (kg) Carton (kg) Handipack Part No.
2.5 300 53 55–90 5 15 (3 x 5) – 611182
2.5 300 53 55–90 half pack 2.5 15 (6 x 2.5) – 612182
2.5 300 53 55–90 – – 50 rods 322135
3.2 380 29 90–135 5 15 (3 x 5) – 611183
3.2 380 29 90–135 half pack 2.5 15 (6 x 2.5) – 612183
3.2 380 29 90–135 – – 25 rods 322136
4.0 380 20 135–180 5 15 (3 x 5) – 611184
Weldcraft Classifications Typical all weld metal analysis (%)

N Rutile – basic type electrode AS / NZS 1553.1: E4113-2 C Mn Si
AWS /ASME-SFA A5.1: E6013. 0.07 0.60 0.50
N Higher radiographic quality
N Excellent mechanical properties Typical all weld metal mechanical properties Approvals
N Versatile “out-of-position” capabilities Yield stress 420 MPa Lloyds Register of Shipping Grade 3
N “On-site” and workshop welding Tensile strength 490 MPa American Bureau of Shipping Grade 3
where better mechanical properties Elongation 28% Det Norske Veritas Grade 3
are required and the work cannot CVN impact values 60J av @ -20°C
be re-positioned to allow welding
in the downhand. The electrode is
recommended for welding joints subject
to radiographic examination in pressure Electrode Approx. Current
vessel, ship building, bridge and storage Size (mm) Length (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Part No.
tank fabrications 2.5 300 51 60–95 5 15 (3 x 5) 611202
3.2 380 27 95–135 5 15 (3 x 5) 611203
4.0 380 17 130–185 5 15 (3 x 5) 611204

8 Mild Steel
MMA Electrodes Iron Powder

N Rutile type, medium iron powder AS / NZS 1553.1: E4814-2 C Mn Si
electrode AWS /ASME-SFA A5.1: E7014 0.06 0.65 0.30
N Excellent operator appeal
N Versatile – all positional capabilities Yield stress 430 MPa Lloyds Register of Shipping Grade 3
N Easy striking – hot or cold Tensile strength 500 MPa American Bureau of Shipping Grade 3
N Ideal for vertical-down fillet welding Elongation 30% Det Norske Veritas Grade 3
CVN impact values 90J av @ -20°C American Bureau of Shipping AWS A5.1
N Workshop or “on-site” repair,
E7014
maintenance and fabrication welding jobs
where the iron powder addition gives
improved usability over conventional Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity
E4112 rutile type electrodes Electrode Approx No. Current Packet Easyweld
N Ideal vertical-down fillet welding Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Handipack Part No.
electrode for-thinner steel sections 2.5 300 50 55–100 5 15 (3 x 5) – 611242
using “touch welding” techniques 2.5 300 50 55–100 – – 20 rods 322130
3.2 380 26 95–140 5 15 (3 x 5) – 611243
4.0 380 17 140–195 5 15 (3 x 5) – 611244
5.0 450 9 200–260 5 15 (3 x 5) – 611245

N Rutile type high iron powder electrode AS / NZS 1553.1: E4824-0 C Mn Si
AWS /ASME-SFA A5.1: E7024. 0.05% 0.75% 0.25%
N High productivity fillet and butt welding
in all downhand positions
N Self releasing slag Yield stress 440 MPa Lloyds Register of Shipping Grade 2Y
N Recommended for high production Tensile strength 512 MPa American Bureau of Shipping Grade 2
welding where large standing fillet welds Elongation 25% Det Norske Veritas Grade 2
are required CVN impact values 60J av @ 0°C American Bureau of Shipping AWS A5.1
N Ideal electrode for heavy structural E7024
welding – tanks, frames, girders, beams,
ship structures, rolling stock and general Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity
fabrication in the workshop or “on-site” Electrode Approx No. Current Packet
Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Part No.
2.5 350 34 85–120 4 12 (3 x 4) 611252
3.2 380 18 130–170 5 15 (3 x 5) 611253
4.0 450 11 185–235 5 15 (3 x 5) 611254
5.0 450 7 260–320 5 15 (3 x 5) 611255
Ferrocraft 22 is formulated to operate with AC (min 45 OCV), DC+ or DC- polarity.
The preferred polarity for DC fillet welding is DC+.

Mild Steel 8
Ferrocraft 16TXP Classifications Typical diffusible hydrogen levels to AS 3752

N Now in Hermetically sealed 3kg Cans AS / NZS 1553.1 E4816-2 H10 7.0–7.5 ml of hydrogen / 100 gm of
AWS /ASME-SFA A5.1: E7016 H8 deposited weld metal*
N “XP series” E4816 / E7016 type
*Reconditioned for 2 hours maximum at 300°C
electrode
Typical all weld metal mechanical properties
N Great operator appeal / hydrogen Yield stress 460 MPa Approvals
controlled Tensile strength 550 MPa Lloyds Register of Shipping Grade 3, 3Y
N Longer 350 mm 2.5 mm size for fewer Elongation 27% H15
electrode change-overs and less wastage CVN impact values 90J av @ -20°C American Bureau of Shipping Grade 3H10,
N Easy operation, reliable Grade 3 weld 3Y
metal properties and low hydrogen Typical all weld metal analysis (%) Det Norske Veritas Grade 3Y H10
status of Ferrocraft 16TXP make the C Mn Si S P
electrode ideal for maintenance welding 0.07 1.50 0.65 0.010 0.015
jobs, including the repair of earth-moving
equipment and the “buttering” of steel Packaging and operating data AC (minimum 45 OCV) DC+ or DC- polarity
sections prior to the application of Electrode Approx No. Current Packet
hard surfacing. Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Part No.
2.5 350 56 50–90 3 12 (4 x 3) 613562
3.2 350 30 85–140 3 12 (4 x 3) 613563
4.0 350 21 135–190 3 12 (4 x 3) 613564
Easyweld blister pack
10 x 2.5 mm, 5 x 3.2 mm rod Ferrocraft 16TXP Blister Pack 322214
Ferrocraft 16TXP is formulated to operate with AC (45 OCV min) DC+ or DC- polarity. The preferred polarity for fillet
welding and fill and capping passes is DC+.
Ferrocraft 7016 Classifications Typical diffusible hydrogen levels to AS 3752

N Fully basic hydrogen controlled AS / NZS 1553.1: E4816-3 H10 5.0–6.0 mls of hydrogen /
E4816 / E7016 type electrode AWS /ASME-SFA A5.1: E7016 H8 100 gm of deposited weld metal*
BS EN 499: E42 4 B 12 H10 *Reconditioned for 2 hours maximum at 300°C
N Excellent operator appeal in all positions
N Ideal for fill and capping passes Typical mechanical properties Approvals
N Excellent impact toughness to -30°C Yield stress 480 MPa Lloyds Register of Shipping Grade 3Y
Tensile strength 570 MPa H10
N Applications include pressure vessel
fabrication, bridge, ship building, Elongation 25% American Bureau of Shipping Grade 3H10,
CVN impact values 125J av @ -20°C 3Y
equipment repair and maintenance work
100J av @ -30°C Det Norske Veritas Grade 3Y
H10
Typical all weld metal analysis (%) American Bureau of Shipping AWS A5.1
C Mn Si S P E7016
0.08 1.10 0.65 0.009 0.019

Electrode Approx No. Current Packet
3.2 380 29 90–130 5 15 (3 x 5) 611743
4.0 380 19 120–180 5 15 (3 x 5) 611744
Ferrocraft 7016 is formulated to operate with AC (55 O.CV), DC+ or DC- polarity. The preferred polarity for fillet welding
and fill and capping passes is DC+.

8 Mild Steel
Ferrocraft 55U Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N Basic, hydrogen controlled E4816 / E7016 Yield stress 460 MPa 7.0–7.5 ml of hydrogen /
type electrode Tensile strength 570 MPa 100 gm of deposited weld metal*
N Thin coated for easier joint access Elongation 29% *Reconditioned for 2 hours maximum at 300°C
N Purple end tip colour for instant CVN impact values 70J av @
identification -20°C Approvals
N Designed specifically for the all Lloyds Grade 3, 3Y H15

Typical all weld metal analysis (%) Register of
positional (except vertical-down) root
C Mn Si S P Shipping
pass welding of-steel pipes and plates
0.07 0.80 0.77 0.007 0.013 Det Norske Grade 3Y H10
Classifications Veritas
AS / NZS 1553.1: E4816-2 H10

AWS /ASME-SFA A5.1: E7016 H8 Packaging and operating data AC (minimum 70 OCV) DC+ or DC- polarity
Electrode
Approx no. Current Packet
2.5 350 53 40–90 5 15 (3 x 5) 611492
3.2 380 31 60–140 5 15 (3 x 5) 611493
4.0 380 19 90–180 5 15 (3 x 5) 611494
Ferrocraft 55U is formulated to operate on low welding current to accommodate poor joint fit up and large root gaps. The
electrode is suitable for AC (minimum 70 O.CV), DC+ or DC- polarity. The preferred polarity for ease of use in root pass
welding is DC-. Where it is necessary to maximise weld metal toughness fill and capping passes should be deposited with
DC+ polarity.
Ferrocraft 61 Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N Basic coated, hydrogen controlled Yield stress 450 MPa 8.5–9.0 ml of hydrogen /
E4818 / E7018 type electrode Tensile 545 MPa 10 gm of deposited weld metal*
N Excellent out-of-position welding strength *Reconditioned for 2 hours maximum at 300°C
N Reliable impact properties to -30°C Elongation 29%

CVN impact 160J av @ -20°C Approvals
N Batch number identification values 130J av @ -30°C Lloyds Register of Shipping Grade 3, 3Y H15
N Designed for all positional (especially
American Bureau of Grade 3H15, 3Y
vertical-up) fillet and butt welding Typical all weld metal analysis (%) Shipping
applications on-heavier steel sections C Mn Si S P Det Norske Veritas Grade 3Y H10
under high restraint such as machinery 0.06 1.45 0.45 0.010 0.012 American Bureau of AWS A5.1 E7018
parts, pressure vessels, mining Shipping
equipment, pipework, ship construction
and all maintenance and-repair-work
Classifications Electrode
Approx No. Current Packet
AS / NZS 1553.1: E4818-3 H10 Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Part No.
AWS /ASME-SFA A5.1: E7018
2.5 350 42 65–100 5 15 (3 x 5) 611342
3.2 380 24 95–150 5 15 (3 x 5) 611343
4.0 380 16 145–220 5 15 (3 x 5) 611344
5.0 450 9 195–270 5 15 (3 x 5) 611345
Ferrocraft 61 is formulated to operate with AC (55 O.CV min), DC+ or DC- polarity. The preferred polarity for fillet welding
and fill and capping passes is DC+.

Mild Steel 8
Ferrocraft 61 H4 Typical All Weld Metal Mechanical Properties Typical Diffusible Hydrogen Levels To AS 3752
N Hermetically Sealed Cans Yield Stress 450 MPa. 3.0–3.5 mls of hydrogen / 100gms of deposited
N Highly Basic, E4818 / E7018 Type Tensile Strength 545 MPa. weld metal
Hydrogen controlled electrode Elongation 28%.
CVN impact Values 150J av @ -20°C Approvals
N Advanced moisture resistant
flux coating 100J av @ -40°C Lloyd’s Register of Shipping Grade 3,
80J av @ -50°C 3YH5
N Very low “H5 / H4” diffusible American Bureau of Shipping Grade 3H5,
hydrogen class Typical All Weld Metal Analysis (%) 3Y
N C-Mn weld deposit for reliable C Mn Si S P Det Norske Veritas Grade 3YH5
Impact properties to -40°C 0.07 1.50 0.35 0.07 0.012
N Recommended for critical DC
welding applications Packaging and Operating Data AC (minimum 55 OCV), DC+ or DC- polarity
N Batch Number Identification Electrode Approx no. Current
Classifications Size (mm) Length (mm) rods / kg Range (A) Can (kg) Carton Part No.
AS / NZS 1553.1: E4818-5 H5R 2.5 350 42 65–100 3 12 (4x3) 614342
AWS /ASME-SFA A5.1: E7018-1 H4R 3.2 380 24 95–150 3 12 (4x3) 614343
4.0 380 16 145–220 3 12 (4x3) 614344

8 Mild Steel
MMA Electrodes Cellulosic
Fleetweld 5P Fleetweld 5P+

All position, deep penetration welding Similar to traditional Fleetweld 5P, plus quick
of pipelines and critical refinery work. striking, easy slag removal and improved
X-ray quality. final appearance.
Classification Classifications
AS / NZS 1553.1: E4110-2 AS / NZS 1553.1: E4110-2
AWS A5.1: E6010 AWS A5.1: E6010
Size (mm) Weight (kg) Part No. Size (mm) Weight (kg) Part No.
2.4 22.68 Can ED010211 2.4 22.68 Can ED010283
3.2 22.68 Can ED010203 3.2 22.68 Can ED010278
4.0 22.68 Can ED010216 4.0 22.68 Can ED010285
4.8 22.68 Can ED010207 4.8 22.68 Can ED010281
Jetweld LH-70 Conarc 49C

Controlled hydrogen, semi-iron powder The offshore electrode if Ni-alloying is
type for X-ray quality all positional welding not allowed, good CTOD at -10°C. Good
with mechanical properties in 495–555 MPa pipe welding properties. Reliable impact
(72,000–80,000 psi) range. toughness at -40°C. Excellent X-ray
soundness. Basic, extremely low hydrogen
Classifications (HDM <5ml / 100g) coated electrode with
120% recovery.
AS / NZS 1553.1: E4818-4H5, AWS A5.1: E7018
Classification
Size (mm) Weight (kg) Part No.
AWS. A5.1: E7018-1-H4R
2.4 22.68 Can ED010568
3.2 22.68 Can ED010561 Size (mm) Packet (kg) Product No
4.0 22.68 Can ED010575 3.20 4.40 509243
4.8 22.68 Can ED010564 4.00 4.70 509359
5.6 27.2 Can ED010577 2.50 1.40 511420
3.20 2.00 511437
4.00 1.60 511505
EMR-Sahara product.(Hermetically sealed packaging i.e.
requires no pre-baking)

Mild Steel 8
GMAW Wire
Recommended Shielding Gases

Argoshield Light
BOC Mild Steel MIG Wire Argoshield Universal

Argoshield Heavy
Argoshield 40
Argoshield 52
Argoshield 54
Argoshield 100
Description Welding Grade CO2
BOC Mild Steel MIG Wire is a premium quality copper coated Flow rate 15-20 L/min.
mig wire produced from high quality double deoxidised rod. The
higher manganese and silicon levels ensure improved weld metal Chemical composition, wt% – Wire
deoxidation, making BOC Mild Steel MIG Wire an excellent choice
Typical C Si Mn
for welding on metal with a medium to high presence of mill scale
0.07 0.85 1.45
or rust. The higher silicon levels promote a smooth bead surface
and a flat fillet bead profile with equal leg length and uniform
wetting is easily achieved. Mechanical properties – all weld metal
Using Argoshield Using CO2
The wire is designed for both single- and multiple-pass welding in
all positions. Yield strength 452 MPa 420 MPa
The wire is copper coated for increased shelf life and to ensure Tensile strength 560 MPa 525 MPa
good electrical conductivity with reduced friction during high Elongation 27% 31%
speed welding.
Impact energy, CVN 84J min av @ –30°C 72J min av @ –30°C
BOC Mild Steel MIG Wire has excellent, smooth wire feedability
and is suitable for welding with dip (short circuit), spray arc and
Packaging Data – Mini spool (100mm Ø)
pulsed arc transfer using Ar / CO2 or CO2 shielding gases.
Dia. (mm) 0.6 0.8 0.9
Application Part No. 1061108 1081108 1091108
Winding Random Random Random
BOC Mild Steel MIG Wire is recommended for welding of mild and
medium tensile strength steels and is an excellent choice for general Spool weight (kg) 1 1 1
steel construction, sheet metal applications, pressure
vessel fabrication, structural welding and pipe welding. Packaging Data – Handi spool (200mm Ø)
Dia. (mm) 0.6 0.8 0.9
Welding positions Part No. 1061150 1081150 1091150
Winding Random Random Random
Spool weight (kg) 5 5 5
Packaging Data – Spool (300mm Ø)

Dia. (mm) 0.6 0.8 0.9 1.0 1.2
Specifications Part No. 1061155 1081155 1091155 1101155 1121155
Classifications AWS /ASME-SFA A5.18 ER70S-6 Winding Random Precision Precision Precision Precision
AS / NZS 2717.1 ES6-GC / M-W503AH PLW PLW PLW PLW
Spool weight (kg) 15 15 15 15 15
Approvals* Lloyds Register of Grade 3S, 3YS Pallet weight (kg) 810 810 810 810 810
Shipping
*with Ar / CO2 shielding gas. Packaging Data – Smoothpak Drum
Dia. (mm) 0.9 1.0 1.2
Part No. 1091250 1101250 1121250
Drum weight (kg) 250 250 250
Welding Parameters
Dia. (mm) 0.6 0.8 0.9 1.0 1.2
Current range (A) 40–100 60–150 90-220 100-240 120-320
Voltage (V) 12–22 15–24 16-30 17-30 18-32

8 Mild Steel
GMAW Wire
Autocraft Super Steel

Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N A low carbon, triple deoxidised steel
wire for GMA welding Argon 1.0–2.0 ml of hydrogen / 100 gm of
20–25% CO2 deposited weld metal.
N For use with welding grade CO2 or
argon based shielding gases Yield stress 425 MPa
Tensile strength 520 MPa Recommended shielding gas
N Triple deoxidised for superior weld
deposit quality and resistance to Elongation 34% Argoshield® Universal
porosity Argoshield® 52
CVN impact values 75J av @ -20°C
Argoshield® Heavy
N The ideal choice for the welding of rusty
or-mill scaled plates and pipes and the Argoshield® Light
Typical wire analysis (%) Industrial Grade CO2
root pass welding of pipes, tanks, and
heavy walled joints C: 0.05 Mn: 1.10 Si: 0.55
Ti: 0.10 Zr: 0.06 Al: 0.08
Classifications
S: 0.007 P: 0.008 Fe: Balance
AS / NZS 2717.1: ES2-GC / M-W503AH
AWS /ASME-SFA A5.18: ER70S-2
Packaging and operating data
Wire feed Current Range Pack
Dia. (mm) Voltage (V) speed (m / min) (A) Pack type* weight (kg) Part No.
1.2 18–32 3.5–15 120–350 Spool 15 720054
* Spool (ø300 mm)
Autocraft LW1 Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N A premium quality low carbon steel Argon Industrial 1.0–2.0 ml of hydrogen / 100 gm of
wire for GMA welding 10–25% CO2 Grade CO2 deposited weld metal
N Suitable for the all positional multi- Yield stress 420 MPa 390 MPa
pass GMA welding of mild, low alloy Tensile 520 MPa 500 MPa Approvals
and medium strength steels, as used in strength CO2 and Argon 10–25% CO2
general fabrication, pressure vessels and Elongation 30% 31% LRS Grade 3S
structural work. CVN impact 110J @ -20°C 100J @ -20°C ABS Grade 3SA
values DNV Grade IIIYMS
Recommended shielding gas
Argoshield® Universal Typical wire analysis (%)
Argoshield® 52 C Mn Si S P
Argoshield® Heavy 0.08 1.16 0.70 0.010 0.015
Argoshield® Light
Industrial Grade CO2 Packaging and operating data
Wire feed Current Pack
Classifications Dia. (mm) Voltage (V) speed (m / min) range (A) type* Pack (kg) Part No.
AS / NZS 2717.1: ES4-GC / M-W503AH 0.9 15–26 3.5–15 70–230 Spool 15 720115
AWS /ASME-SFA A5.18: ER70S-4 1.2 18–32 2.5–15 120–350 Spool 15 720116
* Spool (ø300 mm)

Mild Steel 8
GMAW Wire
Autocraft LW1-6 Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N A higher manganese / silicon steel Welding Argon 1.0–2.0 ml of hydrogen /
wire for-GMA welding Grade CO2 20–25% CO2 100 gm of deposited weld metal
N Use with CO2 and argon based Yield stress 410 MPa 450 MPa
shielding gases Tensile 525 MPa 550 MPa Approvals
strength
N Wide range of minispool, handispool CO2 and Argon 20–25% CO2
and-autopak packaging options Elongation 32% 29%
Lloyds Register of Shipping Grade 3S, 3YS
CVN impact 110J @ -20°C 120J @ -20°C
N Suitable for the positional gas metal arc American Bureau of Shipping Grade 3SA,
values
welding (GMAW) of mild and low alloy 3YSA
steels, used in general fabrication and Det Norske Veritas Grade 111YMS
Typical wire analysis (%)
structural work. *Approvals do not include 0.6 mm and 0.8 mm Autocraft
C Mn Si S P LW1-6 wires
Recommended shielding gas 0.07 1.55 0.88 0.012 0.015
Argoshield® Universal
Argoshield® 52 Packaging and operating data
Argoshield® Heavy Wire feed
Argoshield® Light Dia. Voltage speed Current Pack weight
Industrial Grade CO2 (mm) (V) (m / min) range (A) Pack type* (kg) Part No.
0.6 12–14 3.5–14 35–100 Mini Spool – Packs of 4 4 x 0.8 721104
Classifications 0.6 12–14 3.5–14 35–100 Handi Spool 5 720108
AS / NZS 2717.1: ES6-GC / M-W503AH 0.6 12–14 3.5–14 35–100 Spool 15 720103
AWS /ASME-SFA A5.18: ER70S-6 0.8 14–22 3.5–14 50–180 Mini Spool – Packs of 4 4 x 0.8 721105
0.8 14–22 3.5–14 50–180 Handi Spool 5 720109
0.8 14–22 3.5–14 50–180 Spool 15 720114
0.9 15–26 3.5–15 70–230 Handi Spool 5 720161
0.9 15–26 3.5–15 70–230 Spool 15 720090
0.9 15–26 3.5–15 70–230 AutoPak 250 720122A
1.0 16–29 3.5–15 100–280 Spool 15 720094
1.0 16–29 3.5–15 100–280 AutoPak 250 720123A
1.2 18–32 2.5–15 120–350 Spool 15 720096
1.2 18–32 2.5–15 120–350 AutoPak 250 720124A
1.6 18–34 2.5–10 180–390 Spool 15 720095
1.6 18–34 2.5–10 180–390 AutoPak 350 720125A
* Mini Spool (ø100 mm); Handi Spool (ø200 mm); Spool (ø300 mm); AutoPak (ø510 mm x H.770 mm)

8 Mild Steel
GMAW Wire
Ultramag S4 Ultramag S6
Copper coated, ‘S4’ steel wire for gas metal arc Premium quality copper coated, ‘S6’ high
welding. Suitable for use with carbon dioxide or manganese, high silicon steel wire for gas metal
argon based shielding gases for welding mild and arc welding. Suitable for use with carbon dioxide
medium strength steels. or argon based shielding gases for welding mild
and medium strength steels. Low spatter.
Classifications
AS 2717.1: ES4; Classifications
AWS A5.18: ER70S-4 AS 2717.1: ES6,
AWS A5.18: ER70S-6
0.9 15 Spool 812855 Size (mm) Weight (kg) Part No.
1.0 15 Spool 812879 0.6 5 Spool 801231
1.2 15 Spool 812862 0.8 5 Spool 801248
1.6 15 Spool 812809 0.8 15 Spool 8180815
0.9 15 Spool 8180915
1.0 15 Spool 8181015
1.2 15 Spool 8181215

Mild Steel 8
Gas Assisted General Purpose FCAW Wire

Typical C Si Mn
Argoshield® 52 0.05 0.60 1.35
SmoothCor™ 711 CO2 0.04 0.54 1.27

As Welded Using Argoshield® 52 Using CO2
Yield strength 440 MPa min 430 MPa min
Description Tensile strength 500–620 MPa 490–580 MPa
SmoothCor™ 711 is a general purpose, rutile flux cored wire Elongation 25% min 25% min
that performs exceptionally well in the downhand, vertical up and Impact energy, CVN 95J min av @ -18ºC 90J min av @ -18ºC
overhead positions at the same parameter settings. It is suitable for 65J min av @ -29ºC 60J min av @ -29ºC
use with both Ar / CO2 or CO2 shielding gases. Designed for single
and multi pass welding, SmoothCor™ 711 produces weld metal that Diffusible Hydrogen
is consistently free of inclusions and porosity for X-ray soundness. 1.2 mm, 100% CO2, DC+, 230 amps, 27 volts, 20 mm stick-out:
The wire has Grade 3 shipping society approval for improved weld <8ml / 100g (vacuum packed)
deposit impact toughness. SmoothCor™ 711 welds with a very 1.2 mm, Argoshield® 52, DC+, 230 amps, 27 volts, 20 mm stick-out:
smooth running, low spatter arc and a fine spray type transfer to <8ml / 100g (vacuum packed)
give excellent weld pool control. Bead surface is extremely smooth
with excellent slag detachability. Flat fillet bead profile with equal
Packaging Data
leg length and uniform wetting is easily achieved. SmoothCor™ 711
has a very wide operating window, excellent feedability and easy arc Dia. (mm) 1.2 1.6
starting characteristics. Part No. 1071112 1071116
Type Spool (vacuum packed) Spool (vacuum packed)
Application Weight (kg) 15 15
SmoothCor™ 711 is recommended for welding of mild and medium
tensile strength steels and is an excellent choice for general steel Welding Parameters
construction, shipbuilding, pressure vessel fabrication and structural Welding Flat, Horizontal Vertical up Overhead
welding. Position
Dia. (mm) 1.2 1.6 1.2 1.6 1.2 1.6
Welding Positions Current Range 150– 180– 150– 180– 150– 180–
(A) 290 400 250 300 250 310
Voltage (V) 23–30 25–34 22–26 21–27 23–26 22–27
Electrode 15–20 20–25 15–20 20–25 15–20 20–25
Stick-out (mm)
Specifications Deposition Data
Flux Type Rutile Approx.

Classification AWS /ASME-SFA A5.20 E71T-1 H8, E71T-1M H8 Wire Feed
E71T-9 H8, E71T-9M H8 Current Voltage Speed Deposition Efficiency
Dia. (mm) (A) (V) (m / min) Rate (kg / h) (%)
AS 2203.1 ETP-GMp-W503A.CM1 H10
ETP-GCp-W503A.CM1 H10 1.2 150 28 5.08 1.91 86
Approvals* Lloyds Register of Grade 3 210 29 7.62 2.86 86
Shipping 250 30 10.16 3.86 87
Det Norske Veritas Grade 3 290 33 12.70 4.85 87
,American Bureau Grade 3 330 34 15.24 5.76 87
Shipping 1.6 190 27 3.81 2.77 87
Welding Current DC+ 300 30 6.35 4.63 87
* With Ar / CO2 and CO2 shielding gas 365 33 7.62 5.58 86
410 33 8.89 6.35 88
Recommended Shielding Gases:
Argoshield® 52 or Ar+20–25% CO2 mixtures
Welding Grade CO2
Flow rate 15–20 L / min

8 Mild Steel
FCAW Wire Gas Assisted Hydrogen Controlled

Welding Grade CO2
SmoothCor™ 715 Flow rate 15–20 L / min

Typical C Si Mn
Argoshield® 52 0.07 0.70 1.50
CO2 0.06 0.60 1.35
Description
SmoothCor™ 715 is a basic flux cored wire for which the all Mechanical Properties – All-Weld Metal
round operability has been optimised. It is suitable for use with
both Ar / CO2 or CO2 shielding gases. Using DC-, the wire can As Welded Using Argoshield® 52 Using CO2
be used for welding in all positions. Designed for single and multi Yield strength 430 MPa min 420 MPa min
pass welding, SmoothCor™ 715 produces low temperature – high Tensile strength 500–620 MPa 490–580 MPa
toughness, microscopically clean weld metal with very low H4 Elongation 29% min 28% min
hydrogen Impact energy, CVN 70J min av @ -40ºC 60J min av @ -40ºC
content and superior hot and cold crack resistance. SmoothCor™
715 welds with particularly stable running characteristics and has a
Diffusible Hydrogen
thin easily remelted slag cover which, with its excellent feedability
and easy arc starting characteristics, enhances operator appeal and 1.2 mm, 100% CO2, DC-, 230 amps, 27 volts, 20 mm stick-out:
<4ml / 100g (vacuum packed)
minimises spatter.
1.2 mm, Argoshield® 52, DC-, 230 amps, 27 volts, 20 mm stick-out:
Application
SmoothCor™ 715 is an excellent choice for a wide range of
critical applications including pressure vessels, offshore oil and Packaging Data
gas platforms and heavy earth moving and mining equipment. Dia. (mm) 1.2 1.6
SmoothCor™ 715 is suitable for welding mild and higher carbon Part No. 1071512 1071516
and difficult to weld steels. It combines strength and toughness Type Spool (vacuum packed) Spool (vacuum packed)
and is particularly suitable for heavily restrained sections where Weight (kg) 15 15
there can be a risk of cracking due to weld stress.
Welding Parameters
Welding Positions
Dia. (mm) 1.2 1.6
Current Range (A) 150–290 180–400
Voltage (V) 23–30 25–34
Electrode Stick-out 15–20 20–25
(mm)
Welding Position Flat, Horizontal
Specifications
Flux Type Basic Deposition Data
Classification AWS /ASME-SFA A5.20 E71T-5 H4, E71T-5MJ H4 Approx. Wire
AS 2203.1 ETP-GMn-W504A.CM1 H5 Dia. Current Voltage Feed Speed Deposition Efficiency
ETP-GCn-W504A.CM1 H5 (mm) (A) (V) (m / min) Rate (kg / h) (%)
Approvals* Lloyds Register of Grade 3 1.2 170 29 7.24 3.20 96
Shipping 250 30 11.91 4.90 91
American Bureau Grade 3 1.6 300 30 5.74 4.45 92
Shipping
400 32 9.37 7.30 92
Welding Current DC-
450 32 10.72 8.40 93
* With Ar / CO2 shielding gas.

Mild Steel 8
Metal Cored FCAW Wire

SmoothCor™ 70C6 Tensile strength 500–640 MPa 490–600 MPa
Elongation 22% min 22% min
Impact energy, CVN 27J min av @ -29ºC 27J min av @ -29ºC
Diffusible Hydrogen
Description 1.2 mm, 100% CO2, DC+, 230 amps, 27 volts, 20 mm stick-out:
SmoothCor™ 70C6 is a metal cored wire producing 40% less fume
1.2 mm, Argoshield® 52, DC+, 230 amps, 27 volts, 20 mm stick-out:
than conventional metal cored products. It is suitable for use with <8ml / 100g (vacuum packed)
both Ar / CO2 or CO2 shielding gas. Designed for single and multi
pass welding, the wire can be used in both the flat and horizontal
Packaging Data
positions. SmoothCor™ 70C6 welds with a very smooth running,
low spatter arc. Deposition efficiency is high and slag islands minimal. Dia. (mm) 1.2 1.6
With its wide range of welding parameters, excellent feedability Part No. 1070C612 1070C616
and easy arc starting characteristics, SmoothCor™ 70C6 has superb Type Spool (vacuum packed) Spool (vacuum packed)
welder appeal. Weight (kg) 15 15
Application Welding Parameters

SmoothCor™ 70C6 is ideal for a wide range of high speed fillet Dia. (mm) 1.2 1.6
and butt welding applications where high productivity is required. Current Range (A) 150–350 300–500
SmoothCor™ 70C6 has better wetting action than solid wire, Voltage (V) 24–32 26–34
minimising cold lap on heavier sections of steel. SmoothCor™ Electrode Stick-out 10–20 10–20
70C6 is recommended for general fabrication of mild and medium (mm)
tensile steels. It is also suitable for use on pressure vessel work and Welding Position Flat, horizontal Flat, horizontal
structural welding.
Deposition Data
Welding Positions
Approx.
Wire Feed
Current Voltage Speed Deposition Efficiency
Dia. (mm) (A) (V) (m / min) Rate (kg / h) (%)
1.2 250 28 8.38 3.63 90
Specifications
275 30 10.92 5.03 94
Type Metal cored
300 32 11.79 5.26 94
Classification AWS /ASME-SFA A5.18 E70C-6C H8, E70C-6M H8
350 32 13.00 5.76 96
AS 2203.1 ETD-GMp-W503A.CM1 H10
1.6 300 30 4.60 3.90 89
ETD-GCp-W503A.CM1 H10
350 30 6.12 5.40 94
Approvals* Lloyds Register of Grade 3
Shipping 400 32 7.44 6.62 94
Shipping
Welding Current DC+
* With Ar / CO2 and CO2 shielding gas

Welding Grade CO2

Typical C Si Mn
Argoshield® 52 0.03 0.62 1.68
CO2 0.03 0.59 1.66

8 Mild Steel
FCAW Wire Gas Assisted General Purpose
Satin-Cor XP Typical all weld metal analysis (%) Approvals*

N A rutile type flux cored wire formulated using CO2 shielding gas Lloyds Register of Grade 2YS H15
exclusively for CO2 shielding gas C Mn Si S P Shipping
N For high speed, downhand welding 0.08 1.38 0.55 0.011 0.016. * with welding grade CO2 shielding gas.
applications
Typical diffusible hydrogen levels to AS 3752 Packaging data
5.0–6.0 ml of hydrogen / 100 gm of deposited Wire dia.
N Superior fillet shape and slag lift weld metal* (mm) Pack type Pack (kg) Part No.
N Recommended for the downhand fillet * for ‘as manufactured’ product using welding grade CO2 1.6 Spool 13 720904
welding of structural steels of 6 mm shielding gas
2.4 Coil 25 720906
thickness or heavier
N 1.6 mm Satin-Cor XP is now qualified for Operating data
both CO2 and Mixed Gas All welding conditions recommended below are for use with semi-automatic operation,
N Now Precision Layer Wound DC electrode positive and welding grade CO2 shielding gas with a flow rate of 15–20 L / min.
Dia. Current Electrode stickout Optimum Welding
Classifications (mm) range (A) Voltage (V) ESO (mm) amps Volts positions
AS / NZS 2203.1: 1.6 350–450 28–33 25–30 380 30 Flat
ETD-GCp-W502A. CM1 H10
2.4 400–550 28–33 25–35 450 30
AWS /ASME-SFA A5.20: E70T-1H8
1.6 300–400 26–30 25–30 330 29 HV Fillet
*1.6 mm only ETD-GMp-W502A CM1H10 and
ETD-GCp-W502A CM1 H10 2.4 350–450 26–30 25–30 400 29
1.6 270–350 25–29 25–30 300 28 Horizontal
Typical all weld metal mechanical properties 2.4 320–420 25–29 25–30 360 28
Using welding grade CO2
Yield stress 485 MPa
Tensile strength 595 MPa
Elongation 27%
CVN impact values 84J av @ 0°C

Mild Steel 8
Verti-Cor XP Typical diffusible hydrogen levels to AS 3752 Typical all weld metal analysis (%)
N Now upgraded to Grade 3 on CO2 6.0–7.0 ml of hydrogen / 100 gm of deposited C Mn Si S P
and Mixed Gas weld metal* Argon +20–25% CO2
* for ‘as manufactured’ product using Argoshield® 52 0.07 1.55 0.65 0.007 0.014
N A general purpose, rutile type flux shielding gas
cored wire Using CO2
Approvals* 0.06 1.45 0.60 0.010 0.015
N Versatile, all positional capabilities
Excellent operator appeal Lloyds Register of Grade 3YS H15
N Packaging data
Shipping
N Now Precision Layer Wound American Bureau of Grade 3SA, 3YSA Dia. (mm) Pack type Pack (kg) Part No.
N Recommended for general steel Shipping 1.2 Spool 15 720915
construction / fabrication Det Norske Veritas III YMS 1.6 Spool 15 720917
* Argon +20–25% CO2 and CO2 shielding gas combinations 1.2 Drum 200 720915A
Classifications
1.6 Drum 200 720917A
AS / NZS 2203.1: ETP-GMp-W503A. CM1 H10
ETP-GCp-W503A. CM1 H10 Operating data
AWS /ASME-SFA A5.20: E71T-1H8 / E71T-1M H8
All welding conditions recommended below are for use with semi-automatic operation, DC
electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L / min.
Recommended shielding gases
Argoshield® 52 (mm) range (A) Voltage (V) ESO (mm) amps Volts positions
Welding Grade CO2 1.2 250–300 27–31 20–25 280 31 Flat
1.6 350–400 27–31 25–30 360 31
1.2 230–280 26–30 20–25 260 28 HV Fillet
Argon CO2 1.6 310–360 26–30 25–30 320 29
Yield stress 550 MPa 510 MPa 1.2 170–220 24–28 15–20 200 24 Vertical up
Tensile 630 MPa 600 MPa 1.6 200–250 24–28 15–20 240 25
strength
1.2 160–210 24–28 15–20 200 24 Overhead
Elongation 26% 26%
1.6 190–240 24–28 15–20 220 24
CVN impact 70J av @ 0°C 60J av @ 0°C
values
Verti-Cor Ultra Typical all weld metal analysis (%) using Approvals*
N A rutile type flux cored wire formulated CO2 shielding gas Lloyds Register of Grade 2YS H15
exclusively for CO2 shielding gas C: 0.04 Mn: 1.24 Si: 0.70 Shipping
N Versatile, all positional capabilities Ti: 0.035 B: 0.005 American Bureau of Grade 2YSA H10
Shipping
Typical diffusible hydrogen levels to AS 3752 Det Norske Veritas IIYMS H10
N Grade 2 shipping society approvals *with welding grade CO2 shielding gas
5.0–6.0 ml of hydrogen / 100 gm of deposited
N Low spatter and fume levels weld metal*
Packaging data
N Designed for the single and multi-pass * for ‘as manufactured’ product using welding grade CO2
welding of mild and medium strength shielding gas Wire Pack
steels in the downhand, vertical-up and dia.(mm) Pack type weight / kg Part No.
overhead positions 1.2 Spool 13 720900
N Precision Layer Wound 1.6 Spool 13 720902
Classifications
Operating data
AS / NZS 2203.1:
All welding conditions recommended below are for use with semi-automatic operation,
ETP-GCp-W502A. CM1 H10
DC electrode positive and welding grade CO2 shielding gas with a flow rate of 10–15 L / min.
AWS /ASME-SFA A5.20: E71T-1H8
(mm) range (A) Voltage (V) ESO (mm) (A) Volts positions
1.2 250–300 27–31 20–25 250 28 Flat
Welding Grade CO2
1.6 350–400 27–31 25–30 300 29
Typical all weld metal mechanical properties 1.2 230–280 26–30 20–25 230 27 HV Fillet
1.6 310–360 26–30 25–30 270 27
1.2 170–220 24–28 15–20 190 24 Vertical up
1.6 200–250 24–28 15–20 210 25
1.2 160–210 24–28 15–20 215 26 Overhead
Elongation 28%
1.6 190–240 24–28 15–20 250 27
CVN impact values 80J av @ 0°C

8 Mild Steel
FCAW Wire Gas Assisted General Purpose
Verti-Cor 3XP Typical diffusible hydrogen levels to AS 3752

N A microalloyed, rutile type flux 5.0–6.0 ml of hydrogen / 100 gm of deposited Argoshield® Universal
cored wire weld metal*
Argoshield® 52
* For ‘as manufactured’ product using Argoshield® 52
N Versatile, all positional capabilities shielding gas Argoshield® Heavy
N Excellent operator appeal Welding Grade CO2
Approvals*
N Grade 3 shipping society approvals
Lloyds Register of Grade 3S, 3YS H Packaging data
N Formulated to give smooth (low spatter) Shipping Dia. (mm) Pack type Pack (kg) Part No.
arc transfer, flat mitre fillet welds and American Bureau of Grade 3SA, 3YSA H
excellent slag lift in all positions (except 1.2 Spool 13 720919
Shipping
vertical-down), on a wide range of 1.6 Spool 13 720921
Det Norske Veritas IIIYMS H
mild and medium strength steels * With Argon +20–25% CO2 shielding gas combinations
N Precision Layer Wound
Operating data
Classifications
AS / NZS 2203.1 DC electrode positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L / min.
ETP-GMp-W503A. CM1 H10
ETP-GCp-W503A. CM1 H10 Dia. Current Electrode stickout Optimum Welding
AWS /ASME-SFA A5.20: (mm) range (A) Voltage (V) ESO (mm) (A) Volts positions
E71T-1 H8 , E71T-12M H8 1.2 250–300 27–31 20–25 280 31 Flat
1.6 350–400 27–31 25–30 360 31
1.2 230–280 26–30 20–25 260 28 HV Fillet
Using Using CO2 1.6 310–360 26–30 25–30 320 29
Argoshield® 52
1.2 170–220 24–28 15–20 200 24 Vertical up
Yield stress 480 MPa 460 MPa
1.6 200–250 24–28 15–20 240 25
Tensile 560 MPa 530 MPa
1.2 160–210 24–28 15–20 200 24 Overhead
strength
1.6 190–240 24–28 15–20 220 24
Elongation 28% 30%
CVN impact 110J av @ 0°C 90J av @ 0°C
values 90J av @ -20°C 75J av @ -20°C
Typical all weld metal analysis (%)

Using Argon +20–25% CO2
C: 0.07 Mn: 1.16 Si: 0.52
Ti: 0.035 B: 0.008
Using CO2
C: 0.06 Mn: 1.05 Si: 0.42
Ti: 0.035 B: 0.007

Mild Steel 8
Verti-Cor 3XP H4 Typical Diffusible Hydrogen Levels to AS3752: Recommended Shielding Gases:
N Next generation technology flux cored 2.2 mls of hydrogen / 100gms of deposited weld Argon + 20–25% CO2 . ISO14175:
wire. metal *. M21,M24, M21 (1)
N Copper coated for smooth consistent * - for ‘as manufactured’ product using Argon + 20–25%
CO2 shielding gas.
feedability and current pick up. Packaging Data
N Rutile, all positional capabilities Wire Dia. Pack Type Weight Part No.
Approvals*
producing a flat mitre fillet bead shape. (mm) (kg)
Lloyds Register of Shipping 3S, 3YS H5
1.2 Spool 12.5 722919
N Ultra low splatter and fume levels. American Bureau of Shipping S3A, 3YSA H5
1.6 Spool 12.5 722921
N H4 diffusible hydrogen class with * - with Argon +20–25% CO2 shielding gas combinations.
a typical weldmetal of 2.2 mls of
hydrogen/100 gms.
Operating Data
N Excellent Operator Appeal.
All welding conditions recommended below are for use with semi-automatic operation, DC electrode
N Grade 3 Shipping Society Approvals.
positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min
Wire Dia. Current Voltage CTWD Optimum Volts Welding
Classifications
(mm) Range (A) Range (V) Amps Positions
AS/NZS 2203.1: ETP-GMp-W503A. CM1 H5.
1.2 250–300 27–31 20–25 280 31 Flat
AWS/ASME-SFA A5.20: E71T-12M H4.
1.6 350–400 27–31 25–30 360 31 Flat
Typical All Weld Metal Mechanical Properties 1.2 230–280 26–30 20–25 260 28 HV Fillet
Using Argon + 20–25% CO2 : 1.6 310–360 26–30 25–30 320 29 HV Fillet
Yield Stress 510 MPa 1.2 170–220 24–28 15–20 200 24 Vertical up
Tensile Strength 570 MPa 1.6 200–250 24–28 15–20 240 25 Vertical up
Elongation 30% 1.2 160–210 24–28 15–20 200 24 Overhead
CVN, Impact Values 105J av @ -20°C 1.6 190–240 24–28 15–20 220 24 Overhead
These machine settings are a guide only. Actual voltage, welding current and CTWD used will depend on machine
characteristics, plate thickness, run size, shielding gas and operator technique etc.
Typical All Weld Metal Analysis (%)
C Mn Si P S
0.05 1.25 0.43 0.009 0.007

8 Mild Steel
FCAW Wire Gas Assisted Hydrogen Controlled
Supre-Cor XP H4 Typical all weld metal analysis (%) Recommended shielding glasses
N Fully basic Seamless tubular flux Using Argoshield® 52 Argoshield® 52
cored wire C: 0.08 Mn: 1.34 Si: 0.63 Welding Grade CO2
N Low temperature impact toughness P: 0.20 S: 0.015
to -20°C Packaging data
Typical diffusible hydrogen levels to AS 3752
N Available in 2.4 mm size only Pack
1.5–2.0 ml of hydrogen / 100 gm of deposited Dia. (mm) type Pack (kg) Part No.
N Now Precision Layer Wound weld metal *
2.4 Coil 25 720911
N Recommended for the fillet and butt * For ‘as manufactured’ product using Argon +20–25% CO2
welding of heavy earthmoving and
Approvals*
mining equipment
Lloyds Register Grade 3S, 3YS H15
N Suitable for use with CO2 and Argon of Shipping
+ 20–25% CO2 or equivalent
*With Argon +20 –25% CO2
shielding gases
Classifications
Operating data
AS / NZS 2203.1:
All welding conditions recommended below are for use with semi-automatic operation and DC
ETD-GCn / p-W503A. CM1 H5 and ETD-
electrode positive. Argon +20-25% CO2 shielding gas with a flow rate of 15–20 L / min was used.
GMn / p-W503A. CM1 H5
AWS /ASME-SFA A5.20: Dia. Current Electrode stickout Optimum Welding
(mm) range (A) Voltage (V) ESO (mm) (A) Volts positions
E70T-5 H4, E70T-5M H4
2.4 350–500 27–33 25–30 450 31 Flat
Typical all weld metal mechanical properties 2.4 350–500 27–33 25–30 400 30 HV Fillet
Using Argon
+20–25% CO2
Elongation 29%

Mild Steel 8
Gas Assisted Hydrogen Controlled FCAW Wire
Supre-Cor 5
Typical all weld metal analysis (%) Recommended shielding gases
N Second generation, fully basic flux
cored-wire Using Argoshield® 52 Argoshield® 52
C Mn Si P S Welding Grade CO2
N Improved low temperature impact
toughness to -50°C 0.10 1.45 0.42 0.012 0.015
Using CO2 Packaging data
N Improved positional capabilities of
1.2 mm and 1.6 mm sizes C Mn Si P S Weight
0.09 1.25 0.32 0.012 0.015 Dia. (mm) Pack type (kg) Part No.
N DC electrode negative operation
1.2 Spool 13 720982
N Suitable for a wide range of critical
Typical diffusible hydrogen levels to AS 3752 1.6 Spool 13 720983
applications including the fillet and butt
welding of pressure vessels, offshore oil 1.5–2.0 ml of hydrogen / 100 gm of deposited
and-gas platform structures and heavy weld metal *
earthmoving equipment * For ‘as manufactured’ product using Argoshield® Argon
+20–25% CO2
N Precision Layer Wound
Approvals*
Classifications
Lloyds Register of Grade 3S, 3YS H5
AS/NZS 2203.1: Shipping
ETP-GCn/p-W505A. CM1 H5 ETP-GMn/p-
W505A. CM1 H5 American Bureau of Grade 3SA,3YSA H5
Shipping
AWS/ASME-SFA A5.20:
E71T-5 H4, E71T-5MJ H4 Det Norske Veritas IIIYMS H5
* With Argon +20 -25% CO2 and CO2 shielding gas
Typical all weld metal mechanical properties combinations
Using Argon +20-25% CO

Yield stress 445 MPa Operating data
All welding conditions recommended below are for use with semi-automatic operation, DC electrode negative and Argon
Tensile strength 550 MPa +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.
Elongation 29% Electrode
CVN impact values 160J av @ -20°C Current Voltage stickout ESO Optimum Welding
Dia. (mm) range (A) range (V) (mm) Amps Volts positions
100J av @ -40°C
90J av @ -60°C 1.2 250 – 300 27 – 31 20 – 25 280 29 Flat
Using CO2 1.6 350 – 400 27 – 31 25 – 30 320 31
Yield stress 430 MPa 1.2 230 – 280 26 – 30 20 – 25 250 27 HV Fillet
Tensile strength 530 MPa 1.6 310 – 360 26 – 30 25–30 315 30
Elongation 30% 1.2 170 – 220 24 – 28 15 – 20 140 21 Vertical up
CVN impact values 150J av @ -20°C 1.6 200 – 250 24 – 28 15 – 20 N/A N/A
90J av @ -40°C
1.2 160 – 210 24 – 28 15 – 20 120 20 Overhead
80J av @ -60°C
1.6 190 – 240 24 – 28 15 – 20 N/A N/A

8 Mild Steel
FCAW Wire Metal Cored
Metal-Cor XP Typical all weld metal mechanical properties Approvals*

N Low slag, metal cored wire Using Argon Lloyds Register of Grade 3YS H5
N Grade 3 shipping society approvals +20–25% CO2 Shipping
Yield stress 460 MPa ABS Grade 3SA, 3YSA H5
N High deposition efficiency = 95%
Tensile strength 575 MPa Det Norske Veritas IIIYMS H5
N High deposition rates
Elongation 28% *With Argon +20–25% CO2 shielding gas combinations
N For the high productivity fillet and butt CVN impact values 100J av @ 0°C
welding of mild and medium strength 85J av @ -20°C Recommended shielding gases
steels in all downhand positions 40J av @ -30°C Argoshield® 52
N Precision Layer Wound Argoshield® Universal
Classifications Typical all weld metal analysis (%)*

Packaging data
AS / NZS 2203.1: C: 0.05% Mn: 1.42% Si: 0.75%
Pack
ETD-GMn / p-W503A. CM1 H5 ETP*-GMn / p- S: 0.012% P: 0.014%
Dia. (mm) type Pack (kg) Part No.
W503A. CM1 H5 (*1.2 mm only ) * Using Argon +20–25% CO2 shielding gas
1.2 Spool 13 720912
AWS /ASME-SFA A5.18: E70C-6M*
* The Classifications of metal cored wires to the 1.6 Spool 13 720913
American Welding Society (AWS) has changed.
Detailed information regarding these changes are Operating data
available in the technical section of pocket guide.
DC electrode negative and Argon +20 –25% CO2 shielding gas with a flow rate of 15–20 L / min.
Wire Dia. Current Voltage Electrode stickout Optimum Welding
(mm) range (A) Range (V) ESO (mm) (A) Volts positions
1.2 280–350 28–33 20–25 330 32 Flat
1.6 350–450 29–33 25–30 420 31
1.2 250–300 27–31 20–25 280 30 HV Fillet
1.6 300–380 27–31 25–30 360 28
1.2 250–300 27–31 20–25 250 30 Horizontal
1.6 300–380 27–31 25–30 280 26

Mild Steel 8
Metal-Cor 5
Typical All Weld Metal Analysis*: Typical Diffusible Hydrogen Levels to AS3752:
N High Efficiency Metal Cored Wire with
Excellent Operator Appeal. Using Argon + 20–25% CO2 : <3.5 mls of hydrogen / 100gms of deposited
C Mn Si S weld metal.
N Grade 4 Shipping Society Approvals.
0.07 0.9 0.56 0.014
N Very Low Slag Formation. Recommended Shielding Gases:
P Ni Cr
N Outstanding Low Temperature Impact Argon + 20–25% CO2 or equivalent ISO14175:
Properties. 0.013 0.04 0.03
M21, M24
N High Deposition Efficiency.
Approvals*:
N High Deposition Rates. Packaging Data
Lloyds Register of Grade 3S, 4YS H5
N Precision Layer Wound. Wire Dia. Pack Type Weight Part No.
Shipping
(mm) (kg)
American Bureau of Grade 4SA, 4YSA H5
Classifications 1.2 Spool 15 720552
Shipping
AS 2203.1: ETD-GMp-W505A. CM1 H5. 1.6 Spool 15 720553
Det Norske Veritas IV YMS H5
ETP*-GMp-W505A. CM1 H5. ( *1.2mm only ) 1.2 Autopak 230kg 720552A
*with Argon + 20–25% CO2 shielding gas or equivalent.
AWS/ASME-SFA A5.18: E70C-6M H4
1.6 Autopak 230kg 720553A
Typical All Weld Metal Mechanical Properties

Operating Data
Using Argon + 20–25% CO2 :
All welding conditions recommended below are for use with semi-automatic operation, DC electrode
Yield Stress. 460 MPa. positive using Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.
Tensile Strength 530 MPa. Wire Dia. (mm) Current Range (A) Voltage Range (V) Electrode stickout Welding Positions
ESO (mm)
Elongation 32%
1.2 280–350 28–33 20–25 Flat
CVN Impact Values 135J av @ -20°C.
1.6 350–450 29–33 25–30 Flat
135J av @ -40°C
1.2 250–300 27–31 20–25 HV Fillet
80J av @ -60°C.
1.6 300–380 27–31 25–30 HV Fillet
1.2 250–300 27–31 20–25 Horizontal
1.6 300–380 27–31 25–30 Horizontal

8 Mild Steel
FCAW Wire Self Shielded
Shield-Cor 11 Typical all weld metal analysis (%) Recommended shielding gas
N Self-shielded flux cored wire C: 0.25 Mn: 0.70 Si: 0.40 Not required
N Versatile, all positional capabilities Al: 1.65 S: 0.004 P: 0.007
Packaging data
N Excellent tolerance to joint
Typical diffusible hydrogen levels to AS 3752 Dia. (mm) Pack type Pack (kg) Part No.
misalignment or-poor joint fit-up
15.0–20.0 ml of hydrogen / 100gm of deposited 1.2 Spool 15 720923
N Smooth rippled fillets with good weld metal*
edge wetting
* For ‘as manufactured’ product using the recommended
N Ideal for welding thin section mild ESO lengths
and galvanised steels
Operating data
Classifications All welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only.
AS / NZS 2203.1: ETP-GNn-W500A. CM2 Current range Electrode stickout
AWS /ASME-SFA A5.20: E71T-11 Dia. (mm) (A) Voltage (V) ESO (mm) Welding positions
1.2 150–200 16–18 15–20 Flat
1.2 130–180 16–18 15–20 HV Fillet
Yield stress 445 MPa 1.2 130–180 16–18 15–20 Vertical up
Tensile strength 620 MPa 1.2 180–230 16–18 15–20 Overhead
Elongation 22%
Shield-Cor 15 Typical all weld metal analysis (%) Packaging data

N Self-shielded flux cored wire C: Mn: Si: Al: S: P: 0.007 Dia.
N For single pass applications only 0.25 0.70 0.40 2.10 0.004 (mm) Pack type Pack (kg) Part No.
N Versatile, all positional capabilities Typical diffusible hydrogen levels to AS 3752 0.8 100 spool 0.45 x 721956
(4 / ctn)
N Excellent tolerance to joint 15.0–20.0 ml of hydrogen / 100gm of deposited
weld metal* 0.8 200 handispool 4.5 721923
misalignment or-poor joint fit-up
0.9 100 minispool 0.45 x 721976
N Smooth rippled fillets with good * For ‘as manufactured’ product using the recommended
ESO lengths (4 / ctn)
edge wetting 0.9 200 handispool 4.5 721924
N Ideal for welding thin section mild Recommended shielding gas 1.2 200 handispool 4.5 720302
and galvanised steels Not required
Classifications
Operating data
AS / NZS 2203.1:ETPS-GNn-W500A. CM2 All welding conditions recommended below are for use with semi-automatic operation and DC electrode negative only.
AWS /ASME-SFA A5.20: E71T-14
Electrode stickout
Typical all weld metal mechanical properties Dia. (mm) Current range (A) Voltage (V) ESO (mm) Welding positions
Yield stress 430 MPa 0.8 90–150 14–16 10–12 Flat

Tensile strength 600 MPa 0.8 80–140 14–16 10–12 HV Fillet
Elongation 21% 0.8 60–120 14–16 10–12 Vertical up
0.8 60–120 14–16 10–12 Overhead
0.9 110–180 15–17 12–15 Flat
0.9 100–175 15–17 12–15 HV Fillet
0.9 80–150 15–17 12–15 Vertical up
0.9 80–150 15–17 12–15 Overhead
1.2 180–230 16–18 15–20 Flat
1.2 150–200 16–18 15–20 H-V Fillet
1.2 130–180 16–18 15–20 Vertical
1.2 130–180 16–18 15–20 Overhead

Mild Steel 8
Outershield 70 Outershield 71MX Outershield 71CX

A wire with excellent bead wetting, Designed and manufactured in Australia, Designed and manufactured in Australia,
low spatter and fast follow. Especially Outershield 71MX is an all positional Rutile Outershield 71CX is an all positional rutile
recommended for applications requiring based Microalloyed electrode, providing based micro-alloyed electrode. 71CX
deep penetration. For use in the down-hand excellent operator appeal, producing sound provides an extremely smooth arc transfer,
and horizontal positions. welds, with a clean surface finish under with excellent “ease of use” making good
mixed gas. out of position welds with a clean surface
Classifications finish under 100% CO2 shielding gas.
AS 2203.1: ETD-GCp-W502A. CM1.H10, Classifications
AWS A5.20: E70T-1 AWS. A5.20 E71T-1M H8, E71T-9M-H8 & E71T- Classifications
12M H8 AWS. A5.20 E71T-1 H8, E71T-9 H8 & E71T-12
Size (mm) Weight (kg) Part No. H8
1.6 22.68 Coil ED012782 Size (mm) Weight (kg) Part No.
1.2 13 033502 Size (mm) Weight (kg) Product No
2.0 22.68 Coil ED012785
1.6 13 033506 1.2 13 033602
1.6 13 033606
Outershield MC710 Outershield MC710-H Outershield

Metal cored wire having good deposition For welding with high efficiency in all MC460VD-H
rate, excellent operator appeal with minimal positions. Excellent arc characteristics give
Metal Cored wire for welding with high
slag and spatter. Dip transfer mode can be outstanding operator appeal. Little slag
efficiency. Especially for vertical down
used for positional welding. Suitable for and spatter, fast travel speed and excellent
welding in thin plate. Excellent Arc
automatic applications including robotic wire feeding “robotic” quality. Superior on
characteristics give outstanding operator
welding. scale plate, good resistance to porosity.Very
appeal. Little slag and spatter, fast travel
good mechanical properties (CVN >47J @
speed, good wire feeding. Superior Product
Classifications -30°C). Superior product consistancy with
consistency with optional alloy control.
optimal alloy control
AS 2203.1: ETP-GMp-W503A.CM1.H10;
AWS A5.20: E71T-1
Classification
Classification
AWS. A5.18: E70C-6M H4
Size (mm) Weight (kg) Part No. AWS. A5.18: E70C-6M H4
1.2 15 Readi reel 033101
Size (mm) Weight (kg) Product No
1.6 15 Coil 033102
1.2 15 941859
1.6 200 941937

8 Mild Steel
NR-152 NR-211-MP
Designed primarily for single pass welds General purpose all position wire. Smooth
on carbon steel up to 5 mm maximum spray arc is easy to control with good 0.9 4.54 Spool ED016354
thickness. Especially suited for the welding visibility, low heat and glare. Suitable for 1.2 4.54 Spool ED016363
of galvanised and zinc coated steels. sheetmetal, mild steel, galvanised and zinc
1.2 11.34 Readi reel ED030638
coated steels up to 12 mm thickness
Classifications (8 mm for 0.9 and 1.2 mm sizes). 1.7 6.0* Coil KC211176MP
AS 2203.1: ETPS-GNn-W500A.CM2; 1.7 12.5 Spool KC2111712MP

AWS A5.20: E71T-GS Classifications
2.0 6.0* Coil KC211206MP
AS 2203.1: ETP-GNn-W500A.CM2.H15;
2.0 25 Coil KC211205MP
Size (mm) Weight (kg) Part No. AWS A5.20: 71T-11
2.0 12.5 Spool KC2112012MP
1.7 22.68 Coil ED012186
*4 per box
NR-212 NR-232
The operating characteristics of NR 212 General purpose smooth running wire
are similar to those of NR 211MP. It has the producing high deposition rates in all 1.7 6.0* Coil ED012518
ability to handle poor fit up with very little positions. Excellent choice for out of 1.7 11.34 Coil ED030634
tendency for burn through on sheetmetal position welding requiring high
1.7 22.68 Coil ED012519
and can be used on galvanised and mild productivity and good impact properties.
steel over 12 mm thickness. 2.0 6.0* Coil ED012525
Classifications 2.0 11.34 Coil ED030647
Classifications AS 2203.1: ETP-GNn-W503A.CM1.H15; 2.0 22.68 Coil ED012526
AS2203.1; ETP-GNn-W500A. G.H10: AWS A5.20: E71T-8
*4 per box
AWS A5.20; E71TG-G
Size (mm) Carton (kg) Part No.

1.2 11.34 ED030639
1.7 11.34 ED030642
2.0 11.34 ED030646
NR-233 NR-311 NS-3M

NR-233 is an advanced technology, self- General purpose wire for high Extremely high deposition rates. Has low
shielded flux-cored electrode designed for deposition rates, fast travel speeds penetration which makes it particularly
high deposition rate welding - even when and good penetration in the flat and useful for poor fit up. Can be used for
welding out-of-position in seismic and horizontal positions. both single and multiple pass welds.
non-seismic structural steel applications.
It is also great for fillet welding for ship Classifications Classifications
and barge fabrication. The electrode is
AS 2203.1: ETD-GNn-W500A. CM2; AS 2203.1: ETD-GNp-W500A.CM2.H15;
welder-friendly, making it easier to pass AWS A5.20: E70T-7 AWS A5.20: E70T-4
tough qualification tests and deposit great
looking beads.
Classification AWS. E71T-8 2.0 6 Coil KC311206 2.0 12.5 Coil KCNS32012
2.4 25 Coil KC3112425 2.0 25 Coil KCNS32025
2.8 25 Coil KC3112825 2.4 25 Coil KCNS32425
1.6 11.34 ED030934
*4 per box 3.0 25 Coil KCNS33025
1.8 11.34 ED031030

Mild Steel 8
TIG
Comweld Super Steel Typical rod analysis (%) Joining process

N Low carbon steel filler rod for gas C: 0.06% Mn: 1.08% Si: 0.52% Gas tungsten arc (TIG) welding
tungsten arc (TIG) welding Ti: 0.08% Zr: 0.07% Al: 0.08%
N Triple deoxidised for superior weld S: 0.007% P: 0.008% Fe: Balance
deposit quality and resistance to Argon Welding Grade
porosity
N End stamped with AWS class ‘ER70S-2’
Packaging data
N Ideal for TIG welding rusty or mill Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
scaled plates and pipes and the root
1.6 x 915 5 cardboard tube* 70 321370
pass welding of pipes, tanks and heavy
2.4 x 915 5 cardboard tube* 31 321373
walled joints
*Resealable
Classifications
AS / NZS 1167.2: R2
AWS /ASME-SFA A5.18: ER70S-2
Comweld LW1-3
Joining Process Typical All Weld Metal Mechanical Properties
N Copper Coated, Low Carbon Steel Rod
for Gas TIG & Oxy Welding Applications. Gas (Fusion) and Gas Tungsten Arc (TIG) Yield Stress 400 MPa.
welding.
N End stamped with ‘ER70S-3’ for easy I.D. Tensile Strength 500 MPa.
N Resealable 5kg cardboard tube. Typical Rod Analysis Elongation 30%
C Mn Si S P Fe CVN Impact Values 100 J av @ -20°C

Classifications
0.07 1.1 0.5 0.012 0.015 bal
AS 1167.2: R3.
AWS/ASME-SFA A5.18: ER70S-3.
Packaging Data
Rod Size (mm) Pack Weight/Type Approx. Rods/kg Part No.
1.6 x 1000 5kg Pack 64 321423
2.4 x 1000 5kg Pack 29 321424
Comweld LW1 Typical rod analysis (%) Joining process

N Copper coated, low carbon steel rod C: 0.08 Mn: 1.16 Si: 0.75 Gas (fusion) and gas tungsten arc (TIG) welding
for gas tungsten arc welding applications S: 0.010 P: 0.015 Fe: Balance
N Green end tip for instant identification Recommended shielding gases
N Ideal for root pass welding applications Argon Welding Grade
where tough and ductile welds are
produced
Packaging data
Classifications Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
AS / NZS 1167.2: R4 1.6 x 750 5 plastic pack 84 321411
AWS /ASME-SFA A5.18: ER70S-4 2.4 x 750 5 plastic pack 34 321412

8 Mild Steel
TIG
Comweld LW1-6 Typical rod analysis (%) Joining process

N Copper coated, low carbon steel rod C: 0.07 Mn: 1.55 Si: 0.88 Gas (fusion) and gas tungsten arc (TIG) welding
for gas TIG and oxy welding applications S: 0.012 P: 0.015 Fe: Balance
N End stamped with ‘ER70S-6’ for easy ID Recommended shielding gases
N Recommended for the TIG welding of Argon Welding Grade
steel pipes, plates and castings with a
tensile strength in the 500 MPa class
Packaging data
Classifications Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
AS / NZS 1167.2: R6 1.6 x 1000 cardboard pack 64 321417
AWS /ASME-SFA A5.18: ER70S-6 2.4 x 1000 cardboard pack 29 321418

Mild Steel 8
Submerged Arc Wire
L-50 L-60 L-61

Recommended for high speed, single pass Primarily for multiple pass welding on General purpose wire recommended for
welding on mild steel 12 mm or thinner steel under 25 mm thick using Lincoln 700 both single pass welding with Lincoln 700
because it gives better wetting action, series fluxes. series fluxes and multiple pass welding with
straighter bead edges and better slag most Lincoln 800 series fluxes.
removal. Resists porosity due to rust or Classifications
mill scale. Classifications
AS 1858.1: EL12;
AWS A5.17: EL12 AS 1858.1: EM12K;
Classifications AWS A5.17: EM12K
AS 1858.1: EM13K; Size (mm) Weight (kg) Part No.
AWS A5.17: EM13K Size (mm) Weight (kg) Part No.
2.0 30 Coil KC602030
2.0 30 Coil KC612030
Size (mm) Weight (kg) Part No. 2.4 30 Coil KC602430
2.4 30 Coil KC612430
2.0 27.2 Coil ED011335 3.2 30 Coil KC603230
3.2 30 Coil KC613230
2.4 27.2 Coil ED011328 4.0 30 Coil KC604030
4.0 30 Coil KC614030
3.2 27.2 Coil ED011323 2.4 600 Bulk reel KC6024600
4.8 30 Coil KC614830
3.2 600 Bulk reel KC6032600
2.4 600 Bulk reel KC6124600
4.0 600 Bulk reel KC6040600
3.2 600 Bulk reel KC6132600
4.0 600 Bulk reel KC6140600
L-S3
Designed for use with 880M or 8500
flux. Produces 480 MPa minimum tensile
strength and good low temperature impacts
at higher deposition rate procedures
and after stress relief. Typically used for
off-shore drilling platform leg fabrication
and similar.
Classifications
AS 1858.1: EMH12K;
AWS A5.17: EH12K

2.4 30 Coil 030401
3.2 30 Coil 030402
4.0 30 Coil 030403

8 Mild Steel
Submerged Arc Flux
761 780 781

Recommended for single and some Excellent performance characteristics, Recommended for high speed single pass
multiple pass welding. Provides excellent including very good slag removal make this welding on clean plate and sheet steel. The
resistance to cracking. Slower freezing slag flux suitable for all general purpose single ‘fast-follow’ characteristics of 781 allow
gives good appearance on large, flat fillet run and some multiple pass applications. The uniform welds to be made at high speeds
welds. Excellent impact properties can be faster freezing slag of 780 minimises spilling without undercut or voids.
produced when used with L61 wire. in circumferential welding applications.
Classifications AS 1858.1: FSH
Classifications AS 1858.1: FGH Classifications AS 1858.1: FGH
Weight (kg) Part No.
Weight (kg) Part No. Weight (kg) Part No. Bags 25 KC781025
Bags 45 KC761045 Bags 25 KC780025 Drums 280 KC781280
Drums 250 KC761250 Drums 280 KC780280
860 880 880M

For multiple pass welding. Has excellent For multi-pass welding with stainless steel Suitable for multi-pass welding with solid
operating characteristics and produces electrodes, solid low alloy steel electrodes carbon steel and low alloy steel electrodes.
good impact properties when used with containing a min. 0.20% Si and Lincoln’s LAC Produces excellent mechanical properties,
L60 and L61 wires. series of low alloy flux cored electrodes. including CTODs and low temperature
Not recommended for single arc AC impacts.
Classifications AS 1858.1: FMM welding or as a general purpose flux.
Classifications AS 1858.1: FBL
Weight (kg) Part No. Classifications AS 1858.1: FBL
Bags 25 KC860025 Weight (kg) Part No.

Weight (kg) Part No. Bags 25 KC880025M
Drums 260 KC860260
Bags 25 KC880025 Drums 220 KC880220M
Drums 260 KC880260
882 8500 960

For multiple pass welding with solid Basic flux recommended for single and A low cost general purpose flux for full and
carbon and low alloy steel wires. Produces multiple pass welding with LS3 wire when semi-automatic single and multiple pass butt
excellent low temperature impact excellent mechanical properties including and fillet welding. Welds have good impact
properties when used with L61 wire. low temperature impacts and CTODs strength and good slag removal.
are required.
Classifications AS 1858.1: FBL Classifications AS 1858.1: FMM
Classifications AS 1858.1: FBL
Weight (kg) Part No. Weight (kg) Part No.
Bags 25 KC882025 Weight (kg) Part No. Drums 25 KC960025
Drums 250 KC882250 Drums 220 KC8500220
ST-100
ST-100 is an alloy flux specifically for use
with solid stainless steel wires. Contains
chromium additions to compensate for
chromium lost from the wire during
transfer through the welding arc.
Classifications
AS 1858.1: FMMA (2Cr)

Bags 25 KCST100025

Consumables 8
Low Alloy
MMA Electrodes
Ferrocraft 61Ni H4 Typical all weld metal mechanical properties Typical diffusible hydrogen levels to AS 3752
N Now in Hermetically sealed 3kg cans Yield stress 450 MPa 3.0–3.5 ml of hydrogen / 100 gm of
N Highly basic, E4818-G / E7018-G type Tensile strength 560 MPa deposited weld metal*
hydrogen controlled electrode Elongation 27% *Reconditioned for 2 hours maximum at 350°C
N Very low “H5 / H4” diffusible CVN impact values 130J av @ -20°C
hydrogen class 80J av @ -40°C Approvals
60J av @ -50°C Lloyds Register of Shipping Grade 3,
N C-Mn-Ni weld deposit for reliable
3YH5
impact properties to -50°C Typical all weld metal analysis (%) American Bureau of Shipping Grade 3H10,
N Batch number identification C Mn Si Ni S P 3Y
N Recommended for the critical welding 0.07 1.20 0.25 0.9 0.007 0.012 Det Norske Veritas Grade 3Y H5
of-C-Mn, microalloyed and low alloy
structural steels in the 350–450 MPa Packaging and operating data AC (minimum 70 OCV) DC+ or DC- polarity
yield strength class Electrode Approx. Current Packet
N Applications include the all positional Size (mm) Length (mm) (rods / kg) Range (A) (kg) Carton (kg) Part No.
(except vertical-down) fillet and butt 2.5 350 53 80–110 3 12 (4 x 3) 611812
welding of pressure vessels, offshore 3.2 350 26 110–145 3 12 (4 x 3) 611813
platforms, pipes, earth-moving equipment
4.0 350 17 140–200 3 12 (4 x 3) 611814
Classifications Ferrocraft 61Ni H4i is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for fillet
welding and fill and capping passes is DC+.
AS / NZS 1553.2: E4818-G
AWS /ASME-SFA A5.5: E7018-G

8 Low Alloy
MMA Electrodes
Alloycraft 70-A1
Typical All Weld Metal Mechanical Properties Typical Diffusible Hydrogen Levels to AS3752:
N Hermetically sealed cans
Yield Stress 480 MPa. 3.0–3.5 mls of hydrogen / 100gms of deposited
N Improved high strength, low alloy steel weld metal .
electrode Tensile Strength 570 MPa.
N Advanced moisture resistant flux coating Elongation 25%. Approvals

N Very low ‘H5’ diffusible hydrogen class Lloyd’s Register of Shipping Grade 3, 3YH5.
Typical All Weld Metal Analysis (%)
N 480 MPa tensile class American Bureau of Shipping Grade 3H5, 3Y.
C Mn Si Mo S P
N Recommended for DC welding Det Norske Veritas Grade 3YH5.
0.03 0.77 0.37 0.53 0.013 0.015
applications
N Batch Numbered for identification
Packaging and Operating Data — AC (min 75 OCV), DC+ or DC- polarity.
Classifications Electrode
Approx. Current
AS /NZS 1553.2: E4818-A1. H5R Size (mm) Length (mm) Rods/kg Range (A) Can Carton (kg) Part No.
AWS/ASME-SFA A5.5: E7018-A1 H4R. *2.5 350 42 65–100 3kg 12 (3 x 4) 611842
All positional - except vertical down *3.2 350 26 95–150 3kg 12 (3 x 4) 611843
*4.0 350 17 145–220 3kg 12 (3 x 4) 611844
# -Alloycraft 70-A1 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity. The preferred polarity for DC
welding is DC+.
*Non-stock item available on indent only.
Alloycraft 80-B2
N Improved high strength, low alloy
steel electrode 0.2% Proof stress 570 MPa 3.0–3.5 ml of hydrogen / 100 gm of
deposited weld metal*
N Advanced flux coating Tensile strength 670 MPa
N Very low “H5” diffusible hydrogen class Elongation 24%
N 550 MPa tensile class
N Batch numbered for on-the-job
traceability C: 0.08 Mn: 0.82 Si: 0.39 P: 0.015
N Recommended for the all positional Mo: 0.65 Cr: 1.40 S: 0.013
(except vertical-down) welding of
chromium and chromium – molybdenum
Packaging and operating data — AC (min. 70 OCV) DCEP (DC+) or DCEN (DC-) polarity
bearing steels as-used in elevated
temperature applications Electrode
Approx No. Current
N Hermetically sealed cans Size (mm) Length (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Part No.
2.5 350 22 65–100 3 12 (3 x 4) 611922
Classifications 3.2 350 15 105–150 3 12 (3 x 4) 611923
AS / NZS 1553.2: E5518-B2 4.0 350 8 145–200 3 12 (3 x 4) 611924
AWS /ASME-SFA A5.5: E8018-B2 H4

Low Alloy 8
MMA Electrodes
Alloycraft 80-C1
Typical all weld metal mechanical properties Typical all weld metal analysis (%)
0.2% Proof Stress 550 MPa C: 0.05 Mn: 1.1 Si: 0.38
steel electrode Tensile strength 630 MPa Ni: 2.46 S: 0.013 P: 0.015

CVN impact values 75J av @ -60°C Typical Diffusible hydrogen levels to AS 3752
N 550 MPa tensile class, reliable impact
toughness to -60°C 3.0–3.5 ml of hydrogen / 100 gm of
traceability *Reconditioned for 2 hours maximum at 350°C
N Suitable for the full or under matching

strength welding of high strength Packaging and operating data — AC (minimum 70 OCV) DC+ or DC- polarity
nickel bearing steels as used for low Electrode
temperature applications Approx No. Current
Size (mm) Length (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Part No.
AS / NZS 1553.2: E5518-C1 4.0 350 15 140–200 3 12 (3 x 4) 611834

AWS /ASME-SFA A5.5: E8018-C1 H4 5.0 350 8 190–270 3 12 (3 x 4) 611835
Alloycraft 80-C1 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity.
The preferred polarity for DC welding is DC+.
Alloycraft 90-B3
Typical all weld metal mechanical properties Typical Diffusible hydrogen levels to AS 3752
0.2% Proof Stress 630 MPa 3.0–3.5 ml of / 100 gm of
N Improved high strength, low alloy deposited weld metal*
steel electrode Tensile strength 720 MPa
N 620 MPa tensile class
traceability C: 0.08 Mn: 0.85 Si: 0.35
N Recommended for the all positional Mo: 1.05 Cr: 2.20 S: 0.013
(except vertical-down) welding of Cr-Mo P: 0.015
and
Cr-Mo-V bearing steels as used for high
temperature applications Packaging and operating data AC (min. 70 OCV) DCEP (DC+) or DCEN (DC-) polarity
Electrode
Approx No. Current
Classifications Size (mm) Length (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Part No.
AS / NZS 1553.2: E6218-B3 3.2 350 15 105–150 3 12 (3 x 4) 611963
AWS /ASME-SFA A5.5: E9018-B3 H4
4.0 350 8 145–200 3 12 (3 x 4) 611964

8 Low Alloy
MMA Electrodes
Alloycraft 90
0.2% Proof stress 590 MPa 3.0–3.5 ml of / 100 gm of
N Improved high strength, low alloy deposited weld metal*
steel electrode Tensile strength 680 MPa
N 620 MPa tensile class, reliable impact CVN impact values 90J av @ -40°C Typical all weld metal analysis (%)
toughness to -40°C C Mn Si Ni Mo
N Batch numbered for on-the-job 0.07 1.0 0.40 1.6 0.3
traceability
N Applications include the full or under Packaging and operating data AC (minimum 70 OCV) DC+ or DC- polarity
matching strength welding of high Electrode Approx no. Current
strength steels, including Bisalloy 60,
Size (mm) Length (mm) rods / kg range (A) Packet (kg) Carton (kg) Part No.
70 and 80, Welten 60 and 80, AS2074
Gr L6, Comsteel 023 / 026. ASTM A514 3.2 350 22 110–145 3 12 (3 x 4) 611873
and A517 used in structural, transport, 4.0 350 15 140–200 3 12 (3 x 4) 611874
mining and earthmoving applications
5.0 350 10 190–270 3 12 (3 x 4) 611875
Classifications Alloycraft 90 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity.
The preferred polarity for DC welding is DC+.
AS / NZS 1553.2: E6218M
AWS /ASME-SFA A5.5: E9018M H4
Alloycraft 110
0.2% Proof stress 710 MPa C Mn Si Ni Mo Cr
Tensile strength 820 MPa 0.07 1.5 0.45 2.1 0.4 0.2
steel electrode
N Low “H5” diffusible hydrogen class Elongation 22%
Typical diffusible hydrogen levels to AS 3752
N 760 MPa tensile class, reliable impact CVN impact values 60J av @ -50°C
toughness to -40°C 3.0–3.5 ml of / 100 gm of
traceability
N Applications include the full strength
welding of high strength steels, including Packaging and operating data AC (minimum 70 OCV) DC+ or DC- polarity
Bisalloy 80, USST1 and T1A, welten 80, Electrode Approx no. Current
HY80, AS2074 Grade L6A and ASTM
A533 type A, A514 and A517 grades Size (mm) Length (mm) rods / (kg) range (A) Packet (kg) Carton (kg) Part No.
used in structural transport, mining 3.2 350 22 110–145 3 12 (3 x 4) 611893
and earthmoving applications 4.0 350 15 140–200 3 12 (3 x 4) 611894
Alloycraft 110 is formulated to operate with AC (min 70 OCV), DC+ or DC- polarity.
Classifications The preferred polarity for DC welding is DC+.
AS / NZS 1553.2: E7618-M
AWS /ASME-SFA A5.5: E11018M H4

Low Alloy 8
GMAW Wire
Autocraft Mn-Mo
N A manganese molybdenum steel
wire for the GMA welding of higher Argon20–25% CO2 1.0–2.0 ml of hydrogen / 100 gm of
strength steels deposited weld metal.
N For use with welding grade CO2 Tensile strength 680 MPa
or argon based shielding gases Recommended shielding gas
Elongation 24%
N 550 MPa tensile class weld deposits Argoshield® 52
CVN impact values 80J av @ +20°C
N Suitable for the all positional fillet and Argoshield® 54
butt welding of a wide range of higher Stainshield®
strength steels, particularly those used
C Mn Si Mo S P Welding Grade CO2
in the fabrication of pressure vessels,
boilers and pipelines 0.08 1.73 0.65 0.45 0.011 0.017
Classifications Packaging and operating data

AWS /ASME-SFA A5.28: ER80S-D2 Wire feed Current Range Pack
0.9 16–28 3.5–15 70–230 Spool 15 720049
1.2 18–32 3.5–15 120–350 Spool 15 720052
* Spool (ø300 mm)
Autocraft NiCrMo
N A low alloy steel wire for the GMA
welding of high strength steels Argon Argon 1.0–2.0 ml of hydrogen /
1–3% O2 20–25% CO2 100 gm of deposited weld metal
N For use with welding grade CO2 or
argon based shielding gases Yield stress 730 MPa 707 MPa
Tensile 790 MPa 770 MPa Recommended shielding gas
N 760 MPa tensile class weld deposits
strength Argoshield® 52
N Suitable for the all positional fillet and
butt welding of a wide range of high Elongation 17% 21% Argoshield® 54
strength steels, particularly quenched CVN impact 130J @ -29°C 72J @ -29°C Stainshield®
and tempered types such as Bisalloy 80, values 80J @ -51°C 50J @ -51°C
Welding Grade CO2
USS-T1 types and Welten 80C etc.
Classifications
C: 0.08 Mn: 1.40 Si: 0.60
AS / NZS 2717.1: ESMG-GC / M-W769AH
AWS /ASME-SFA A5.28: ER110S-G Ni: 1.40 Cr: 0.40 Mo: 0.25
V: 0.10%

Wire feed Current Range Pack
1.2 18–32 3.5–15 120–350 Spool 15 720053
* Spool (ø300 mm)

8 Low Alloy
GMAW Wire
Autocraft CrMo1
Typical wire analysis (%) Typical diffusible hydrogen levels to AS 3752
N A low alloy steel wire for the GMA
welding of matching Cr-Mo-steels C: 0.09 Mn: 0.60 Si: 0.60 1.0–2.0 ml of hydrogen / 100 gm of
deposited weld metal.
N Recommended for the GMA welding Cr: 1.30 Mo: 0.50 P: 0.015
of-1 / 2Cr-1⁄2Mo, 1Cr-1⁄2Mo and S: 0.010 Fe: Balance
1 1⁄4Cr-1⁄2Mo steel pipes, plates Recommended shielding gas
and castings Argoshield® 52
Stainshield®
Classifications
AS / NZS 2717.1: ESB2-GM-W559AH
AWS /ASME-SFA A5.28: ER80S-B2
Dia. (mm) Voltage (V) Wire feed Current Range Pack type* Pack Part No.
speed (m / min) (A) weight (kg)
Argon 1–3% O2
1.2 18–32 3.5–15 120–350 Spool 15 720029
0.2% Proof stress 500 MPa * Spool (ø300 mm)
Elongation 20%
Post weld heat treated at 620°C as required
by AWS A5.28

Low Alloy 8
Gas Assisted FCAW Wire

™
SmoothCor 811K2 Tensile strength 560–640 MPa 560–640 MPa
Impact energy, CVN 125J av @ -29ºC 120J av @ -29ºC
85J av @ -40ºC 80J av @ -40ºC
76J av @ -60ºC 73J av @ -60ºC
Description
SmoothCor™ 811K2 is a rutile type flux cored wire designed to provide PWHT*
excellent low temperature impact toughness. It is suitable for use with Using Argoshield® 52 Using CO2
both Ar / CO2 or CO2 shielding gas and can be used in all positions
including downhand, vertical up and overhead. Designed for single and Yield strength 480 MPa min 470 MPa min
multi pass welding, SmoothCor™ 811K2 deposits a weld metal containing Tensile strength 550–620 MPa 550–620 MPa
approximately 1.5% nickel. The nickel content of the weld metal ensures
excellent impact properties at temperatures below -60ºC with radiographic Elongation 25% min 25% min
quality which is consistently high. The very low H4 hydrogen class ensures Impact energy, CVN 75J av @ -29ºC 70J av @ -29ºC
superior crack resistance. A rutile based wire, SmoothCor™ 811K2 welds 65J av @ -40ºC 60J av @ -40ºC
with a very smooth running, low spatter arc and a fine spray type transfer to 50J av @ -60ºC 45J av @ -60ºC
give excellent weld pool control. With its excellent feedability and easy arc
* PWHT 625ºC 2 hours
starting characteristics, SmoothCor™ 811K2 has excellent operator appeal.
Application Diffusible Hydrogen

SmoothCor™ 811K2 is recommended for welding fine-grained low alloy 1.2 mm, 100% CO2, DC+, 230 amps, 27 volts, 20 mm stick-out:
steels intended for service at low temperatures and for matching strength <4ml / 100g (vacuum packed)
on 490 MPa yield strength steels. It is also eminently suitable for welding
fine-grained and quench and tempered steels where undermatching 1.2 mm, Argoshield® 52, DC+, 230 amps, 27 volts, 20 mm stick-out:
strength weld metal is desirable. <4ml / 100g (vacuum packed)
Welding Positions Packaging Data

Dia. (mm) 1.2 1.6
Part No. 10811K212 10811K216
Weight (kg) 15 15
Specifications
Flux Type Rutile Welding Parameters
Classification AWS /ASME-SFA A5.29 E81T1-K2 H4, E81T1-K2M Welding Position Flat, Vertical up Overhead
H4 Horizontal
AS 2203.1 ETP-GCp-W559A.K2 H5 Dia. (mm) 1.2 1.6 1.2 1.6 1.2 1.6
ETP-GMp-W559A.K2 H5 Current Range (A) 150– 180– 150– 180– 150– 180–
290 400 250 300 250 310
Approvals* Lloyds Register of Grade 5Y 40S H5
Shipping Voltage (V) 23–30 25–34 22–26 21–27 23–26 22–27
Det Norske Veritas Grade 4YSA H5 Electrode Stick-out 15–20 20–25 15–20 20–25 15–20 20–25
(mm)
American Bureau Grade 5YMS H5
Shipping Deposition Data
Welding Current DC+ Wire Feed
* With Ar / CO2 and CO2 shielding gas Dia. Current Voltage Speed (m / min) Deposition Efficiency
(mm) (A) (V) Approx. Rate (kg / h) (%)
1.2 150 28 5.08 1.91 86
210 29 7.62 2.86 86
250 30 10.16 3.86 87
Welding Grade CO2
290 33 12.70 4.85 87
Flow rate 15–20 L / min 330 34 15.24 5.76 87
1.6 190 27 3.81 2.77 87
Chemical Composition, wt% – All-Weld Metal 300 30 6.35 4.63 87
Typical C Si Mn Ni 365 33 7.62 5.58 86
Argoshield® 52 0.05 0.45 1.15 1.54 410 33 8.89 6.35 88
CO2 0.04 0.38 1.07 1.54

8 Low Alloy
FCAW Wire Gas Assisted

™
SmoothCor 115 Yield strength
Tensile strength
690 MPa min
760–880 MPa
690 MPa min
760–840 MPa
Impact energy, CVN 30J min av @ -51ºC 50J min av @ -51ºC
Description Diffusible Hydrogen

SmoothCor™ 115 is a basic type flux cored wire designed for the welding
1.2 mm, 100% CO2, DC+, 230 amps, 27 volts, 20 mm stick-out:
of high tensile low alloy steels. It is suitable for use with both Ar / CO2 or
CO2 shielding gas and can be used in both the flat and horizontal position.
Designed for single and multi pass welding, SmoothCor™ 115 deposits 1.2 mm, Argoshield® 52, DC+, 230 amps, 27 volts, 20 mm stick-out:
a weld metal containing approximately 2.25% nickel, 0.5% molybdenum <4ml / 100g (vacuum packed)
and 0.3% chromium which, apart from having good tensile properties, is
extremely tough and ductile. The very low H4 hydrogen class ensures
superior crack resistance. The wire produces weld metal of the highest Packaging Data
radiographic and metallurgical quality. SmoothCor™ 115 welds with Dia. (mm) 1.2 1.6
particularly stable running characteristics, a minimum amount of spatter
Part No. 1011512 1011516
and easy slag removal for this class of wire. Feedability is excellent.
Application
Weight (kg) 15 15
SmoothCor™ 115 is recommended for welding a range of high strength
fine-grained structural steels, low temperature steels and quench and
tempered steels. Produces matching strength and hardness on 690 MPa Welding Parameters
yield strength and 230 HB steels e.g. AS 3597 grade 700, ASTM A514. Weld Dia. (mm) 1.2 1.6
deposits are resistant to cracking in heavy sections or under high restraint.
Current Range (A) 150–290 180–400
Welding Positions Voltage (V) 23–30 25–34
Electrode Stick-out 15–20 20–25
(mm)
Welding Position Flat, Horizontal
Specifications
Flux Type Basic Deposition Data
Classification AWS /ASME-SFA A5.29 E110T5-K4 H4 E110T5-K4M Approx. Wire

H4 Dia. Current Voltage Feed Speed Deposition Efficiency
(mm) (A) (V) (m / min) Rate (kg / h) (%)
AS 2203.1 ETD-GMp-W769A.K4 H5
ETD-GCp-W769A.K4 H5 1.2 170 29 7.24 3.20 96
Approvals* American Bureau AWS A5.29 E110T5-K4M 250 30 11.91 4.90 91

Shipping 300 32 15.39 6.44 92
Welding Current DC+ 300 30 5.74 4.45 92
* With Ar / CO2 shielding gas 1.6 400 32 9.37 7.30 92
450 32 10.72 8.40 93
Recommended Shielding Gases
Welding Grade CO2

Typical C Si Mn Ni Mo Cr
Argoshield® 52 0.07 0.38 1.55 2.29 0.44 0.27
CO2 0.06 0.30 1.40 2.29 0.44 0.22

Low Alloy 8
Verti-Cor 81Ni1
Typical all weld metal analysis (%)* Recommended shielding gas
N A higher strength low alloy steel, rutile
type flux cored wire C: 0.06 Mn: 1.35 Si: 0.35 Argoshield® 52
N Formulated for use with argon +20 Ni: 0.90 Ti: 0.035 B: 0.007
–25% CO2 shielding gases *Using Argon +20–25% CO2
Packaging data
N Versatile, all positional capabilities Dia. (mm) Pack Pack weight

Typical diffusible hydrogen levels to AS 3752 type (kg) Part No.
5.0–6.0 ml of hydrogen / 100 gm of deposited 1.2 Spool 13 720390
N Now Precision Layer Wound
weld metal* 1.6 Spool 13 720391
N A nominal 1% nickel steel deposit of
* For ‘as manufactured’ product using Argoshield® Argon
the 550 MPa tensile class +20–25% CO2
N Typical applications include the under
matching strength fillet welding of Operating data
Bisalloy 60, 70 and 80 quenched and
tempered steels DC electrode positive and welding grade CO2 shielding gas with a flow rate of 10–15 L / min.
Electrode
Classifications
Current stickout ESO Optimum Welding
AS / NZS 2203.1: Dia. (mm) range (A) Voltage (V) (mm) amps Volts positions
ETP-GMp-W554A. Ni1 H10
1.2 250–300 27–31 20–25 280 31 Flat
AWS /ASME-SFA A5.29: E81T1-Ni1MH8
1.6 350–400 27–31 25–30 360 31
1.2 230–280 26–30 20–25 260 28 HV Fillet
1.6 310–360 26–30 25–30 320 29
1.2 170–220 24–28 15–20 200 24 Vertical up
1.6 200–250 24–28 15–20 240 25
1.2 160–210 24–28 15–20 200 24 Overhead
Elongation 26%
1.6 190–240 24–28 15–20 220 24

8 Low Alloy
Verti-Cor 81 Ni1 H4
Approvals* Typical Diffusible Hydrogen Levels to AS 3752
N Higher Strength Copper coated
seamless Low Alloy, Rutile Type Flux Lloyds Register of Grade 4Y, 4YS H10. <3 mls of hydrogen / 100gms of deposited weld
Cored Wire. Shipping metal for as manufactured product using Argon
+20–25% CO2 or CO2 .
N Formulated for use with either Argon + American Bureau of Grade 4YSA H5.
Shipping
20–25% CO2 or CO2 shielding gases.
Recommended Shielding Gas
N Versatile, All Positional Capabilities. Det Norske Veritas IV YMS H10.
Ar + 20–25% CO2 or ISO14175: M21, M24
*with Argon + 20–25% CO2 or CO2 shielding gases
N Outstanding Operator Appeal. equivalent
N Low Fume Levels. Welding Grade CO2 ISO14175: C1
Typical All Weld Metal Analysis
N Precision Layer Wound. C Mn Si Ni
Packaging Data
Using Argon + 20–25% CO2
Classifications Wire Dia. Pack Type Weight Part No.
0.06 1.4 0.5 1.00% (mm) (kg)
AS 2203.1: ETP-GC/Mp-W554A. Ni1 H5
AWS/ASME-SFA A5.29: E81T1-Ni1M H4; Using CO2 1.2 Spool 15 720550
E81T1-Ni1 H4 0.05 1.1 0.38 1.16% 1.6 Spool 15 720551

Operating Data
Using Argon + CO2
20–25% CO2 All welding conditions recommended below are for use with semi-automatic operation, DC electrode
positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.
Yield Stress 540 MPa 500 MPa
Wire Dia. (mm) Current Range (A) Voltage Range (V) CTWD Welding Positions
Strength 1.2 250–300 27–31 20–25 Flat
Elongation 22% 23% 1.6 350–400 27–31 25–30 Flat
CVN Impact 85J av @ 75J av @ 1.2 230–280 26–30 20–25 HV Fillet

Values -40°C -50°C 1.6 310–360 26–30 25–30 HV Fillet
1.2 170–220 24–28 15–20 Vertical up
1.6 200–250 24–28 15–20 Vertical up
1.2 160–210 24–28 15–20 Overhead
1.6 190–240 24–28 15–20 Overhead

Low Alloy 8
Verti-Cor 91 K2
Typical all weld metal analysis (%)* Recommended shielding gas
N A higher strength low alloy steel, rutile
type flux cored wire formulated for C: 0.06 Mn: 1.30 Si: 0.50 Argoshield® 52
use with argon +20–25% CO2 shielding Ni: 1.60 Ti: 0.035 B: 0.007
gases * Using Argon +20–25% CO2 Packaging data
N Versatile, all positional capabilities
Pack Pack weight
N Excellent operator appeal Typical diffusible hydrogen levels to AS 3752 Dia. (mm) type (kg) Part No.
N A nominal 1.5% nickel steel deposit 5.0–6.0 ml of hydrogen / 100 gm of deposited 1.2 Spool 13 720394
of the 620 MPa tensile class weld metal*
1.6 Spool 13 720396
N Typical applications include the full * For ‘as manufactured’ product using Argoshield® Argon
+20–25% CO2
strength butt welding of Bisalloy 60
or the under matching strength fillet
welding of Bisalloy 70 and 80 steels Operating data
Electrode
Classifications Current stickout ESO Optimum Welding
AS / NZS 2203.1: Dia. (mm) range (A) Voltage (V) (mm) amps Volts positions
ETP-GMp-W629A. K2 H10 1.2 250–300 27–31 20–25 280 31 Flat
AWS /ASME-SFA A5.29: E91T1-K2MH8 1.6 350–400 27–31 25–30 360 31
1.2 230–280 26–30 20–25 260 28 HV Fillet
1.6 310–360 26–30 25–30 320 29
Using Argon +20 –25% CO2
1.2 170–220 24–28 15–20 200 24 Vertical up
1.6 200–250 24–28 15–20 240 25
1.2 160–210 24–28 15–20 200 24 Overhead
Elongation 23%
1.6 190–240 24–28 15–20 220 24

8 Low Alloy
Verti-Cor 91 K2 H4
Typical All Weld Metal Analysis* Recommended Shielding Gas
N Copper coated seamless wire delivering
very low H4 class hydrogen levels. C Mn Si Ni Argon + 20–25% CO2 or equivalent ISO14175:
0.05 1.3 0.3 1.2 M21, M24
N Higher Strength Low Alloy, Rutile Type
Flux Cored Wire *Using Argon + 20–25% CO2 shielding gas
Packaging Data
N Formulated for Use with Argon +
20–25% CO2 . Typical Diffusible Hydrogen Levels to AS 3752: Wire Dia. Pack Type Weight Part No.
(mm) (kg)
N Very low hydrogen status. <3.5 mls of hydrogen / 100gms of deposited
weld metal *. 1.2 Spool 15 720554
N Low fume levels.
* for ‘as manufactured’ product using Argon + 20–25% 1.6 Spool 15 720555
CO2 shielding gas.
Classifications
AS 2203.1: ETP-GMp-W629A. K2 H5. Operating Data
AWS/ASME-SFA A5.29: E91T1-K2M H4 All welding conditions recommended below are for use with semi-automatic operation, DC electrode
positive and Argon +20–25% CO2 shielding gas with a flow rate of 15–20 L/min.
Typical All Weld Metal Mechanical Properties Wire Dia. (mm) Current Range (A) Voltage Range (V) Electrode stickout Welding Positions
Using Argon + 20–25% CO2 ESO (mm)
Yield Stress 560 MPa 1.2 250–300 27–31 20–25 Flat
Tensile Strength 670 MPa 1.6 350–400 27–31 25–30 Flat
Elongation 22% 1.2 230–280 26–30 20–25 HV Fillet
CVN Impact Values >40J av @ -40°C 1.6 310–360 26–30 25–30 HV Fillet
1.2 170–220 24–28 15–20 Vertical up
1.6 200–250 24–28 15–20 Vertical up
1.2 160–210 24–28 15–20 Overhead
1.6 190–240 24–28 15–20 Overhead

Low Alloy 8
Verti-Cor 111 K3 Typical all weld metal (AWM) analysis* (Wt%) Recommended shielding gas
N A high strength low alloy steel, C: 0.06 Mn: 1.65 Si: 0.36 Argoshield® 52
rutile type flux cored wire Ni: 2.05 Mo: 0.46 B: 0.004.
N Formulated for use with argon *Using Argon +20–25% CO2 Packaging data
+ 20–25% CO2 shielding gases
Dia. (mm) Pack Pack weight Part No.
N Versatile, all positional capabilities Typical diffusible hydrogen levels to AS 3752 type (kg)
N A nickel molybdenum steel deposit 1.5–2.0 ml of hydrogen / 100 gm of deposited 1.2 PLW 15 721381
of the 760 MPa tensile class weld metal *
1.6 PLW 15 721382
N Typical applications include the full * For ‘as manufactured’ product using and Electrode
strength butt welding and fillet stickout ESO of 20 mm with 1.2 mm wire and 25 mm
with 1.6 mm wire and mid-range current and Voltage (V)
welding of Bisalloy 80 and similar settings.
quenched and tempered steels
N Precision Layer Wound Operating data
Classifications DC electrode positive and Argoshield® 52 shielding gas with a flow rate of 15–20 L / min.
AS / NZS 2203.1: Current range Electrode stickout Optimum Welding
ETP-GMp-W768A. K3 H10 Dia. (mm) (A) Voltage (V) ESO (mm) amps Volts positions
AWS /ASME-SFA A5.29: E111T1-K3M H8 1.2 250–300 27–31 20–25 280 31 Flat
1.6 350–400 27–31 25–30 360 31
1.2 230–280 26–30 20–25 260 28 HV Fillet
1.6 310–360 26–30 25–30 320 29
0.2% Proof stress 775 MPa
1.2 170–220 24–28 15–20 200 24 Vertical up
1.6 200–250 24–28 15–20 240 25
Elongation 18%
1.2 160–210 24–28 15–20 200 24 Overhead
1.6 190–240 24–28 15–20 220 24
Tensi-Cor 110TXP H4 Typical all weld metal (%)* Recommended shielding gases
N Fully basic, high strength low alloy C Mn Si Ni Mo: Cr Welding Grade CO2 and Argon + 20–25% CO2
steel, Seamless Flux cored wire or equivalent.
0.08 1.50 0.40 1.90 0.4 0.3
N Formulated for use with CO2 *Using CO2 shielding gas
and Argon + 20–25% CO2 Packaging data
N Premium quality weld deposits Dia. Pack type Pack weight Part No.
Typical diffusible hydrogen levels to AS3752
(mm) (kg)
N “Very low H5” hydrogen status 1.5–2.0 ml of hydrogen / 100 gm of deposited
1.6 Spool 15 720387
N For the crack free full strength weld metal*
butt welding of Bisalloy 80 and 2.4 Coil 25 720389
*For ‘as manufactured’ product using welding grade CO2
similar quenched and tempered steels shielding gas
N Seamless Copper Coated
N Precision Layer Wound Operating data
Classifications DC electrode positive and welding grade CO2 shielding gas with a flow rate of 15–20 L / min.
AS / NZS 2203.1: Electrode
Current stickout ESO Optimum Welding
ETD-GCn / p-W769A. K4 H5
Dia. (mm) range (A) Voltage (V) (mm) amps Volts positions
ETD-GMn / p-W769A. K4 H5 1.6 300–350 28–32 25–30 320 29 Flat
AWS /ASME-SFA A5.29: E110T5-K4 2.4 400–450 28–32 25–35 450 32
1.6 280–330 27–31 25–30 300 28 HV Fillet
2.4 380–430 27–31 25–30 400 28
1.6 220–270 25–30 25–30 280 26 Vertical up
1.6 260–310 27–31 25–30 N /A N /A Horizontal
2.4 360–410 27–31 25–30 N /A N /A
Elongation 22%

8 Low Alloy
Outershield 81Ni1-H Outershield 91K2-H Outershield 690-H

Produces weld deposits exhibiting excellent For HY-80, HSLA-80 and similar steels. For high strength steel grades like grade
low temperature impacts and CTOD values. Produces weld deposits exhibiting excellent S690.Outstanding operators appeal.
Ideally suited to applications requiring low temperature impact values. Exceptional mechanical properties (CVN
superior mechanical properties in the >50J @ -40°C). Good wire feeding.
as welded condition. Classifications Superior product consistency with optimal
alloy control.
AS 2203.1: ETP-GMp-W629A.K2.H5;
Classifications AWS A5.29: E91T1-K2
AS 2203.1: ETP-GMp-W554. Ni1.H5; Classifications
AWS A5.29: E81T1-Ni1 Size (mm) Weight (kg) Part No. AWS. A5.29: E111T1-K3 MJ H4
1.2 11.34 ED017708

Size (mm) Weight (kg) Part No. Readireel Size (mm) Weight (kg) Product No
1.2 15 Readireel 941357 1.6 11.34 ED017709 1.2 15 942422
1.6 15 Readireel 942750* Readireel 1.6 15 942828
*No spool adaptor required
Pipeliner NR-207 Pipeliner NR-208P

Primarily used for hot, fill and cap pass Similar to NR-207-H, but with higher
welding on cross-country pipelines. It strength. Produces weld deposits exceeding
is designed to produce weld deposits 80,000 psi yield strength with excellent low
exceeding 490 MPa tensile strength temperature impacts. Recommended for API
with excellent low temperature impact Pipe Grade X80.
properties.
Classification
Classifications
AWS. E91T8-G
AS 2203.1:ETP-GNn-W509A.Ni1.H15;
AWS A5.29: E71T8-K6
2.0 6.0 KC208206
*4 per box
2.0 6.0* Coil KC207206
*4 per box

Low Alloy 8
TIG
Comweld CrMo 1
Typical rod analysis (%) Recommended shielding gases
N Nominal 1.25% Cr 0.5% Mo steel TIG
rod C: 0.09% Mn: 0.60% Si: 0.60% Argon Welding Grade
N End stamped with AWS class ‘ER80S-B2’ Cr: 1.30% Mo: 0.50% P: 0.015% Alushield® Light
for-easy identification S: 0.010% Fe: Balance
N For the gas tungsten arc (TIG) welding
of matching Cr-Mo creep resistant Packaging data
steels for elevated temperature and Rod Size (mm) Weight (kg), Pack type Approx. (rods / kg) Part No.
corrosive service
2.4 x 1,000 5 cardboard tube* 29 321379
*Resealable
Classifications
AS / NZS 1167.2: RB2
Comweld CrMo 2
Typical rod analysis (%) Recommended shielding gases
N Nominal 2.5% CR 1% Mo steel TIG rod
C: 0.08% Mn: 0.70% Si: 0.60% Argon Welding Grade
N End stamped with AWS class ‘ER90S-B3’
for-easy identification Cr: 2.50% Mo: 1.00% P: 0.015%
N For the gas tungsten arc (TIG) welding S: 0.010% Fe: Balance
of Cr-Mo and Cr-Mo-V creep resistant
steels for elevated temperature and Packaging data
corrosive service
Rod Size (mm) Weight (kg) Pack type Approx. (rods / kg) Part No.
Classifications 2.4 x 1,000 5 Cardboard 29 321383

tube*
AS / NZS 1167.2: RB3
*Resealable

8 Low Alloy
Submerged Arc Wire
L-70 LAC-B2 LAC-M2

Special purpose 0.5% Mo electrode Alloy cored wire designed for welding Alloy cored wire designed to weld steels
recommended for multiple pass welding chromium-molybdenum steels having requiring 690 MPa yield strength (as welded
or stress relieved) and 20 J minimum
with 860 flux on 480 MPa tensile (stress 1.25% Cr – 0.5% Mo or less.
Charpy V-notch at -45°C.
relieved) applications when the use of Mo is
not restricted. Also suitable for single pass Classifications
welding with Lincoln 700 series fluxes. Classifications
AS 1858.2: ECB2;
AS 1858.2: ECM2;
AWS A5.23: ECB2
Classification: AWS A5.23: ECM2
AS 1858.2: EA1; Size (mm) Weight (kg) Part No.

AWS A5.23: EA1 Size (mm) Weight (kg) Part No.
2.4 22.68 Coil ED010954
2.4 22.68 Coil ED010981
4.0 22.68 Coil ED010955
Size (mm) Weight (kg) Part No. 4.0 22.68 Coil ED010982
2.0 30 Coil KC702030
3.2 30 Coil KC703230
4.0 27.2 Coil ED012053
4.0 30 coil KC704030
4.0 600 Bulk reel KC7040600
spool
LAC-Ni2
Alloy cored wire designed to weld weathering
steels, 2.5% Ni steels, 3.5% Ni steels, and other
steels requiring 480 MPa tensile strength
(as welded or stress relieved) and excellent
low temperature impact properties.
Classifications
AS 1858.2: ECNi2;
AWS A5.23: ECNi2

2.4 22.68 Coil ED010986
Submerged Arc Flux

Refer to page 376 for a listing of Submerged
Arc Flux

Consumables 8
Stainless Steel
Weldability of Stainless Steel

Introduction temperatures between 500–900°C, delta ferrite in weld metal is
Stainless steels are a group of high alloy steels which contain at least necessary to overcome the possibility of hot cracking (tearing).
12% chromium. In general these steels are alloyed with a number of In general austenitic welding consumables deposit a weldment
other elements which make them resistant to a variety of different containing 4–12% delta ferrite. For special applications, i.e. when
environments. dissimilar steels are welded under conditions of high restraint,
In addition these elements modify the microstructure of the alloy austenitic consumables having weld metal delta ferrite contents
which in turn has a distinct influence on their mechanical properties as high as 40% may be required. The delta ferrite content can be
and weldability. Stainless steels can be broadly classified into five calculated using the procedure given at the end of this section with
groups as detailed below: the aid of the Schaeffler diagram.
N Austenitic stainless steels which contain 12–27% chromium and The carbon content of austenitic stainless steels is kept at very low
7–25% nickel. levels to overcome any possibility of carbide precipitation, where
chromium combines with available carbon in the vicinity of the grain
N Ferritic stainless steels which contain 12–30% chromium with a boundaries to produce an area depleted in chromium and thus
carbon content below 0.1%. becomes susceptible to intergranular corrosion.
N Martensitic stainless steels which have chromium content
The titanium and niobium stabilised AISI 321 and 347 steels
between 12–18% with 0.15–0.30% carbon.
together with ELC (extra low carbon) grades are available to
N Ferritic-austenitic (Duplex) stainless steels which contain 18– further overcome this problem.
25% Chromium, 3–5% nickel and up to 3% molybdenum.
N Martensitic-austenitic steels which have 13–16% chromium, 5–6% Ferritic stainless steels
nickel and 1–2% molybdenum. The first three of these groups will These steels which contain 12–30% chromium with a carbon
be discussed in greater detail below. content below 0.10% do not exhibit the good weldability of the
austenitic types. The steels which become fully ferritic at high
Austenitic stainless steels temperatures and undergo rapid grain growth, leads to brittle
This is by far the largest and most important group in the stainless heat affected zones in the fabricated product. No refinement
steel range. These steels which exhibit a high level of weldability are of this coarse structure is possible without cold working and
available in a wide range of compositions such as the 19/9 AISI 304 recrystallization. In addition, austenite formed at elevated
types, 25/20 AlSI 310 types and 19/12/2 AISl 316 types, etc which are temperatures may form martensite upon transformation which can
used for general stainless steel fabrications, elevated temperature cause cracking problems. The brittleness and poor ductility of these
applications and resistance to pitting corrosion respectively. materials have limited their applications in the welded condition.
As the name implies the microstructure of austenitic stainless steel Ferritic stainless steels are also subject to intergranular corrosion as
consists entirely of fine grains of austenite in the wrought condition. a result of chromium depletion from carbide precipitation. Titanium
When subjected to welding however, a secondary ferrite phase may and niobium stabilised ferritic steels and steels with extra low
be formed on the austenite grain boundaries, in the heat affected interstitials (i.e. C,N) are available to overcome this problem.
zone and in the weld metal. The extent of the formation of this As this material has a coefficient of expansion lower than that of
secondary phase maybe dependent on the composition of the steel carbon manganese steels, warpage and distortion during welding is
or filler material and the heat input during welding. considerably less. They are magnetic, however, and therefore subject
While delta ferrite formation can have negative effects on the to magnetic arc blow. Ferritic stainless steels cannot be hardened by
resistance to corrosion and formation of sigma phase at operating conventional heat treatment processes.

8 Stainless Steel
Martensitic stainless steels electrode is recommended. This would tend to alleviate many of the
Martensitic stainless steels contain between 12–18% chromium toughness problems of ferritic stainless steel weld metal and could
with 0.15–0.30% carbon. Because of their composition these steels obviate the need for post-weld heal treatment (i.e. in many cases
are capable of air hardening and thus special precautions should be the narrow notch sensitive heat affected zone could be tolerated).
taken during welding to overcome possible cracking. Cold cracking,
Martensitic steels
as a result of hydrogen, which is experienced with low alloy steels
can also occur in martensitic stainless steels and thus hydrogen- These steels require a preheat of 200–300°C followed by slow
controlled consumables should be used. cooling after welding. This should be followed if possible by a post-
weld heat treatment.
Martensitic steels, because of their lower chromium content and
responsiveness to heat treatment, have limited applications for Austenitic stainless steel electrodes are normally used for welding
corrosion resistance but are successfully used where their high this material.
strength and increased hardness can be utilised, e.g turbine blades,
cutlery, shafts etc. Procedure for welding clad steels
As in the case of ferritic stainless steels the martensitic types have a The use of a clad-material, consisting of a mild or low alloy
lower coefficient of expansion than mild steels and are magnetic. steel backing faced with stainless steel, usually from 10–20% of
the total thickness, combines the mechanical properties of an
Procedure for welding stainless steels economic backing material with the corrosion resistance of the
more expensive stainless steel facing. This facing usually consists
The procedure for welding stainless steel does not differ greatly of austenitic stainless steel of the 18% chromium 8% nickel or
from that of welding mild steel. The material being handled, however, 18% chromium 10% nickel type, with or without additions of
is expensive and exacting conditions of service are usually required molybdenum, titanium and niobium, or a martensitic stainless steel
which necessitate extra precautions and attention to detail. of the 13% chromium type.
Stainless steel can be welded using either AC or DC, using as The backing should be welded first at the same time making sure
short an arc as possible, to overcome any possibility of alloy loss that the root run of the mild steel electrode does not come into
across the arc. When using AC a slightly higher current setting may contact with the alloyed cladding. This can be achieved in two ways,
be required. either by cutting the cladding away from both sides of the root,
When welding in the flat position stringer beads should be used and or welding with a closed butt preparation and a sufficiently large
if weaving is required this should be limited to 2 times the electrode root-face.
diameter. The heat input, which can adversely affect corrosion After welding the mild steel side the root run should be back
resistance and lead to excessive distortion, should be limited by grooved and the stainless clad side welded with a stainless electrode
using the correct electrode diameter to give the required bead of matching composition. The use of a more highly alloyed electrode
profile and properties at the maximum travel speed In all cases the (e.g. Smootharc S309) for the initial root run on the clad side is first
heat input should be limited to 1.5 kJ/mm. advisable. This applies particularly to preparations in which the back-
Specific points to be noted for the different stainless steel types are cutting of the cladding makes pick-up from the mild steel difficult
given below. to avoid. For the best resistance to corrosion, at least two layers of
stainless weld metal on the clad side are recommended.
Austenitic steels
The welding of material which is clad or lined with 13% chromium
As austenitic stainless steels have a coefficient of expansion 50% (martensitic) steels usually requires a preheat of 250°C and the
greater than carbon manganese steels, distortion and warping can use of austenitic electrodes of appropriate type. Welding should be
be a problem. Welding currents should therefore be kept as low as followed by a post-weld heat treatment, though satisfactory results
possible with high travel speeds, tacking should be carried out at can be obtained without these precautions if, during welding, heat
approximately half the pitch used for mild steel and welding should dissipation is kept to a minimum. This will help to temper the heat-
be balanced and properly distributed. Preheating should not be affected zone by utilising the heat build-up from adjacent weld runs.
applied and post-weld heat treatment of this material is seldom
required after welding. Procedure for welding stainless steels
Austenitic stainless steels are normally welded with electrodes of to mild or low alloy steels
matching composition to the base material. See table at the end of Situations frequently arise when it becomes necessary to weld
this section for specific recommendations. an austenitic stainless steel to a mild or low alloy ferritic steel. In
selecting a suitable electrode, the effect of dilution of the weld metal
Ferritic steels by the base material must be considered.
The need for preheating is determined to a large extent by
The weld metal may be diluted from 20–50% depending on the
composition, desired mechanical properties, thickness and
welding technique used, root runs in butt joints being the most
conditions of restraint. Preheat, when employed, is normally no
greatly affected since all subsequent runs are only in partial contact
more than 200°C.
with the base material and share dilution with neighbouring runs.
Some ferritic stainless steels can form chromium carbides at the
If a mild or low alloy steel electrode is used to weld stainless to
ferrite grain boundaries during welding. For these types a post-weld
mild steel, the pick up of chromium and nickel from the stainless
heat treatment of 700–800°C will restore the corrosion properties
steel side to the joint could enrich the weld metal by up to 5%
of the material.
chromium and 4% nickel. This would result in a hardenable crack-
For mildly corrosive applications, and where the presence of nickel sensitive weld.
bearing weld metal can be tolerated, an austenitic stainless steel

Stainless Steel 8
Austenitic stainless steel electrodes are therefore used for joining Niobium (Nb)
dissimilar metal combinations of stainless materials to mild and low 1 A strong carbide former. Used to stabilize austenitic stainless
alloy ferritic steels. However, the correct type, which has sufficient steels against the harmful precipitation of chromium carbides in
alloying to overcome the effects of dilution from the mild or low the range 480–820°C
alloy steel side of the joint, must be selected since if the weld metal
2 A strong ferrite former.
does not start with an adequate alloy content the final weld may
contain less than 17% chromium and 7% nickel. Weld metal with 3 Added to some high strength alloys for hardening and
lower chromium and nickel contents are crack sensitive. Also if as a strengthening effects.
result of dilution the weld metal is incorrectly balanced with nickel 4 Added to some martensitic straight chromium stainless steels to
and chromium, there may not be sufficient ferrite present in the tie up the carbon and hence reduce the hardening tendency of
weld metal to prevent fissuring and subsequent cracking. the steels.
For these reasons the austenitic stainless steel electrodes such
as Smootharc S319, etc should be used as their composition has Titanium (Ti)
been specially balanced to ensure that the total alloy content is 1 A strong carbide former. Used to stabilize austenitic stainless
adequate to accommodate dilution effects and their ferrite content steels against the harmful precipitation of chromium carbides in
is sufficient to provide high resistance to hot cracking. the range 480–820°C.
2 A strong ferrite former.
Effects of alloying elements and
3 Added to some high-strength heat resisting alloys for its
impurities in stainless steels hardening and strengthening effects.
Carbon (C)
Cobalt (Co)
1 A strong austenite former.
1 Added to various alloys to impart strength and creep resistance
2 Added to some high-strength alloys for hardening and at high temperatures.
strengthening effects.
Tungsten (W)
Manganese (Mn)
1 Improves the high-temperature strength and creep resistance of
1 Austenite former. some high-temperature alloys.
Silicon (Si) Nitrogen (N)
1 A ferite former. 1 A strong austenite former.
2 Used to increase the corrosion resistance of austenitic steels. 2 Used to minimize grain grown in high chromium straight
3 Used to improve high-temperature scaling resistance. chromium steels at high temperatures.
4 Used to improve resistance of high-temperature steels to
carburization.
5 Promotes wetting by weld metal at 0.8–1.0%.
Chromium (Cr)
1 A ferrite former.
2 Primary contributor to resistance to scaling and corrosion.
3 12% chromium minimum essential for passivation.
Nickel (Ni)
1 An austenite former.
2 Provides good low temperature toughness
3 Used to improve the general corrosion resistance against
non-oxidizing liquids.
4 Sometimes added in small amounts to straight chromium grades
to improve the mechanical properties.
Molybdenum (Mo)
1 A ferrite former.
2 Used to improve high-temperature strength and creep resistance
3 Used to improve general corrosion resistance of steels in
non- oxidizing media, and the resistance to pitting corrosion in
all media.
Copper (Cu)
1 Used to improve corrosion resistance of stainless steel in
environments which are reducing rather than oxidizing.

8 Stainless Steel
Types of corrosion
Uniform surface corrosion Oxidation
This occurs when the general corrosion resistance of a steel is Steels for heat resistance must possess one or both of two
inadequate to withstand the attack of the corrosive medium. It is properties - resistance to oxidation or scaling, and the retention of
then necessary to choose another steel having higher corrosive correct shape under stress at elevated temperatures, i.e. AISI 310.
resistance, i.e. usually one of higher alloy content. The scaling or oxidation resistance of these steels is deprived
primarily from chromium which is increasingly effective from 8%
Pitting corrosion
upwards. Nickel also improves oxidation resistance but only when
Certain chemicals, such as chlorides and some organic acids, cause present in large amounts. It is, however, more effective in promoting
localised pitting of the steel surface. The presence of molybdenum in dimensional stability under stress at elevated temperatures, that is,
the stainless steel has been found to reduce this tendency. it imparts creep resistance. Other elements contributing to creep
resistance are titanium, niobium, molybdenum, cobalt and tungsten.
Stress corrosion
Some stainless steels having high residual stresses remaining after Sigma phase embrittlement
fabrication will, in certain cases, fail very rapidly due to stress- A feature which occurs when some stainless steels are exposed to
corrosion The most satisfactory method of preventing this is to temperatures in the range to 450–900°C is the formation of sigma
solution treat the fabrication. Another method involves redesigning phase. This is a brittle constituent which develops from the ferrite in
to reduce the stress concentration. If neither of these methods the ‘duplex’ austenitic type of stainless steels, and results in loss of
is possible or economical a change to a higher alloy material may ductility and toughness in steel.
provide the solution. The use of duplex austenitic-ferritic stainless
steels can also be effective in preventing stress corrosion cracking. Sulphur attack
Sulphidation may occur in nickel-bearing steel exposed to high-
Weld decay
temperature atmospheres containing sulphurous gases. The nickel
If unstabilised Cr-Ni steels are heated to 500–900°C and allowed is attacked and forms nickel sulphide causing cracking of the steel.
to cool slowly they become more easily prone to corrosion. Such Under such conditions plain chromium steels must be used.
a condition may occur in the heat affected zone to a weld when a
band is formed parallel to the weld where corrosion resistance is Schaeffler and Delong diagrams
greatly reduced. This is due to the chromium in the grain boundary
A useful method of assessing the general metallurgical
areas combining with the carbon. The subsequent precipitation of
characteristics of any stainless steel weld metal is by means of
chromium carbides leaves a chromium depleted alloy in the grain
the Schaelflar and Delong diagrams. The various alloying elements
boundaries of much lower corrosion resistance. When the steel is
are expressed in terms of nickel or chromium equivalents i.e.
immersed in a corrosive medium, these depleted areas are eaten
elements which, like nickel, tend to form austenite and elements like
out and the grains of metal simply fall apart.
chromium which tend to form ferrite. By plotting the total values
Titanium or niobium additions are frequently made to stainless for the nickel and chromium equivalents on these diagrams a point
steels to act as ‘stabilisers’. These elements have a greater affinity for can be found indicating the main phases present in the stainless steel
carbon than has chromium and combine with it to form harmless in terms of % ferrite and ferrite number, respectively. This provides
titanium or niobium carbides. In this way the grain boundaries are certain information as to its behavior during welding.
not depleted of chromium and retain their corrosion resistance.
The Schaeffler diagram indicates that the comparatively low alloyed
Unstabilised steel which has been welded may have corrosion steels are hardenable since they contain the martensitic phase in
resistance restored by quenching from 1100°C. This method is the as-welded state. As the alloying elements increase, the austenite
limited by size considerations and the tendency to distort during and ferrite phases become more stable and the alloy ceases to be
the heat treatment quench hardenable. Steels with a relatively high level of carbon,
An even better method of avoiding carbide precipitation is to nickel and manganese become fully austenitic (‘austenitic’ area),
reduce the carbon content in the steel of such a low level that while those with more chromium, molybdenum, etc. tend to be fully
negligible carbide formation is possible at any temperature. A carbon ferritic (‘ferritic’ area).
level of less than 0.03% is effective in achieving this. Such extra There is also an important intermediate region of ‘duplex’
low carbon steels are not subject to harmful carbide precipitation compositions indicated as A + F on the diagram. In this region the
during welding and also display superior impact properties at low welds contain both austenite and ferrite. This leads to the general
temperatures. classification of stainless steel into austenitic, ferritic and martensitic,
Welding electrodes are available with either extra low carbon according to which phase is pre-dominant.
content (L grade, i.e. 308L, 316L) or containing niobium to stabilise
the higher carbon weld deposit against weld decay. Titanium, used to
stabilise wrought material, i.e. AISI 321, is not suitable for stabilising
weld metal since much of it is oxidized during transfer across the
arc and is lost to the slag and is replaced by niobium as a stabiliser
in electrodes.

Stainless Steel 8
Schaeffler diagram
Nickel equivalent = %Ni + (30 x %C) + (0.5 x %Mn)
28
904L te
rri
310 % Fe
24 0
5%
AUSTENITE
%
10
20
20%
16 A+M 309L 40%
316L
317L A+F
80%
12 308L
318
8 MARTENSITE 100%
A+M+F
4
FERRITE
M+F
F+M
0
0 4 8 12 16 20 24 28 32 36 40
Chromium equivalent = %Cr + %Mo + (1.5 x %Si) + (0.5 x %Nb)
Delong diagram
Nickel equivalent = %Ni + (30 x %C) + (30 x %N) + (0.5 x %Mn)
21
r
be
20 um
i t en
rr 0
Fe
19 2
AUSTENITE 4
18 6
8
17 10
te 12
rri 14
16 Fe 0%
16
2% 18
15 4%
Sch 6%
14 a 7.6
%
A + effler %
ML 9.2 %
13 ine .7
10 .3%
12 .8%
13
12
AUSTENITE + FERRITE
11
10
16 17 18 19 20 21 22 23 24 25 26 27
Chromium equivalent = %Cr + %Mo + (1.5 x %Si) + (0.5 x %Nb)

8 Stainless Steel
Types of corrosion (cont)

The Schaeffler diagram also lets us forecast the composition of N Minimise heat build-up in the component so that the
heterogenous welds (different materials). temperature is below 200 degrees Celsius by:
Suppose we want to weld 410 plate (13% chromium; 0.8% a) Sequence of staggered welding
manganese; 0.5% silicon; 0.08% carbon) point B, to a carbon-steel b) Direct cooling of the welded area by an air blast
(0.2% carbon; 1.0% manganese) point D, using (23% chromium; 12%
nickel; 1.0% manganese; 0.5% silicon and 0.4% carbon) point A. We c) Indirect cooling with water
assume that both plates (410 and carbon steel) play equal parts in N Any surfaces prepared by thermal cutting should be ground prior
the weld and the dilution is 30%. Point E is the resultant of both to welding
plates and point F, the resultant of applying 30% dilution to the AE
N For strength welding of 11-14% manganese the use of the
section. Therefore the resulting weld will have 4% ferrite.This weld
following BOC electrodes are recommended: BOC Smootharc S
is also possible without the danger of hot cracking.
309 MoL
28
Nickel equivalent = %Ni + 30 x %C + 0.5 x %Mn
te
rri
24 Fe
0%
AUSTENITE 5%
%
20 10
20%
16 A+M A 40%
F A+F
12 80%
8 MARTENSITE 100%
D A+M+F
4 E B FERRITE
M+F
F+M
0
0 4 8 12 16 20 24 28 32 36 40
Chromium equivalent = %Cr + %Mo + 1.5 x %Si + 0.5 x %Nb
Welding of 11-14% manganese steel

Owing to its great ductility, toughness and work hardening
properties, 11-14% manganese steel is extensively used for the
wearing parts of stone-breaking and ore-crushing machinery,
tumblers, buckets, digger teeth, rail points and crossings and similar
applications subject to high impact service.
The inherent toughness of 11-14% manganese steel can be seriously
reduced if the material is excessively heated during welding;
the degree of embrittlement which occurs being greater as the
temperature and heating period is increased.
For this reason, very careful control over the amount of reheating
must be exercised during welding.
Points to note when welding manganese steel

N NEVER use preheating or stress relieving
N Use minimum currents consistent with a stable arc

N Weld beads should be of high build-up to avoid dilution of the
weld by the base material
N Prior to welding care should be taken to remove work
hardened areas

Stainless Steel 8
Coating Types
A WS A5.4-2000
Usability Designation -15

The electrodes are usable with DCEP (electrode positive) only.
While use with alternating current is sometimes accomplished,
they are not intended to qualify for use with this type of current.
Electrode sizes 5/32 in. (4.0 mm) and smaller may be used in all
positions of welding.

The covering for these electrodes generally contains readily ionizing
elements, such as potassium, in order to stabilize the arc for welding
with AC. Electrode sizes 5/32 in. (4.0 mm) and smaller may be used
in all positions of welding.

The covering of these electrodes is a modification of the -16
covering in that considerable silica replaces some of the titania of
the -16 covering. Since both the -16 and the -17 electrode coverings
permit AC operation, both covering types were classified as -16 in
the past because there was no classification alternative until this
revision of ANSI/AWS A5.4. However, the operational differences
between the two types have become significant enough to warrant
a separate classification.
On horizontal fillet welds, electrodes with a -17 covering tend to
produce more of a spray arc and a finer rippled weld-bead surface
than do those with the -16 coverings. A slower freezing slag of the
-17 covering also permits improved handling characteristics when
employing a drag technique. The bead shape on horizontal fillets is
typically flat to concave with -17 covered electrodes as compared
to flat to slightly convex with -16 covered electrodes. When making
fillet welds in the vertical position with upward progression, the
slower freezing slag of the -17 covered electrodes requires a slight
weave technique to produce the proper bead shape. For this reason,
the minimum leg-size fillet that can be properly made with a -17
covered electrode is larger than that for a -16 covered electrode.
While these electrodes are designed for all-position operation,
electrode sizes 3/16 in. (4.8 mm) and larger are not recommended
for vertical or overhead welding.

8 Stainless Steel
Problem Steels
Introduction N The coefficients of expansion should preferably be between
Steels containing carbon in excess of 0.25%, chromium and those of the base materials in order to reduce possible stress
molybdenum over 1.5% and manganese over 1.5%, exhibit, increased concentrations.
strength and hardenability and decreased weldability. N The corrosion resistance of the weld metal should be superior
Additional elements such as vanadium, silicon, nickel, boron, niobium to at least one of the base materials to avoid preferential attack
and titanium also influence hardenability and weldability. Steels of of the weld metal.
increased hardenability tend to form brittle microstructures in the In many instances it is not possible to satisfy all of the foregoing
heat-affected zone which may result in cracking. Steels featuring points and a compromise has to be made. BOC Smootharc S 309
reduced weldability are commonly referred to as ‘problem steels’ as and 312 problem steel electrodes have been specially designed to
a result of the problem areas which are directly caused by shrinkage weld a large number of dissimilar materials such as stainless steels
stresses, rapid cooling rates and the presence of hydrogen. to carbon manganese steels and low alloy steels, and low alloy steels
Electrodes for welding problem steels are chromium nickel to 11–14% manganese steels, high carbon and tool steels, etc.
austenitic types containing delta ferrite in the range of 10–80%. The
weld metal is insensitive to hot cracking above 1200°C. At ambient
Calculation of final weld metal structures
temperatures, the weld metal is strong and tough and is capable of The final weld metal chemistry and therefore properties, depends
withstanding heavy impact and shock loading in service. on the amount of dilution that occurs during welding.
Problem steels fall into two categories, i.e. ferritic types which Weld metal dilution is normally expressed as a percentage of
require preheat and austenitic steels such as 11–14% manganese the final weld metal composition, the effect being dependent on
steels which require minimum heat input. a number of factors such as the joint configuration, the welding
technique and the welding process. With the manual metal arc
When hardenable ferritic steel types are to be welded, reference
process, dilution in the vicinity of ±25% can occur. This will obviously
should be made to the section on mild and medium tensile
be greatest in the root pass and least in fill-in passes where two or
steels for the calculation of the carbon equivalent and pre-heat
more runs per layer are used.
temperatures.
The Schaeffler diagram is a useful tool in that it allows us to
Problem steel electrodes are suitable for welding combinations of
determine the microstructures after dilution theoretically. This is
dissimilar steels such as chromium, molybdenum. creep-resistant
illustrated by means of the following example:
steels and stainless steels to mild and low alloy steels. Care should
be taken when welding such combinations to ensure that excessive Suppose we want to weld 410 steel (13% Cr; 0.8% Mn;
dilution between the base and weld metal does nor occur. 0.5% Si and 0.08% C) with BOC Smootharc S 309 MoL (23% Cr;
12% Ni; 1.0% Mn; 0.5% Si and 0.03% C), and we assume 30% dilution
The welding of dissimilar steels (the base metal contributes 30% of the union and the electrode the
When welding dissimilar steels a number of factors must be taken other 70%).What is the composition of the resultant weld metal?
into account. i.e: The 410 plate is represented by point B (Cr equivalent 13.75%; Ni
N The weld metal must be capable of accepting dilution from equivalent 2.8%) and the BOC Smootharc S 309 MoL electrode by
both dissimilar base materials without forming crack-sensitive point A (Cr equivalent 23.75%; Ni equivalent 14.5%). Any resultant
microstructures. These structures must remain stable at the weld metal from this mixture of A and B will be on the line that
desired operating temperatures. joins them. As we have assumed 30% dilution, point C will give the
N The mechanical properties of the weld metal should be superior resultant microstructure. i.e. austenite with 10% ferrite. This weld is
to the weaker of the two base materials. therefore possible without any danger of hot cracking.
28
Nickel equivalent = %Ni + 30 x %C + 0.5 x %Mn
te
rri
24 Fe
0%
AUSTENITE 5%
%
20 10
20%
16 A+M A 40%
A+F
12 80%
C
8 MARTENSITE 100%
A+M+F
4 B FERRITE
M+F
F+M
0
0 4 8 12 16 20 24 28 32 36 40
Chromium equivalent = %Cr + %Mo + 1.5 x %Si + 0.5 x %Nb

Stainless Steel 8
Stainless Steels (BOC Smootharc S)
S30815, 409, Duplex

Base Metal 317L, (253MA), 430, S31500 Carbon
ASTM, AISI, 201, 304, 309, 310, 317, 316L, 321, 904L, 446, 410, S31803 and Low
UNS 202 304L 309S 310S 316 316Ti 347 (N08904) 5CR12 420 S32304 Alloy Steels
201, 347 347 347 347 318 308L 347 347 309MoL 309MoL Duplex 309MoL
202 308L 308L 309MoL 310 347 316L 309MoL 309L 309L 309MoL
309MoL 347
304, 347 347 347 347 347 347 347 309MoL 309MoL Duplex 309MoL
304L 308L 309MoL 310 318 318 308L 308L 309L 309MoL 309L
308L 308L 308L 308L 309L
309L
309, 309MoL 309MoL 309MoL 309L 347 Match above 309MoL 309MoL Duplex 309MoL
309S 309L 309L 318 316L 309MoL 309MoL 309L 309L 309MoL 309L
310 316 318 347 309L
309L
310, 310 316L 316L 347 Match above 309MoL 309MoL Duplex 309L
310S 318 318 310 309L 309L 309L 309MoL 309MoL
310 310 310 316L 310 309L 310
317, 318 316L 347 Match above 309MoL 309MoL Duplex 309MoL
316 316L 318 316L 309MoL 309L 309L 309MoL 309L
316L 309L
317L, 316L 347 Match above 309MoL 309MoL Duplex 309MoL

316L, 316L 309MoL 309L 309L 309MoL 309L
316Ti
309L 309L
321, 347 Match above 309MoL 309MoL Duplex 309MoL

347 309MoL 309L 309L 309MoL 309L
347 347
S30815, Matching 309MoL 309MoL Duplex 309MoL

(253MA), 309L 309L 309MoL 309L
904L,
309L
(N08904)
409, 309L 309MoL Duplex 309MoL

430, 309MoL 309L 309MoL 309L
446,
309L
5CR12
410, Matching Duplex 309MoL

420 or 309MoL 309L
309MoL 309L
309L
Duplex, Matching Duplex

S31500, 309MoL
S31803,
309L
S32304
Carbon Matching
and Low
Alloy
Steels
NOTES
(1) Consumables listed against a steel may not achieve matching corrosion resistance or mechanical properties.
(2) Welding procedure qualification should be carried out prior to welding in critical applications.
(3) Consult you BOC welding process specialist or visit BOC’s Inform website (subscription required) for more detailed information.
This table can also be found on page 643 of this manual.

8 Stainless Steel
MMA Electrodes
Specifications
Coating Type Rutile
™
Smootharc S 308L Classification AWS /ASME-SFA A5.4
AS / NZS 1553.3
E308L-17
E308L-17
Welding current AC, OCV 50V or DC+
Scaling temperature Approx. 850°C in air

Description
C Si Mn Cr Ni
Smootharc S 308L is a rutile coated, low carbon grade, AC / DC
electrode for the high quality welding of austenitic stainless steel Typical 0.02 0.8 0.7 20.0 10.2
of the 19Cr / 9Ni type. The electrode is very easy to strike and Ferrite content FN 5 (WRC-92)
restrike. Welding performance is excellent with a very smooth,
low spatter arc producing a finely rippled bead surface with Mechanical Properties – All-Weld Metal
excellent slag detachability.
Typical (as welded)
Application Yield strength 450 MPa
Smootharc S 308L is recommended for single and multi-pass Tensile strength 580 MPa
welding of austenitic stainless steel 302, 304 and 304L grades. Elongation 39% min
Austenitic stainless steel of the 19Cr / 9Ni type may be used in the
Impact energy, CVN 60J @ –20°C
following applications: brewing equipment, steam piping, vacuum
pump parts, dairy equipment, textile drying equipment, chemical 35J @ –196°C
handling equipment, pharmaceutical and food handling equipment.
Packaging Data
Stainless steel can be welded using either AC or DC, using as short Part No. 188082 188083 188084
an arc as possible to minimise alloy loss across the arc and control
Length (mm) 300 350 350
ferrite level. When using AC a slightly higher current setting may
be required. Weight can (kg) 2.5 3.0 3.0
When welding in the flat position stringer beads should be used and Weight carton (kg) 7.5 9.0 9.0
if weaving is required this should be limited to 2 times the electrode Electrodes pkt (approx) 141 86 59
diameter. The heat input, which can adversely affect corrosion
resistance and lead to excessive distortion, should be limited by using Welding Parameters
the correct electrode diameter to give the required bead profile and
Dia. (mm) 2.5 3.2 4.0
properties at the maximum travel speed.
Current (A) 40–80 80–120 100–160
Storage Voltage (V) 28 29 30
Smootharc S 308L electrodes are packaged in hermetically sealed
containers. For critical applications in damp environments, once Deposition Data
the seal is broken electrodes should be stored in heated cabinets Dia. (mm) 2.5 3.2 4.0
at 70–120°C.
Kg weld metal / 0.62 0.64 0.64
kg electrode
All electrode coatings are hydroscopic and when left in the opened No. of electrodes / 91 45 31
kg weld metal
state for a period of time will absorb moisture. Austenitic materials
are generally insensitive to the presence of hydrogen. However, Kg weld metal / 1.0 1.5 2.0
moisture in the electrode coating can lead to porosity in the weld hour arc time
metal. Start porosity is generally indicative of damp electrodes and Burn off time / 33 45 55
is more common in fillet welds than in butt welds where pores only electrode (sec)
occur at high moisture contents.
Electrodes which have been stored outside of their hermetically
sealed cans and have become damaged by moisture pick-up can
be redried at temperatures of 300–350°C for 1–2 hours.
Redrying should be restricted to a maximum of 3 cycles.
Welding Positions

Stainless Steel 8
MMA Electrodes
Specifications
Coating Type Rutile
™
AS / NZS 1553.3
E316L-17
E316L-17
Approvals American Bureau of Shipping
Description
Smootharc S 316L is a rutile coated, low carbon, 19% Cr, 12% Ni, 3% Chemical Composition, wt% – All-Weld Metal
Mo, AC / DC electrode for the high quality welding of molybdenum C Si Mn Cr Ni Mo
alloyed, acid resisting austenitic stainless steels of the 316 / 316L type. Typical 0.02 0.8 0.7 18.5 12.0 2.7
The electrode is very easy to strike and restrike. Welding performance Ferrite content FN 6 (WRC-92)
is excellent with a very smooth, low spatter arc producing a finely
rippled bead surface with excellent slag detachability. Fillet welds have
slightly concave profile with excellent toe line blend-in.
Typical (as welded)
Smootharc S 316L is recommended for single and multi-pass Tensile strength 600 MPa
welding of molybdenum alloyed austenitic stainless steels 316
Elongation 32% min
and 316L. It is also suitable for welding the Nb or Ti stabilised
steels, provided service temperatures are below 4000C. Austenitic Impact energy, CVN 55J @ –20°C
stainless steels of the 316 / 316L type may be used for applications 45J @ –120°C
such as food handling equipment, structures in marine environments,
heat exchangers, chemical storage and transportation tanks, oil Packaging Data
refining equipment and pharmaceutical equipment. Dia. (mm) 2.5 3.2 4.0 5.0
Part No. 188162 188163 188164 188165
Technique
Length (mm) 300 350 350 450
Stainless steel can be welded using either AC or DC, using as short an
Weight can (kg) 2.5 3.0 3.0 5.0
arc as possible to overcome any possibility of alloy loss across the arc.
Weight carton (kg) 7.5 9.0 9.0 15.0
When using AC a slightly higher current setting may be required.
Electrodes pkt (approx) 136 84 58 45
When welding in the flat position stringer beads should be used
and if weaving is required this should be limited to 2 times the Welding Parameters
electrode diameter. The heat input, which can adversely affect
Dia. (mm) 2.5 3.2 4.0 5.0
corrosion resistance and lead to excessive distortion, should be
limited by using the correct electrode diameter to give the Current (A) 40–80 80–120 100–160 170–230
required bead profile and properties at the maximum travel speed. Voltage (V) 29 29 30 30
Storage Deposition Data

Smootharc S 316L electrodes are packaged in hermetically sealed Dia. (mm) 2.5 3.2 4.0 5.0
containers. For critical applications in damp environments, once
Kg weld metal / 0.64 0.64 0.65 0.65
the seal is broken electrodes should be stored in heated cabinets at
kg electrodes
70–120°C.
No. of electrodes / 85 44 30 14
Re-Drying / Conditioning kg weld metal
All electrode coatings are hydroscopic and when left in the opened Kg weld metal / 1.1 1.5 2.1 2.8
state for a period of time will absorb moisture. Austenitic materials hour arc time
are generally insensitive to the presence of hydrogen. However, Burn off time / 35 43 56 89
moisture in the electrode coating can lead to porosity in the weld electrode (sec)
metal. Start porosity is generally indicative of damp electrodes and
is more common in fillet welds than in butt welds where pores only
sealed cans and have become damaged by moisture pick-up can be
redried at temperatures of 300–350°C for 1–2 hours. Redrying
should be restricted to a maximum of 3 cycles.
Welding Positions

8 Stainless Steel
MMA Electrodes
Specifications
Coating Type Rutile
™
Smootharc S 347 Classification AWS /ASME-SFA A5.4
AS / NZS 1553.3
E347-17
E347-17
Description Chemical Composition, wt% – All-Weld Metal
Smootharc S 347 is a rutile coated, niobium stabilised, AC / DC C Si Mn Cr Ni Nb

electrode of the 19% Cr, 10%Ni type. The electrode is very easy to Typical 0.02 0.9 0.6 19.0 10.2 0.5
strike and restrike. Welding performance is excellent with a very Ferrite content FN 4 (WRC-92)
smooth, low spatter arc producing a finely rippled bead surface
with excellent slag detachability. The electrode has good positional
welding characteristics.
Typical (as welded)
Smootharc S 347 has been especially designed for the welding of
321 and 347 stabilised steels. The electrode is also suitable for the
unstabilised grades 304 and 304L. Smootharc S 347 is primarily Elongation 35% min
intended for use where resistance to weld metal sensitisation Impact energy, CVN 40J @ –60°C
and intergranular corrosion is required. Stabilised 321 and 347
austenitic stainless steel grades may be used for applications such
Packaging Data
as aircraft exhaust manifolds, fire walls, pressure vessels and
elevated temperature chemical handling equipment. Dia. (mm) 2.5 3.2 4.0
Part No. 188472 188473 184164
Technique Length (mm) 300 350 350
Stainless steel can be welded using either AC or DC, using as short Weight can (kg) 2.5 3.0 3.0
an arc as possible to minimise alloy loss across the arc and control Weight carton (kg) 7.5 9.0 9.0
ferrite level. When using AC a slightly higher current setting may Electrodes pkt (approx) 139 88 58
be required.
When welding in the flat position stringer beads should be used and Welding Parameters
if weaving is required this should be limited to 2 times the electrode Dia. (mm) 2.5 3.2 4.0
diameter. The heat input, which can adversely affect corrosion
Current (A) 50–80 80–110 130–170
resistance and lead to excessive distortion, should be limited by
using the correct electrode diameter to give the required bead Voltage (V) 21 22 22
profile and properties at the maximum travel speed.
Deposition Data
Smootharc S 347 electrodes are packaged in hermetically sealed
Kg weld metal / 0.62 0.64 0.63
containers. For critical applications in damp environments, once kg electrodes
the seal is broken electrodes should be stored in heated cabinets
at 70–120°C. No. of electrodes / 90 46 31
kg weld metal
Re-Drying / Conditioning Kg weld metal / 1.0 1.3 1.9
All electrode coatings are hydroscopic and when left in the opened hour arc time
state for a period of time will absorb moisture. Austenitic materials Burn off time / 34 55 62
are generally insensitive to the presence of hydrogen. However, electrode (sec)
moisture in the electrode coating can lead to porosity in the weld
be redried at temperatures of 300–350°C for 1–2 hours. Redrying
Welding Positions

Stainless Steel 8
MMA Electrodes
Specifications
Coating Type Rutile
™
AS / NZS 1553.3
E309L-17
E309L-17

Smootharc S 309L is a rutile coated, AC / DC electrode which C Si Mn Cr Ni
deposits a low carbon, 23% Cr, 13% Ni austenitic stainless steel Typical 0.02 0.8 0.8 23.0 13.0
weld metal. The electrode is very easy to strike and restrike.
Ferrite content FN 9 (WRC-92)
Welding performance is excellent with a very smooth, low
spatter arc producing a finely rippled bead surface with excellent
slag detachability. Mechanical Properties – All-Weld Metal
Typical (as welded)
Application
Yield strength 470 MPa
Smootharc S 309L is recommended for welding corrosion resistant
and heat resistant steels of the 309 type, which are often used for Tensile strength 560 MPa
furnace parts, aircraft and jet engine parts, heat exchangers and Elongation 34% min
chemical processing equipment.
Impact energy, CVN 48J @ –20°C
Smootharc S 309L can also be used for welding dissimilar carbon 45J @ –60°C
manganese steels and low alloy steels, welding stainless steels to
mild steels and as a buffer for hardfacing applications.
Packaging Data
Stainless steel can be welded using either AC or DC, using as short Part No. 188092 188093 188094
an arc as possible to minimise alloy loss across the arc and control Length (mm) 300 350 350
ferrite level. When using AC a slightly higher current setting may Weight can (kg) 2.5 3.0 3.0
be required. Weight carton (kg) 7.5 9.0 9.0
When welding in the flat position stringer beads should be used and Electrodes pkt (approx) 207 126 84
if weaving is required this should be limited to 2 times the electrode
diameter. The heat input, which can adversely affect corrosion Welding Parameters
resistance and lead to excessive distortion, should be limited by Dia. (mm) 2.5 3.2 4.0
using the correct electrode diameter to give the required bead
Current (A) 40–80 80–120 100–160
profile and properties at the maximum travel speed.
Storage
Smootharc S 309L electrodes are packaged in hermetically sealed Deposition Data
containers. For critical applications in damp environments, once Dia. (mm) 2.5 3.2 4.0
the seal is broken electrodes should be stored in heated cabinets
Kg weld metal / 0.67 0.67 0.67
at 70–120°C.
kg electrodes
Re-Drying / Conditioning No. of electrodes / 83 42 28
kg weld metal
All electrode coatings are hydroscopic and when left in the opened
state for a period of time will absorb moisture. Austenitic materials Kg weld metal / 0.9 1.4 1.9
are generally insensitive to the presence of hydrogen. However, hour arc time
moisture in the electrode coating can lead to porosity in the weld Burn off time / 42 53 59
metal. Start porosity is generally indicative of damp electrodes and electrode (sec)
is more common in fillet welds than in butt welds where pores
only occur at high moisture contents.
Redrying should be restricted to a maximum of 3 cycles.
Welding Positions

8 Stainless Steel
MMA Electrodes
Specifications
Coating Type Rutile
™
Smootharc S 309MoL Classification AWS /ASME-SFA A5.4
AS / NZS 1553.3
E309MoL-17
E309MoL-17

Smootharc S 309MoL is a rutile coated, AC / DC electrode which C Si Mn Cr Ni Mo
deposits a low carbon, 23% Cr, 12% Ni, 2.5% Mo austenitic stainless Typical 0.02 0.8 0.8 22.8 12.8 2.4
steel weld metal with a ferrite content of FN 20. The high alloy
Ferrite content FN 20 (WRC-92)
content and ferrite level enable the weld metal to tolerate dilution
from dissimilar and difficult-to-weld materials without hot cracking.
The electrode is very easy to strike and restrike. Welding performance
is excellent with a very smooth, low spatter arc producing a finely Typical (as welded)
rippled bead surface with excellent slag detachability. Yield strength 555 MPa
Application
Elongation 33% min
Smootharc S 309MoL is recommended for welding corrosion-
resistant CrNiMo steels to themselves and to mild and low alloy Impact energy, CVN 50J @ –20°C
steels without hot cracking. The electrode is suitable for welding
armour plate, austenitic manganese steel, medium and high carbon Packaging Data
hardenable steels, tools, dies, springs, etc. which may be of unknown
Dia. (mm) 2.5 3.2 4.0
composition.
Part No. 188096 188097 188098
Smootharc S 309MoL is also recommended for welding dissimilar Length (mm) 300 350 350
steels such as stainless steels to carbon manganese or low alloy Weight can (kg) 2.5 3.0 3.0
steels and for welding austenitic manganese steel to carbon
manganese and low alloy steel.
Electrodes pkt (approx) 210 129 87
Technique
Welding Parameters
Stainless steel electrodes can be welded using either AC or DC,
using as short an arc as possible to minimise alloy loss across Dia. (mm) 2.5 3.2 4.0
the arc and control ferrite level. When using AC a slightly higher Current (A) 40–80 80–120 100–160
current setting may be required. When welding in the flat position
stringer beads should be used and if weaving is required this should
be limited to 2 times the electrode diameter.
Deposition Data
Smootharc S 309MoL electrodes are packaged in hermetically Kg weld metal / 0.64 0.65 0.65
sealed containers. For critical applications in damp environments, kg electrodes
once the seal is broken electrodes should be stored in heated
No. of electrodes / 84 43 29
cabinets at 70–120°C. kg weld metal
Re-Drying / Conditioning Kg weld metal / 1.1 1.5 2.1

hour arc time
All electrode coatings are hydroscopic and when left in the opened
state for a period of time will absorb moisture. Austenitic materials Burn off time / 38 55 59
electrode (sec)
are generally insensitive to the presence of hydrogen. However,
moisture in the electrode coating can lead to porosity in the weld
sealed cans and have become damaged by moisture pick-up can be
redried at temperatures of 300–350°C for 1–2 hours. Redrying
Welding Positions

Stainless Steel 8
MMA Electrodes
Specifications
Coating Type Rutile
™
Smootharc S 312 Classification AWS /ASME-SFA A5.4
AS / NZS 1553.3
E312-17
E312-17

Description
Smootharc S 312 is a rutile coated, AC / DC electrode which C Si Mn Cr Ni
deposits a 29%Cr / 9%Ni austenitic / ferritic stainless steel weld metal Typical 0.10 1.2 0.8 28.8 9.7
with a ferrite content of FN 50. The resultant weld metal is high Ferrite content FN 50 (WRC-92)
strength with high ductility and the structure is highly resistant to
hot cracking and extremely tolerant of dilution from medium
and high carbon steels. Mechanical Properties – All-Weld Metal
The electrode is very easy to strike and restrike. Welding Typical (as welded)
performance is excellent with a very smooth, low spatter Yield strength 590 MPa
arc producing a finely rippled bead surface with excellent
slag detachability.
Elongation 25% min
Application
Smootharc S 312 is a universal electrode specifically designed for Packaging Data
welding steels of poor weldability. The electrode is suitable for Dia. (mm) 2.5 3.2 4.0
welding armour plate, austenitic manganese steel, medium and high Part No. 188122 188123 188124
carbon hardenable steels, tools, dies, springs etc which may be of
Length (mm) 300 350 350
unknown composition. It is also suitable for welding dissimilar
Weight can (kg) 2.5 3.0 3.0
steels eg. stainless to mild steel.
Technique Electrodes pkt (approx) 225 141 93
Stainless steel electrodes can be welded using either AC or DC,

using as short an arc as possible to minimise alloy loss across Welding Parameters
the arc and control ferrite level. When using AC a slightly higher Dia. (mm) 2.5 3.2 4.0
current setting may be required. When welding in the flat position
Current (A) 40–80 80–120 100–160
stringer beads should be used and if weaving is required this
should be limited to 2 times the electrode diameter. Voltage (V) 25 26 27
Storage Deposition Data

Smootharc S 312 electrodes are packaged in hermetically sealed Dia. (mm) 2.5 3.2 4.0
containers. For critical applications in damp environments, once
the seal is broken electrodes should be stored in heated cabinets Kg weld metal / 0.64 0.64 0.65
kg electrodes
at 70–120°C.
No. of electrodes / 90 47 31
Re-Drying / Conditioning kg weld metal
All electrode coatings are hydroscopic and when left in the opened Kg weld metal / 1.1 1.5 2.1
state for a period of time will absorb moisture. Austenitic materials hour arc time
are generally insensitive to the presence of hydrogen. However, Burn off time / 36 51 55
moisture in the electrode coating can lead to porosity in the weld electrode (sec)
Redrying should be restricted to a maximum
of 3 cycles.
Welding Positions

8 Stainless Steel
MMA Electrodes
Satincrome 308L-17
N Rutile type, stainless steel electrode
0.2% Proof stress 500 MPa C: 0.025 Mn: 0.76 Si: 0.87
N Outstanding operator appeal,
improved slag lift Tensile strength 630 MPa Cr: 20.4 Ni: 9.8 S: 0.010
N All positional (except vertical-down) Elongation 40% P: 0.017

welding capabilities CVN impact values 75J av @ +20°C Ferrite number
N Applications include the single and 3.0–10.0 FN (using Severn Gauge)
multi-pass welding of 19Cr / 10Ni type
stainless steel grades including 201, 202,
Approvals
301, 302, 303, 304, 304L, 305, 308 etc,
American Bureau AWS A5.4: E308L-17
of Shipping
Classifications
AS / NZS 1553.3: E308L-17
AWS /ASME-SFA A5.4: E308L-17 Packaging and operating data — AC (minimum 45 OCV) DC+ polarity
Electrode Approx No. Current

2.5 300 47 40–70 2.5 15 (6 x 2.5) 611602
3.2 350 28 75–110 2.5 15 (6 x 2.5) 611603
4.0 350 18 110–150 2.5 15 (6 x 2.5) 611604
Satincrome 316L-17
N Rutile type, stainless steel electrode
0.2% Proof stress 480 MPa C: 0.025 Mn: 0.8 Si: 0.85
N Outstanding operator appeal,
improved slag lift Tensile strength 600 MPa Cr: 19.4 Ni: 11.5 Mo: 2.5
N All positional (except vertical-down) Elongation 40% S: 0.011 P: 0.017

welding capabilities CVN impact values 30J av @ -120°C Ferrite number
N Applications include the single and 3.0–10.0 FN (using Severn Gauge)
multi-pass welding of matching
Molybdenum bearing stainless steels,
Approvals
316 and 316L. Also suitable for the
general purpose welding of other American Bureau AWS A5.4: E316L-17
“300 series” austenitic stainless steels of Shipping
including 301, 302, 303 and 304 / 304L,
305, 3CR12-types Packaging and operating data — AC (minimum 45 OCV) DC+ polarity
Electrode
Classifications Approx No. Current Packet
AS / NZS 1553.3: E316L-17
AWS /ASME-SFA A5.4: E316L-17 2.0 300 87 35–55 2.5 15 (6 x 2.5) 611661
2.5 300 46 40–70 2.5 15 (6 x 2.5) 611662
3.2 350 28 75–110 2.5 15 (6 x 2.5) 611663
4.0 350 18 110–150 2.5 15 (6 x 2.5) 611664

Stainless Steel 8
MMA Electrodes
Satincrome 318-17 Typical All Weld Metal Mechanical Properties Typical All Weld Metal Analysis (%)
(Supersedes Satincraft 318-16) 0.2% Proof Stress 490 MPa C Mn Si Cr Ni
N Rutile Type, Stainless Steel Electrode. Tensile Strength 610 MPa 0.04 0.8 0.90 19 12
Mo Nb S P
N Outstanding Operator Appeal! Elongation 36%
2.30 0.35 0.017 0.02
N Now with Improved Slag Lift!
Ferrite number
N All Positional (except vertical down)
Welding Capabilities. 5.0 – 10.0 FN (using Severn Gauge)
N Advanced Moisture Resistant Flux
Packaging and Operating Data
Coating.
AC (min 45 OCV), DC+ polarity.
Electrode Approx Current Packet Easyweld Part No.
Classifications
Size (mm) Length No. Range (A) Carton Handipaks
AS/NZS 1553.3: E318-17. (mm) Rods/kg (kg)
AWS/ASME-SFA A5.4: E318-17.
2.5 300 46 40–70 2.5kg 15 (6 x 2.5) 611652
All positional - except vertical down 2.5 300 46 40–70 20 rod 322105
3.2 350 28 75–110 2.5kg 15 (6 x 2.5) 611653
Satincrome 309Mo-17 Typical all weld metal mechanical properties Typical all weld metal analysis (%)
N Rutile type, stainless steel electrode 0.2% Proof stress 500 MPa C: 0.05 Mn: 0.75 Si: 0.9
N Outstanding operator appeal, Tensile strength 620 MPa Cr: 23.0 Ni: 13.0 Mo: 2.2
improved slag lift Elongation 35% S: 0.012 P: 0.017
N All positional (except vertical-down)
CVN impact values 60J av @ +20°C Ferrite number
welding capabilities
15.0 – 20.0 FN (using Severn Gauge)
N Applications include the single and
multi-pass welding of matching 309 and
309L stainless steels. Also suitable for Approvals
the dissimilar welding of other “300 American Bureau AWS A5.4: E309Mo-17
series” austenitic stainless steels and of Shipping
selected “400 series” ferritic grades
to mild or low alloy steels Packaging and operating data AC (minimum 45 OCV) DC+ polarity
Classifications Electrode Approx No. Current Packet

AS / NZS 1553.3: E309Mo-17
AWS /ASME-SFA A5.4: E309Mo-17 2.5 300 52 40–70 2.5 15 (6 x 2.5) 611692
3.2 350 30 75–110 2.5 15 (6 x 2.5) 611693
4.0 350 19 110–150 2.5 15 (6 x 2.5) 611694
Weldall Typical all weld metal mechanical properties Typical all weld metal analysis (%)
N Easy-to-use rutile type, high alloy 0.2% proof stress 630 MPa C: 0.11 Mn: 0.60 Si: 0.88
electrode Tensile strength 780 MPa Cr: 27.0 Ni: 9.10 S: 0.011
N Outstanding operator appeal Elongation 25% P: 0.020
N Welds all steels
N Ideal for repair and maintenance jobs
N Easy arc starting and excellent stability
Packaging and operating data AC (minimum 45 OCV) DC+ polarity
on low OCV welding machines
Electrode
N Not recommended for welding Approx No. Current Packet Easyweld
cast irons Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Handipack Part No.
2.5 300 57 40–80 2.5 15 (6 x 2.5) – 611702
Classifications 2.5 300 – – – – 20 rods 322101
AS / NZS 1553.3 312-17 3.2 350 30 75–110 2.5 15 (6 x 2.5) – 611703
AWS /ASME-SFA A5.4: E312-17
3.2 350 – – – – 15 rods 322102
4.0 350 20 110–150 2.5 15 (6 x 2.5) – 611704

8 Stainless Steel
MMA Electrodes
Limarosta 304L Limarosta 316L Limarosta 309S

A rutile-basic all position stainless steel A rutile-basic all position stainless steel A rutile-basic all position CrNi over alloyed
electrode for 304L or equivalent steels. electrode for 316L or equivalent steels. buffer electrode. Developed for welding
Mirror like bead appearance. Self releasing Molybdenum level min 2.7%. Mirror stainless steel to mild steel and for clad
slag. Excellent side wall wetting, no like bead appearance. Self release slag. steel. Self releasing slag. Excellent side wall
undercut. Highly resistant to porosity. Good side wall fusion, no undercut. High wetting, no undercut, mirror like bead
resistance to porosity. Weldable on AC and appearance. High resistance to porosity.
Nearest classification DC+ polarity. Weldable on AC and DC+ polarity.
AWS E308L-16
Nearest classification Nearest classification
Size (mm) Carton(kg) Part No AWS E16L-16 AWS E309L-16
2.50 2.7 557329
3.20 4.7 557367 Size (mm) Carton (kg) Part No. Size (mm) Carton (kg) Part No.
4.00 5.8 557398 2.50 2.7 557442 2.50 2.8 556534

3.20 4.8 557466 3.20 4.9 557565
4.00 5.9 557497 4.00 5.9 557589
Limarosta 312 Arosta 304L Arosta 309

A rutile-basic high CrNi alloyed all position Rutile basic all position stainless steel A high CrNiMo alloyed all position rutile
electrode. Excellent for repair welding. electrode for 304L or equivalent steels. basic electrode. High corrosion resistant
Specially developed for welding steels Excellent corrosion resistance to deposit. Specially developed for welding
difficult to weld such as: armour plate, intergranular corrosion and in oxidising stainless steel to mild steel and root runs
austenitic Mn-steel, high C-steel. Excellent environments such as nitric acid. Smooth in cladding. max plate thickness in butt
weldability and self releasing slag. bead appearance and easy slag release. welds - 12mm. Suitable for repair welding in
AC/DC+ dissimilar joints and steels difficult to weld.
Nearest classification AC/DC+
AWS E312-16 Classification AWS E308L-16
Classification AWS E309Mo-16
Size (mm) Carton (kg) Part No. Size (mm) Carton (kg) Part No.
2.60 2.6 527537 Size (mm) Carton (kg) Part No
2.50 2.6 557640
3.20 4.8 527834 2.50 2.6 528633
3.20 5.0 557664
4.00 4.5 527940 3.20 4.7 528824
4.00 5.0 557671
4.00 4.8 528930
Arosta 316L Limarosta electrodes are predominantly

used for welding downhand fillets, although
Rutile basic all position stainless steel out of position welds are possible. On the
electrode for 316L or equivalent steels. other hand, Arosta electrodes have superior
Molybdenum level minimum 2.7%. High out of position capabilities.
resistance to general and intergranular
corrosion. Smooth weld appearance and
easy slag release. AC/DC+.
Classification AWS E316L-16

2.50 2.7 529180
3.20 4.9 529487
4.00 4.8 529593

Stainless Steel 8
GMAW Wire
Classifications
AS / NZS 2717.3, ES308LSi, AWS /ASME-SFA, A5-9, ER308LSi
BOC Stainless Steel Approvals: TÜV X2 CrNi 19 9 DIN 8556

MIG Wire 308LSi DB (Ü-Sign) SG-X2 CrNi 19 9
Mechanical properties – all weld metal

Welding characteristics Typical as welded
N High silicon levels improve arc characteristics, weld pool
Yield strength ( MPa) 415
fluidity and flatten weld bead profile
Tensile strength ( MPa) 570
N Low carbon increases resistance to corrosion and maintains
mechanical properties Elongation (%) 35
Reduction of area 40
Applications
Impact LevelsJ @ 20ºC 140
N Welding of 18% Cr 8% Ni type Stainless Steels i.e. 301, 302,
321, 347, 409 and 444-type alloys J @ -110ºC 84
N Welding of 304 and 304L in cryogenic applications J @ -196ºC 52

Ferrite No. FN 14
Welding current DC+
Welding positions
Welding data
Dip Transfer Spray Transfer
Dia. (mm) 0.9 1.2 0.9 1.2
Wire Feed 4–8 3–7 7–14 5–9
Current (A) 50–130 90–160 130–220 180–260
Voltage (V) 15–19 17–21 22–25 24–29
Shielding Gas Stainshield® Stainshield® Heavy
Stainshield® 66
Packing data
Dia. (mm) 0.9 1.2
Part No. 109308 112308
Spool Weight (kg) 15 15
Chemical Composition, wt% – all weld metal

C Mn Si S P Cr Ni Mo Co Cu N
Min. 1.50 0.65 0.005 19.5 10.00
Typical as welded 0.014 1.78 0.85 0.001 0.015 19.67 10.4
Max. 0.02 2.00 1.00 0.015 0.020 20.50 10.75 0.30 0.20 0.20 0.060

8 Stainless Steel
GMAW Wire
Classifications
AS / NZS 2717.3 ES309LSi
AWS /ASME – SFA A5 – 9 ER309LSi
BOC Stainless Steel
MIG Wire 309LSi Mechanical properties – all weld metal
Typical as welded
Welding characteristics Tensile strength ( MPa) 600
N High silicon levels improve arc characteristics, weld pool Elongation (%) 40
Impact levelsJ @ 20°C 160
Ferrite No. FN 15
mechanical properties
Welding current DC+
Applications
N Welding of 23% Cr / 12% Ni type Stainless steels Packaging
N For welding mild or low alloy steels to 300 and selected 400 Dia. (mm) 0.9 1.2
series stainless steels Part No. 112309 112309
N Ideal for buttering layer on carbon for hardfacing consumables Spool Weight (kg) 15 15
N A stainless overlay on mild steels
Welding data
Welding positions Dia. (mm) 0.9 1.2 0.9 1.2
Wire Feed 4–8 3–7 7–14 5–9
Current (A) 50–130 90–160 130–220 180–260
Voltage (V) 15–19 17–21 22–25 24–29
Stainshield® 66
Chemical composition, wt% – all weld metal

Min. 1.50 0.65 0.005 23.0 13.00
Typical as welded 0.015 1.79 0.80 0.012 0.014 23.4 13.63
Max. 0.02 2.00 1.00 0.015 0.020 24.0 14.00 0.30 0.20 0.20 0.060

Stainless Steel 8
GMAW Wire
Classification
AS / NZS 2717.3, ES316LSi, AWS /ASME – SFA, A5 – 9, ER316LSi
BOC Stainless Steel Approvals:

MIG Wire 316LSi TÜV X 2 CrNiMo 1912
DIN 8556
DB SG – X2 CrNiMo 19 12
Welding characteristics Mechanical properties – all weld metal

N High silicon levels improve arc characteristics, weld pool Typical as welded
mechanical properties Tensile strength ( MPa) 630
Elongation (%) 32
Applications Reduction of area 46
N Welding of 18% Cr / 8% Ni and 18%Cr / 8%Ni / 3%Mo type
Impact levelsJ @ 20°C 152
Stainless Steels
J @ – 110°C 110
N Most suitable for the welding of 316, 318, and-316l alloys
J @ – 196°C 53
N Suitable for 301, 302, 304, 321, 347, 410, and-430 alloys
Ferrite content FN 13
Welding positions Welding current DC+
Packaging
Dia. (mm) 0.9 1.2
Part No. 109316 112316
Spool Weight (kg) 15 15
Welding data
Dia. (mm) 0.9 1.2 0.9 1.2
Wire Feed 4–8 3–7 7–14 5–9
Current (A) 50–130 90–160 130–220 180–260
Voltage (V) 15–19 17–21 22–25 24–29
Stainshield® 66

Min. 1.50 0.65 0.005 18.00 12.00 2.50
Typical as welded 0.012 1.70 0.93 0.008 0.016 18.58 12.2 2.63
Max. 0.02 2.00 1.00 0.015 0.020 19.00 13.00 3.300 0.30 0.20 0.060

8 Stainless Steel
GMAW Wire
Autocraft 307Si
Typical Wire Analysis Comparable Cigweld Products:
N For the GMAW Welding of hardenable
steels, 13% Mn steels & difficult to weld C Mn Si Cr Coabalarc Austex
steels. 0.07 8.9 0.8 18.5 AS/NZS 2576 1315-A4
N Extra Low Carbon ( < 0.07% ) Weld Ni P S Fe
Deposits for Resistance to Intergranular 8.5 0.03 0.015 Balance Recommended shielding gas
Corrosion. Stainshield®
N High Silicon level for Improved Arc Ferrite Number Stainshield® Heavy
Stability and Increased Weld Pool Fluidity 10 – 15 FN
and Edge Wetting.
N New Ultrafeed matt finish. Packaging and Operating Data
These machine settings are a guide only. Actual voltage and welding current used will depend on
Classifications machine characteristics, plate thickness, run size, shielding gas and operator technique etc.
AS 2717.3: ES307Si. Wire Feed
AWS/ASME-SFA A5.9: ES307Si. Wire Dia. Voltage Speed Current
(mm) Range (V) (m/min) Range (A) Pack Type* Weight (kg) Part No.
Typical All Weld Metal Mechanical Properties 0.9 16–24 4.5–15.0 70–200 Spool 15kg 721300
Stainshield 1.2 20–28 3.0–10.0 150–280 Spool 15kg 721301
0.2% Proof Stress 450 MPa * Spool (ø300mm).
Tensile Strength 640 MPa
Elongation 40%
CVN Impact Values 150 J av @ 20°C
Autocraft 308LSi Typical wire analysis (%) Recommended shielding gas

N A steel wire for the GMA welding of C: 0.02 Mn: 2.05 Si: 0.80 Stainshield®
304 and 304L type stainless steels Cr: 19.95 Ni: 10.25 P: 0.020 Stainshield® Heavy
N Recommended for the general welding S: 0.005 Fe: Balance
of-201, 302, 321, 347, 409 and 444 type
stainless steels
Ferrite number
Classifications 5–10 FN
AS / NZS 2717.3: ES308LSi
AWS /ASME-SFA A5.9: ER308LSi Packaging and operating data
Wire feed
Typical all weld metal mechanical properties speed Current Pack weight
Dia. (mm) Voltage (V) m / min range (A) Pack type* (kg) Part No.
Argon 1–3% CO2
0.9 16–24 4.5–15.0 70–200 Spool 15 721271
1.2 20–28 3.0–10.0 150–280 Spool 15 721272
Tensile strength 620 MP
Elongation 36%

Stainless Steel 8
GMAW Wire

N A stainless steel wire for the GMA C: 0.02 Mn: 2.10 Si: 0.75 Stainshield®
welding of 309 and 309L type Cr: 23.75 Ni: 13.75 P: 0.020 Stainshield® 66
stainless steels
S: 0.005 Fe: Balance Stainshield® Heavy
N Also suitable for a wide range of other
welding applications including: the
dissimilar joining of “300 series” and Ferrite Number
stainless steel grades to mild or low 10–15 FN
alloy steels, an intermediate or buttering
layer in the butt welding of clad steel
Classifications Wire feed

speed Current Pack weight
AS / NZS 2717.3: ES309LSi Dia. (mm) Voltage (V) m / min range (A) Pack type* (kg) Part No.
AWS /ASME-SFA A5.9: ER309LSi
0.9 16–24 4.5–15.0 70–200 Spool 15 721276
Typical all weld metal mechanical properties 1.2 20–28 3.0–10.0 150–280 Spool 15 721277
Argon 1–3% CO2

Elongation 36%

N A stainless steel wire for the GMA C: 0.02 Mn: 2.05 Si: 0.80 Stainshield®
welding of 316 and 316L type Cr: 19.95 Ni: 10.25 P: 0.020 Stainshield® 66
stainless steels
S: 0.005 Fe: Balance Stainshield® Heavy
N Also suitable for the general welding of
other 300 and 400 series stainless steels
including 301, 302, 304 / 304L, 321, 347, Ferrite number
410 and 430 5–10 FN
Classifications
AS / NZS 2717.3: ES316LSi
Wire feed
AWS /ASME-SFA A5.9: ER316LSi
Dia. (mm) Voltage (V) m / min range (A) Pack type* (kg) Part No.
Typical all weld metal mechanical properties Mini spool –
Argon 1–3% CO2 0.8 16–20 5.0–15.0 60–150 Pack of 4 4x1 721285
0.2% Proof stress 450 MPa 0.9 16–24 4.5–15.0 70–200 Handi spool 5 720283
Tensile strength 620 MPa Spool 15 721286
Elongation 36% 1.2 20–28 3.0–10.0 150–280 Spool 15 721287
CVN impact values 90J av @ -60°C 0.9 16–24 4.5–15.0 70–200 Drum 150 722286

8 Stainless Steel
GMAW Wire
Autocraft 2209
Typical Wire Analysis Comparable Cigweld Products:
N For the GMAW welding of 22%Cr/5%Ni/
3%Mo duplex type stainless steels. C Mn Si Cr Ni Mo Comweld 2209 TIG rod
0.012 1.6 0.44 22.8 8.63 3.1 AWS A5.9: ER 2209
N Extra low carbon (<0.03%) corrosion
resistance weld deposits. N P S Cu Fe
0.14 0.018 0.007 0.06 bal Recommended Shielding Gas
N Precision layer wound for improved
feedability and performance. Stainshield®
Ferrite Number Some nitrogen bearing shielding gases assist in maintaining
N New Ultrafeed matt finish.
an optimum Austenite/Ferrite ratio. Consult your gas
30- 50 FN (Procedure dependent) supplier for specific details.
Classifications
AS 2717.3: ES2209
AWS/ASME-SFA A5.9: ER2209. Packaging and Operating Data
Werkstoffe No: 1.4462
These machine settings are a guide only. Actual voltage and welding current used will depend on
machine characteristics, plate thickness, run size, shielding gas and operator technique etc.
Wire Dia. Voltage Wire Feed Current Pack Type* Weight (kg) Part No.
Welding grade Argon (mm) Range (V) Speed Range (A)
0.2% Proof Stress 600 MPa (m/min)
Tensile Strength 765 MPa 0.9 16–24 4.5–15.0 65–165 Spool 15kg 721261
Elongation 28% 1.2 20–26 3.0–10.0 180–280 Spool 15kg 721262
CVN Impact Value 60J av @ -40°C
80J av @ -20°C
100J av @ +20°C

Stainless Steel 8
GMAW Wire
Lincoln 308 LSi Lincoln 309 LSi Lincoln 316 LSi

For joining common austenitic stainless For joining higher alloyed austenitic stainless The undiluted weld metal is designed to contain
steel grades referred to as “18-8” steels. steels. Can also be used on “18-8” steels since considerable ferrite for high crack resistance in
it over matches the corrosion resistance, if the 316L joining and cladding. Should not be used
weldment will not be exposed to temperatures on 316L joints or overlay for service in urea
Classifications AWS ER308LSi
of 535–927°C. manufacture, as this environment will attack the
ferrite. Can also be used on “18-8” steels.
Size (mm) Carton (kg) Part No. Classifications AWS ER309LSi
0.80 15.0 331088 Classifications AWS ER 316LSi
0.90 15.0 331089
0.80 15.0 331098 Size (mm) Carton (kg) Part No.
1.20 15.0 331082
0.90 15.0 331099 0.80 15.0 331068
1.60 15.0 331086
1.20 15.0 331092 0.90 15.0 331069
1.60 15.0 331096 1.20 15.0 331062
1.60 15.0 331066

8 Stainless Steel
Shieldcrome 308LT Typical all weld metal mechanical properties Recommended shielding gases
N Gas shielded stainless steel flux Elongation 43% 40% Argoshield® 52
cored wire Welding Grade CO2
N Formulated for CO2 or Argon+20–25% Typical all weld metal analysis (%)
CO2 shielding gases Using welding grade CO2 Packaging data
N Vacuum sealed in aluminised C: 0.03 Mn: 1.30 Si: 0.70 Dia. Pack type Pack Part No.
plastic packs (mm) weight (kg)
Cr: 19.5 Ni: 9.9 P: 0.020
N All positional capabilities 1.2 Spool 12.5 720889
S: 0.003
N High deposition rate welding of
stainless steels
Operating data
N For a wide range of positional and
downhand welding applications on All welding conditions recommended below are for use with semi-automatic operation and
19Cr / 9Ni stainless steel grades including DC electrode positive and welding grade CO2 shielding gas with a flow rate of 15–20 L / min.
AISI types 301, 302, 304 and 304L etc Electrode stickout Welding
Dia. (mm) Current range (A) Voltage (V) ESO (mm) positions
Classifications 1.2 150–250 23–28 15–20 Flat
Shieldcrome 308LT 1.2 150–200 23–28 15–20 HV Fillet
AWS /ASME-SFA A5.22: E308LT1-1(CO2)
E308LT1-4 (Ar + 20–25%CO2) 1.2 120–180 22–27 15–20 Vertical up
1.2 140–180 22–27 15–20 Overhead
Using CO2 Using Argon
+20–25% CO2
0.2% Proof 390 MPa 400 MPa
stress
Tensile strength 550 MPa 580 MPa
Shieldcrome Typical all weld metal mechanical properties Recommended shielding gases
309LT / 309LTD Using

CO2
Using Argon
+20–25% CO2
Argoshield® 52
N Gas shielded stainless steel flux Welding Grade CO2

0.2% Proof stress 410 MPa 430 MPa
cored wires
Tensile strength 550 MPa 580 MPa
N 309LT- all positional capabilities Packaging data
Elongation 40 % 38 % Dia. (mm) Pack Pack Part No.
N 309LTD – fast downhand capabilities
type weight
N Vacuum sealed in aluminised plastic Typical all weld metal analysis (%) (kg)
packs
Using welding grade CO2 1.2 / 309LT Spool 12.5 720881
N Formulated for CO2 or argon
C: 0.03 Mn: 1.12 Si: 0.60 1.6 / 309LTD Spool 12.5 720882
+20–25% CO2 shielding gases
N High deposition rate welding of Cr: 23.6 Ni: 13.0 P: 0.023
stainless steels S: 0.003
N For a wide range of positional and
downhand welding applications on Operating data
matching 309 and 309L stainless steels.
All welding conditions recommended below are for use with semi-automatic operation and
Classifications
Electrode stickout Welding
Shieldcrome 309LT AWS /ASME-SFA A5.22: Dia. (mm) Current range (A) Voltage (V) ESO (mm) positions
E309LT1-1 (CO2) / E309LT1-4 (Ar + 20–
25%CO2) 1.2 / 309LT 150–250 23–28 15–20 Flat
Shieldcrome 309LTD AWS /ASME-SFA A5.22: 1.6 / 309LTD 300–400 28–35 25–30
E309LT0-1 (CO2) / E309LT0-4 1.2 / 309LT 150–200 23–28 15–20 HV Fillet
(Ar + 20–25%CO2)
1.6 / 309LTD 250–350 28–35 25–30
1.2 / 309LT 120–180 22–27 15–20 Vertical up
1.2 / 309LT 140–180 22–27 15–20 Overhead

Stainless Steel 8
Shieldcrome 316LT
Typical all weld metal mechanical properties Recommended shielding gases
N Gas shielded stainless steel flux
cored wires, all positional capabilities Using CO2 Using Argon Argoshield® 52
+20–25% CO2
N Vacuum sealed in aluminised plastic Welding Grade CO2
packs stress
N Formulated for CO2 or argon Tensile 555 MPa 580 MPa
Packaging data
+20–25% CO2 shielding gases strength Dia. (mm) Pack type Pack weight Part No.
N High deposition rate welding of mm (kg)
Elongation 42% 39%
stainless steels 1.2 Spool 12.5 720885
N For a wide range of positional and Typical all weld metal analysis (%)
downhand welding applications on
matching molybdenum bearing 316 Using welding grade CO2
and 316L stainless steels C: 0.03 Mn: 1.10 Si: 0.60
Cr: 18.8 Ni: 12.0 Mo: 2.5
Classifications
P: 0.024 S: 0.002
Shieldcrome 316LT AWS /ASME-SFA A5.22:
E316LT1-1 (CO2) / E316LT1-4 (Ar + 20–
25%CO2) Operating data
All welding conditions recommended below are for use with semi-automatic operation and
Electrode stickout
Dia. (mm) Current range (A) Voltage (V) ESO (mm) Welding positions
1.2 150–200 23–28 15–20 HV Fillet
1.2 120–180 22–27 15–20 Vertical up
1.2 140–180 22–27 15–20 Overhead
These machine settings are a guide only. Actual Voltage (V), welding current and ESO used will depend on machine

8 Stainless Steel
TIG
Weld Deposit Properties

Typical weld metal 0.2% proof stress 450 MPa
ProFill 308L Typical weld metal tensile strength 600 MPa

Approx. melting point 1,400ºC
Weld metal density 7.95 g / cm3
All weld metal microstructure Austenite with 5–8% ferrite
ProFill 308L stainless steel is a high quality low carbon rod for the Gas or
Gas Tungsten Arc (TIG) welding of a wide range of low carbon and stabilised
Procedure for Gas Tungsten Arc (TIG) Welding
300 series stainless steels. It is recommended for the critical welding of 304 N Thoroughly clean all areas to be joined.
and 304L stainless steels in corrosion resistant and cryogenic applications.
N For the butt welding of thick plates, bevel edges to 60–70°
N Resealable 5 kg tube included angle.
N Suitable for gas and GTA (TIG) welding N Use a Thoriated or Ceriated tungsten electrode, ground to a
sharp needle point making sure the grinding lines run with the
Classification length (longitudinally) of the electrode’s axis. The length of the
AS1167.2:308LSi
needle point should be approximately 2–3 times the diameter
of the tungsten electrode.
AWS /ASME-SFA A5.9:ER308LSi
N Use Direct current electrode negative (DC-) and welding
grade-argon.
Dia. (mm) Weight (kg) Part No.
N Preheat surfaces to be welded. Heat a spot on the base metal
1.2 mm 5 kg BTGS308L12 until it shows signs of melting and progressively add the filler
1.6 mm 5 kg BTGS308L16 rod to the weld-pool.
2.0 mm 5 kg BTGS308L20
N For the best cleaning and finishing results use BOC
Weld-Guard™ Pickling-Paste.
Weld deposit properties


Approx. melting point 1400ºC
Gas Tungsten Arc (TIG) welding of highly alloyed 309 or 309L type stainless Procedure for Gas Tungsten Arc (TIG) Welding
steels. ProFill 309L is also suitable for the dissimilar joining of other 300 N Thoroughly clean all areas to be joined.
series austenitic stainless steels ferritic steels.
N For the butt welding of thick plates, bevel edges to 60–70°
AS1167.2:309LSi needle point should be approximately 2 to 3 times the diameter
ASME-SFA A5.9: ER309LSi of the tungsten electrode.
grade-argon.
Dia. (mm) Weight (kg) Part No.
2.0 mm 5 kg BTGS309L20 rod to the weld-pool.
2.4 mm 5 kg BTGS309L24 N For the best cleaning and finishing results use BOC Weld-Guard™
Pickling-Paste.

Stainless Steel 8
TIG


Gas Tungsten Arc (TIG) welding of Molybdenum bearing stainless steels; in Procedure for Gas Tungsten Arc (TIG) Welding
particular matching 316 and 316L alloys. ProFill 316L is also suitable for the
general welding of 304 and 304 stainless steels and ferritic stainless steels N Thoroughly clean all areas to be joined.
including 409, 444 and 3Cr12. N For the butt welding of thick plates, bevel edges to 60–70°
AS1167.2:316LSi of the tungsten electrode.
AWS /ASME-SFA A5.9:ER316LSi
grade-argon.
Dia. (mm) Weight (kg) Part No. N Preheat surfaces to be welded. Heat a spot on the base metal
rod to the weld-pool.
N For the best cleaning and finishing results use BOC
Weld-Guard™ Pickling-Paste.

ProFill 347 Typical weld metal tensile strength 640 MPa

ProFill 347 stainless steel is a high quality Gas or Gas Tungsten Arc (TIG)
welding rod. Niobium stabilised for improved resistance to intergranular Procedure for Gas Tungsten Arc (TIG) Welding
corrosion, ProFill 347 is recommended for the TIG welding of 347, 348 and
321 type stainless steels stabilised with either Niobium or Titanium. N Thoroughly clean all areas to be joined.
ProFill 347 is also suitable for the general purpose welding of other 300 N For the butt welding of thick plates, bevel edges to 60–70°
series stainless steels including 301, 302, 304 and 304L etc. included angle.
N Resealable 5 kg tube N Use a Thoriated or Ceriated tungsten electrode, ground to a
N Suitable for gas and GTA (TIG) welding
length (longitudinally) of the electrode’s axis. The length of the
Classification
of the tungsten electrode.
AS1167.2:347
AWS /ASME-SFA A5.9:ER347
grade-argon.
Dia. (mm) Weight (kg) Part No. until it shows signs of melting and progressively add the filler
1.6 mm 5 kg BTGS34716 rod to the weld-pool.
2.0 mm 5 kg BTGS34720 N For the best cleaning and finishing results use BOC Weld-Guard™
Pickling-Paste.
3.2 mm 5 kg BTGS34732
2.4 mm 5 kg BTGS34724

8 Stainless Steel
TIG
Comweld 308L
Typical rod analysis (%) Recommended shielding gas
N Resealable 5 kg plastic tube
C: 0.015 Mn: 1.90 Si: 0.50 Argon Welding Grade
N Suitable for gas and GTA (TIG) welding
Cr: 19.90 Ni: 9.75 P: 0.020
N End stamped with AS /AWS Class ‘308L’
S: 0.005 Fe: Balance
N Dark blue colour coded label for instant
identification
Packaging data
Classifications Rod Size (mm) Weight (kg), Pack type Approx. (rods / kg) Part No.
AS / NZS 1167.2: R308L 1.6 x 914 5 plastic tube* 69 321406
AWS /ASME-SFA A5.9: ER308L
2.4 x 914 5 plastic tube* 30 321407
*Resealable
Comweld 309L
Typical rod analysis (%) Recommended shielding gas
N Resealable 5 kg plastic tube
C: 0.015 Mn: 1.90 Si: 0.45 Argon Welding Grade
N Suitable for Gas and GTA (TIG) welding
of highly alloyed 309 or 309L type Cr: 23.5 Ni: 13.5 P: 0.020
stainless steel S: 0.005 Fe: Balance
N End stamped with AS /AWS class ‘309L’
N Red colour coded pack label for instant Packaging data
identification Rod Size (mm) Weight (kg), Pack type Approx. (rods / kg) Part No.
N Also suitable for the dissimilar joining 1.6 x 914 5 plastic tube* 69 321403
of other 300 series austenitic stainless
steels to ferritic steels 2.4 x 914 5 plastic tube* 30 321404
*Resealable
Classifications
AS / NZS 1167.2: R309L

Stainless Steel 8
TIG
Comweld 316L Typical rod analysis (%) Recommended shielding gas

N Resealable 5 kg plastic tube C: 0.012 Mn: 1.57 Si: 0.50 Argon Welding Grade
N Suitable for gas and GTA (TIG) welding Cr: 19.00 Ni: 12.6 Mo: 2.50
of-molybdenum bearing stainless steels; P: 0.015 S: 0.001 Fe: Balance
in particular matching 316 and
316L alloys
Packaging data
N End stamped with AS /AWS class ‘316L’
Rod Size (mm) Weight (kg), Pack type Approx. (rods / kg) Part No.
N Gold colour coded pack label for
instant identification 1.6 x 914 5 plastic tube* 69 321400
N Also suitable for the general welding 25 rod Handipack – 322054
of other 300 series stainless steels 2.4 x 914 5 plastic tube* 30 321401
including 302 and 304; as well as ferritic
*Resealable
stainless steels grades such as 409,
444 and 3Cr12
Classifications
AS / NZS 1167.2: R316L
Comweld 2209
Ferrite Number Comparable Cigweld Products:
N For the GTA (TIG) welding of
22%Cr/5%Ni/3%Mo duplex type 30-50 FN (Procedure dependent) Autocraft 2209 GMAW wire
stainless steels. AWS A5.9: E2209
N Resealable 5kg cardboard tube. Typical Rod Analysis
N Suitable for GTA (TIG) welding. C Mn Si Cr Ni Mo Recommended shielding gas
N End stamped with AWS Class ‘ER2209’ 0.012 1.06 0.44 22.8 8.63 3.1 Argon Welding Grade
for easy identification. N P S Cu Fe
0.14 0.018 0.007 0.06 Bal.
Classifications
AWS/ASME-SFA A5.9: ER2209. Packaging Data
Werkstoffe No: 1.4462 Rod Size (mm) Weight (kg), Pack Type Approx. Rods/kg Part No.
1.6 x 1,000 5 Cardboard Tube* 69 321393
Joining Process
2.4 x 1,000 5 Cardboard Tube* 30 321394
Gas Tungsten Arc (TIG) welding.
* Resealable
Typical All Weld Deposit Mechanical Properties

0.2% Proof Stress 600 MPa.
Tensile Strength 765 MPa.
Metal Density 7.95 gms / cm3
Microstructure Austenite & ferrite
(z 50:50)

8 Stainless Steel
Lincoln 308L Lincoln 309L Lincoln 316L

For joining the more common austenitic For joining more high alloyed austenitic Undiluted weld metal is designed to contain
stainless steel grades referred to as "18-8" stainless steels. Can also be used on "18-8" considerable ferrite for maximum crack
steels. steels since it over matches the corrosion resistance. Should not be used on 316L
resistance, if the weldment will not be joints in service for urea manufacture, as
Classification AWS ER308L exposed to temperatures of 540–925°C. this environment will attack the ferrite.
Size (mm) Carton (kg) Part No. Classification AWS ER309L Classification AWS ER316L
2.40 25.0 330082

Size (mm) Carton (kg) Part No. Size (mm) Carton (kg) Part No.
3.20 25.0 330083
2.40 25.0 330092 2.40 25.0 330062
3.20 25.0 330093 2.40 25.0 330063
Lincoln 2209
Solid wire for welding duplex stainless
steels. High resistance to general corrosion,
pitting and stress corrosion conditions.
Classification AWS ER2209

2.40 25.0 330222
Submerged Arc Flux

Refer to page xx for a listing of Submerged
Arc Flux

Consumables 8
Aluminium
or two digit number; in US, casting alloys are given a two or three
Aluminium Welding digit number, some being prefixed with a letter. Similar systems
Aluminium is a light, ductile, readily worked metal, with good are also used in Australia and New Zealand.
thermal and electrical properties. It has a tenacious oxide film on Many aluminium casting alloys are based on the Al-Si or Al-Cu
the surface that gives it good corrosion resistance. It is also the systems. The Al-Si system has good fluidity and can be used for
most abundant metal on earth. intricately shaped cast sections. Silicon reduces hot shortness and
Aluminium alloys may be sub-divided into two main groups, cast the tendency for castings to crack on solidification. These alloys
alloys and wrought alloys. Wrought materials also come in a wide have good corrosion properties and often have copper as a second
variety of product forms. element to enhance their strength.
Wrought alloys are further sub-divided into heat-treatable and There are only a few Al-Mg casting alloys, for while they have good
non-heat-treatable alloys. corrosion properties in marine environments, and good strength,
they are somewhat more difficult to cast than Al-Si alloys.
Heat-treatable alloys are based on aluminium-copper, aluminium-
silicon-magnesium and aluminium-zinc-magnesium alloy systems. Wrought Alloys
They can develop high strength by solution treatment followed
by age hardening at elevated temperature. Wrought alloys consist of cast material that has been worked by
processes such as forging, extrusion, drawing, or rolling, thereby
Non-heat-treatable alloys include pure aluminium, and those improving the homogeneity and enhancing the mechanical
based on aluminium-manganese, aluminium-silicon, and aluminium- properties of the material. This renders many forms of wrought
magnesium. They can be strengthened only by cold work. alloys more suitable for welded construction.
Types Wrought alloys may be:

Aluminium and aluminium alloys can be divided into two main N Hot or cold rolled, to produce plate, sheet, strip, or foil
groups that refer to the form in which they are used and these are N Extruded, to give bars, sections, or tube
“Cast Alloys” and “Wrought Alloys”. Each of these two groups may N Drawn, to make wire, bolts, screws, rivets, or tube
then be further sub-divided into alloy type by composition.
N Forged, to give a variety of shapes
Cast Alloys Wrought aluminium alloys are of two main types:
Aluminium alloy castings may be produced in sand moulds, metal N heat treatable, those which can be strengthened by heat
moulds, and by gravity or pressure die-casting. The castings possess treatment
rigidity and good corrosion resistance, with strength and ductility
N non-heat treatable, those which can only be strengthened
generally being of secondary importance.
by cold working
Alloying elements frequently used in aluminium castings are copper,
Wrought aluminium alloys are also further classified into groups,
silicon, magnesium, zinc, iron, manganese and nickel. Cast alloys are
according to the main alloying element or elements. Each group, or
of two main types,
‘series’, has a four-digit designation conferred by the International
N those which rely solely on alloying for their properties, such as Standards Organisation (ISO). The first number relates to the main
Al-Mg and Al-Si alloys alloying element(s), the second number to the alloy modification
N those where heat-treatment can be used to enhance properties, (zero being the original alloy) and the next two numbers indicate
like the Al-Cu alloys the order in which the alloys were developed and subsequent
variations. A letter following the four-digit number indicates a
As yet there is no agreed international standard numbering system
national variation in composition, for instance alloy 1200A is a
for castings and each country uses its own identification method. In
compositional variation
UK, casting alloys are prefixed by the letters ‘LM’, followed by a one
of alloy 1200.

8 Aluminium
Wrought aluminium alloys, in numerical series order, are described Welding

briefly below. Some of the alloys in each series, and their Although at first sight it appears to be a relatively simple alloy
approximate compositions, are given in tables in each section. system to weld compared with steel, because no solid state phase
Elements are only quoted if included as a deliberate addition, with change occurs, there are several important factors influencing the
a minimum requirement, or as a maximum and minimum range in weldability of aluminium and its alloys to be considered. There are
specifications. Other elements may be present as impurities with some general factors, covering all alloys, and some individual alloy
a maximum limit. characteristics, the latter making some alloys more difficult to
weld than others.
Mechanical Properties
The main factors to be taken into consideration, and dealt with
Aluminium is ductile and malleable, enabling it to be manufactured
in detail in Welding Aluminium, are:
in many different forms by such methods as hot rolling, cold rolling,
extrusion, forging, drawing, stamping, spinning, pressing or bending. N The presence of a tenacious, refractory, surface oxide film,
which if not removed before welding, can cause lack of fusion
Aluminium has good toughness, even down to cryogenic
or porosity
temperatures (below –100˚C), because no ductile to brittle phase
transition takes place, even with rapid cooling. N The high solubility of hydrogen in liquid aluminium compared
with its solubility in solid aluminium can lead to porosity in
Although the strength of pure aluminium is low compared with weld metal
steel and other common engineering materials, it can be improved
by cold working or by alloying with different elements, and these N The tendency for some alloys, notably 2XXX, 6XXX and 7XXX
alloys can be further improved with heat treatment or cold working. series alloys, to suffer hot cracking or HAZ liquation cracking
The elements most commonly used to form alloys with aluminium N The reduction in mechanical properties that occurs across the
are copper, magnesium, silicon, manganese and zinc, singly or in weld zone when aluminium alloys are welded
combinations.
Alloying with these elements can strengthen aluminium by one of Welding Processes
two mechanisms: Aluminium and many of its alloys can be readily welded, most
frequently using inert gas shielded processes, such as MIG and
N Strength may be increased by the presence of alloying elements
TIG. MMA is still used occasionally, particularly for site repair
that become entrapped in solid solution within the aluminium
work, but it is difficult to obtain good quality welds with the
by a process called solid solution hardening. Alloys which are
consumables available.
solid solution hardened can be cold worked to further increase
strength and this is called work hardening. Work hardening the MIG welding of aluminium is always carried out with a completely
material involves cold rolling, extrusion, pressing, drawing, etc. inert gas shield, traditionally argon, but now increasingly
and the strength achieved depends on the amount of cold work helium / argon mixtures, such as the BOC Alushield range, which
applied, and may be described as the ‘temper’ of the alloy. Alloys help to increase penetration and to reduce the incidence of
of this type include Al-Mn and Al-Mg, and they are known as porosity.
non-heat-treatable alloys. It must be remembered that aluminium and its alloys must not
N The properties of some aluminium alloys may be improved by be MIG welded using active gases like carbon dioxide, or Ar-CO2
heat treatment, a process in which precipitation of constituents mixtures, since these will lead to severe oxidation and failure to
held in solid solution is allowed to take place by holding at produce a weld.
a suitable temperature. The process is usually described as TIG welding must also be carried out using inert gas shield, argon
ageing or age hardening. If age hardening takes place at room or argon / helium mixtures, not only to prevent oxidation of the
temperature it is referred to as natural ageing, but if elevated weld but also to prevent the tungsten electrode being consumed.
temperatures are used this is called artificial ageing. Alloys of this
type include Al-Cu, Al-Mg-Si, and Al-Zn-Mg, and they are known High power density processes, like Laser and Electron Beam, and
as heat-treatable alloys. the more recently developed Friction Stir Welding Process are
Aluminium
Cu Mn Si Mg Zn Other Alloy elements
2xxx Not recommended

2014A for welding
1xxx 3xxx 5xxx 8xxx Non heat treatable

1050A 3103 5063 8090
6xxx 7xxx Heat treatable
6082 7020
4xxx 5183 Filler wire
1080 4043/4047 5356

Aluminium 8
also suitable for welding all alloys. Brazing and Resistance Welding 3XXX series: Manganese as Main Alloying Element
techniques are applicable to some alloys. The 3XXX series alloys are weldable alloys, welded with
The Submerged Arc and Flux Cored Wire processes are not used matching filler metals, but are welded infrequently, the main
for welding aluminium alloy systems. joining method being brazing. Furnace brazing and gas torch
brazing are suitable methods.
Welding Casting Alloys
4XXX series: Silicon as Main Alloying Element
Aluminium castings find limited use in welded construction,
principally because of their low ductility and high porosity content, These alloys are weldable by all processes using Al-Si filler
but re-instatement and repair of castings by welding is often metals where appropriate. However, as stated before a major
required. Many casting alloys, notably those containing copper, are use for these alloys is as welding wire containing 5%Si or 12%Si.
not recommended for welding, as they are very crack sensitive.
Pure aluminium, and alloys based on Al-Si and Al-Mg, may be 5XXX series: Magnesium as Main Alloying Element
welded with appropriate filler metals. Alloys with magnesium contents under about 3%, such as 5251
and 5454, are susceptible to cracking and it is usual to use higher
Welding Wrought Alloys magnesium fillers to overcome this tendency. Alloys with more
A brief resume of the welding characteristics of each group of alloys than 4.5%Mg are readily welded.
is given below. MIG and TIG are the most frequently used welding processes for
these alloys, and they tend not to respond well to MMA or to gas
1XXX series: Non-alloyed Aluminium welding and brazing.
The 1XXX alloys are readily welded using filler metals of matching
composition. It is also possible to use Al-Si or Al-Mg filler metals 6XXX series: Magnesium and Silicon
for some applications. They may be welded using all main processes, as Main Alloying Elements
including MIG, TIG, MMA, gas welding and brazing, resistance and These alloys can be welded with care, since with less than 1%Si and
friction welding methods. 1%Mg they have a tendency to crack in the HAZ, by a mechanism
called liquation cracking, if high heat inputs are used. To avoid weld
2XXX series: Copper as Main Alloying Element metal cracking they require a MIG or TIG filler metal containing
These alloys are virtually unweldable because the formation of 5%Mg or 5%Si to be used. Care must be taken not to mix the two
aluminium-copper intermetallics in weld metal renders them brittle. filler compositions or cracking will result.
They tend to crack if attempts are made to weld them using fusion
welding processes, although use of Al-12%Si filler may sometimes 7XXX series: Zinc as Main Alloying Element
give reasonable results. Non-fusion techniques, such as friction The series includes both weldable and unweldable grades, although
welding and friction stir welding may give some success. even the weldable alloys are prone to suffer HAZ liquation cracking.
It is usual to use filler metals containing zinc and magnesium,
Non-heat treatable Heat treatable

1xxx 3xxx 5xxx 6xxx 7xxx 2xxx 8xxx
Du
ctil
ity h
ngt
Stre
Property
Packaging and Electrical
Transport, Engineering, Aero

Military
Building and Construction and Space
Al Al-Mn Al-Mg Al-Mg-Si Al-Zn-Mg Al-Cu- Al-Zn-Mg-Cu

Mg-Si
Alloy Element

8 Aluminium
although it is possible to use Al-5.5%Mg fillers in some instances. How much Preheat to Apply
MIG and TIG tend to be the main processes used on these alloys. The actual preheat temperature required for a specific welding
operation depends not only on the material or materials being
8XXX series: Miscellaneous Alloys welded, but also the combined thickness of the joint, the heat
Most of the alloys in this series are not commonly welded, and input from the welding process being used, and the amount of
some are not weldable. However, there have been developments restraint imposed upon the components. There are no hard and
in aluminium-lithium alloys for aerospace applications that have led fast rules regarding how much preheat to apply, but there are many
to weldable grades becoming available. publications available giving helpful guidance. These publications
include national and international standards or codes of practice,
Cutting guides from steel and aluminium alloy producers, and from
Cutting processes that use an electric arc in a stream of inert consumable manufacturers. Some guidelines are included here, and
gas may be used to cut all aluminium alloys. The cut surfaces are as in the previous section, categorised for convenience by alloy type.
generally quite smooth and clean, but the plate retains narrow,
melted and partially melted, zones, which with heat-treatable alloys Aluminium Alloys
may lead to intergranular cracking. Corrosion properties may also be As a rule, aluminium alloys are only preheated to temperatures
adversely affected in the immediate HAZ of the cut. It is, therefore, between 80˚C and 120˚C. Certain heat treatable aluminium alloys
advisable to trim back by about 3mm from the cut surface to give a (Al-Si-Mg) are sensitive to HAZ liquation cracking if overheated,
sound welding surface, free from possible stress raisers. and preheat must be carefully controlled within this range. With less
It should be noted that some standards call for levels of up to 6mm sensitive alloys preheat may be increased up to a maximum of 180-
to be removed after cutting. 200˚C. Remember that aluminium alloys have relatively low melting
points and care must be taken to avoid overheating which can result
Relevant standards should be consulted to establish requirements. in poor weld quality and cracking in some alloys.
Cutting Processes
There are several different thermal processes for cutting aluminium
and its alloys, but the most frequently used is Plasma Cutting, with
Laser Cutting also finding some applications.
For most industrial fabricators today, plasma cutting is probably
the first choice as a cutting technique for aluminium from 3mm to
50mm and above in thickness. Plasma cutting gives a smooth cut
surface, free from major contamination, but should be trimmed
prior to welding, as described above.
Preheating of Aluminium and Aluminium alloys

When to Preheat
Preheat is needed when there is a risk that if a welding operation
is carried out ‘cold’ an unsound weld could be produced. Whilst
it is not possible here to cover all eventualities, there are certain
guidelines that can be followed in making the decision whether
to preheat or not, and these are outlined here, categorised for
convenience, by alloy type.
Aluminium Alloys
Aluminium Alloys have a high thermal conductivity and preheat is
used to provide additional heat to the weld area in order to help
ensure full fusion of the weld. Application of preheat is also used
to drive off any moisture in the surface oxide. Preheating may not
be necessary when welding thin sheet, but becomes increasingly
important as thickness, and therefore thermal conduction away
from the weld increases.

Aluminium 8
Aluminium and Aluminium Alloys
1060,
1100,
Base (1050), 5005, 5154, 6005, 356,0
Metal 3003 3004 5050 5052 5083 5086 5354 5454 5456 6061 7005 443,0
1060, 1100 4043 4043 4043 5356 5356 4043 4043 5356 4043 (e) 5356 4043 (e)
1100, (1050) (d)(e) (d)(e) (d)(e) (b)(d) (b)(d) (d)(e) (d)(e) (b)(d) (b)(d)
(1050), (b)(e)
3003
3004 4043 4043 4043 5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 4043 5356 4043 (e)
(d)(e) (d)(e) (d)(e) (d)(e) (b)(e)
5005, 4043 4043 5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 4043 5356 4043 (e)
5050 (d)(e) (d)(e) (d)(e) (b)(d)
5052 5356 5356 (d) 5356 (d) 5356 (a) 5356 (a) 5356 (d) 5356 5356 (a) 4043
(a)(b) (a)(b) (a)(e)
5083 5183 (d) 5356 (d) 5356 (d) 5356 (d) 5183 (d) 5356 (d) 5183 (d) 5356
(b)(d)
5086 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356 (d) 5356
(b)(d)
5154, 5356 (a) 5356 (a) 5356 (a) 5356 (a) 5356 (d) 4043 (a)
5254
5454 5554 5356 (d) 5356 5356 (a) 4043

(b)(d) (a)(b) (a)(e)
5456 5556 (d) 5356 (d) 5556 (d) 5356

(b)(d)
6005, 4043 5356 4043

6061, (a)(e) (a)(b) (a)(e)
6063,
6351
7005 5356 (d) 4043

(a)(e)
356,0 4043
443,0 (c)(e)
NOTES a) 5813, 5356, 5554, 5556 and 5654 may be used. In some cases they provide: improved
(1) The filler metal that is shown for each combination of base metals is that most commonly colour match after anodising treatment, higher weld ductility, higher weld strength. 5554 is
used. However, the specific filler metal depends upon usage and type of joint and, in a suitable for elevated-temperature service. Castings welded with these filler metals should
number of cases, acceptable alternates is recommended (footnotes a to c). not be subjected to post-weld artificial aging.
(2) Filler metals conform to requirements of AWS specification A5.10-80. b) 4043 may be used for some applications.
(3) Exposure to specific chemicals or a sustained high temperature (over 150°F) may limit c) filler metal with the same analysis as the base metal is sometimes used.
the choice of the metals. Filler alloys 5183, 5356, 5556 and 5654 should not be used in d) 5183, 5356 or 5556 may be used.
sustained elevated-temperature service. e) 4047 may be used for some applications.

8 Aluminium
GMAW Wire

Typical as welded
BOC Aluminium Yield strength (Rm) 22
MIG Wire 1080 Tensile strength ( MPa)

Elongation (%)
60
40%

Si Fe Cu Mn Mg Zn Ti
Welding characteristics Min.
Triple shaved for smoother feeding and consistent contact Typical <0.15 <0.15 <0.02 <0.02 <0.02 <0.06 <0.02
Applications Max.
For welding of 99.9% pure aluminium

Packing and welding data
Recommended shielding gases Weight /
Dia. (mm) Current (A) Voltage (V) spool (kg) Part No.
Welding grade argon
0.8 70–110 16–18 5.0 S970850
Alushield® Light
0.9 90–130 17–19 6.0 S970960
Alushield® Heavy
1.0 100–140 17–19 6.0 S971060
Classifications 1.2 120–150 24–29 6.0 S971260
AS 2717.2 No equivalent 1.6 200–320 25–33 6.0 S971660
AWS /ASTM A5.10 No equivalent
DIN 1732 SG. Al Mg 4.5 Mn Werks. 3.3548 BS 2901 Pt.4 5183
Welding positions

Aluminium 8
GMAW Wire

Typical as welded

Elongation (%)
120
8%

Welding characteristics Min. 4.5
N Excellent flow characteristics and penetration Typical <0.40 <0.05 <0.05 <0.05 <.010 <0.015
N Excellent crack resistance Max. 5.5
N Triple shaved for smoother feeding and consistent contact
Applications Packing and welding data

N Used to weld alloys with a maximum of 2% alloying elements Weight /
and for castings containing up to 7% Si Dia. (mm) Current (A) Voltage (V) spool (kg) Part No.
N Many general construction and automotive applications 0.8 70–110 16–18 0.5 S430805
0.8 70–110 16–18 5.0 S430850
0.9 90–130 17–19 0.5 S430905
Welding grade argon
0.9 90–130 17–19 6.0 S430960
Alushield® Light
1.0 100–140 17–19 0.5 S431005
Alushield® Heavy
1.0 100–140 17–19 6.0 S431060
AS 2717.2 E4043 AWS / ASTM A5.10 ER4043 1.2 150–250 20–25 6.0 S431260
DIN 1732, SG. AL SI.5 Werks. 3.2245, BS 2901 Pt.4 4043 A 1.6 200–350 23–28 6.0 S431660
Welding positions

8 Aluminium
GMAW Wire

Typical as welded

Elongation (%)
130
5%
Melting Range 573–585°C

Welding characteristics Si Fe Cu Mn Mg Zn Ti
N Good mechanical properties Min. 11.0
N Excellent corrosion resistance Typical <0.50 <0.05 <0.15 <0.05 <0.10 <0.15
N Low melting point ensures reduction in parent metal distortion Max. 13.0
N Triple shaved for smoother feeding and consistent contact
Applications
N General purpose welding of aluminium sheets, extrusions Weight /
Dia. (mm) Current (A) Voltage (V) spool (kg) Part No.
and castings
N Many general construction and automotive applications 1.0 100–140 17–19 6.0 S471060
1.2 120–150 24–29 6.0 S471260
Welding grade argon
Alushield® Light
Alushield® Heavy
Classifications
AS 2717.2 E4047
AWS / ASTM A5.10 ER4047
DIN 1732SG. AL Si.12 Werks. 3.2585
BS 2901 Pt.4 4047 A
Welding positions

Aluminium 8
GMAW Wire

Typical as welded

Elongation (%)
275
17%
Lloyd’s D O BF 5083 0and F S NA
Recommended shielding gases DNV AlMg4.5Mn / I1
Welding characteristics Chemical composition, wt% – all weld metal

N High strength Si Fe Cu Mn Mg Zn Ti
N Triple shaved for smoother feeding and consistent contact Min. 0.60 4.3 0.07
Applications Typical <0.25 <0.40 <0.05 <0.25

N Where high strength and resistance to sea water are required Max. 1.0 5.2 0.15
N Applications in shipbuilding, offshore, cryogenic equipment,
railway constructions and automotive Packing and welding data
Weight /
Welding grade argon Dia. (mm) Current (A) Voltage (V) spool (kg) Part No.
ABS AWS A5.10–92 0.8 70–110 16–18 5.0 S510850
Alushield® Light BV
Alushield® Heavy 0.9 90–130 17–19 6.0 S510960
1.0 100–140 17–19 6.0 S511060
AS 2717.2, E5183, AWS / ASTM A5.10, ER5183, DIN 1732, SG. Al Mg 4.5
Mn Werks. 3.3548, BS 2901 Pt.4 5183
Welding positions

8 Aluminium
GMAW Wire

Typical as welded

Elongation (%)
240
17%

Welding characteristics Min. 0.10 4.5 0.07
N Excellent corrosion resistance and high strength Typical <0.25 <0.40 <0.05 <0.10
N Triple shaved for smoother feeding and consistent contact Max. 0.30 5.6 0.15
Applications
N Used to weld aluminium magnesium base metal alloys with a Packing and welding data
maximum of 5% Mg Suitable for a wide range of 3XXX, 5XXX, Weight /
6XXX and 5XX series Dia. (mm) Current (A) Voltage (V) spool (kg) Part No.
N Applications in shipbuilding, storage tanks, railways and 0.8 50–150 14–21 0.5 S530805
car industry 0.8 50–150 14–21 5.0 S530850
0.9 80–180 16–22 0.5 S530905
Classifications
0.9 80–180 16–22 2.0 S530920
AS 2717.2 E5356
AWS /ASTM A5.10 ER5356 0.9 80–180 16–22 6.0 S530960
DIN 1732 SG. AL Mg 5
1.0 110–220 17–23 0.5 S531005
BS 2901 Pt.4 5356
1.0 110–220 17–23 2.0 S531020
Approvals 1.0 110–220 17–23 6.0 S531060
Lloyd’s D O BF 5083-OandF S NA 1.2 150–250 20–25 0.5 S531205

DNV AlMg5 / 11 1.2 150–250 20–25 2.0 S531220
ABS AWS A5.10.92
BV 1.2 150–250 20–25 6.0 S531260
Welding positions
Recommended hielding gases

Alushield® Light
Alushield® Heavy
Welding Grade Argon

Aluminium 8
GMAW Wire
Autocraft AL1100
Wire analysis limits Recommended shielding gas
N A high purity aluminium wire for the
GMA welding of selected wrought Si: 0.06% Fe: 0.06% Cu: 0.005% Alushield® Light
aluminium alloys Mn: 0.01% Mg: 0.01% Zn: 0.03% Alushield® Heavy
N Recommended for the joining of Ti: 0.01% Total others: Al: 99.88% min Welding Grade Argon
selected high purity 1XXX series 0.01%
aluminium alloys used extensively * Single values are maximum allowable, unless
in electrical and chemical industry otherwise stated.
applications
Classifications Pack
Wire feed Current range Pack weight
AS / NZS 2717.2: E1188
Dia. (mm) Voltage (V) speed (m / min) (A) type* (kg) Part No.
AWS /ASME-SFA A5.10: ER1188
1.6 23–28 5.0–9.5 200–350 Spool 7.0 722218
Typical all weld metal mechanical properties 2.0 25–31 53.0–7.5 250–400 Spool 7.0 723218
Single ‘V’ butt weld with 1060 Aluminium
(reduced section tensile specimen)
Welding grade Argon
0.2% Proof stress 34.5 MPa
Tensile strength 69.0 MPa
Elongation 29%
(in 2 inches)
Autocraft AL4043
N An aluminium -5% silicon wire for GMA
welding of selected wrought and cast Single values are maximum allowable, unless Alushield® Light
aluminium alloys otherwise stated
Alushield® Heavy
N For the repair welding of aluminium alloy Si: 4.5–6.0% Fe: 0.80% Cu: 0.30%
Welding Grade Argon
castings (mainly 4XX and 6XX series) Mn: 0.05% Mg: 0.05% Zn: 0.10%
N For welding selected wrought (1XXX, Ti: 0.20% Total others: Al: Balance
5XXX and 6XXX series) aluminium 0.15%
alloys
Classifications
Wire feed Current range Pack
AS / NZS 2717.2: E4043 Dia. (mm) Voltage (V) speed (m / min) (A) Pack type* weight (kg) Part No.
1.2 20–25 5.5–12.0 150–250 Spool 7.0 722237
1.6 23–28 5.0–9.5 200–350 Spool 7.0 722238
Single ‘V’ butt weld with 6061-T6 Aluminium
(reduced section tensile specimen) using
welding grade Argon: Postweld heat
As welded Treated
and aged
stress
strength
Elongation 8% 5%
(in 2 inches)

8 Aluminium
GMAW Wire
Autocraft AL5356
N An aluminium -5% magnesium wire
for the GMA welding of a wide range Single values are maximum allowable, unless Alushield® Light
of wrought and cast aluminium alloys otherwise-stated Alushield® Heavy
containing magnesium Si: 0.25% Fe: 0.40% Cu: 0.10% Welding Grade Argon
Mn: 0.05–0.2% Mg: 4.5–5.5% Cr:
Classifications 0.05–0.20%
AS / NZS 2717.2: E5356 Zn: 0.10% Ti: 0.06–0.20%
Total others: Al: Balance
0.15%
Single ‘V’ butt weld with 5086 Aluminium Packaging and operating data
(reduced section tensile specimen) Wire feed Pack
Welding grade Argon Dia. speed Current range weight
(mm) Voltage (V) (m / min) (A) Pack type* (kg) Part No.
0.8 14–21 6.0–20.0 50–150 Mini Spool 4 x 0.5 721221
Tensile strength 269 MPa – Pack of 4
Elongation 17% 0.9 16–22 6.0–17.5 80–180 Spool 7.0 722226
(in 2 inches)
1.0 17–23 6.0–16.5 110–220 Spool 7.0 722224
1.2 20–25 5.5–12.0 150–250 Spool 7.0 722227

Aluminium 8
GMAW Wire
Superglaze 4043 Superglaze 5183 Superglaze 5356

Popular filler metal chemistry containing Magnesium based alloy providing outstanding 5% Magnesium alloy which is the most
silicon to lower melting point and provide strength, making this chemistry an excellent commonly used. It is suitable for welding
fluidity. Developed for welding of heat candidate for structural applications such as most of the 5XXX base materials. The wire
marine, storage or rail cars.
treatable base alloys and more specifically exhibits good strength, stiffness and good
the 6XXX series alloys. Moderately soft, wire feeding characteristics.
Classifications AWS ER5183
provides good weld appearance, melting
action and penetration. Excellent operating Classifications AWS ER5356
characteristics. Size (mm) Carton (kg) Part No.
0.9 7.26 ED028435A Size (mm) Carton (kg) Part No.
Classifications AWS ER4043 1.2 7.26 ED028437A 0.9 7.26 ED028385A
1.6 7.26 ED028438A 1.0 7.26 ED028386A
0.9 7.26 ED028395A 1.2 7.26 ED028387A
1.2 7.26 ED028397A 1.6 7.26 ED028388A
1.6 7.26 ED028398A

2.4 7.26 ED028399A

8 Aluminium
TIG
Comweld AL1100
Rod analysis limits Recommended shielding gases
N 99.88% pure aluminium alloy rod
Single values are maximum allowable, unless Argon Welding Grade
N Suitable for gas welding and gas tungsten otherwise stated. Alushield® Light
arc-(GTAW /TIG) welding applications
Si: 0.06% Fe: 0.06% Cu: 0.005%
N Embossed with AS /AWS class ‘1100’
Mn: 0.01% Mg: 0.01% Zn: 0.03%
N For the joining of selected high purity
1XXX series aluminium sheets and Ti: 0.01% Others each: Al: 99.88% min
plates used extensively in the electrical 0.01%
and chemical industries
Packaging data
Classifications Rod Size (mm) Weight (kg), Pack type Carton size / kg Approx No. (rods / kg) Part No.
AS / NZS 1167.2: R1188 1.6 x 914 2.5 cardboard 15 30 321600
AWS /ASME-SFA A5.10: R1188
2.4 x 914 2.5 cardboard 15 30 321601
Comweld AL4043
N Aluminium – 5% silicon alloy rod
Single values are maximum allowable, Argon Welding Grade
N Suitable for gas welding and gas tungsten unless otherwise stated Alushield® Light
arc (GTAW /TIG) welding applications
Si: 4.5–6.0% Fe: 0.80% Cu: 0.30%
N Embossed with AS /AWS class ‘4043’
Mn: 0.05% Mg: 0.05% Zn: 0.10%
N For the repair welding (fractures and
blow holes etc.) of selected aluminium Ti: 0.20% Total others: Al: Balance
alloy castings 0.15%
Classifications Packaging data

AS / NZS 1167.2: R4043 Rod Size (mm) Weight (kg), Pack type Carton size / kg Approx No. (rods / kg) Part No.
1.6 x 914 2.5 cardboard 15 210 321610
2.4 x 914 2.5 cardboard 15 90 321611
3.2 x 914 2.5 cardboard 15 51 321612

Aluminium 8
TIG
Comweld AL4047
N Aluminium – 10% silicon alloy rod
N Suitable for gas welding and gas tungsten otherwise stated Alushield® Light
arc (GTAW /TIG) welding applications
Si: 11.0–13.0% Fe: 0.80% Cu: 0.30%
N Embossed with AS /AWS class 4047
Mn: 0.15% Mg: 0.10% Zn: 0.20%
N Used extensively for the brazing of
many types of aluminium alloy sheets, Total others: Al: Balance
extruded shapes and castings 0.15%

AS / NZS 1167.2: R4047 Rod Size (mm) Weight (kg), Pack type Carton size / kg Approx No. (rods / kg) Part No.
1.6 x 914 2.5 cardboard 15 210 321620
AWS /ASME-SFA A5.8: BAlSi-4
1.6 x 914 100 rod Handipack 8 Pks – 322070
2.4 x 914 2.5 cardboard 15 90 321621
3.2 x 914 2.5 cardboard 15 51 321622
Comweld AL5356
N Aluminium – 5% magnesium alloy rod
N Suitable for gas welding and gas tungsten otherwise stated. Alushield® Light
Arc (GTAW /TIG) welding applications
Si: 0.25% Fe: 0.40% Cu: 0.10%
N Embossed with AS /AWS class 5356
Mn: 0.05– Mg: 4.5–5.5% Cr: 0.05–
N Produces intermediate deposit strength 0.20% 0.20%
and good ductility and corrosion
resistance for the welding of a wide Zn: 0.10% Ti: 0.05–0.20%
range of 3XXX, 5XXX, 6XXX and Total others:
5XX aluminium alloys 0.15%
Al: Balance
Classifications
AS / NZS 1167.2: R5356 Packaging data
Rod Size (mm) Weight (kg), Pack type Carton size / kg Approx No. (rods / kg) Part No.
1.6 x 914 2.5 cardboard 15 210 321640
2.4 x 914 2.5 cardboard 15 90 321641
3.2 x 914 2.5 cardboard 15 51 321642

8 Consumables
Copper
Copper and Copper Alloys

Copper is a metal with some very important properties, the Welding
main ones being its high electrical conductivity, its high thermal As has been stated earlier, copper has a very high thermal
conductivity, its excellent resistance to corrosion, and its ease of conductivity and a high coefficient of expansion. These provide the
fabrication, either hot or cold. main problems encountered during welding of unalloyed copper.
Copper is also ductile and malleable and has a relatively low melting High levels of preheat and heat inputs are required for fusion
point at just over 1080°C. welding. These in turn can cause distortion problems. Copper is also
susceptible to hot cracking so heavy restraint needs to be avoided.
The three basic commercial grades of copper that are available are:
The thermal conductivity of many copper alloys is relatively low and
N Tough pitch copper, containing up to 0.1%oxygen
welding without preheat may be possible. However, many alloys will
N Phosphorous deoxidised (PDO) copper, containing up to crack readily when welded if too much heat is put into the weld
0.04%phosphorus area or if welding is carried out under restraint. Any copper alloys
N Oxygen-free copper, containing no deoxidants containing lead should not be welded.
The phosphorus deoxidised grade was originally developed to
Welding Processes
overcome problems encountered when flame welding tough pitch
copper. It is now the standard commercial weldable grade used for Copper and its alloys can be welded, most frequently using inert gas
pressure vessels and radiators. Oxygen-free grades have significantly shielded processes, such as MIG and TIG. MMA is used occasionally
higher electrical conductivity than oxygen-containing grades and are for welding some copper alloys and gas welding and brazing are also
therefore used widely as electrical conductors. used for some applications.
Types
Copper and copper alloys are generally grouped by compositional
type and identified in standards by number or letter/number
designations. However, it has been, and still is, common practice to
refer to copper and copper alloys by their traditional names, such as
brass and bronze, rather than by letters and number designations.
Copper and copper alloys may be divided into groups by general
composition, and each group contains a range of specific alloys.
The main groups considered here are:
N Unalloyed copper
N Beryllium copper
N Brasses
N Bronzes
N Silicon bronzes
N Aluminium bronzes
N Cupro-nickels TIG welding bronze statue

Copper 8
Shielding gases for TIG or MIG welding may be pure argon or If it is essential to weld brass, use of TIG welding, using a silicon
helium-argon mixtures, such as the BOC range of Alushield gases. bronze filler rod, such as AWS A5.7 type ERCuSi-A or
Pure argon tends to produce a narrow penetration profile that is BS 2901-3 type C9, would be the preferred option. Zinc will
not very deep. This means than high levels of preheat are required inevitably be lost from the brass and some weld metal porosity
to avoid fusion defects. Helium-argon mixtures with between 50% will occur, but may be kept to a minimum with care.
and 75% helium increases the energy available to the weld so that Welding of free-machining brass, containing significant amounts of
good weld fusion and penetration can be achieved at minimum lead, should not be attempted since they will almost certainly crack.
preheat temperatures.
Silver Brazing or soldering of brass is a better bet than welding and
High power density processes, like laser and electron beam, are also can be carried out using suitable braze metals and fluxes.
suitable for welding copper and copper alloys.
The Submerged Arc and Flux Cored Wire processes are not used Bronzes
for welding copper or copper alloy systems. Bronzes, such as phosphor bronze and gunmetal, are not normally
welded during manufacture but may require repairs to be carried
Welding copper out from time to time. They are not the easiest materials to weld
and are frequently brazed or soldered rather than welded.
Unalloyed Copper
Phosphor bronzes are likely to suffer hot cracking when welded
Tough pitch copper contains oxygen and welding this type of copper
but reasonable results can be achieved using MIG or TIG welding
can result in weld metal porosity and embrittlement if hydrogen
with copper-tin filler metals, such as AWS A5.7 type ERCuSn-A or
is present. The oxygen and hydrogen combine to form steam and
BS 2901-3 type C10. Moderate preheat is normally required, and
‘steam porosity’ is likely to occur if these types of copper are
high restraint should be avoided.
welded with the oxy-acetylene process. Oxygen-free and PDO
grades of copper have better weldability than tough pitch copper. Gunmetal too may be welded similarly with care (provided it does
not contain lead) but hot cracking is a distinct possibility.
The usual welding processes for copper are MIG and TIG. Filler
metals, such as AWS A5.7 type ERCu or BS 2901-3 type C1A, with ‘Leaded’ phosphor bronzes and gunmetals are generally considered
additions of de-oxidants, should be used to control porosity. to be unweldable and hot cracking is virtually certain to result if
attempts are made to weld these materials.
With all coppers the main problem is that heat is rapidly dissipated
from the weld and this can lead to fusion defects if enough heat is Bell metal is very difficult to weld because it is hard and brittle
not put into the joint area. Preheat is, therefore, recommended for and prone to hot cracking. However, cracked church bells have
thicknesses above 5mm. Preheat levels range from about 200°C at been successfully repair-welded using gas welding and TIG welding
5mm to 600°C and above at 20mm. Highest preheats are required with strips of matching bell metal composition as filler metal.
when welding with argon shielding gas but may be lowered or High preheat, continuous heating throughout the welding process,
avoided if helium or helium gas mixtures are used, due to the and very slow cooling after welding are essential measures to be
increase in heat input these gases provide. adopted to prevent cracking.
Beryllium Copper Aluminium Bronzes

Welding of beryllium copper is not carried out extensively but when Aluminium bronzes are generally weldable and usually without
it is the preferred processes are MIG and TIG. Filler metals used to preheat since the thermal conductivity of aluminium bronze is
weld unalloyed coppers are used for copper beryllium alloys since relatively low. Welding with MMA electrodes is possible but MIG
filler metals containing beryllium are not available. and TIG are the preferred welding processes. When TIG welding
with argon shielding gas the use of AC current is necessary to
However, welding can present a few problems. Cracking in the
break down the tenacious aluminium oxide film, but DC electrode
HAZ, due to the presence of age-hardening precipitates, may occur
negative may be used with helium-rich shielding gas.
if insufficient preheat is applied. Also, beryllium will oxidise rapidly
and be given off as fume if the arc region is not properly protected Matching aluminium bronze filler metals are generally used when
with inert shielding gas and the main problem here is that fume welding these alloys, and include fillers such as AWS A5.7 types
containing beryllium oxide is highly toxic and can cause death. ERCuAl-A2 and ERCuAl-A3, or BS 2901-3 types C12Fe and C13.
Welding of copper alloys containing beryllium must be carried Porosity is likely to be a problem in multi-pass welds if correct
out with care and use of fume extraction equipment and personal cleaning procedures are not adopted, and high restraint may
respiratory protection is essential. induce cracking.
Brasses Silicon Bronzes

Brasses are not readily weldable since the application of a welding Silicon bronzes are reasonably weldable and again preheat is
arc causes the zinc to boil off as zinc oxide fume. Zinc oxide may be generally not required. MMA electrodes are available but the
identified during welding as dense white fumes rising from the brass, preferred welding processes are MIG and TIG. Silicon bronze
impairing the welder’s visibility, and they also leave white ‘cobwebs’ filler metals with about 3% silicon are used and fillers of this type
on equipment and surrounding attachments, as further evidence. conform to specifications such as AWS A5.7 types ERCuSi-A or
Zinc oxide will cause zinc fume fever if inhaled in sufficient quantity. BS 2901-3 types C9.
Loss of zinc from the vicinity of the weld can affect the properties
of the material and also causes porosity in the weld metal.

8 Copper
Although an oxide film is likely to form on the weld, it is still

standard practice to used DC electrode negative when TIG welding
with either argon shielding gas or with a helium-argon mixture.
Hot cracking is a potential problem with silicon bronzes and so
excessive heating and high restraint should be avoided.
Cupro-nickels
Cupro-nickel alloys are readily weldable and may be welded using
MMA, MIG, or TIG welding processes, generally without preheat.
High quality welds can be obtained with all these welding processes.
Electrodes and filler metals conforming to 70/30 copper-nickel are
readily available. These conform to specifications such as AWS A5.7
types ECuNi (MMA) and ERCuNi (MIG and TIG) or BS 2901-3 type
C18. Filler metal conforming to 90/10 copper-nickel is listed in BS
2901-3 as type C16. Fillers for cupro-nickels usually include titanium
as deoxidant, to prevent the formation of porosity.
Argon or Alushield shielding gases are generally preferred for
MIG and TIG welding, the latter often being carried out using DC
electrode negative. Specialist shielding gases such as Specshield
11% He/ 2% H2 are used to reduce the incidence of surface oxides
which can form on these materials especially when multi-pass
TIG welding.
Contaminants such as sulphur, phosphorus, and lead are detrimental
to cupro-nickels and are likely to cause cracking. Thorough cleaning
of these alloys before welding is required.

Copper 8
MMA Electrodes
Bronzecraft AC-DC
N Phosphor bronze electrode containing
7% tin 0.2% Proof stress 315 MPa Mn Sn Al P Fe Cu
N For welding copper and copper alloys Tensile strength 460 MPa 0.02 7.50 0.008 0.26 0.20 Bal
N Also for joining copper and copper Elongation 22%

alloys to-steel Hardness 120 HV30
N Easy to use, high quality weld deposit
appearance Packaging and operating data AC (minimum 45 OCV) DC- polarity
Electrode Approx no.
Classifications Current
Size (mm) Length (mm) rods / kg range (A) Packet (kg) Carton (kg) Part No.
AS / NZS 2576: E 6200 – A2
AWS /ASME-SFA A5.6: E CuSn – C 3.2 350 30 70–110 2.5 15 (6 x 2.5) 611783

8 Copper
GMAW Wire
Autocraft Deoxised Typical all weld metal mechanical properties Typical wire analysis (%) limits
Copper Welding grade Argon Mn Si P Sn Cu Others
N A high copper alloy for GMA joining 0.2% Proof stress 55 MPa 0.5 0.5 0.15 1.0 >98.0 0.50
and overlay applications Tensile strength 200 MPa Single values are maximum allowable, unless
otherwise-stated.
N Fabricating deoxidised copper and Elongation (in 2 30%
electrolytic pitch copper components inches)
N Repair of copper castings Electrical conductivity 40% IACS
Alushield® Light
N Lower strength welding of galvanised Hardness 55 HB
Alushield® Heavy
steels and deoxidised copper to mild
Weld metal density 7.47 x 103 / m3 Welding Grade Argon
steel joints
N Typical applications include the
GMA welding of copper transformer Packaging and operating data
connectors, copper bus bars, billet
moulds and heater elements etc. Wire feed Current Pack weight
Dia. (mm) Voltage (V) speed (m / min) range (A) Pack type* (kg) Part No.
Classifications 1.6 28–32 5.5–11.5 160–380 Spool 13.6 720260
AWS /ASME-SFA A5.7: ERCu
Autocraft Silicon
Typical all weld metal mechanical properties Recommended shielding gas
Bronze Welding grade Argon Welding Grade Argon
N A copper based wire for the GMA Argoshield® 100
welding of copper-silicon alloys including
Argoshield® Universal
cusilman and everdur Tensile strength 380 MPa
Argoshield® 52
N Used for the lower strength welding Elongation 50% Stainshield®
of-steels (in 2 inches)
N Extensively used for the GMA welding
of-copper-silicon alloys used in hot Typical wire analysis (%)
water systems, heat exchangers, Fe Mn Si Sn Zn Cu
calorifiers and marine components
for their corrosion resistance 0.25 1.0 3.40 0.90 0.90 Bal
Classifications Packaging and operating data

AWS /ASME-SFA A5.7: ERCuSi–A Wire feed
Dia. (mm) Voltage (V) (m / min) range (A) Pack type* (kg) Part No.
0.8 15–20 4.5–10.5 65–150 Handi Spool 4.5 720159
0.9 21–26 7.5–14.5 100–250 Spool 13 720015
1.2 22–28 5.5–11.5 160–380 Spool 13 720255

Consumables 8
Cast Iron
Malleable Cast Iron

Welding of Cast Iron Malleable cast iron is produced by heat treating white cast iron
Cast irons, like steels, are essentially alloys of iron and carbon, but of a suitable composition. As pointed out earlier, iron carbide can
whereas the carbon content of steel is limited to a maximum of decompose into iron and carbon under certain conditions. This
2%, cast irons generally contain more than 2% carbon. reaction is favoured by high temperatures, slow cooling rates and
In order to facilitate a better understanding of these materials, high carbon and silicon contents
they can be divided into five groups, based on composition and
Ferritic Malleable Cast Iron
metallurgical structure: white cast iron, malleable cast iron, grey
cast iron, ductile cast iron and alloy cast iron At room temperature the microstructure therefore consists of
temper carbon nodules in a ferrite matrix, generally known as
White Cast Iron ferritic malleable cast iron. The compact nodules of temper carbon
White cast iron derives its name from the white, crystalline crack do not break up the continuity of the tough ferritic matrix, resulting
surface observed when a casting fractures. Most white cast irons in high strength and improved ductility. The graphite nodules also
contain <4.3% carbon, with low silicon contents to inhibit the serve to lubricate cutting tools, which accounts for the very high
precipitation of carbon as graphite machinability of malleable cast iron.
It is used in applications where abrasion resistance is important

and ductility not required, such as liners for cement mixers, ball
mills, certain types of drawing dies and extrusion nozzles.
Microstructure of ferritic malleable cast iron (x200)
Ferritic malleable cast iron has been widely used for automotive,
agricultural and railroad equipment; expansion joints and railing
Microstructure white Cast Iron (x200) castings on bridges; chain-hoist assemblies; industrial casters; pipe
fittings; and many applications in general hardware.
White cast iron is generally considered unweldable. The absence
of any ductility that can accommodate welding-induced stresses in Pearlitic Malleable Cast Iron
the base metal and heat-affected zone adjacent to the weld results If full graphitisation is prevented and a controlled amount of carbon
in cracking during cooling after welding. remains in the iron during cooling, finely distributed iron carbide
plates nucleate in the iron at lower temperatures. This can be
achieved by alloying with manganese, or by replacing the second-
stage anneal by a quench (usually in air or oil).

8 Cast Iron
addition of small amounts of magnesium or cerium to the ladle

just before casting. The spherical graphite particles do not disrupt
the continuity of the matrix to the same extent as graphite flakes,
resulting in higher strength and toughness compared with grey
cast iron of similar composition
Microstructure of pearlitic malleable cast iron (x200)
Due to the presence of iron carbide in the microstructure, the

strength and hardness of these castings are increased over those
of ferritic malleable cast iron.
Grey Cast Iron

Microstructure of SG cast iron with bulls eye ferrite (x200)
Grey cast iron is one of the most widely used casting alloys and
typically contains between 2,5% and 4% carbon, and 1% and 3% Typical applications are agricultural (tractor and implement parts);
silicon. With proper control of the carbon and silicon contents and automotive and diesel (crankshafts, pistons and cylinder heads);
the cooling rate, the formation of iron carbide during solidification electrical fittings, switch boxes, motor frames and circuit breaker
is suppressed entirely, and graphite precipitates directly from the parts; mining (hoist drums, drive pulleys, flywheels and elevator
melt as irregular, generally elongated and curved plates in an iron buckets); steel mill (work rolls, furnace doors, table rolls and
matrix saturated with carbon. bearings); tool and die (wrenches, levers, clamp frames, chuck bodies
and dies for shaping steel, aluminium, brass, bronze and titanium).
When a grey iron casting fractures, the crack path follows these
graphite flakes and the fracture surface appears grey because of
Mechanical Properties
the presence of exposed graphite.
Due to the low toughness and ductility of cast iron (especially
white and grey cast iron), standard tensile and impact toughness
tests have limited applicability, and elongation and absorbed energy
values are not always available. Some of the mechanical properties
of the different types of cast iron are shown in the table below. The
wide variation in mechanical properties within a particular class
of cast iron, as shown below, can be attributed to a variation in
microstructure.
The machinability of grey, malleable and ductile cast irons is superior
to that of carbon steel, and these alloys even outperform free-
cutting steel. The excellent machinability can be attributed to the
lubricating effect of the graphite particles in the microstructure.
Grey cast iron has a very high damping capacity (ability to quell
Microstructure of grey cast iron (x200) vibrations), and is therefore well suited for bases and supports, as
well as for moving parts.
The strength of grey cast iron depends almost entirely on
the matrix in which these graphite flakes are embedded. Slow Welding
cooling rates and high carbon and silicon contents promote full Cast irons include a large family of ferrous alloys covering a wide
graphitisation, and the majority of the carbon dissolved in the iron range of chemical compositions and metallurgical microstructures.
at high temperatures is deposited as graphite on the existing flakes Some of these materials are readily weldable, while others
during cooling. The structure then consists of graphite flakes in a require great care to produce sound welds. Certain cast irons are
ferrite matrix, referred to as ferritic grey cast iron. considered unweldable.
If graphitisation of the carbon dissolved in the iron at high A major factor contributing to the difficulty of welding cast iron
temperatures is prevented during cooling, iron carbide precipitates is its lack of ductility. If cast irons are loaded beyond their yield
out and the matrix is pearlitic (referred to as pearlitic grey cast points, they break rather than deform to any significant extent. Weld
iron). Ferritic grey cast iron is normally soft and weak. filler metal and part configuration should therefore be selected to
minimise welding stresses.
Ductile Iron
Ductile cast iron, also known as nodular iron or spheroidal graphite MMA, Flux Cored Arc, MIG, TIG and Gas Welding welding processes
(SG) iron, is very similar in composition to grey cast iron, but the are normally used with nickel-based welding consumables to
free graphite in these alloys precipitate from the melt as spherical produce high-quality welds, but cast iron and steel electrodes can
particles, rather than flakes. This is accomplished through the also produce satisfactory welds in certain alloys.

Cast Iron 8
Iron castings are generally welded to: Grey Cast Iron

N repair defects in order to salvage or upgrade a casting As grey cast iron contains graphite in flake form, carbon can readily
before service, be introduced into the weld pool, causing weld metal embrittlement.
N repair damaged or worn castings, and Consequently, techniques that minimise base metal dilution are
recommended. Care must be taken to compensate for shrinkage
N fabricate castings into welded assemblies. stresses, and the use of low strength filler metals helps reduce
Repair of defects in new iron castings represents the largest single cracking without sacrificing overall joint strength.
application of welding cast irons. Defects such as porosity, sand Grey cast iron welds are susceptible to the formation of porosity.
inclusions, cold shuts, washouts and shifts are commonly repaired. This can be controlled by lowering the amount of dilution with the
Fabrication errors, such as inaccurate machining and misaligned base metal, or by slowing the cooling rate so that gas has time to
holes, can also be weld repaired. escape. Preheat helps reduce porosity and reduces the cracking
Due to the widely differing weldability of the various classes of tendency. A minimum preheat of 200°C is recommended, but
cast iron, welding procedures must be suited to the type of cast 315°C is generally used.
iron to be welded. The most common arc welding electrodes for grey cast iron are
nickel and nickel-iron types. These electrodes have been used with
White Cast Iron
or without preheating and / or postweld heat treatment. Cast iron
Because of its extreme hardness and brittleness, white cast iron and steel electrodes must be used with high preheats (550°C) to
is considered unweldable. prevent cracking and the formation of hard deposits.
Malleable Cast Iron Ductile Cast Iron

During welding, the ductility of the heat-affected zone (HAZ) of Ductile cast irons are generally more weldable than grey cast irons,
malleable cast iron is severely reduced because graphite dissolves but require specialised welding procedures and filler materials.
and precipitates as iron carbide. Although postweld annealing Pearlitic ductile iron produces a larger amount of martensite in
softens the hardened zone, minimal ductility is regained. Despite the HAZ than ferritic ductile iron and is generally more susceptible
these limitations, malleable cast irons can be welded satisfactorily to cracking.
and economically if precautions are taken.
MMA using nickel-iron electrodes is the most common welding
Because most malleable iron castings are small, preheating is seldom technique for welding ductile iron. Most castings do not require
required. If desired, small welded parts can be stress relieved at preheating, but preheats of up to 315°C are used on large
temperatures up to 550°C. For heavy sections and highly restrained components.
joints, preheating at temperatures up to 200°C and a postweld
Electrodes should be dried to minimise hydrogen damage and
malleabilising heat treatment are recommended. However, this
porosity. If machinability or optimum joint properties are desired,
costly practice is not always followed, especially when the design
castings should be annealed immediately after welding.
of the component is based on reduced strength properties of the
welded joint.
Ferritic malleable grades display the best weldability of the malleable
cast irons, even though impact strength is reduced by welding.
Pearlitic malleable irons, because of their higher combined carbon
content, have lower impact strength and higher crack susceptibility
when welded. If a repaired area must be machined, welding should
be performed with a nickel-based electrode.
MMA welding cast iron using low-carbon steel and low-hydrogen
electrodes at low currents produces satisfactory welds in malleable
iron. If low-carbon steel electrodes are used, the part should be
annealed to reduce the hardness in the weld (due to carbon pick-
up) and in the HAZ.
Table of mechanical properties of a range of cast irons
Tensile strength Compressive strength

Cast iron ( MPa) ( MPa) Hardness (HB) Elongation (%) Toughness (J)
White 200–410 Not available 321–500 Very low Very low
Malleable 276–724 1350–3600 110–156 (ferritic) 1–10% 4–12 J @ 20°C
(pearlitic and martensitic) 149–321 (pearlitic and martensitic)
Grey 152–431 572–1293 156–302 <0.6% Very low
Ductile 345–827 359–920 143–302 2–20% 16–27 J @ 20°C

8 Cast Iron
Typical applications for the filler metal If localised degassing is preferred, the weld area can be heated by
types used for welding cast iron depositing a weld pass, which usually becomes very porous and
then removing it by grinding. This welding and grinding operation
Filler Type Typical Application is repeated until the weld metal is sound. The weld may then be
completed as specified in the welding procedure. Castings that have
Cast Iron Oxy-acetylene and arc welding of grey, ductile been impregnated with a plastic or glass sealer should not be repair
and blackheart malleable irons where good colour
welded, because the sealer may inhibit fusion or produce excessive
match is required. Different consumables give either
a flake or a nodular graphite structure. porosity in the weld.
Ni Joining and repair of grey irons and for surfacing high It is also important that the outer surface of the casting and any
dilution welds in stronger grades. Produces ground surfaces be wiped with mineral spirits, such as acetone, to
a soft peenable deposit. Special electrode coverings remove residual surface graphite prior to welding. Residual graphite
are available to help repair deep inhibits wetting and prevents complete joining and fusion. When
cavities and blow holes. wetting difficulties are encountered, the following cleaning methods
NiFe Joining and repair of ductile, blackheart malleable and can be used:
higher strength grey irons. Also used to join cast iron N Electrochemical cleaning in a molten salt bath operating at
to dissimilar metals and for welding austenitic irons. temperatures of 455–510°C in a steel tank. By passing direct
Can also be used on irons with high sulphur and
current through the bath, a surface essentially free of graphite,
phosphorus levels.
sand, silicon, oxides and other contaminants can be produced.
NiFeMn Similar applications to NiFe fillers, but a stronger
more crack resistant deposit is produced. N Abrasive blasting with steel shot is suitable for preparing the
surfaces of ductile and malleable cast iron, but should not be
NiCu Used when a soft peenable deposit with good colour used for grey cast iron.
match is required on grey, nodular and blackheart
malleable irons. Also useful for welding castings of N Searing the surfaces to be welded with an oxidising flame or
unknown type and composition. heating the casting to about 900°C in a strongly decarburising
CuSn Mostly used for its good sliding and anti-seizing
atmosphere may be suitable in some applications.
properties i.e. for surfacing applications, particularly Before any cleaning procedure is used in production, wetting tests
on grey irons. should be conducted using the proposed filler metal and welding
CuAl Similar applications to CuSn but with poorer surfacing procedure. The filler metal should be applied to a clean, flat surface
properties, but higher strength. and then examined visually. If the surface is not uniformly wetted, it
CuMnNiAl Similar application to CuAl fillers, but used where
has not been cleaned sufficiently.
higher strength is required.
Special welding techniques for cast irons
Improved weld performance can be achieved by application of
Practical Considerations
several special techniques. These include
Base Metal Preparation N Joint design modifications
Proper preparation of a casting prior to welding is very important. N Groove face grooving
All traces of the defect must be removed from the casting, usually
N Studding
by chipping, grinding, arc gouging or flame gouging. Dye-penetrant
inspection is recommended to ensure complete removal of all N Peening
defects. Thorough cleaning of the joint faces and adjacent material N Special deposition sequences and electrode manipulation
prior to welding is essential for ensuring successful repair welding
and for preventing porosity and wetting difficulties. Joint design modification
Castings that have been in service are often saturated with oil or Full penetration welds are better than partial penetration ones,
grease. Exposure to high temperatures during the weld thermal since the crevice left unfused can act as a stress concentration,
cycle can cause dissociation of these hydrocarbon compounds, increasing the risk of cracking. It is therefore advisable, where
resulting in the formation of porosity in the weld. For this reason possible, to modify joint design to allow full penetration weld to
any surface oil or grease must be removed prior to welding using be made, as shown below. Welds at changes in thickness can suffer
solvents or steam cleaning. The surface skin of the casting, that may uneven expansion and contraction stresses during the welding cycle,
contain burned-in sand or other impurities from the mould, should and also are located at stress concentrations. A change in design
also be removed. Castings that have been in service for extended to move the weld to a region of constant thickness is therefore
periods of time may also require degassing by heating the casting beneficial in some cases since the weld is then removed from the
uniformly to about 370°C for 30 minutes, or for a shorter time to ‘danger area’. A backing fillet weld can also be used to support a
almost red heat (approximately 540°C), using an oxy-fuel gas torch weld in a region of stress concentration.
or circulating air furnace.

Cast Iron 8
Poor Design Improved Design Stagged Studs (top view)
Partial penetration welds Full penetration welds
50 mm
Uneven thickness Constant thickness
Stagged Studs (cross section)

Without backing fillet weld With backing fillet weld
Screwing or driving staggered studs into the joint face before welding to improve
joint strength
Modifications to joint design that would lead to the minimisation of stress
concentrations and so reduce the risk of cracking in cast iron welds Peening
By hammering (peening) a deformable weld bead, thereby putting
Groove face grooving it into a state of compressive stress, the tensile stresses caused
Grinding or gouging grooves into the surface of the prepared weld by thermal contraction can be opposed, thereby reducing the risk
groove, then filling the grooves with a weld bead, before filling the of cracking in and around the weld. This requires a ductile weld
whole joint, as shown below, is sometimes recommended. This metal. Nickel fillers are very suitable, and when welding brittle grey
reduces the risk of cracking by deflecting the path of a crack. Also, cast irons this process is extremely useful. When stronger joints
as with conventional buttering, the beads that are in contact with are required and iron-nickel consumables are used, then peening
the casting, and therefore most highly diluted, are deposited first, must be done at higher temperatures, while the metal is still
when the stresses on the fusion line and heat affected zone of the sufficiently soft. Peening can be mechanised as well as done manually.
weld are lowest. For manual work a 13–19 mm ballpeen hammer is used to strike
moderate blows perpendicular to the weld surface. Mechanised
hammers should operate at 620 kPa, and at 750–1000 mm / min.
Gooving Joint face
The hammer head should be no wider than the weld bead and
should have a radius equal to half the width.
Deposition techniques and electrode manipulation

Arc welding
Stringer or weave techniques can be used in depositing the weld
bead, though weaving should be kept to within three times the
electrode core diameter. Minimum dilution will result from using the
stringer technique in the flat position, with the arc directed at the
weld pool rather than the base metal. When re-striking the arc, this
should be done on deposited metal, rather than base metal, though
any slag must first be removed. This can be done with a cold chisel
The technique of grooving the joint face before filling.This interrupts the line of the
heat affected zone or chipping hammer.
In long welds, or welds on thick base material, depositing short,
Studding staggered beads will help minimise distortion, by balancing
Improved joint strength can be achieved by driving or threading contraction stresses. Buttering of thick joint faces before filling in
studs into the joint face. These should be staggered as shown below, the rest of the joint is recommended. This is particularly effective if
so that a stud does not face another directly opposite it across the the buttering layers are of a composition more tolerant to dilution
joint. Provided the studs are of material compatible with the filler by the base metal.
metal this technique can help reduce underbead cracking in the To minimise penetration, short circuit dip-transfer modes should
HAZ or along the fusion line. be used with MIG, MAG and flux-cored welding processes, and arc

8 Cast Iron
lengths in MMA welding should be kept as short as possible whilst Braze welding
still maintaining good weld shape. In general, the welding current Since this process is particularly sensitive to the wetting of the base
should be kept as low as possible within the range specified by the metal surface by the filler, cleanliness of the iron before welding
consumable manufacturer. is essential. This means that smeared graphite on the surface after
grinding must be removed. The bronze welding rod is melted by
Oxy-acetylene welding contact with the base metal after preheating by the gas flame to
When depositing cast iron by the gas welding process the torch 425–480°C. The slightly oxidising inner cone of the flame should not
flame should not be oxidising, as the resulting loss of silicon be brought into contact with the consumable rod or the base metal.
promotes the formation of brittle white iron in the deposit. The rounded edges recommended for the joint faces in bronze
Similarly, the tip of the inner cone of the flame should be kept welding increase the interface area between the casting and the
between 3–6 mm from the casting surface, and should not actually deposited metal.
touch. The welding rod should be melted by immersion into the
molten weld pool, and not melted directly by the torch flame. Cracking
Two types of sequence are recommended for depositing cast iron All cast irons have a common problem affecting their weldability,
by gas welding. With the so-called ‘block’ sequence, filler metal can namely their high carbon contents. Welding of cast iron is associated
either be deposited in blocks of ~2.5cm, before filling between with rapid cooling of the weld pool and adjacent base metal,
the blocks. With the so-called ‘cascade’ sequence, thin layers are compared with the slower cooling rates experienced during casting,
deposited, with each one being slightly longer than the preceding and tends to produce undesirable microstructures, such as iron
one. Both the block and cascade sequences are illustrated below. carbide and high-carbon martensite. Martensite and iron carbide
are both very brittle and may cause cracking, either spontaneous or
Block sequence of bead deposition during service. The degree of embrittlement depends on the amount
of iron carbide and martensite formed, which in turn depends on
the cast iron composition and thermal treatment. The presence
of hard, brittle martensite in the HAZ also increases the risk of
hydrogen-induced cracking.
Martensite in the HAZ may be tempered to a lower strength or
a more ductile structure during post weld heat treatment, or it
may be totally eliminated by ensuring very slow cooling rates after
welding. Multiple-pass welding and minimum preheat and interpass
temperatures are commonly specified to retard the cooling of
cast iron welds and to prevent the transformation to martensite.
Cascade sequence of bead deposition
Alternatively, welding procedures designed to reduce the size of
the HAZ and thus minimise cracking can be used. Methods of
accomplishing this include:
N reduction of heat input,
N use of small-diameter electrodes,
N use of low melting point welding rods and wires, and
N use of lower preheat temperatures.
Cast Irons
Type MMAW FCAW Gas Welding Gas Brazing

Grey Cast Iron BOC Smootharc C Cast NiFe Nicor 55 Super Silicon Profill Mang Bronze
BOC Smootharc C Cast Ni Profill Nickel Bronze
Profill Nickel Coat
SG and Nodular Cast Iron BOC Smootharc C Cast NiFe Nicor 55 Super Silicon Profill Mang Bronze
White Cast Iron (Chilled Iron) NR NR NR NR
Malleable Cast Iron BOC Smootharc C Cast NiFe Nicor 55 Super Silicon Profill Mang Bronze
NOTES
(1) Use BOC Smootharc C Cast NiFe for joining, build up and crack repairs.
(2) Use BOC Smootharc C Cast Ni for cosmetic repairs.
NR = Not Recommended

Cast Iron 8
MMA Electrodes
Coating type Special

™
Smootharc C Cast Ni Welding current DC+, AC
Classifications
AWS A5.15-90, E Ni-C1
DIN 8573-83E Ni-BG 1
Applications
Typical all weld metal properties
BOC Smootharc™ C Cast Ni is a pure nickel electrode for general
purpose welding of all types of cast iron. It is suitable for the joining Chemical composition, wt%
and repair of grey and malleable cast irons and dissimilar joints C Fe Ni
between these and steel, monel and stainless steels. Grey and
0.5 1.0 Bal
malleable cast irons, machine bases, engine blocks and gear housings.
Preparation Mechanical properties

The electrode will tolerate dirty and contaminated surfaces. Tensile strength 250–300 MPa
No preheat is required for small castings and thin sections up to
Hardness 140–160 HV 40
15 mm. Above this, preheat up to about 150º is recommended.
Joint surfaces should be prepared by gouging. Select smallest
diameter electrode practical, deposit short thin stepped layers and
lightly ball peen the weld beads during welding to reduce shrinkage Welding parameters Packing
strains. Avoid arc striking on the base metal. On completion, allow Dia. (mm) Current (A) kg / pack Part No.
the work piece to cool slowly. The deposit
2.5 60–80 3.0 189002
is soft and fully machinable.
3.2 70–110 3.0 189003
Welding positions
Coating type Special
Smootharc™ C Cast NiFe Welding current DC+, AC
Classifications
AWS A5.15-90, E NiFe-C1, DIN 8573-83 E NiFe-1-BG 1
Applications Typical all weld metal properties

™
BOC Smootharc C Cast NiFe is designed to produce a higher Chemical composition, wt%
matching strength weld metal for joining malleable, nodular and C Fe Ni
S.G. irons. It is also suitable for joining these to mild, low alloy and
stainless steels. Smootharc™ C Cast NiFe is less sensitive to hot 1.3 42 55
cracking sometimes caused by impurities in castings, compared to
pure nickel type electrodes. Spheroidal graphite, nodular and ductile Mechanical properties
cast irons, eg machine bases, transmission housings, gearboxes,
engine blocks and pump bodies.
Hardness 170–200 HV
Preparation
Thin sections may require preheat of approx. 150–300ºC. When Packing and welding data
welding without preheat, use low heat input method. Lightly ball Welding parameters Packing
peen weld beads during welding of thicker sections. On completion
allow the work-piece to cool slowly. The deposit Dia. (mm) Current (A) kg / pack Part No.
is fully machinable. 3.2 70–110 3.0 189103
Welding positions

8 Cast Iron
MMA Electrodes
Castcraft 55
N Maintenance welding of S.G. cast irons
Tensile strength 500 MPa C Mn Si
N Higher strength nickel / iron deposit 0.95% 0.65% 0.25%
Hardness 220 HV30
N Easy starting and stable running on Al Ni Fe Bal
portable 240V welding machines 0.25% 53%
Core wire
N Applications include the higher strength
repair and maintenance welding Nickel Iron (55% Ni, 45% Fe)
of spheroidal graphite (S.G.) irons,
austenitic cast irons, meehanites and Packaging and operating data AC (minimum 45 OCV) DC- polarity
a wide range of grey cast-irons
Electrode
Approx no. Current Packet Carton
Classifications Size (mm) Length (mm) rods / kg range (A) (kg) (kg) Part No.
AWS /ASME-SFA A5.15: ENiFe-CI 2.5 300 49 35–85 2.5 15–6 x 2.5 611722
3.2 350 31 75–120 2.5 15–6 x 2.5 611723
Castcraft 100
Maintenance welding of cast irons
Soft, ductile and machinable nickel deposit Tensile strength 400 MPa C Mn Fe
1.0% 0.05% 0.5%
Easy starting and stable running on portable Hardness 170 HV30
240V welding machines Si Al Ni Bal
Smoother weld deposit surface finish 0.1% 0.2%
Applications include the repair and reclamation
of engine blocks, cylinder heads, differential
housings, gear boxes, pump and machine Packaging and operating data AC (minimum 45 OCV) DC- polarity
housings and cast iron pulleys etc. Electrode
Approx No. Current Packet Easyweld
Classifications Size (mm) Length (mm) (rods / kg) range (A) (kg) Carton (kg) Handipack Part No.
AWS /ASME-SFA A5.15: ENi-CI 2.5 300 49 55–85 2.5 15 (6 x 2.5) 611732
20 rods 322110
Core wire 3.2 350 31 75–120 2.5 15 (6 x 2.5) 611733
Nickel (98% Ni) 15 rods 322111
Easyweld Blister Pack
10 x 2.5 mm / 5 x 3.2 mm rod Castcraft 100 Blister Pack 322217
FCAW Wire
Nicore® 55 Typical all weld metal mechanical properties Recommended shielding gases
– using Stainshield®
Composite nickel-iron flux cored wire Argoshield® 40
for the joining and repair of cast irons. Tensile strength 500 MPa
Also recommended for the dissimilar Elongation 12%
joining of cast iron to steels
Hardness 200 HV
Classifications
Meets AWS /ASME-SFA A5.15: ENiFe-CI Packing and operating data
(equivalent electrode classification) Electrode
Current Range Voltage stickout
Typical all weld metal analysis (%) – Dia. (mm) (A) range (V) ESO (mm) Pack type Pack (kg) Part No.
using Stainshield® 1.2 220–250 27–29 13 Handispool 4.5 724046
C Mn Si Nicore 55 is a registered trademark of The Esab Group, Inc Hanover, PA 17331, USA.
1.10% 0.40% 0.45%
Fe Balance Ni
50.0%

Cast Iron 8
MMA Electrodes
Softweld
For welding cast iron when weld must be
machined. Electrode is 96% nickel with
low penetration.
Classifications AWS A5.15 ENi-CI

3.2 0.45 ED025116

8 Consumables
Gouge
The arc air gouging process uses the heat generated by an arc struck The main feature of the process is a forceful, piercing arc capable of
between the electrode and the workpiece to melt metal and a high making deep grooves and cuts.
velocity jet of air to force the melted metal away. Conventional The process may be used for cutting and removing weld metal in a
welding power sources are suitable for the process. Electrode wide range of ferrous and non-ferrous alloys although its main use is
holders are designed to provide both the current and the air jet. for cutting carbon and alloy steels.
The electrodes used are made of carbon covered by a layer The main safety issues with the process are electrical, high levels of
of copper. The supply of air is generally provided from a shop noise, ejection of hot metal, and fume generation.
compressor.

Gouge 8
Arc Air Gouging
Description Dia. (mm) Length (mm) Pack size Part No.

Carbon DC 4 305 100 40G
BOC Gouging Carbons Carbon DC 5 305 100 50G

Carbon DC 6.5 305 50 65G
Carbon DC 8 305 50 80G
Carbon DC 9.5 305 50 95G
The BOC Carbons have been produced for both effective and Carbon DC 11 305 50 110G
efficient metal removal by the arc-air gouging process.
Carbon AC 4 305 100 40AG
They are manufactured for high quality gouging with:
Carbon AC 5 305 100 50AG
N First grade quality carbon / graphite mixture
Carbon AC 6.5 305 50 65AG
N Premium copper coating to ensure consistent levels of
Carbon AC 9.5 305 50 95AG
conductivity and-resistivity
Carbon Jointed 8 355 50 80J
N Densely compacted carbon
Carbon Jointed 9.5 355 50 95J
N Copper coating ensures consistent conductivity, resistivity
and arc stability Carbon Jointed 11 355 50 110J
N Compacted quality carbon / graphite ensures fast and Carbon Jointed 16 432 25 160JL
efficient metal removal Carbon Jointed 19 432 25 190JL
Applications Carbon DC Flat 10 x 5 50 0510S
N Removes metal from a wide range of commonly found metals, Carbon DC Flat 15 x 5 50 0515S
both ferrous and non-ferrous
N Pointed carbons are the most popular general purpose for
most applications of metal removal
N Jointed carbons have a male and female socket design allowing
either semi or completely automated metal removal
N Flat carbons are used when finer detail is required, including
scarfing and special joint preparation
N Coating type: premium copper coating

8 Consumables
Gas Welding,
Brazing and
Soldering
Fundamentals of Gas Welding and Brazing
Welding Technique Fluxing
Successful welding depends on the following factors: The choice of the correct flux is just as important as the choice of
1 Selection of correct consumables filler material. There are three desirable properties of a flux:
2 Selection of the correct flame setting 1 The flux must melt and become active below the melting
point of the brazing alloy. Borax or borax based fluxes are not
3 Selection of the correct application techniques sufficiently molten at the low temperatures at which silver
a Correct angle of rod to work brazing alloys are used. A low temperature fluoride based flux
b Correct travel speed such as Easyflo needs to be employed.
4 Selection of the welding preparation 2 The flux must be capable of removing the oxides found on
(For Gas Welding Application Techniques refer to Welding Process the parent materials. Easyflo flux will remove the oxides found
section on page XX). on most of the common engineering materials such as mild
steel, brass and copper. Special fluxes may be required on
certain types of highly alloyed steel and tungsten carbide tool
Silver Brazing tips. It is also necessary to use a specially formulated flux on
aluminium bronze or aluminium brasses containing more than
Choice of Filler Metal 2% aluminium.
Listed on page 458 are details of BOC ProSilver brazing alloys 3 The flux must remain active at the brazing temperature for
commonly used in all general purpose joining operations. long enough to allow the brazing operation to be carried out.
An alloy is normally selected for its melting and flow characteristics. Fluxes are chemical compounds which dissolve oxides formed in
heating. Like most chemical compounds a flux eventually reaches
The easiest to use filler materials are the high silver, free flowing
the point where it is saturated and becomes unable to dissolve
alloys, because of their low melting temperatures and narrow
any more oxide. If the flux residues appear blackened and glassy,
melting ranges. The higher the brazing temperature and the
the flux has very likely been exhausted during heating, and a flux
wider the melting range of the alloy the more difficult the brazing
with higher time / temperature stability should be used.
operation will be.
For most engineering requirements there are two fluxes which will
Pre-Cleaning take care of most needs. These are Easyflo flux paste and Tenacity
It is important that the mating surfaces of the components to be No. 4A flux paste.
brazed are fee from oil, grease and any surface oxide layer prior to
Easyflo Flux
joining. Most engineering components require nothing more than
degreasing before assembly. This is the accepted general-purpose flux for use with all low-
temperature silver brazing alloys with brazing temperatures
Oxide removal can be accomplished either chemically or
not exceeding 800°C. It will successfully flux all the common
mechanically. Mechanical removal is preferable because the surface
engineering materials, and its residues are soluble in hot water.
is roughened and excellent bonding is obtained. A medium emery
Where difficulty is encountered removing residues, immersion in
cloth provides about the right amount of surface roughness.
10% caustic soda is suggested.
Oil and grease removal is best carried out using a solvent
degreasing agent but hot, soapy water is better than nothing at all. Tenacity No. 4A
This is a higher temperature flux suitable for use with alloys with
brazing temperatures not exceeding 900°C or where long heating

times are involved. In common with Easyflo flux it will deal with all Removal of Flux Residues
common engineering materials and may be used on stainless steels. The method of residue removal depends on the type of flux
Tenacity No. 4A residues cannot be removed in hot water, and are which has been used. Easyflo flux residues can be quite simply
best removed mechanically or by the use of 10% sulphuric acid. removed by soaking in hot water, provided they are not in a
burnt and blackened condition. Complete flux residue removal is
Flux Application
usually possible within 10–15 minutes of soaking in water with a
The best way to apply a flux is to paint it onto the joint as a paste temperature of 60°C or above. After soaking, the joints should be
before assembly. It is common to see operators heating the rod scrubbed under running water to ensure complete cleanliness.
end and dipping it into the flux, and then applying both to the joint.
This ‘hot rodding’ technique has the disadvantages that the flux Tenacity No.4A flux residues are not water soluble and are best
does not protect the joint during the heating cycle and that the removed by some mechanical means, e.g. shot blasting.
limited amount of flux applied does not allow alloy penetration into Acid pickling is not effective in removing flux unless the residues
the capillary gap. are in a burnt and blackened condition. If pickling is necessary it
If a flux powder is used, it should be mixed to a double cream should be carried out after the flux residue removal operation.
consistency with water and a few drops of detergent. It should be
applied to the joint by means of a paint brush. Too much flux will
Health and Safety
rarely result in a bad joint but too little flux will invariably give Brazing alloys and fluxes contain elements which, if overheated,
joints of poor quality. produce fumes which may be harmful or dangerous to health.
Brazing should be carried out in a well ventilated area with
Heating the Joint and Applying the Alloy operators positioned so that any fume generated will not be
When heating a joint for brazing it is essential that it is slowly and inhaled. Adequate ventilation to prevent an accumulation of fumes
evenly heated to the brazing temperature. and gases should be used. Where fume levels cannot be controlled
below the recognised exposure limits, use local exhaust to reduce
The type and size of flame used will depend on the parent fumes and gases; in confined spaces without adequate ventilation,
materials and the mass of the components. Oxy /Acetylene, an air fed breathing system should be used; outdoors a respirator
Air /Acetylene and Air / Propane or MAPP are commonly used but may be required. Precautions for working in confined spaces should
care should be taken with the first due to the high flame intensity, be observed.
which may melt the parent materials.
Apart from fume hazards, flux can be irritating to the skin and
If the mass of metal is very large, more than one torch should prolonged contact should be avoided.
be used to raise the components to temperature before the flux
becomes exhausted. Before use, read all the manufacturer’s instructions and refer to
the warning labels on the packaging and ask your employer for the
As a temperature guide, either the colour of the metals or the Materials Safety Data Sheet. You can obtain the MSDS by referring
condition of the flux may be used. The flux on a joint that has to our web site www.boc.com.au or www.boc.co.nz or by calling
reached the correct temperature for brazing should be clear, fluid 131 262 in Australia or 0800 111 333 in New Zealand.
and flow over the joint area like water.
When the brazing temperature is reached, the filler metal is applied Joint Design
by touching the joint gap with the rod and applying some indirect The best brazed joints are those which have a capillary joint gap
or splash heat from the torch to the parent material. The molten into which the molten filler metal can flow. A comparison of the
filler metal will follow the heat from the flame as it is directed different joint designs used in welding and brazing is shown below.
along the joint. The brazing alloy should be applied according to its
flow characteristics; an alloy with free flowing characteristics such
as ProSilver 56T should be touched at one point on the joint, from
where it will flow into and around the joint by capillary action,
whereas a less-free flowing alloy such as ProSilver 39T should be
applied along or around the entire joint, building up a fillet of alloy.
If phosphorus bearing filler rods are being used, for example
ProSilver 5, the colour of the metal should be a dull cherry red
before the rod is applied to the joint gap.
Once brazing has been completed the heating should be
discontinued, as excess heating may cause metallurgical problems
with the parent materials, and porosity in the filler materials.
When the alloy has solidified the joint can be quenched in water to
help remove flux residues.
Quenching should only be carried out when it will not damage
the properties of the parent metals, or cause cracking because of
stresses caused by the thermal shock (e.g. in the case of Tungsten
Carbide pieces).

8 Gas Welding, Brazing and Soldering
Welding Techniques
The heat generated by an oxy-fuel flame is used to melt the parent
metal in the joint forming a weld pool. If a filler rod is to be used
then it must also be melted into the weld pool. The flame envelope
also protects the molten weld pool and the end of the filler rod
from the atmospheric contamination.
The weld is continuous and progresses at the speed in which the
parent and filler materials can be melted to form the weld pool
but fast enough not to allow the weld pool to burn through the
component creating a hole.
The filler rod, if used, is constantly fed into the weld pool at the
rate required to give the correct bead width, depth of penetration
and reinforcement height for the application. The length of the weld
will dictate how much filler rod is required, usually more than one
length of will be needed and when a new length of rod is needed
a stop and re-start will have to be effected. Stop-Start’s can affect
the quality of the weld if care is not taken to ensure the weld pool
is free of contamination and enough time is given to allow the weld
pool to become fully molten.
There are three recognised gas welding techniques used, these are:
N Leftward welding.
N Rightward welding.
N All Position rightward welding.
Leftward Welding, or Forward Welding

Leftward welding is the most common techniques used of gas
welding. In this technique the flame follows the filler rod along
the joint of the weld and with the torch in the right hand the
movement is from right to left and from left to right if the torch is
held in the left hand.
Leftward Welding Technique
The most common type of joint used for brazing is the lap joint, or
the sleeve joint in the case of tubular components. To design a good
30–40° 40–50°
lap joint, two criteria should be considered:
1 The joint gap.
2 The degree of overlap.
It is these two parameters that determine the ultimate joint
strength, rather than the properties of the filler metal.
A correctly designed brazed joint will often be stronger than the
parent materials from which it is constructed. This technique can be used in all welding positions and the method
is the same with the flame following the filler rod irrespective of
The best degree of overlap for a brazed joint is 3–4 t where t is the the position welding is taking place.
thickness of the thinnest parent metal part making up the joint.
The general rule for tubular parts is that the overlap should be one
pipe diameter for sizes up to 25 mm diameter tube.
The most suitable joint gap depends mainly on the flow
characteristics of the filler metal. The joint gaps for the various
alloys listed in the following section have been indicated. The
gaps quoted are those which should be present at the brazing
temperature, the cold clearances being adjusted as necessary to
account for any difference in the expansion properties of the
parent materials.

Rightward Welding, or Backhand or Backward welding WARNING

With this technique the filler rod follows the flame along the joint Brazing can give rise to excessive noise, eye and skin burns due to
of the weld, with the torch in the right hand the movement is from the flame and its radiation, and can be a potential health hazard if
left to right and the opposite when the torch is in the left hand. you breathe in the emitted fumes and gases.
Rightward welding is limited in its uses and is only used in the flat
Brazing should be carried out in a well ventilated area with
(1G, PA) position and for material thicknesses between 4 –16mm
operators positioned so that any fume generated will not be inhaled.
thick. When welding butt joints of between 4–6 mm no edge
Adequate ventilation to prevent an accumulation of fumes and
preparation is required, for thicker materials of up to 16 mm edge
gases should be used. Where fume levels cannot be controlled
preparation will be required. However, it is possible to complete this
below the recognised exposure limits, use local exhaust to reduce
joint in one pass.
fumes and gases; in confined spaces without adequate ventilation,
an air fed breathing system should be used; outdoors a respirator
Rightward Welding Technique may be required. Precautions for working in confined spaces should
be observed.
Apart from fume hazards, flux can be irritating to the skin and
prolonged contact should be avoided.
Before use, read all the manufacturer’s instructions and refer to
the warning labels on the packaging and ask your employer for the
Materials Safety Data Sheet (MSDS). You can obtain the MSDS by
40–50°
referring to our web site www.boc.com.au or www.boc.co.nz
30–40° or by calling 131 262 in Australia or 0800 111 333 in New Zealand.
All-Position Rightward Welding (APR)

With this technique the wire can follow, precede or be in-line with
the flame, depending upon the welding position being used. The
all-position rightward technique is for welding thicker materials in
the vertical up, vertical down, horizontal-vertical and the overhead
positions.
All-position Rightward Welding Technique
45–60°
The technique is mainly used for gas welding pipe of all diameters
and wall thicknesses of up to 6mm in a single pass with no edge
preparation to the material. This technique was developed to
compete with Manual Metal Arc welding and is used mainly on
construction sites for welding heating and ventilating pipe work.

Melting Range, Recommended

Name Composition (°C) Joint Gap (mm) Remarks
ProSilver 56T 56% Ag:Cu:Zn:Sn 620–650 0.05–0.15 These two alloys have similar low melting temperatures and
quick flowing characteristics. ProSilver 45T is the popular
SilverCoat 56T
choice.
ProSilver 45T 45% Ag:Cu:Zn:Sn 640–680 0.05–0.15 ProSilver 56T is used where maximum ductility and smoother
SilverCoat 45T joint fillets are required. Both alloys need well-fitted joints
with small gaps for their best performance.
ProSilver 39T 39% Ag:Cu:Zn:Sn 650–705 0.075–0.2 This series of three alloys of silver, copper, zinc and tin gives
a range of fillet-forming materials designed for use where
ProSilver 34T 34% Ag:Cu:Zn:Sn 630–730 0.075–0.2
wide joint gaps may arise or where pronounced fillets may be
ProSilver 30T 30% Ag:Cu:Zn:Sn 665–755 0.075–0.2 required. They are not suitable for applications where slow
heating may produce liquation.
ProSilver 15 15% Ag:Cu:P 645–800 0.05–0.15 Designed primarily for brazing copper without flux, these
alloys can be used with flux on copper alloys but should
ProSilver 5 5% Ag:Cu:P 645–810 0.05–0.15
not be used on ferrous or nickel-base metals. As the silver
ProSilver 2 2% Ag:Cu:P 645–800 0.05–0.15 content of these alloys decreases, so does joint ductility.
Where service conditions are severe, ProSilver 15 should be
the alloy chosen.
PhosCopper 7% P:Cu 705–820 0.075–0.2 A free flowing self fluxing alloy for use on unstressed copper
to copper joints. Higher melting temperature than the silver
containing alloys.
ProSilver 494 49% Ag:Cu:Zn:Ni:Mn 680–705 0.1–0.25 ProSilver 494 and ProSilver 402 are specialised alloys designed
for brazing of tungsten carbide.
ProSilver 402 40% Ag:Cu:Zn:Ni 660–780 0.1–0.25

Self fluxing Brazing
Classification
AS / NZS 1167.1–B1
PhosCopper Chemical Composition, wt%

Phosphorous 7.00–8.25%
Copper 91.75–93.00%
Physical Properties
Self fluxing for pure copper brazing due to the action of Density 6.9 g/cc
phosphorous; copper alloys like brasses and bronzes will require
Solidus 705°C
additional fluxes. Is not suitable for steel or alloys containing
Liquidus 820°C
more than 10% nickel.
Brazing Temp. 720–840°C
Produces rough-textured fillets of a greyish colour and when
permitted to run uncontrolled over the work will roughen the Application
surface. Not recommended where good appearance is desired
Suitable Flux Tenacity 4A.
or where subsequent electroplating is necessary. No flux required for pure copper
The alloy has a relatively wide melting range and the parent metals Optimum Joint Gap 0.08–0.2 mm
brazed almost always have high thermal conductivity. For these
reasons the work should be heated quickly to brazing temperature Packaging Data
and oxy-acetylene is preferable to either natural-gas or propane.
Wire Size (mm) Pack Size Part No.
Brazing of tough pitch copper should be carried out with a slightly
oxidizing flame to avoid hydrogen embrittlement. 3.0 x 750 5.0 (kg) LTAP0043
5.0 x 750 5.0 (kg) LTAP0044
Due to its wide melting range there is a tendency for low melting
3.0 x 750 15 rods LTAP0083
phases to run out of the joint if the heating rate is too low hence
care has to be taken to heat quickly to the brazing temperature.
Biggest use of this alloy is in return bends in evaporative air-
conditioner heat exchangers. It is also used in auto air-conditioners.
The alloy is used in non-vibration situations and is not
recommended for plumbing due to hammering / vibration.
It is not recommended for use in shock-loading situations,
sulphurized gas or marine environments.

Brazing Self fluxing
Classification
AS / NZS 1167.1–B2
ProSilver 2 Chemical Composition, wt%

Silver 1.80–2.20%
Copper Balance
Self fluxing for pure copper brazing due to the action of Physical Properties
Density 7.05 g / cc
Solidus 645°C
Liquidus 800°C
Produces rough-textured fillets of a greyish colour and when Brazing Temp. 740–820°C
permitted to run uncontrolled over the work will roughen the
surface. Not recommended where good appearance is desired Application
or where subsequent electroplating is necessary.
Suitable Flux Tenacity 4A
The alloy has a relatively wide melting range and the parent metals No flux required for pure copper
brazed almost always have high thermal conductivity. For these Optimum Joint Gap 0.05–0.2 mm
reasons the work should be heated quickly to brazing temperature
and oxy-acetylene is preferable to either natural-gas or propane. Packaging Data
oxidizing flame to avoid hydrogen embrittlement. Wire Size (mm) Pack Size Part No.
2.5 x 750 5.0 (kg) LTAP0242
3.0 x 750 5.0 (kg) LTAP0243
care has to be taken to heat quickly to the brazing temperature. 2.5 x 750 1.0 (kg) LTAP0212
3.0 x 750 1.0 (kg) LTAP0213
ProSilver 2 is the main alloy used in plumbing and in the
2.5 x 750 15 rods LTAP0282
manufacture of copper hot water tanks where water hammer
2.5 x 750 rod LTAP0296
necessitates a silver content.
3.0 x 750 rod LTAP0298

Self fluxing Brazing
Classification
AS / NZS 1167.1–B3

Silver 4.75–5.25%
Copper Balance
Density 7.24 g / cc
Solidus 645°C
Liquidus 810°C
Suitable Flux Tenacity 4A.
2.0 x 750 2.5 (kg) LTAP0521
2.5 x 750 2.5 (kg) LTAP0522
2.0 x 750 1.0 (kg) LTAP0511
ProSilver 5 has improved strength / ductility and gap filling
2.5 x 750 1.0 (kg) LTAP0512
properties compared to ProSilver 2.
2.5 x 750 10 rods LTAP0572
It is not recommended for use in shock-loading situations, 2.0 x 750 rod LTAP0599
sulphurized gas or marine environments. 2.5 x 750 rod LTAP0596

Brazing Self fluxing
Classification
AS / NZS 1167.1–B4

Silver 14.50–15.50%
Copper Balance
Density 7.5 g / cc
Solidus 645°C
Liquidus 800°C
2.0 x 750 2.5 (kg) LTAP1521
2.5 x 750 2.5 (kg) LTAP1522
1.5 x 750 1.0 (kg) LTAP1550
ProSilver 15 is used for high vibration joints on refrigerator
2.0 x 750 1.0 (kg) LTAP1511
copper pipes. It is also used for brazing contacts onto copper-
2.5 x 750 1.0 (kg) LTAP1512
based parts because of its good flow characteristics and good
electrical conductivity. 3.0 x 750 1.0 (kg) LTAP1513
2.5 x 750 5 rods LTAP1562
1.5 x 750 rod LTAP1551
2.0 x 750 rod LTAP1599
2.5 x 750 rod LTAP1596
3.0 x 750 rod LTAP1598

Cd Free Brazing
Classification
AS / NZS 1167.1–A16
ProSilver 30T Chemical Composition, wt%

Silver 29.00–31.00%
Copper 34.50–36.50%
Zinc 30.00–34.00%
Tin 2.25–2.75%
Suitable for brazing of all low alloy and carbon steels, copper and
copper alloys, nickel alloys. Physical Properties
Can be used for brazing where close tolerances on joint gaps Density 8.57 g / cc
cannot be held and can form large fillets. Solidus 665°C
The joint area should be brought to the brazing temperature before Liquidus 755°C
application of the alloy to prevent liquation – separation of low Brazing Temp. 760–800°C
melting components from the alloy under slow heating conditions.
Should not be quenched after brazing to avoid risk of cracking. Application
Maximum continuous operating service temperature should not
Optimum Joint Gap 0.075–0.2 mm
exceed 200°C.
Packaging Data
1.5 x 750 0.5 (kg) LTAT3001
2.5 x 750 0.5 (kg) LTAT3003
Classification
AS / NZS 1167.1–A18

Silver 33.00–35.00%
Copper 35.00–37.00%
Zinc 25.50–29.50%
Tin 2.50–3.50%
This alloy was developed as the cadmium-free replacement
for ProSilver 34. Physical Properties
Suitable for carbon and low alloy steels, copper and copper Density 8.71 g / cc
alloys (aluminium bronzes with more than 2% aluminium requires Solidus 630°C
special flux), nickel and nickel alloys, stainless steels (not exposed Liquidus 730°C
to continuous contact with water). Brazing Temp. 730–780°C
Due to its wide melting range, this alloy can be used to fill joint
gaps that can not be closely controlled. Application
Should not be quenched from high temperatures (>300°C). Suitable Flux Tenacity 4A, Easyflo
Should not be quenched when used to braze components with Optimum Joint Gap 0.075–0.2 mm
widely differing coefficients of thermal expansion, due to risks
with cracking. Packaging Data
Suitable for continuous service operating temperatures up Wire Size (mm) Pack Size Part No.
to 200°C. 1.5 x 750 0.5 (kg) LTAT3401
2.5 x 750 0.5 (kg) LTAT3403
1.5 x 750 rod LTAT3492

Brazing Cd Free
Classification AS / NZS 1167.1–A15
Chemical Composition, wt%

ProSilver 39T Silver 38.00–40.00%
Copper 29.50–31.50%
Zinc 26.00–30.00%
Tin 2.25–2.75%
Suitable for brazing of all low alloy and carbon steels, copper and Physical Properties
copper alloys, nickel alloys. Density 8.76 g / cc
Can be used for brazing where close tolerances on joint gaps Solidus 650°C
cannot be held and can form large fillets. Liquidus 705°C
The joint area should be brought to the brazing temperature before Brazing Temp. 710–760°C
application of the alloy to prevent liquation – separation of low
melting components from the alloy under slow heating conditions. Application
Suitable Flux Easyflo
Should not be quenched after brazing to avoid risk of cracking.
exceed 200°C. Packaging Data
1.5 x 750 0.5 (kg) LTAT3901
2.5 x 750 0.5 (kg) LTAT3903

Cd Free Brazing
Classification AS / NZS 1167.1–A19
Chemical Composition, wt%

ProSilver 45T Silver 44.00–46.00%
Copper 26.00–28.00%
Zinc 23.50–27.50%
Tin 2.00–3.00%
This alloy was developed as the cadmium-free replacement for Physical Properties
ProSilver 45. Density 9.2 g / cc
Suitable for carbon and low alloy steels, copper and copper alloys Solidus 640°C
(aluminium bronzes with more than 2% aluminium requires special Liquidus 680°C
flux), nickel and nickel alloys, stainless steels for food and medical Brazing Temp. 680–710°C
applications (not exposed to continuous contact with water).
Low brazing temperature coupled with a narrow melting range Application
makes it free flowing and produces joints with small, smooth fillets. Suitable Flux Easyflo, Tenacity 4A
Good corrosion resistance.
Used widely in marine applications due to its resistance to Packaging Data
de-zincification.
Suitable for continuous service operating temperatures up 1.5 x 750 2.5 (kg) LTAT4520
to 200°C. 1.5 x 750 0.5 (kg) LTAT4501
2.5 x 750 0.5 (kg) LTAT4503
3.0 x 750 0.5 (kg) LTAT4504
1.5 x 500 5 rods LTAT4563X
1.5 x 750 rod LTAT4592X
2.5 x 750 rod LTAT4596X
0.125 x 25 25g coil LTAT4559
Classification
AS / NZS 1167.1–A19
SilverCoat 45T Chemical Composition, wt%

Silver 44.00–46.00%
Copper 26.00–28.00%
Zinc 23.50–27.50%
This alloy was developed as the cadmium-free replacement for
Tin 2.00–3.00%
SilverCoat 45.
SilverCoat 45T is the extruded flux coated version of the standard Physical Properties
ProSilver 45T.
Density 9.2 g / cc
Suitable for carbon and low alloy steels, copper and copper alloys Solidus 640°C
(aluminium bronzes with more than 2% aluminium requires special Liquidus 680°C
flux), nickel and nickel alloys, stainless steels for food and medical
applications (not exposed to continuous contact with water).
Low brazing temperature coupled with a narrow melting range Application
makes it free flowing and produces joints with small, smooth fillets. Suitable Flux No flux required.
Good corrosion resistance. Use Easyflo for large overlaps.
Used widely in marine applications due to its resistance to
de-zincification.
Packaging Data
Suitable for continuous service operating temperatures up
to 200°C.
1.5 x 500 250 (g) LTAF4530T
1.5 x 500 500 (g) LTAF4531T
1.5 x 500 2 rods LTAF4550T
1.5 x 500 rod LTAF4589TX

Brazing Cd Free
Classification
AS / NZS 1167.1–A2

Silver 55.00–57.00%
Copper 21.00–23.00%
Zinc 15.00–19.00%
Tin 4.50–5.50%
Cadmium-free brazing alloy with a short melting range, suitable for
brazing of most metals such as copper alloys and stainless steels for Physical Properties
food and medical applications.
Density 8.76 g / cc
Very free flowing and produces neat joints with small fillets. Solidus 620°C
Has some resistance to de-zincification and is used for brazing Liquidus 650°C
of stainless steel food handling equipment. Brazing Temp. 650–750°C
Should not be quenched after brazing to avoid risk of cracking.
Application
Suitable Flux Easyflo
exceed 200°C.
Packaging Data
Wire Size (mm) Pack Size (kg) Part No.
1.5 x 750 0.5 LTAT5601
2.5 x 750 0.5 LTAT5603
Classification
AS / NZS 1167.1–A2
SilverCoat 56T Chemical Composition, wt%

Silver 55.00–57.00%
Copper 21.00–23.00%
Zinc 15.00–19.00%
Tin 4.50–5.50%
SilverCoat 56T is the extruded flux coated version of the standard
ProSilver 56T. Physical Properties
Cadmium-free brazing alloy with a short melting range, suitable for Density 8.76 g / cc
brazing of most metals such as copper alloys and stainless steels for Solidus 620°C
food and medical applications. Liquidus 650°C
Very free flowing and produces neat joints with small fillets. Brazing Temp. 650–750°C
Has some resistance to de-zincification and is used for brazing of
stainless steel food handling equipment. Application
Suitable Flux No flux required
Should not be quenched after brazing to avoid risk of cracking. Use Easyflo for large overlaps
Maximum continuous operating service temperature should not Optimum Joint Gap 0.05–0.15 mm
exceed 200°C.
Packaging Data
1.5 x 500 250 (g) LTAF5630

Tungsten Carbide Brazing
Classification
AS / NZS 1167.1–A8

Silver 39.00–41.00%
Copper 29.00–31.00%
Zinc 26.00–30.00%
Nickel 1.50–2.50%
Cadmium-free brazing alloy with a wide melting range, suitable
for forming fillets. Suitable for brazing of stainless steel for dry Physical Properties
applications and for brazing tungsten carbide up to 9 mm long
Density 9.81 g / cc
– for longer lengths use ProSilver 494.
Solidus 660°C
Liquidus 780°C
Application
Packaging Data
1.5 x 750 0.5 (kg) LTAN45214
1.5 x 750 5 rods LTAN45213
1.5 x 750 rod LTAN45212
Classification
AS / NZS 1167.1–A20

Silver 48.00–50.00%
Copper 15.00–17.00%
Zinc 21.00–25.00%
Nickel 4.00–5.00%
This alloy was developed as the cadmium-free replacement for Manganese 6.50–8.50%
ProSilver 503.
Recommended for brazing of tungsten carbide up to 19 mm long. Physical Properties
The presence of nickel and manganese helps in wetting carbides Density 9.81 g / cc
even those containing titanium. Solidus 680°C
Liquidus 705°C
Application
Packaging Data
1.5 x 750 0.5 (kg) LTAT5301
1.5 x 750 5 rods LTAT5360
1.5 x 750 rod LTAT5392X

Gas Welding

Length Weight per Rods per
ProFill Nickel Bronze Dia. (mm) (mm) pack (kg) pack Part No.
3.2 750 1.000 — GRNB321
5.0 750 2.500 — GRNB5025
5.0 750 1.000 — GRNB501
N Fusion welding of similar copper alloys
N Suitable for steel, cast iron and malleable iron
Specifications
Coating Bare
Classification AWS RBCuZn-D
Joining process Braze welding and fusion welding
Welding characteristics High strength and wear resistant, self fluxing
Brazing of nickel based alloys
Brazing of nickel based Build up of worn ferrous components
alloys
Melting range 920–935

Dia. (mm) Length (mm) Weight per Rods per Part No.
pack (kg) pack
ProFill Nickelcoat 2.4 500 — 5 GRNC24H5
3.2 750 2.500 — GRNC3225
3.2 750 1.000 — GRNC321
N Fusion welding of similar copper alloys, brazing of nickel 3.2 750 — 5 GRNC32H5
based alloys
N Suitable for steel, cast iron and malleable iron
Specifications
Coating Flux coated
Classification AWS RBCuZn-D
Welding characteristics High strength and wear resistant, self fluxing

Gas Welding

Wire Dia. Length (mm) Weight per Rods per Part No.
(mm) pack (kg) pack
ProFill Tobin Bronze 1.6 750 2.500 — GRTB1625
1.6 750 1.000 — GRTB161
1.6 750 0.060 5 GRTB16H5
N For mild steel low strength applications e.g. car panel filling 2.4 750 2.500 — GRTB2425
N Suitable for brass and bronzes, mild steel and ferrous materials 2.4 750 1.000 — GRTB241
2.4 750 0.135 5 GRTB24H5
3.2 750 2.500 — GRTB3225
Specifications
3.2 750 1.000 — GRTB321
Coating Bare rod
3.2 750 0.250 5 GRTB32H5
Classification DIN L-Cu40Zn
5.0 750 2.500 — GRTB5025
5.0 750 1.000 — GRTB501
Welding characteristics Low fume
Tensile strength (MPa) 400

Length Weight per Rods per
Dia. (mm) (mm) pack (kg) pack Part No.
ProFill Mang Bronze 1.6 750 2.500 GRMB1625
1.6 750 1.000 GRMB161
1.6 750 5 GRMB16H5
N Due to dezincification, not suitable for copper pipes 2.4 750 2.500 GRMB2425
carrying hot water or sea water 2.4 750 1.000 GRMB241
N Suitable for steel, cast iron and malleable iron 2.4 750 5 GRMB24H5
3.2 750 2.500 GRMB3225
Specifications 3.2 750 1.000 GRMB321
Coating Bare rod 3.2 750 5 GRMB32H5
Classification AWS RBCuZn-C 6.3 750 2.500 GRMB6325
Joining process Braze welding 6.3 750 5 GRMB631
Welding characteristics Low fume and high strength, self fluxing

Gas Welding

Wire dia. Length Weight per Rods per
(mm) (mm) pack (kg) pack Part No.
ProFill Mangcoat 2.4 500 2.500 — GRMC2425
2.4 500 1.000 — GRMC241
2.4 500 — 5 GRMC24H5
N Due to dezincification, not suitable for copper pipes 3.2 750 2.500 — GRMC3225
carrying hot water or sea water 3.2 750 1.000 — GRMC321
N Suitable for steel, cast iron and malleable iron 3.2 750 — 5 GRMC32H5
Specifications
Classification AWS RBCuZN-C
Joining process Braze welding
Welding characteristics Low fume and high strength, self fluxing

Gas Welding
Comweld Mild Steel Typical rod analysis (%) Joining process

N Annealed, low carbon steel rod for C: 0.07% Mn: 0.50% Si: 0.008% Gas (fusion) welding only
oxy-acetylene welding S: 0.008% P: 0.011% Fe: Balance
N Recommended for gas welding of steels Recommended shielding gases
and wrought irons Not recommended
N Not suitable for gas tungsten arc welding
Packaging data
Classifications
Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
AS / NZS 1167.2: RG
AWS /ASME-SFA A5.2: R45 1.6 x 500 1 Handipack 130 322045
1.6 x 1,000 5 plastic pack 64 321334
2.4 x 750 5 plastic pack 29 321337
3.2 x 750 5 plastic pack 16 321339
Comweld High Test Typical rod analysis (%) Joining process

N Copper coated, steel filler rod for gas C: 0.12% Mn: 1.17% Si: 0.25% Gas (fusion) and gas tungsten arc (TIG) welding
and gas tungsten arc (TIG) welding S: 0.009% P: 0.015% Fe: Balance
N Higher strength (400–450 MPa) Recommended shielding gases
oxy-acetylene and TIG welding of steels
Argon Welding Grade
Classifications
AS / NZS 1167.2: R1 Packaging data
AWS /ASME-SFA A5.2: R60 Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
1.6 x 750 5 plastic pack 84 321357
2.4 x 750 5 plastic pack 34 321360
3.2 x 750 5 plastic pack 21 321362
Comweld Nickel Packaging data
Bronze Rod Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
N High strength, wear resistant 2.4 x 750 5 plastic pack 35 321224
brazing alloy 3.2 x 750 5 plastic pack 19 321225
N High strength braze welding of steels 5.0 x 750 5 plastic pack 8 321226
and cast or malleable irons
N Fusion welding of copper based alloys
of similar composition
N Crimson end tip colour for instant
identification
Classifications
AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-D
AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-D

Gas Welding
Comweld Comcoat N Packaging data

N Flux coated nickel bronze rod Rod size Easyweld Blister Approx No.
N High strength, excellent wear resistance (mm) Pack (kg) / type Handipack Pack (rods / kg) Part No.
N High strength braze welding of steels 2.4 x 500 3 rod pack – 322208
and cast or malleable irons 10 rod Handipack – 322029
N Fusion welding of copper based alloys 3.2 x 750 2.5 plastic pack 19 321215
of similar composition
8 rod Handipack – 322030
N Pink flux colour for instant identification
Classifications
AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-D
AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-D
Comweld Tobin Classifications
Bronze Rod AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-A

AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-A
N Low strength copper-zinc brazing alloy
N Recommended for the fusion or braze
Packaging data
welding of selected brasses
and bronzes Rod Size (mm) Weight (kg), Pack type Blister Pack Approx No. (rods / kg) Part No.
N Suitable for low strength brazing 1.6 x 750 5 plastic pack 83 321246
of steels 2.4 x 750 5 plastic pack 37 321247
N Not suitable for cast irons 3.2 x 750 5 plastic pack 20 321249
N White end tip colour for instant 15 rod Handipack – 322038
identification
5.0 x 750 5 plastic pack 8 321250
Comweld Comcoat T Classifications

N Flux coated tobin bronze rod AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-A
AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-A
N Recommended for the ‘self fluxing’
fusion braze welding of selected
brasses and bronzes Packaging data
N Suitable for low strength brazing Rod Size (mm) Weight (kg), Pack type Blister Pack Approx No. (rods / kg) Part No.
of steels
2.4 x 500 5 rod blister pack – 322207
N Not suitable for cast irons
3.2 x 750 5 plastic pack 19 321236
N White flux colour for instant
identification

Gas Welding
Comweld Manganese
Packaging data
Bronze Rod
Rod Size (mm) Pack (kg) / type Approx No. (rods / kg) Part No.
N General purpose brazing alloy
1.6 x 750 5 plastic pack 90 321195
N Recommended for braze welding of
steels and-cast and malleable irons 2.4 x 750 5 plastic pack 37 321199
N Not suitable for copper pipes in hot 3.2 x 750 5 plastic pack 20 321202
water systems 5.0 x 750 5 plastic pack 8 321203
N Blue end tip colour for instant 6.3 x 750 5 plastic pack 5 321204
identification
Classifications
AS / NZS 1167.1, AS / NZS 1167.2: R Cu Zn-C
AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-C
Comweld Comcoat C Packaging data

N Flux coated manganese bronze rod Rod size Easyweld Blister Approx No.
N General purpose brazing alloy (mm) Pack (kg) / type Handipack Pack (rods / kg) Part No.
N Recommended for braze welding of 2.5 50 321191

steels and-cast and malleable irons 2.4 x 500 20 rod Handipack 322020
N Not suitable for copper pipes in hot 5 rod blister pack 322206
water systems
3.2 x 790 5 plastic pack 19 321186
N Blue flux colour for instant identification
15 rod Handipack 322021
Classifications
AS / NZS 11671, AS / NZS 1167.2: R Cu Zn-C
AWS /ASME-SFA A5.8 /A5.27: RB Cu Zn-C
Comweld Silicon Packaging data
Bronze Rod Rod Size (mm) Pack weight (kg) / type Approx No. (rods / kg) Part No.
N Premium quality deoxidised 3.2 x 750 5 plastic pack 19 321295
silicon-bronze alloy
N Recommended for the braze welding
and GTA (TIG) welding
of copper silicon alloys (Everdur
and Cusilman)
N Canary yellow end tip colour
Classifications
AS / NZS 1167.1, AS / NZS 1167.2: R Cu Si-A
AWS /ASME-SFA A5.7: R Cu Si-A
(UNS no. C65600)

Gas Welding
Comweld General Packaging data
Purpose, Cast Iron Rod Size (mm) Weight (kg), Pack type Approx No. (rods / kg) Part No.
Rod (Super Silicon) 5.0 x 700 2.5 Plastic 8 321420
N A high strength, general purpose,

cast iron alloy for joining and building
up grey cast iron castings
N Machinable weld deposit
Classifications
AS / NZS 1167.2: RC11
Soldering
Comweld 40 / 60 Colour code and identification Typical properties
Soft Solder Cored wire reels – green label Tensile strength 42 MPa
Comweld 40 / 60 solder is a low cost Sticks – marked 40 / 60 Shear strength 37 MPa

general purpose solder for general Handipack (H / P) coil, yellow backing card Approx. melting range 183–234°C
sheet metal work, plumbing (not water and label
Electrical conductivity 10.1% IACS
pipes) such as gutters and flashings and
automotive radiator repairs. Joining process Packaging data
N General purpose low cost solder
Soldering only Rod Size
N General for sheet metal and plumbing (mm) Pack weight / type Part No.
Soldering iron bit 294°C
applications temperature 12 x 6 x 400 250 g stick 322305
N General wide range of packaging options (W x B x L)
Typical rod analysis (%)
3.2 250 g acid core wire 322313
Classifications Sn Pb
1.6 15 g resin core H / P 322220
AS 1834 Part 1 40Sn 40% (Tin) 60% (Lead)
Comweld 50 / 50 Colour code and identification Packaging data
Soft Solder Cored wire reels – orange label Rod size

(mm) Pack weight / type Part No.
Comweld 50 / 50 solder is a higher quality Sticks – marked 50 / 50
general purpose solder for general sheet 12 x 6 x 400 250 g stick 322306
(W x B x L)
metal work, and plumbing (not water pipe) Joining process
applications where better free flowing Soldering only 3.15 250 g solid wire 322310
characteristics are important. 500 g acid core wire 322318
Soldering iron bit 272°C
N Higher quality general purpose solder temperature 1.6 250 g acid core wire 322317
N For electrical and electronic applications 250 g resin core wire 322319
N Wide range of packaging options Typical properties
Classifications Shear strength 40 MPa
AS 1834 Part 1 50Sn Approx. melting range 183–212°C
Electrical conductivity 10.9% IACS

Soldering
Comweld 965 Solder Classifications Typical properties
(Soft Silver Solder) AS 1834 Part 1 96.5Sn / 3.5Ag Electrical conductivity 17% IACS
Comweld 965 Solder is a tin / silver eutectic

Colour code and identification Packaging data
solder which has the highest strength of
all soft solders. Due to it’s high strength, Blue labels and backing cards Rod size
good electrical and thermal conductivity, (mm) Pack weight / type Part No.
non toxicity (lead, zinc and cadmium free) Joining process 3.15 250 g solid wire 322320
and also the fact that it remains bright and
Soldering only 3.15 500 g solid wire 322321
shiny, make Comweld 965 Solder the most
universal of soft solders. Comweld 965 Soldering iron bit 281°C 1.6 250 g acid core wire 322324
Solder is used for the joining and repair of temperature
1.6 15 g HandiPack coil 322221
copper, bronze, brass, nickel, monel, steel, acid core wire
stainless steel, pewter, chrome plate, metal Typical rod analysis (%)
sculpture, model making, costume jewellery Sn Ag
and or a combination of metals with the
exception of aluminium and magnesium. 96.5% (Tin) 3.5% (Silver)
N Highest strength soft solder

Typical properties
N Lead, zinc and cadmium free
N Non toxic solder for electrical, surgical
Density 7.5 g / cm3
and food equipment applications
Approx. melting point 220°C
N Wide range of packaging options
Comweld Metal Mate

Solder Kit AS 1834 Part 1 96.5 Sn / 3.5Ag Rod Size
Comweld Metal Mate Solder Kit contains a (mm) Pack weight / type Part No.
14 gm 965 solid solder coil complete
Identification 1.6 1.6 mm x 14 g solid 321690
with a 14 ml bottle of Comweld 965 wire coiled around a
Soldering Flux. Clear plastic jar, white lid and white label with 14 ml bottle of 965
blue print soldering flux
Typical rod analysis (%)

Sn Ag
96.5% (Tin) 3.5% (Silver)

Fluxes
SB Flux Easyflo
Preferred general purpose flux suitable for most engineering
materials. Suitable for use with all ProSilver alloys. Residue soluble in
hot water or 10% caustic soda.
N Temperature range 550–880°C
Size Part No.

250g Efloflux
GP SB Flux Tenacity 4A
For higher melting point applications and longer heating cycles.
Suitable for use with all ProSilver alloys. Preferred for ProSilver 2.5
and 15 if heating cycle is long.
Size Part No.

250g Ten4AFlux
Flux Tenacity 20
For copper, brass gas welding and steel brazing. Suitable for higher
temperatures and extended cycle times. Suitable for ProFill bronze
alloy range. Use as a powder or mix with water for a paste.
Size Part No.

250g Ten20Flux

Fluxes
Comweld Comweld Copper Comweld Silver Brazing

Aluminium Flux and Brass Flux Flux No. 2
Description and application Description and application Description and application
Comweld Aluminium Flux is an all purpose flux Comweld Copper and Brass Flux is specially Comweld Silver Brazing Flux no. 2 and Silver
for fusion welding sheet and cast aluminium. developed for the braze welding of-copper, brass Brazing Alloys with a high silver content
Comweld Aluminium Flux is recommended for and bronze and the brazing of copper, steel, etc. (42–50%) produce excellent joints on carbon
use with the following Comweld Aluminium Comweld Copper and Brass Flux is particularly steel, stainless steel, nickel alloys and copper
welding rods, AL1100 (Pure), AL4043 (5% Silicon) suitable for use with Manganese Bronze, Tobin and brass. Dissimilar metals in the above
and AL5356 (5% Magnesium). Bronze, Nickel Bronze and Silicon Bronze rods. groups can be easily brazed.
Identification Identification Identification
White powder in black plastic jars Pink powder in black plastic Jars or drums. White paste in either a black / white plastic jar
Melting point 545°C Melting point: 645°C Melting point: 450°C
Packaging data Packaging data Packaging data
Pack weight / type Part No. Pack weight / type Part No. Pack weight / type Part No.
250 gm black plastic jar 321740 250 gm black plastic jar 321822 200 gm black plastic jar 321840
500 gm black plastic jar 321841
3.5 kg white plastic Jar 321843
Comweld G.P. Silver Comweld 965 Comweld Vapaflux

Brazing Flux Soldering Flux N For Braze Welding of Steel
N Used with Comweld Manganese &
Description and application Description and application Nickel Bronze Rods
Comweld General Purpose Silver Brazing Flux Comweld 965 Soldering Flux, when used
N Used in a Liquid Form Only
is recommended for use with Cadmium bearing in-conjunction with Comweld Soft Solders,
and Cadmium free silver brazing alloys with a enables excellent joints to be made on almost
low to medium silver content (2–40%). all-metals and combinations of metals. Identification:
Clear Liquid in a Tin Plate Can.
Identification Identification
White paste in either a black or white plastic jar Pink liquid in black plastic bottles and drums Flash Point
Melting point: 485°C (True Closed Cup) 17°C
Packaging data
Packaging data Pack weight / type Part No. Packaging Data
Pack weight / type Part No. 125 ml bottle 321890 Pack Volume Pack Type Part No.
200 gm black plastic jar 321850 1 litre bottle 321894 19 L Tin Plate Can 321885
500 gm black plastic jar 321851
3.5 kg white plastic jar 321853

8 Consumables
Hardfacing
Millions of dollars worth of equipment is thrown away each year Processes

because it no longer performs efficiently. The standard welding processes employed during both reclamation
A large percentage of this equipment could, however, be and preventative maintenance may include:
protected by hardfacing or reclaimed by welding. In many cases, 1 Manual metal arc welding (MMA)
the degeneration of the equipment could have been stopped if
preventative maintenance was carried out, as a matter of routine. 2 Gas shielded metal arc welding (GMAW)
3 Submerged arc welding (SAW)
There should be differentiation between repair welding, reclamation
and preventative maintenance. 4 Flux cored arc welding (FCAW)
N open arc
Repair Welding
N gas shielded
Repair welding is aimed at repairing structural damage, such
as fatigue, cracks, fractures, etc. The principle governing repairs N submerged arc
is normally based on either matching the welding consumable The biggest advances have been made in the area of flux cored
chemically or mechanically (tensile strength, proof stress, elongation, welding consumables. It is also the area which has the widest selection
etc) to the base metal. of alloys available as well as a wide range of material properties.
Reclamation Wear Mechanisms

Reclamation is aimed at restoring the dimensions of the For effective reclamation and preventative maintenance, a proper
components that have been altered due to wear, corrosion, thermal understanding of the mechanism causing the degeneration is
fatigue, machining defects, etc. required before welding consumables can be selected.
Typical components that are normally reclaimed include:
1. Abrasion
N Steel mill rolls Abrasion is labelled as the single most important mechanism of all
N Idler rolls wear in industry.
N Track rolls
Abrasion 50%
N Dragline jewellery
Impact 10%
N Carrier rolls
Metal-to-metal wear 14%
Preventative Maintenance Chemical (corrosion) 10%
Preventative maintenance is the pro-active use of welding, to
Temperature 5%
prevent excessive wear taking place on components.
Hard surfacing is a form of preventative maintenance. Abrasion or metal-to-mineral wear is further subdivided into:
Typical components that are normally hard surfaced include: a) High stress abrasion
This occurs when abrasive materials are deliberately broken into
N Front end loader buckets
smaller sizes, i.e. crushing operations
N Crusher jaws and mantles
b) Low stress abrasion
N Sugar mill rollers This occurs when abrasive materials are transported along the
N Agricutural tyres surface in both a sliding and rolling action, in such a way that a
N Brick and paver mixer paddles reduction in particle size does not normally take place, i.e. feed
chutes slurry pipelines, etc.

Hardfacing 8
2. Metal-to-metal wear 4. Corrosion

This occurs when there is movement of one component relative to This is the degradation of metals due to chemical reaction, whether
the other. by an acidic medium flowing through a pipe or the exposure of
Typical examples of metal-to-metal wear are: components to corrosive atmospheres, i.e. coastal operations.
a) Journal ends of steel mill rolls 5. Impact

b) Track rolls of earth moving equipment This is the degradation of metals due to the repeated point loading
of the component that causes the surface to fatigue rapidly and
3. Temperature disintegrate, i.e. impact crusher or gyratory crushers.
Temperature, when it becomes sufficiently high, will cause oxidation
and subsequently scaling. Welding Consumables Classification
More detrimental, however, are fluctuating temperatures, which Welding consumables are further grouped in terms of alloy types,
lead to thermal fatigue cracking or fire cracking, as in steel mill roll where each exhibits certain characteristics that would make
applications. them suitable to apply when certain tribological conditions are
encountered.
1XXX Steels
Alloy type Description Features Typical applications

11XX Pearlitic Steel Strong, multi-run capabilities General rebuilding, butter layers, spindles, rollers, track
lines, sprockets, tractor idler wheels
12XX Austenitic manganese steel Tough, work hardening, impact resistant Crusher jaws, rolls, mantles, ball mill liners, railway points
13XX Austenitic stainless steel Tough, corrosion/heat resistant, forms Crossings, bearings at medium temperatures, track
strong welds between dissimilar steels grousers, anvils, pneumatic tools, butter layers under
2XXX hardfacing
14XX Low carbon martensitic steel Strong Clutch parts, railway points and crossings, track
components
15XX Tool steel Very hard, hot strength Machine tools, shears, guillotine blades, metal forming
tools
16XX Martensitic stainless steel Hard, corrosion/heat resistant Cutting knives, punches, dies, steel mill rolls.
17XX High carbon austenitic steel Tough, work hardened Crushing rolls, hammers, tractor grousers
18XX High carbon Martensitic steel Very hard, abrasion resistant Post-hole augers, earth scoops, conveyor screws, loader
buckets, pump housings
19XX High carbon Martensitic steel with Hard, check crack-free abrasion Clinker crushing rolls, hammers, drill collars
primary alloy carbide resistant
2XXX Chromium White Irons

21XX Austenitic iron Corrosion, abrasion and impact Crushing equipment (jaws, rolls, hammers, mantles) pump
resistant casings, impellors, pipeline elbows
22XX Martensitic iron Very hard, corrosion, erosion resistant Agricultural plough shares, tines mill scraper blades, wear
bars, bucket lips, crushing rolls
23XX Austenitic chromium carbide iron High abrasion resistance Screen butt straps, quarry screen plates, chutes, grizzly
bars, dragline teeth dredge bucket lips, shovel teeth
24XX Complex chromium carbide iron Very highly abrasion resistant plus hot Sizing screens, ball mill liner plates, pump impellors,
includes types containing up to 45% abrasion resistance crusher jaws, agricultural implements, scapers
tungsten
25XX Martensitic chromium carbide iron Highly erosion resistant Wet applications in mining and crushing industries (ball
mill liners)
26XX Low chromium white iron Resistant to fine abrasion Pug mill praddles, clay augers, screens and granulators

8 Hardfacing
3XXX Tungsten Carbide Composites (Minimum 45wt% Tungsten Carbide)

31XX Carbide chips in Cu alloy matrix Protruding carbides useful as individual Rock drills, oil drills, oil well tools
>4000 μm cutting edges
32XX Tungsten carbide granules in an Fe rich Cutting and wear resistant applications Bucket teeth, ripper points, oil drill collars, auger blades
matrix >850 μm and teeth, oil well drills, bulldozer end tips
33XX 425–850 μm Gouging resistant Rock drills, ditcher teeth, dry cement pump screws,
suction dredge blades
34XX 150-425 μm Gouging resistant Ripper lines, ditcher teeth, cement pump screws,
churn-drills
35XX <150 μm Extreme abrasion resistance Tool joints
36XX Tungsten carbide granules in a Ni-B Hot abrasion resistance and cutting Plough share edges, knives, boring bars, bottle machine
matrix < 75 μm parts, sand slingers, sand mixer blades
4XXX Cobalt Alloys

41XX Complex Co-base solid solution Tough, creep resistant, cavitation Hot shear blades, valve seats
resistant
42XX Hypo-eutectic Co-Cr-W alloy Strong, cavitation resistant Exhaust valves in diesel engines, cold shear blades
43XX Hypo-eutectic Co-Cr-W alloy Hard, cavitation resistant Scrapers, feeders, screws etc. in chemical, mining and
cement industries
44XX Co-Cr-Ni-W alloy (powder) Strong, cavitation resistant Timber saw blades, valve seats, shear blades
5XXX Nickel Alloys

51XX Complex Ni-base solid solution Tough, creep resistant, hot hardness Hoppers, forging dies and hammers, hot trimming and
punching dies.
52XX Low melting point Ni-B alloy High hot erosion resistance Slurry pumps and piping
53XX Tungsten carbide (<45 wt%) in a Ni-B Lower abrasion resistance than 36XX Hot forging dies, parts subjected to hot erosion in
matrix chemical plants
54XX Solid solution Highly corrosion resistant Valve bodies and parts subject to oxidation
6XXX Copper Alloys

61XX Phosphor bronze (4–6% Sn) Soft corrosion resistant Light load bearings
62XX Phosphor bronze (7–9% Sn) Good bearing properties, wear/ Medium load bearings, crank press, transmission housing,
corrosion resistant pump rotors
63XX High tensile brass (Cu-Zn-Mn) Low friction bearing, wear/corrosion Light load bearings, hydraulic rams and pistons
resistant
64XX Nickel bronze (9–13% Ni) Low friction bearing, work hardens, Gear teeth, cams, bearings, percussion heads, slides,
corrosion resistant service where work hardening required
65XX Aluminium bronze (9.5–14% Al) Tough erosion/cavitation resistant Heavy load bearings, valve seats, marine castings, overlay
deposited on steel
66XX Nickel aluminium bronze Tough, work hardens, impact/ corrosion Form dies, impellers, axles, valve seats, propellers
resistant
67XX Complex aluminium bronze Erosion/cavitation/corrosion resistant Seawater pumps, impellers under heavy load, propellers
(Cu-Mn-Fe-Ni-Al) and applications subject to severe cavitation

Hardfacing 8
Application and Finishing

The success of any reclamation or preventative maintenance
repair does not lie only in the correct identification of the wear
mechanism or choice of the consumable, but also in the application
and finishing of the build-up material.
Pre-heating
Many components that can be reclaimed are made from either cast
steel or alloyed steel plate.
As a precautionary step, components should never be welded cold,
with the exception of manganese steel. The degree of preheating
is highly dependant on the composition of the component (see
page 332).
Buffer Layers
Buffer layers are applied when the base material has a low
weldability or to reduce the dilution when welding highly alloyed
consumables.
Austenitic buffers will stop cracks from progressing into the base
material, but are not suitable for use under Martensitic steels
(14XX, 18XX, 19XX alloys).
Dilution
Deposit dilution occurs when base metals melted by the electric
arc, mix with the molten weld metal during the welding process.
Dilution can result in:
a) The depletion of alloying elements in the weld metal resulting in
lower hardness figures or
b) The absorption of elements like carbon into the deposited weld
metal with increased hardness and possible relief cracking in low-
alloyed surfacing materials
Relief Checking
Relief checking occurs in high hardness and carbide bearing
hardfacing alloys as a result of a large difference between the rate of
expansion and contraction between it and the base material. Relief
checking occurs only in the weld metal itself. Often the amount of
relief checking can be minimised if high pre-heat temperatures are
used and cooling occurs at a very slow rate.
Finishing
Reclaimed components are often re-machined. It is therefore
necessary to establish beforehand the final hardness of the required
reclamation.
Hardness of 450 HB can still be machined, although deposits harder
than 480 HB are normally ground.

8 Hardfacing
MMA Electrodes
Cobalarc Austex
Typical weld deposit hardness HRC HV30 Finishing recommendations
N Metal enriched, rutile type electrode
All weld metal deposit 20 240 Machinable with carbide tools
N For joining dissimilar steels or as a 3.2 mm size can be used for vertical welding
buffer layer prior to hard surfacing Work hardened deposit 40 400
by depositing overlapping horizontal stringer
N Tough, machinable austenitic stainless passes
steel-deposit
Packaging and operating data AC (minimum 50 OCV) DC- polarity
Classifications Electrode Approx no. Current range
AS / NZS 2576:1315-A4 Size (mm) Length (mm) rods / kg (A) Packet (kg) Carton (kg) Part No.
W.T.I.A. Tech. Note 4: 1315-A4 3.2 380 20 105–140 5 15 (3 x 5) 613973
4.0 380 13 140–180 5 15 (3 x 5) 613974
Typical all weld metal deposit analysis (%)
5.0 450 7 170–210 5 15 (3 x 5) 613975
C Mn Si Cr Ni
0.10 1.50 0.90 24.5 9.3
Cobalarc Mangcraft Typical weld deposit hardness HRC HV30 Finishing recommendations
N Austenitic manganese steel electrode All weld metal deposit 15 – Machinable with carbide tools
N For building up and reinforcing 11–14% Work hardened deposit 43 425
manganese steels
N Tough and impact resistant weld deposit Packaging and operating data AC (minimum 55 OCV) DC- polarity
N Work hardens under heavy impact Electrode
Approx No. Current range
Size (mm) Length (mm) (rods / kg) (A) Packet (kg) Carton (kg) Part No.
Classifications
4.0 380 17 130–170 5 15 (3 x 5) 611504
AS / NZS 2576: 1215 - A4
W.T.I.A. Tech. Note 4: 1215 - A4 5.0 450 10 150–200 5 15 (3 x 5) 611505
Typical all weld metal deposit analysis (%)

C Mn Si
0.60 12.0 0.10
Cobalarc 350 Typical all weld metal deposit analysis (%) Finishing recommendations
N Metal enriched, rutile type electrode. C Mn Si Cr Mo Machinable
N For re-building worn steel components 0.07 0.85 0.30 1.85 0.5
N Tough, machinable low carbon
martensitic steel deposit Typical weld deposit hardness HRC HV30
N For the manual arc build-up and Single layer on mild steel 28 290
surfacing of steel gear, shafts, rails, shovel
All weld metal deposit 35 350
pads, track links, rolls and wheels etc.
Classifications Packaging and operating data AC (minimum 55 OCV) DC- polarity
AS / NZS 2576: 1435-A4 Electrode

Approx No. Current range
W.T.I.A. Tech. Note 4: 1435-A4 Size (mm) Length (mm) (rods / kg) (A) Packet (kg) Carton (kg) Part No.
3.2 380 25 100–150 5 15 (3 x 5) 611443
4.0 380 16 140–200 5 15 (3 x 5) 611444

Hardfacing 8
MMA Electrodes
Cobalarc 650
Classifications Typical weld deposit hardness HRC HV30
N Metal enriched, rutile type electrode
AS / NZS 2576: 1855-A4 Single layer on mild steel 55 600
N For re-building or surfacing worn W.T.I.A. Tech. Note 4: 1855-A4
steel components All weld metal deposit 57 640
N Air hardening, crack free, martensitic Typical all weld metal deposit analysis (%):
steel deposit Finishing recommendations
C Mn Si Cr Mo
N Typical applications include the surfacing Not machinable / grinding only
0.58 1.1 0.6 5.3 0.25
of-agricultural points, shears and tynes,
grader and dozer blades, conveyor
screws and post hole augers etc. Packaging and operating data AC (minimum 55 OCV) DC+ or DC– polarity
Electrode
Approx No. Current
3.2 380 31 105–135 5 15 (3 x 5) 611463
4.0 380 21 140–180 5 15 (3 x 5) 611464
Cobalarc 750 Typical all weld metal deposit analysis (%): Finishing recommendations
N Rutile type, AC / DC hard surfacing C Mn Si Cr Mo Not machinable / grinding only
electrode 0.60 0.46 0.75 5.9 0.40 3.2 mm and 4.0 mm sizes can be used for
N Easy arc starting and stable running vertical welding by depositing overlapping
on-portable AC welding sets Typical weld deposit hardness HRC HV30 horizontal stringer passes.
( r 45 OCV)
Single layer on mild steel 64 800
N Air hardening, crack free, martensitic
Two layers on mild steel* 62 750
steel deposit
* Not recommended for multi-pass welding heavier than
N Typical applications include the 3 layers
surfacing of-agricultural equipment
and components including points,
Packaging and operating data AC (minimum 45 OCV) DC– polarity
shears, post hole augers, ripper
teeth and tynes etc. Electrode
Approx No. Current
AS / NZS 2576: 1860-A4 4.0 380 17 120–170 5 15 (3 x 5) 611474
W.T.I.A. Tech. Note 4: 1860-A4
Easyweld Blister Pack
10 x 3.2 mm rod Cobalarc-750 Blister Pack 322218

8 Hardfacing
MMA Electrodes
Cobalarc Toolcraft Typical all weld metal deposit analysis (%):

N Versatile manual arc welding electrode C Mn Si Cr Mo
Finishing recommendations
N Secondary hardening, shock resistant 0.58 0.10 0.20 5.5 6.8
Not machinable / grinding only
properties
3.2 mm size can be used for vertical welding
N Crack free Cr-Mo steel deposit for Typical weld deposit hardness HRC HV30 by depositing overlapping horizontal stringer
repairing blades, dies, punches etc. Single layer on mild steel 55 600 passes
N Also suitable for general hard surfacing All Weld Metal Deposit 60 700
in low stress abrasion conditions
Packaging and operating data — AC (minimum 45 OCV) DC+ polarity

Classifications
Electrode
AS / NZS 2576: 1560-A4 Approx No. Current
W.T.I.A. Tech. Note 4: 1560-A4 Size (mm) Length (mm) (rods / kg) range (A) Packet (kg) Carton (kg) Part No.
3.2 380 28 90–125 5 15 (3 x 5) 611523
2.5 300 54 60–90 20 Rod 322115
Cobalarc CR70 Typical weld deposit analysis (%) Typical weld deposit hardness HRC HV30
N Highly alloyed manual arc electrode Single layer on mild steel: Single layer on mild steel 55 600
N High chromium carbide iron deposit C Mn Si Cr All weld metal deposit 59 690
N Primary chromium iron carbides 3.3 1.5 1.0 25 Deposits contain chromium carbides with hardness up
to 1,500 HV
in-a-single-layer All weld metal deposit:
N Ideal for coarse abrasion and low C Mn Si Cr Finishing recommendations
to-moderate impact loading
4.0 1.8 1.2 31 Grinding only
N Typical applications of Cobalarc CR70
include the hard surfacing of crusher 3.2 and 4.0 mm sizes can be used for vertical welding by
depositing overlapping horizontal stringer passes.
cones and mantles, swing hammers,
bucket teeth and lips, dozer end
plates and sugar mill rolls-etc. Packaging and operating data — AC (minimum 50 OCV) DC+ polarity
Electrode
Approx No. Current
Classifications
AS / NZS 2576: 2355-A4
3.2 380 18 90–140 5 15 (3 x 5) 613493
4.0 380 11 130–200 5 15 (3 x 5) 613494
5.0 450 6 180–250 5 15 (3 x 5) 613495

Hardfacing 8
MMA Electrodes
Cobalarc Borochrome Typical weld deposit analysis (%) Typical weld deposit hardness HRC HV30
N Highly alloyed manual arc electrode Single layer on mild steel Single layer on mild steel 58 660
N Martensitic chromium carbide iron C Mn Si Cr V B All weld metal deposit 60 700
deposit 2.7 0.4 1.8 20.0 1.4 1.0 Deposits contain chromium carbides with hardness up
to 1,500 HV
N Ideal for fine particle (wet or dry) All weld metal deposit
abrasion and low impact loading.
C Mn Si Cr V B Finishing recommendations
N Primary chromium iron carbides in a
3.2 0.4 2.4 24.0 1.7 1.2 Grinding only
hard, martensitic matrix
N Typical applications include the hard
surfacing of sand chutes, dredge Packaging and operating data AC (minimum 50 OCV) DC+ polarity
components, ripper shanks, screens, Electrode
grizzly bars, scraper blades and bucket Approx No. Current
lips and teeth
4.0 380 11 140–180 5 15 (3 x 5) 613964
AS / NZS 2576: 2560-A4
Stoody Tube
Operational Characteristics/Welding Typical Weld Deposit Hardness
Borium AC/DC Parameters:
HRC HV30
Replaces Cobalarc 4 Dia. (mm) 4.0 4.8 6.4
Single Layer on Mild Steel 62 750
N Highly Alloyed Tubular Electrode. Mesh Size 20–30 20–30 10–30
All Weld Metal Deposit 64 800
N Partially Dissolved Tungsten Carbides Position Flat Flat Flat
Deposits contain Tungsten Carbides with
bonded in an Iron Rich Matrix.
hardness up to 2,200 HV.
N Resistant to Extreme Abrasion and Low Typical Weld Deposit Analysis*:
* Actual weld deposit consists of undissolved Tungsten
Impact Loading. C Mn W Cr Carbide particles in a eutectic matrix of C-W-Cr-Fe. The
analysis of the matrix will vary with the proportion of
Single Layer on Mild 3.1 0.9 44 6 Tungsten Carbides dissolved during welding.
Classifications
Steel
AS/NZS 2576: 3460-A4. Finishing Recommendations
All Weld Metal 3.7 1 53 7
W.T.I.A. Tech Note 4: 3460-A4. Deposit Grinding only.

AC (min 50 OCV), DC+ polarity.
Electrode Electrodes/ Current Packet Carton Part No.
kg Range (A)
Size (mm) Length (mm)
5.5 350 9 120–150 4.5kg vac 10229500
pack
NOTE: one size only

8 Hardfacing
MMA Electrodes
Cobalarc 9e
N Highly alloyed extruded electrode Typical weld deposit analysis (%) Finishing recommendations
N Versatile, complex carbide iron deposit Single layer on mild steel: Grinding only
N Resistant to both coarse and fine C Mn Si Cr Ni Mo V
abrasion and moderate to heavy impact Identification colours
loading 4.0 0.9 1.1 25.0 0.4 1.5 0.2
White (Single dot near holder end)
N Typical applications include the hard All weld metal deposit:
3.2 mm and 4.0 mm sizes can be used for vertical surfacing
surfacing of railway ballast tampers, C Mn Si Cr Ni Mo V by depositing overlapping horizontal stringer passes
dredge buckets and lips, earth-moving 4.8 1.1 1.4 30.0 0.5 1.7 0.2
equipment, power shovels, rolling mill
guides, sizing screens, ripper teeth and
Typical weld deposit hardness HRC HV30
crushing equipment
Classifications All weld metal deposit 63 780
AS / NZS 2576: 2460-A4 Deposits contain complex chromium carbides with
hardness up to 1,500 H.
Packaging and operating data AC (minimum 50 OCV) DC+ polarity

Electrode
Approx No. Current
3.2 380 17 60–120 5 15 (3 x 5) 613350
4.0 380 10 70–150 5 15 (3 x 5) 613360
5.0 450 5 150–300 5 15 (3 x 5) 613370

Hardfacing 8
FCAW Wire
Stoody Super Typical all weld metal deposit analysis (%) Recommended shielding gases
Build Up G / O C: 0.10 Mn: 1.50 Si: 0.40 1.2 mm and 1.6 mm Cobalarc 350-G
N Gas (-G) and self shielded (-O), Cr: 2.60 Mo: 0.70 Fe: balance Stainshield®
tubular hardfacing wires. 2.4 mm Cobalarc 350-O
N Tough, machinable low carbon Typical weld deposit hardness HRC HV30 Open arc or Industrial grade CO2
martensitic steel deposit. Single layer on mild steel 30 300 1.2 mm and 1.6 mm sizes can be used for vertical surfacing
N Recommended for the build-up and All weld metal deposit 35 350
by depositing overlapping horizontal stringer passes.
surfacing of steel track rolls, idler
wheels, track pads, drive sprockets, pins,
links and other components subject to Finishing recommendations
abrasion and / or metal-to-metal wear. Machinable carbide tools recommended
Classifications Packaging and operating data DC Electrode Positive

1.2* and 2.4† mm Current Rec. stickout Pack weight
1.6 mm Dia. (mm) range (A) Voltage (V) ESO (mm) Pack type (kg) Part No.
AS / NZS 2576: 1435-B5 1435-B7 1.2 120–220 18–24 15–20 300 mm Spool 15 11423600
W.T.I.A. Tech. Note 4: 1435-B5 1435-B7 1.6 140–260 23–26 15–25 300 mm Spool 15 11946200
*1.2 mm and 1.6 mm Stoody Super Build 2.4 250–450 24–28 20–35 Coil 27 11183600
Up-G wires are B5 type wires which require
a shielding gas.
†
2.4 mm Stoody Super Build Up-O is a B7 type
open arc wire which requires no shielding gas.
Stoody 965 G / O Typical all weld metal deposit analysis (%): Recommended shielding gases
N Gas (-G) and self shielded (-O), C: 0.50 Mn: 1.70 Si: 1.40 1.2 mm and 1.6 mm Cobalarc 650-G
tubular hardfacing wires Cr: 6.20 Fe: balance Stainshield®
N Air hardening, crack free, martensitic 2.4 mm Cobalarc 650-O
steel deposit
Typical weld deposit hardness HRC HV30 Open arc or Industrial grade CO2
N Resistant to hard particle abrasion and
Single layer on mild steel 55 600 1.2 mm and 1.6 mm sizes can be used for vertical surfacing
moderate impact loading by depositing overlapping horizontal stringer passes.
N Typical applications include the surfacing
of agricultural points, shares and tynes,
sand dredge cutter heads, dredge rollers Finishing recommendations
and tumblers, conveyor screws, bucket Not machinable, grinding only
lips, etc.
Packaging and operating data DC Electrode Positive

Classifications
Current Rec. stickout Pack weight
1.2* and 2.4† mm
Dia. (mm) range (A) Voltage (V) ESO (mm) Pack type (kg) Part No.
1.6 mm
1.2 120–250 18–24 15–20 300 mm Spool 15 11423100
AS / NZS 2576: 1855-B5 1855-B7
1.6 140–260 23–26 15–25 300 mm Spool 15 11501500
W.T.I.A. Tech. Note 4: 1855-B5 1855-B7
2.4 250–450 24–28 20–35 Coil 27 11946100
*1.2 mm and 1.6 mm Stoody 965-G wires are B5 type
wires which require a shielding gas.
†
2.4 mm Stoody 965-O is a B7 type open arc wire which
requires no shielding gas.

8 Hardfacing
FCAW Wire
Stoody 850-O
Typical all weld metal deposit analysis (%) Finishing recommendations
N Self shielded (-O), tubular hardfacing wire
C: 0.95 Mn: 0.6 Si: 0.9 Grinding only
N Air hardening, crack prone high carbon,
martensitic steel deposit Cr: 6.5 Mo: 3.5 B: 1.5
N Resistant to severe abrasion and low
impact loading Typical weld deposit hardness HRC HV30 Open arc or welding grade CO2
N Typical applications include the hard Single layer on mild steel 62 750 1.2 mm size can be used for vertical surfacing by depositing
overlapping horizontal stringer passes.
surfacing of agricultural, mining and All weld metal deposit 65 830
materials handling equipment including
tynes, points, conveyor screws, dredge
buckets, cane harvester cutters / elevators Packaging and operating data DC Electrode Positive
and sugar mill scraper plates Current Rec. stickout Pack weight
Dia. (mm) range (A) Voltage (V) ESO (mm) Pack type (kg) Part No.
Classifications 1.2 120–250 18–24 15–20 300 mm Spool 15 11945500
AS / NZS 2576: 1865-B7.
W.T.I.A. Tech. Note 4: 1865-B7
Stoody Dynamang-O
Typical all weld metal deposit analysis (%) Typical weld deposit hardness HRC HV30
N Self shielded (-O), tubular
hardfacing wire C: 0.90% Mn: 13.40% Si: 0.37% All weld metal deposit 17 220
N Tough, work hardening austenitic Ni: 2.7% Cr: 2.50% Work hardened 52 540
manganese steel deposit
N Typical applications include the repair Typical weld deposit properties Finishing recommendations
of manganese steel crusher rolls, jaw Yield stress 480 MPa Machinable as deposited.
and hammer crushers, gyratory mantles, Tensile strength 810 MPa
blow bars and dredge pump cutters etc. Recommended shielding gas
Elongation 42%
Open arc or welding grade CO2
Classifications
1.6 mm size can be used for vertical surfacing by
AS / NZS 2576: 1215-B7 depositing overlapping horizontal stringer passes.

Current Electrode Pack weight
Dia. (mm) range (A) Voltage (V) stickout (mm) Pack type (kg) Part No.
1.6 150–220 22–26 15–25 Spool 15 11446700
2.8 200–375 25–28 20–35 Coil 27 11249900

Hardfacing 8
FCAW Wire
Stoody 101 HC G / O Typical weld metal deposit analysis (%) Finishing recommendations
1.2 and 1.6 mm Single layer on mild steel: Grinding only
N High alloy, tubular hardfacing wire C: 4.0 Mn: 0.7 Si: 0.7 Cr: 14.0
N High chromium carbide iron deposit All weld metal deposit: Recommended shielding gas
or ground engaging applications C: 5.2 Mn: 0.7 Si: 0.7 Cr: 19.0 1.2 mm Coarseclad-G
N Resistant to severe abrasion and low Stainshield®
to moderate impact loading
Typical weld deposit hardness HRC HV30 1.6 mm Coarseclad-O
N Typical applications include the hard
Single layer on mild steel 55 600 Open arc or Industrial grade CO2
surfacing of crusher cones and mantles,
swing hammers, earthmoving buckets, All weld metal deposit 60 700 1.2 mm size is suitable for vertical-up surfacing using a
wide weaving technique.
scarifier points and sugar harvesting Deposits contain chromium carbides with hardness up to
and milling equipment 1,500 HV (80 HRc)
Classifications Packaging and operating data DC Electrode Positive

1.2* mm 1.6† mm Current Rec. stickout Pack
Dia. (mm) range (A) Voltage (V) ESO (mm) Pack type weight (kg) Part No.
AS / NZS 2576: 2360-B5 2360-B
1.2 Coarseclad-G 150–200 22–26 12–20 Spool 15 11436300
W.T.I.A. Tech. Note 4: 2360-B5 2360-B7
*1.2 mm Stoody 101 HC-G is a B5 type wire which
1.6 Coarseclad-O 200–260 24–28 15–25 Spool 15 11304700
requires a shielding gas.
†
1.6 mm Stoody 101 HC-o is a B7 type wire which
requires no shielding gas
Stoody 100 HC-O

Typical weld metal deposit analysis (%) Finishing recommendations
2.4 and 2.8 mm
N Self shielded (-O), tubular Single layer on mild steel: Grinding only
hardfacing wire C: 4.2 Mn: 0.7 Si: 0.7 Cr: 20
N High chromium carbide iron deposit All weld metal deposit: Recommended shielding gas
or ground engaging applications Open arc or welding grade CO2
C: 5.5 Mn: 1.0 Si: 0.9 Cr: 25
N Resistant to coarse abrasion and low
to moderate impact loading
Typical weld deposit hardness HRC HV30
N Typical applications include hard
surfacing of crusher cones and mantles,
swing hammers, earthmoving buckets, All weld metal deposit 63 780
blades and rippers Deposits contain chromium carbides with hardness up to
1,500 HV (80 HRc)
Classifications
AS / NZS 2576: 2360-B7
Current Rec. stickout Pack
Dia. (mm) range (A) Voltage (V) ESO (mm) Pack type weight (kg) Part No.
2.4 250–350 25–30 35–55 Coil 27 11313400
2.8 300–450 27–33 35–55 Coil 27 11001000

8 Hardfacing
FCAW Wire
Stoody Fineclad-O
Typical weld deposit analysis (%) Finishing recommendations
N Self shielded (-O), tubular
hardfacing wire Single layer on mild steel: Grinding only
N Chromium iron carbides in a hard, C: 3.5 Mn: 0.3 Si: 0.4

martensitic matrix Recommended shielding gas
Cr: 14 B: 0.5
N Resistant to fine, wet or dry abrasion Open arc or welding grade CO2
All weld metal deposit:
1.6 mm size can be used for vertical surfacing by depositing
N Typical applications include the surfacing C: 4.8 Mn: 0.5 Si: 0.6 overlapping horizontal stringer passes
of sand chutes, dredge components,
Cr: 20 B: 0.75
ripper shanks, screens, grizzly bars,
scraper blades, and bucket teeth and
lips etc Typical weld deposit hardness HRC HV30
Classifications
AS / NZS 2576: 2565-B7
Deposits contain chromium carbides with hardness up
W.T.I.A. Tech. Note 4: 2565-B7 to 1,500 HV (80 HRc)

Wire dia. Current Electrode Pack
mm range (A) Voltage (V) stickout (mm) Pack type weight (kg) Part No.
1.6 200–260 24–28 15–25 Spool 15 11945800
2.4 250–350 25–30 35–55 Coil 27 11945900
Stoody 104
Typical All Weld Deposit Analysis Deposit Characteristics:
(Replaces Cobalarc 104-SA)
C Mn Si Cr Fe Abrasion resistance Low
N Submerged arc (-SA) tubular build-up
wire. 0.07 2.9 1.25 1.15 bal Impact resistance Excellent
N Tough, machinable, low carbon pearlitic Compressive strength Excellent

steel deposit. Typical Weld Deposit Hardness
Hardness 29 HRc
N Resistant to high compressive loading. HRC HV30
Surface cross checks No
N For the unlimited build-up of worn steel All weld metal deposit 29 290
Magnetic Yes
components.
Finishing Recommendations: Deposit Layers Unlimited
Classifications Machinable. Machinability Yes
AS/NZS 2576: 1125-B1.

Recommended Flux: Comparable Cigweld Products:
W.T.I.A.Tech Note 4: 1125-B1.
Stoody S Stoody Build Up-O self shielded tubular wire
AS/NZS 2576:1125-B7

AC, DC electrode positive or negative
Wire Current Voltage Electrode Pack Type Weight (kg) Part No.
diameter Range (A) Range (V) Stickout
mm (ESO) mm
3.2 350–400 26–30 25–35 Coil 27kg 11820300
3.2 350–400 26–30 25–35 Half Pack 90kg 11040900
3.2 350–400 26–30 25–35 Drum 226kg 11039500

Hardfacing 8
FCAW Wire
ChainLinc Lincore 30-S Lincore 33

A self shielded, flux cored electrode for Extremely tough and forgeable deposit A hard wearing low alloy steel for
rebuilding heavily worn components such as for rebuilding mild and alloy steels. For rebuilding and hardfacing heavily worked
dragline chains. It is characterised by a soft, rebuilding idlers, crane and mine car wheels, machinery components. For rebuilding
low penetrating arc and is suitable for semi- build-up of steel rolls. gears, idlers, pins, chains and trunnions.
auto or auto welding. It produces a tough
low alloy deposit. Classifications (with 802, 860 or 880 flux) Classifications
AS 2576 : 1130-B1. 29–31 Rc. DIN 8555 Part 1: AS 2576: 1130-B7. DIN 8555 Part 1:UP1-GF-
Classifications UP1-GF-802 / 860 / 880-300 880M-300 (with 880M flux)
AS 2576: 1125-B7 (metal-to-metal wear),
26–29 Rc. DIN 8555 Part 1: MF1-250 Size (mm) Weight (kg) Part No. Size (mm) Weight (kg) Part No.
3.2 22.68 Coil 032403 1.6 9.98 Readi reel ED016872
3.2 272.16 Speed 032413 2.0 6.35* Coil ED011237
2.8 25 Coil 032401 feed drum
2.0 25 Coil ED011238
2.8 25 Coil ED011240
1.6 11.34 reel ED031117
*4 per box
Lincore 36LS Lincore 40-S Lincore 42-S

A highly versatile wire for semi and fully A long-lasting alloy steel that resists Multi-layer weld deposit resistant metal-
automatic rebuilding of metal-to-metal metal-to-metal and abrasive wear. For final to-metal wear. For final overlay on tractor
wearing parts. For rebuilding drill rods, rail overlay on tractor idlers, rollers, and mine idlers, rollers, shafts etc.
car wear surfaces, mining machinery, gears car wheels.
and pins. Classifications (with 802 or 880 flux)
Classifications (with 802 or 880 flux) AS 2576: 1440-B1 (metal-to-metal wear)
Classifications AS 2576: 1440-B1 (metal-to-metal wear)
AS 2576: 1440-B7. DIN 8555 Part 1: UP2-GF- 38-41 Rc. DIN 8555 Part 1: UP2-GF-802 / 880- Size (mm) Weight (kg) Part No.
880M-350 (with 880M flux) 40
3.2 22.68 Coil ED029159
3.2 136.2 Drum ED029264
1.6 12.5 Spool 032510 3.2 22.68 Coil ED015892
Lincore 40-O Lincore 50 Lincore 55

Open arc version of the above product, Hardfacing protection of parts that must An excellent general purpose deposit
used in similar applications, in areas where resist both abrasion and moderate impact. for protection against metal-to-metal
submerged arc welding is not practical. For crusher rolls and grinding equipment, and abrasive wear. For earthmoving
agricultural points and digger teeth. equipment, high hardness gears, augers and
Classification AS 2576: 1440-B7 agricultural tools.
Classifications
Size (mm) Weight (kg) Part No. AS 2576: 2150-B7 (or 802 flux) 2155-B1 Classifications
(with 880 flux) AS 2576: 1855-B1. DIN 8555 Part 1: UP6-GF-
2.8 22.68 Coil ED025908
880M-55 (with 880M flux)
1.2 9.98 Readi reel ED020826 Size (mm) Weight (kg) Part No.
1.6 9.98 Readi reel ED020827 2.0 6.35 Coil ED011277
2.8 22.68 Coil ED011275 2.0 22.68 Coil ED031122

2.8 22.68 Coil ED011280

8 Hardfacing
FCAW Wire
Lincore 60-O Lincore 65-O Lincore 15CrMn

High alloy abrasion resistant deposit for Self-shielded, flux-cored wire that resists Premium austenitic manganese steel
crushing equipment, mixing paddles, ground severe abrasion with light impact. Higher for joining manganese steel to itself or
engaging tools, hammers and augers. carbon and chrome deposits than Lincore dissimilar metals, or as a build-up prior to
60-0. Use on wear plate, coal pulveriser hardfacing with Lincore 50 or Lincore 60-0.
Classifications rolls, earth engaging tools, and on slurry
pipe and elbows. Classifications
AS 2576: 2355-B7 (severe abrasion and
moderate impact), 56-60 Rc. DIN 8555 Part 1 AS 2576: 1720(b)-B7 (severe impact).
1983: MF10-60-RGNZ Work hardens to 50 Rc DIN 8555 Part 1:
2.8 22.68 Coil ED026077 MF8-250RKNP
Size (mm) Weight (kg) Part No. 3.2 22.68 Coil ED026076
1.2 9.98 Readi reel ED031131 Size (mm) Weight (kg) Part No.
2.8 226.8 Drum ED026083
1.6 9.98 Readi reel ED031132 2.0 11.34 Spool ED031126
2.0 22.68 Coil ED019887 2.8 22.68 Coil ED022061
Lincore M Crushcore Lincore T & D

Produces austenitic manganese steel Specifically designed for roller arcing on Hot tool steel deposit for rebuilding cutting
deposit. For crusher cones, jaws and rotating sugar crushing rolls. tools, dies, blades and edges. Can be temper
manganese rail points. hardened to above 55 Rc.
Classifications
Classifications AS 2576:2155-B7 (impact and abrasion)* Classifications
AS 2576: 1220-B7 (severe impact). Work 54–58 Rc. DIN 8555 Part 1: MF10-55GRN AS 2576:1550-B7 (severe metal-to-metal wear)
hardens to 50 Rc DIN 8555 Part 1: MF7- 52-55 Rc. DIN 8555 Part 1: MF3-50-T
250KNP
2.0 25 Coil 032601 Size (mm) Weight (kg) Part No.
2.8 25 Coil 032600 1.6 11.34 Spool ED031134
2.0 11.34 Spool ED031130
*Note: Deposit carbon content may exceed
2.8 22.68 Coil ED011164 Classifications limits.

Hardfacing 8
Submerged Arc Wire
Lincore 420 Lincore 423Cr Lincore 424A

A high hardness, crack free 420-type A high chromium wire giving excellent Metal-cored wire with higher nickel content
stainless steel deposit that resists heat, corrosion resistance. Also resists softening than 41NiMo alloy. Flux recommendation is
corrosion and frictional wear. For steel mill while tempering due to alloying with 801 / 880.
rolls, cable sheaves; stainless steel cladding. vanadium and molybdenum. For steel mill
castor rolls and other applications where Size (mm) Weight (kg) Part No.
Classifications (with 802 or 880 flux) low coefficients of friction are required. 3.2 22.68 Coil ED018560
AS 2576 1650-B1 (multi-purpose hardfacing)
48-51 Rc. DIN8555 Part 1 1983: Classifications (with 802 flux)
UP5-GF802 / 880 50-CR
AS 2576 1640-B1 (metal-to-metal wear)
41-45 Rc. DIN 8555 Part 1-1983:
Size (mm) Weight (kg) Part No. UP5-GF-802-40-CR
3.2 22.68 Coil 032505
3.2 230 Drum 032523
2.4 22.68 Coil ED018553
Lincore 96S
A martensitic 420 type of stainless steel
deposit that resists heat corrosion and
metal-tometal wear. For steel with rolls,
cable sheaves, stainless steel cladding.
Classification (with 802 or 880 flux)

AS 2576 4650-B1: 51-53HRC
Size (mm Weight (kg) Part No.

3.2 22.68 Coil 032507
3.2 230 Drum 032522

8 Hardfacing
Submerged Arc Flux Unalloyed
802 880 801

A neutral flux designed for use with solid A neutral flux that may be used with A neutral flux that may be used with some
stainless steel electrodes and some Lincore some hardfacing and build-up wires. hardfacing and build-up wires.
build-up and 400 series martensitic stainless
steel hardfacing wires. Classification AS1858.1 FBL Weight (kg) Part No.
45 Bag KC80104
Classification AS1858.1 FBL Weight (kg) Part No.
45 Bag KC880045
260 Drum KC880260
40 Bag KC802040
Submerged Arc Flux Alloyed
H535 QR8045
Versatile hardfacing flux for abrasive Low alloy flux for semi-automatic or
wear resistance that still allows for some automatic submerged arc surfacing with
machinability. Can also be used for build-up. L-50 or L-60 wire. Applications include
Applications include steel mill rolls, crane rebuilding and hardsurfacing worn low alloy
wheels, idlers and tractor rollers. and carbon steel wheels, rolls, rails and
other components where metal-to-metal
Classification (with L-60 wire) friction is the major cause of wear.
25-45 Rc. DIN 8555 Part 1: Classification (with L-50 wire)
UP1-GZ-H535-350 AS 2576 1440-B4 (metal to metal wear)
DIN 8555 Part 1:UP1-GZ-QR8045-40
45 Bag KC535045 Classification (with L-60 wire)
28-30 Rc. DIN 8555 Part 1:
UP1-GZ-QR8045-300

50 Bag KCQR8045050

Hardfacing 8

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What safety precautions should be taken when welding?

What safety precautions should be taken when welding?

What are some common welding consumables mentioned in the document?

What are some common welding consumables mentioned in the document?

Fundamentals of Manual Metal Arc (MMA) Welding 295

Fundamentals of Metal Inert Gas (MIG) Welding 304

IPRM 2006 : SECTION 8 : CONSUMABLES 293

Important Safety information

Read and understand this information.

Flying particles from Welding arc rays

Colour Code Explanation

Hardfacing Mild Steel Stainless Steel

Low Alloy and

Aluminium Low Hydrogen Copper

294 IPRM 2006 : SECTION 8 : CONSUMABLES

IPRM 2006 : SECTION 8 : CONSUMABLES 295

Recommended Electrode Sizes Electrode Angle

4.0 140–165 Types of Joints

5.0 170–260 Butt Welds

296 IPRM 2006 : SECTION 8 : CONSUMABLES

Butt Weld with Backing Material

Used on thick plates as an alternative to a single

The lower member in this case is bevelled to

IPRM 2006 : SECTION 8 : CONSUMABLES 297

Fillet Welds Throat Thickness

The following terms and deﬁnitions are important in specifying and

298 IPRM 2006 : SECTION 8 : CONSUMABLES

1st Run 2nd Run

IPRM 2006 : SECTION 8 : CONSUMABLES 299

Welding Defects and Problems

Defects Caused by Welding Technique

300 IPRM 2006 : SECTION 8 : CONSUMABLES

Wormhole Porosity (Piping Porosity) Lack of Fusion

IPRM 2006 : SECTION 8 : CONSUMABLES 301

302 IPRM 2006 : SECTION 8 : CONSUMABLES

Care and Conditioning of Consumables

IPRM 2006 : SECTION 8 : CONSUMABLES 303

Chemical composition Grade 316 BOC Stainless Steel 316LSi

As a general rule the selection of a wire is straightforward, in that Aluminium

304 IPRM 2006 : SECTION 8 : CONSUMABLES

4 Portability 5–12 mm Argoshield Universal

Wire Operating Limits

Undercutting and burnback

Defect Free Zone

Spray Transfer (Steel Thickness (mm))

IPRM 2006 : SECTION 8 : CONSUMABLES 305

Correct Application Techniques Torch position for ﬁllet welds

The electrical stickout is the distance between the end of the

Short Normal Long

306 IPRM 2006 : SECTION 8 : CONSUMABLES

Advantage of BOC Smoothpak

IPRM 2006 : SECTION 8 : CONSUMABLES 307

1 Selection of correct consumables Quench and tempered steels 343

Designates the diffusable

308 IPRM 2006 : SECTION 8 : CONSUMABLES

Current / Voltage Envelope for Argoshield 52

Undercutting and burnback 1.6 mm

Burnback and arc instability Positional Welding

Defect Free Zone

Plate Thickness (mm) Flat and Horizontal