CREUSABRO 8000(P) 5 - WELDING

April 2001 Issue (Ed.1 Rev 02)

CREUSABRO 8000 (P) plates can be joined using any

conventional welding technology : manual welding with coated
electrode, gas metal arc welding with flux cored wire,
submerged arc welding.

CREUSABRO 8000 (P) plates can be welded without preheating

for combined thickness up to 50 mm (2").

There is a wide range of welding electrodes and ancillary

products available for CREUSABRO 8000(P) welding.

1.
Room temperature : temp of plates must be cut > 10 C (50 F)
PREPARATION
Surfaces to be welded

They have to be sufficiently clean, to avoid deterioration of weld quality

by any oxide, oil, grease or other contamination.
Whenever it is required a shotblasting or sandblasting can be performed.

Raw edges after thermal cutting

These should be ground to remove any residual oxides dross or slag.

Edges before welding

These should be clamped in position, preferably with mechanical

devices.

Tack welding

These should be made by skilled welders and under conditions required

for welding :
- Electrodes dried and conserved according to the recommendations
of producers
- Possibly pre and post-heating.

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April 2001 Issue (Ed.1 Rev 02)

Their length should be greater than 50 mm (2 ").

The parent metal dilution should be limited to avoid risk of weld metal
deposited cracks.
Backward welding done at the end of each bead to properly fill the
craters of welding pass end and, thus, avoid incipient cracks.
Any cracked tack weld must be seriously removed before the welding
operation.

Alignment tolerances

Fastening of welded edges should ensure compliance with alignment

tolerances during all the welding operations.

Wettability and shape of the beads

Good wettability and appropriate shape of the beads are suggested. For
instance one might prefer continuous welds to discontinuous ones.
Geometrical stress concentrations must be avoided.

2. General information
FILLER Electrodes (low hydrogen) currently used in welding of E 255 (A 350 LF1
MATERIALS and LF2) steel grades are suitable for joining abrasion resistant plates.
These products provide much softer weld beads than the plate itself. We
advise, in cases where designs of equipment lead to wear exposure of
welded joints, to carry out protective passes using harder metals such as :
electrode E 13018 according to AWS A 5 - 5
hardfacing materials ensuring 350 to 450 BHN
In case of use solid wire, we recommand to avoid any external coating
(such as borax, molykote,) which may introduce hydrogen in the weld.

For MAG and Gas protected cored wire welding processes we

suggest to use preferably an Argon/18-20 % CO2 gas mixture (M21
mixture according to DIN).

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Ferritic welding materials for joints not exposed to wear

n Shielded manual welding with coated electrode

AFNOR DIN AWS
Specification Specification Specification
AWS A5-1
A 81309 DIN 1913
E 7016 class
E 514/3 B E 5143 B10 class
Or E 7018 class

Welding materials with very low hydrogen content must be used

Some examples of products :

BHLER Fox EV 50
ESAB OK 48-04
KLCKNER Firma 5520 R
OERLIKON Tenacito 38 R
SAF SAFER NF 58 - SAFDRY NF 58
UTP 613 Kb
SMITWELD Conarc 49 C - EMR Sahara
and any other equivalent product.

CREUSABRO 8000 (P) : example of SMAW welded joint

Plate thickness = 40mm (1.63") stick SAFDRY 4mm (0.15") butt
weld
Combined thickness = 80 mm (3.15") - preaheating at 150C (300F)

Photomacrograph (x2)

Hardness profile

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In case of on-site welding, we recommend the use of coated electrodes

with under-vacuum packaging to consume in the course of the day after
opening of the pack.

Example : EMR Sahara, Safdry NF

n Gas Metal Arc Welding (GMAW)

AFNOR DIN AWS
Specification Specification Specification
AWS A5-18
A 81311 DIN 8559
ER 70S4 class
GS 2 SG2
Or ER 70S6 class
A81350
DIN 8559 AWS A-5-20
TGS 51BH
SGB 1 CY 4255 ER 71 T5
TGS 47 BH

Some examples of products

Solid wire Flux coared wire

BHLER EMK7
ESAB OK 12-51 OK 15.00
KLKNER VDG 15/60 EWB1-MF
LINCOLN LNM 27 MC710 H
OERLIKON - Fluxofil 31
SAF NiC 70S Saf Dual 200
and any equivalent product

n Submerged Arc Welding

AFNOR DIN AWS
Specification Specification Specification
DIN 8557 AWS A5-17
NFA 81316 UP-Y 35 or Y31-43S [1 to 3] Wire EM 12K
FP/F or B.IFB F AB Flux F6.A4.EL 12
SA2.47.0302 or - or 1 or
B FB Flux F7.A4.EM 12
Some examples of products
ESAB OK Autrod 12-10 + OK Flux 10-71
SAF Wire AS 26 + Flux AS 72
WIRE AS 35 + Flux AS 72
LINCOLN Wire Lincolnweld 860 + Flux L-61
Wire Lincolnweld 882 + Flux L-60
and any equivalent product

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Ferritic welding materials for joints exposed to wear

These welding materials can be used in surface-protective runs

n Manual welding using coated electrode

AFNOR DIN AWS
Specification Specification Specification
A 81340 DIN 8529 AWS A5-5
EY 89 EY 89 E 12018 class

Some examples of products

BHLER Fox EV 85
ESAB OK-78.05
OERLIKON Tenacito 100
SAF SAFER ND100 - SAFDRY ND100
SMIDWELD Conarc 85 EMR Sahara
and any equivalent product

n GMAW
AFNOR AWS
Specification Specification
A31852 AWS A5-28
TG5 Y89 E 120 S1 class

Some examples of products

Solid wire Coated wire
BHLER Ni Cr Mo 90 IG -
OERLIKON - Fluxofil 45
KLKNER EW X90 -
SAF NIC 88 -
and any equivalent product

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April 2001 Issue (Ed.1 Rev 02)

Hardfacing - Welding material

To use in overlay passes.

In this case, the preheating conditions will be defined by the welding

material being more alloyed than the parent metal

Some examples of products

Manual welding GMAW

with coated electrode
BHLER Fox dur 350 Dur 350 IG
COMMERCY Cydur 2
KLKNER Dura EA 350 Dura EA 300SG.
SOUDOMETAL Soudodur 400
ESAB OK Tubrod 1403

Austenitic or austeno-ferritic material

In case of on-site repairs when it is difficult to maintain the necessary

conditions (for lack of electrodes with under-vacuum packing, electrode
drying system, pre-heating of thick plates, very restrained assembly)
austenitic welding material can be used.

Despite the obvious security provided by such filler materials, it is

strongly recommended to dry the electrodes or fluxes according to
supplier requirements.

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3. General environment conditions

WELDING To avoid risk of cracks :
CONDITIONS For high productive processes to limit dilution of the parent metal.
All welded joints should be protected from wind and rain until
complete cooling of weld has been obtained.
Vibration inducing operations carried out in the vicinity of welded
plates (for example chipping) have an adverse effect on soundness
of welded joints and should be prohibited during welding operations.

Preheating conditions
CREUSABRO 8000 (P) grade can be welded with ferritic filler material
without preheating, if combined thickness does not exceed 50mm (2").
Above this combined thickness, it is recommended to respect the
preheating parameters shown in following table wiht stainless steel filler
material no preheating required.

Table of welding temperatures (plate temperature > 10C (50F))

Heat Pre and post heating conditions
Welding input Combined thickness (mm) (")
processes (kJ/cm) 10 20 30 40 50 60 70 80 90
.4 0.8 1.2 1.6 2 2.4 2.8 3.1 3.5
Stick manual
FERRITIC 1 arc welding 15/20

Semi-automatic 15
FILLER 2
under gas
30

Submerged 20
MATERIAL 3 arc welding
30
STAINLES
S STEEL NO PREHEATING REQUIRED
FILLER
MATERIAL

Without Pre-post heating Pre-post heating

pre-heating at 100C (210F) at 150C (300F)

Sticks or fluxes must be dried and stored according to supplier

requirements. To avoid any drying of filler materials, we suggest to use
under-vacuum packed sticks
Only welding gas free of hydrogen use preferably mixture of Argon,
CO2, O2, He (Atal 5, Arcal 14, Arcal 21, Mi-gaz 18, Argon Mix 1, ...).
In the case of welding with high tensile filler materials, a preheating
can be necessary even for low combined thickness, because of
cracking in weld metal.

Then, it is recommended to ask the filler materials supplier for more

details.
For the same reasons, we suggest to avoid too much dilution with base
material. For high deposition rate processes (SAW), high travel speeds
are then suggested.

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Determination of combined thickness (Ct)

t2

t1 t2 t1

C. thick.= t1 + t2 C. thick.= 2 x t1 + t2

t2 t2

t1 t1
C. thick.= 2 x t1 + t2 C. thick.= t1 + t2

t2 t2

t1 t1

C. thick.= t1 + t2 C. thick.= 2 x t1 + t2

t2 t3

t1
t2

t1

C. thick.= 2 x t1 + 2 x t2 C. thick.= 2 x t1 + t2 + t3
if l < 3 x t2 or
2 x t2 + t1 + t3

Nb - Combined thickness is only a way to assess clamping in

weldments. When several plates are welded together a weldment is
highly clamped, one might over evaluate combined thickness
toguarantee sufficient security.

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Limitation of welding stresses

A proper sequence of welding operations should be followed in order to
limit welding stresses.

Prefer the internal welding to the external welding

Surface repairs in thick plates :

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April 2001 Issue (Ed.1 Rev 02)

As for all the high abrasion resistance steels, it is not recommended to

practise a post-welding heat treatment. Indeed any softening of the
CREUSABRO 8000 (P) base material would affect its excellent anti-
abrasive properties (for your guidance, to refer to the softening
resistance curve Chapter 2 - Page 2.3).

Welding of thin plates (thickness < 0.3")

As it was defined earlier, take care for the preparation of the plates.
(grinding on sand blasting).
When thin plates are welded together, it is better to control the heat
input (1,3 kJ/mm). Too big beads are deleterious because they
cause distorsions and heat affectation through the thickness of the
plates.
Some care must be handled to use appropriated welding sequences.
A shrinkage direction must be kept free to avoid too high stresses
and distorsions.
Welding sequences must be optimised to weld without too much
residual stresses.
Welding consumables must have medium mechanical properties and
GMAW should be used preferably.

Remarks
When welding with GMAW a wire speed lower than 4,5 m/min
(14.8"/min) can guaranty a heat input lower than 1,3 kJ/mm.
When pulsed GMAW is used, we suggest to use 10/10mm (0.4/0.4")
instead of 12/10mm (0.5"/0.4") diameter wires.

Equivalent Carbon
Equivalent carbon formulas are not applicable to
CREUSABRO 8000 which is a high hardness steel grade with alloy
(P)

additions.

Equivalent carbon formulas or HAZ hardness criterias have been

defined for carbon manganese steels. Therefore they are inoperative on
high wear resistance steels. One might, for instance, wonder of the
validity of criterias such hardness in HAZ lower than 350 HV when the
base material itself has an hardness of 460 HV.

Recommendations for CREUSABRO 8000(P) welding have been

determined on a welding test basis. They have been confirmed by
industrial experiments.

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4.
It is recommended to use studs in mild steels S 235 J2 (A 350 LF1)
FLASH STUD grade.
WELDING
Precautions :
In order to guarantee good quality of welds, it is necessary :
- to grind and to centre punch the position where the stud must be
welded.
- to keep welding gun perpendiculary to the surface on which the stud
has to be welded.
- to check for the good selection of welding parameters by carrying
out five preliminary flash welds followed by a pull-off test according
to
NFA 89020 part 2 specification, (+ XPA 89022, performance
classes).
- to check periodically for current operational parameters at manufacturing.

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