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Stainless Steel Electrodes For Flux Cored Arc Welding

Guideline for Welding Stainless Steel with GFW Wires

Guideline for Welding Stainless Steel with GFW Wires

Characteristics GFW wires are electrodes consisting of a stainless steel sheath and flux consisting with mineral and metal powder. They provide good arc stability, produce welds with beautiful bead appearance, and enable joining and overlay welding of stainless steel with ease and at high efficiency. qWire diameter and power sourcer 0.8 mm, 0.9 mm, 1.2 mm, and 1.6 mm of wire diameter are available. Constant potential DC power source such as MAG and MIG power source is applicable. It is noted that pulsed power source is not suitable for FCA welding. qDeposition rate and efficiencyr As shown in Fig.1, deposition rate is high and the deposition efficiency is as high as 90%. Therefore, GFW wires provide higher efficiency in joint and overlay welding compared with SMAW.

120 Deposition rate (g/min) 100 80 60 40 20 0 50 100 150 200 250 Welding current (A) 300 350 SMAW with 4.0mm electrode 0.9mm 1.2mm 1.6mm

Fig.1 Welding current and deposition rate qShielding gasr Recommended shielding gas is CO2 or Ar-20 CO2i more than 20 CO2j . Please refer to the page of each brand. When CO2 is used as shielding gas, metal transfer becomes globular and provides deep penetration and good wettabilty to the sidewall of weld pool, which minimize the weld defects such as the lack of fusion or slag inclusions. Moreover air cooled light torch is available in long time welding operation. On the other hand, Ar-20 CO2 shielding provides metal transfer like splay arc, provides less spatter than CO2 shielding.

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TA S E T O W e l d i n g M a t e r i a l s
Stainless Steel Electrodes For Flux Cored Arc Welding
Guideline for Welding Stainless Steel with GFW Wires

qWelding positionsr Welding in flat position, horizontal position, and vertical position is possible. However, the 1.6 mm wire is limited to flat or horizontal welding. For positional welding, AP series wires are preferable. Please see GFW AP Series. qWelding conditionsr As shown in Fig.2, because of a wide range of welding currents and voltages, it is easy to set up welding conditions and can apply various thickness plate.
40 Welding voltage(V) 35 30 25 20 15 10 50 100 150 200 250 300 350 Welding current (A) 0.9mm 0.8mm 1.2mm 1.6mm

2 Recommended welding conditions

qBead appearancer As GFW wire produces a smooth weld with thin and easy removable slag, there is little post weld cleaning required. Multi-pass welding is easy and there are minimal defects such as porosity, slag inclusions or lack of fusion.

qStandard packing style and unit weightr

Spool 12.5 kg (1.2mm and 1.6 mm) 5.0 kg (0.8mm and 0.9 mm)

Pail-pack

150kgi 1.2mmj

TASETO Co., Ltd

TA S E T O W e l d i n g M a t e r i a l s
Stainless Steel Electrodes For Flux Cored Arc Welding
Guideline for Welding Stainless Steel with GFW Wires
Notes on Usage

qTorch positioningr To control weld pool properly and promote defect free sidewall fusion, trailing torch is preferable. In horizontal fillet welding, please refer the torch positioning shown in Fig.3. qOverlay weldingr In overlay welding with GFW wire on carbon steel, welding parameters varies dilution rate of weld metal 40` 50 with base metal, as shown in Fig.4 and Fig.5. Generally speaking, properties of Type309, frequently used for 1st layer of overlay welding, weld metal overlayed on carbon steel is affected by dilution rate, excess dilution 0` 2mm provides hot cracking or hardening by martensite formation, too little dilution results only slag inclusion Fig.3 Torch positioning in horizontal or lack of fusion but embrittlement of weld metal in fillet welding severe PWHT condition. So, set up welding parameters which provide 20 ` 30% dilution rate. Dilution rate is varied with torch position, keep constant welding parameter and torch position to keep constant dilution.
Stringer 40 Dilution rate(%)

Weaving 40 Dilution rate(%)

220A

220A 30 20 10 0 190A 160A

30 20 10 0 10 20 30

190A 160A

40

50

10

15 Welding speed(cm/min)

20

Welding speed(cm/min)

Oscillate widthF10mm, Oscillate cycleF0.75H z Wire positionFtow of previous bead Fig. 4 Variation of dilution rate with welding parametersi wire diameterF1.2mmj
Stringer
Dilution rate(%)

Weaving 300A 250A 200A 40 30 20 10 0 300A 250A 200A

40
Dilution rate(%)

30 20 10 0 10 20 30

40

50

10

15 Welding speed(cm/min)

20

Welding speed(cm/min)

Wire positionFtow of previous bead 3

Oscillate widthF10mm, Oscillate cycleF0.75H z

TASETO Co., Ltd

TA S E T O W e l d i n g M a t e r i a l s
Stainless Steel Electrodes For Flux Cored Arc Welding
Guideline for Welding Stainless Steel with GFW Wires Fig. 5 Variation of dilution rate with welding parametersi wire diameterF1.6mmj
35

qGroover Keep dry and remove scale, rust and organic such as oil, greases and paints from groove before welding. Also, do not apply the spatter-guard on welding groove.

Dilution ratei%j

30 25

20

qShielding gasr 15 -3 -2 -1 0 1 2 3 Too little or excess flow rate of Distance from towimmj shielding gas cause weld defects such as blowholes. Control the flow rate of shielding gas at 20 to 25L/min for 1.6 Fig.6 Variation of dilution rate with torch mm and 1.2 mm diameter and 15to position 20L/min for 0.9 mm and 0.8 mm diameter. Wind decreases shielding effect and permits nitrogen mixing in molten pool. So it is afraid of hot cracking or other defects such as blowholes in weld metal. Provide a proper protection measure against the wind in windy condition. qFumer Because of higher deposition rate, GFW wires generate more fumes than covered electrodes do. For this reason, wear a dust repirator and use enough ventilation to keep fumes away from breathing zone. Before using, read and understand the material safety data sheet MSDS for the wire to be used. qStorager GFW wires do not adsorb moisture as much as covered electrodes do. However, storage for a long time in hot and humid environment or dew condensation on the wire surface caused weld defects such as blowhole. Keep the wire storage situation in dry condition.

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