SELECTION OF WELDING

CONSUMABLES FOR HEAVY

FABRICATION

BY












SELECTION OF WELDIND
CONSUMABLES FOR HEAVY
FABRICATION









SELECTION OF WELDIND
CONSUMABLES FOR HEAVY
FABRICATION

R.D.Pennathur
MAILAM INDIA LIMITED



EVALUTION OF WELDING

HOW ?

WHEN ?

WHERE ?
TUBAL CAIN
FORGE WELD
KJELLBERG
METAL ARC
1910
BERNADO
CORBON ARC
1885
BC
FUNCTION OF FLUX MATERIALS
Deoxidation of Scavengers- Helps to
Purify The Weld Metal
Slag Formers -Slag Protects Weld
Puddle From Atmosphere During
Solidification
Arc Stabilisers - Produce a Smooth Arc
& Help Reduce Spatter & Smoke
Alloying Elements - Provide the
Necessary mechanical Properties
Gasifier - Provide a Shielding Gas
CRITERIA FOR SELECTION

METALLURGICAL

MECHANICAL

PROCESS
METALLURGICAL
BASE MATERIAL
CHEMICAL COMPOSITION
MECHANICAL PROPERTIES
CORROSION REQUIREMENTS
PHYSICAL PROPERTIES
SOUNDNESS &STRUCTURAL
STABILITY
HEAT TREATMENT

MECHANICAL


THICKNESS OF MATERIAL

DIMENTION & NO. OF COMPONENTS
PROCESS

AVAILABLE FORM OF CONSUMABLES

ADAPTABILITY TO JOB

WELDING PROCESS SELECTED
SMAW
Advantages
Variety of electrodes with different features
Most versatile in use all position joints /joints
with limited access
Suitable for most alloys
Equipment simple,inexpensive & portable.
Disadvantages
Finite length
High dependence on welder skill
Not amenable for automation

GAS METAL ARC WELDING
GMAW/MIG-MAG/CO2/SOLID WIRE
Advantages
Continuous electrode
Higher currents possible
Minimal post weld cleaning required
Highly amenable to automation
Disadvantages
Equipment more complex & Costlier
than SMAW
Welder skill dependence still
high,especially for out-of position
welding
Not amenable for customisation
SUBMERGED ARC
WELDING
SAW
Advantages
Highest deposition rate
Most suited for automation
Consumables can be customised
Lower operator fatigue
Disadvantages
Not versatile-no positional capability
Generally not used for thin section
Joint fit-up very critical
Arc not visible
FLUX CORED WIRE- FCAW
FCAW Consumable is Often known as
Inside Out as flux is inside & metal is
outside .
Modern Technology of Manufacture of
FCAW wire involves Strip & Dry Premixed
Flux as Basic Raw Materials
The Quantum of Flux Addition & Flux Fill
Ratio are Continuously Monitored to
deliver Consistent Quality Products.
` FCAW -CORED WIRE
ADVANTAGES
High productivity of Continuous Wire
Welding
Metallurgical Benefit of Flux
Higher Current than Solid Wire
Versatile Use-All Positional ,Wide Thickness
Range
Visible Arc -Easy to Use
DISADVANTAGES
Equipment more complex & Costlier than
SMAW
FCAW Wires more Expensive on Weight
Basis but compensated by higher
Productivity
`TYPES OF CORED WIRES
CS/LAS
SS
Gasless (Self Shielded) A 5. 20
5.22

Gas Shielded Flux Cored A 5.20
5.22

Composite Submerged Arc

Gas Shielded Metal Cored A5.18
GASLESS (SELF SHIELDED)
Generates its Own Protective Shielding
Gas. Normally used in Flat & Horizontal
Positions only .
For CS most commonly used for Out
Door Fabrication & also extensively used
for Repair & Maintenance application
For SS Mainly used for Joining & Overlay
Welding Application
GAS SHIELDED FLUX CORED WIRES
For CS/LAS Currently Available in Two
Types
Positional Welding type - Rutile Slag
Flat/ Horizontal type - Basic Slag
Both Types Typically Run with Ar-
25%Co2 or 100% CO2
Diameter Down to 0.9 mm Available
For SS Positional Welding Type
available in all grades suitable for CO2
Shielding
CLASSIFICATION OF FCAW
CONSUMABLES
For Metal Cored Wires as per AWS A 5.18
E 70 C X Y N HZ
For FCAW Wires as per AWS A 5.20
E XXT XMJ HZ
For SS FCAW Wires as per A 5.22
E XXX T X-X
COMPOSIT SUBMERGED ARC
FCAW Consumables used mainly with Neutral
Flux to give desired Weld metal Chemistry
Typical Application include High Alloy Steel
Compositions with special TDC Required in
Small Quantity.(Tailor Made Product)
GAS SHIELDED METAL
CORED
Composit or Metal Cored FCAW consumables
most commonly used for robotic application in
view of
Higher Deposition Efficiency
Bead on Bead Welding (NO Slag )
Better Wire Feeding.


` FCAW -CORED WIRE
ADVANTAGES
High productivity of Continuous Wire
Welding
Metallurgical Benefit of Flux
Higher Current than Solid Wire
Versatile Use-All Positional ,Wide Thickness
Range
Visible Arc -Easy to Use
DISADVANTAGES
Equipment more complex & Costlier than
SMAW
FCAW Wires more Expensive on Weight
Basis but compensated by higher
Productivity
COMMOMLY AVAILABLE FCAW
PRODUCTS
FCAW Product for Positional Welding
of CS / LAS With Gas Shielding.
Self Shielded FCAW Product for CS
Self Shielded for HF Products
Gas Shielded SS Small Dia.Cored
Wire Product for Fabrication
Self shielded SS Cored Wire for SS
Overlay /Cladding

WHY FCAW
FCAW AS PROCESS HAS GREAT ADVANTAGE
OVER OTHER CONVENTIONAL PROCESS

FCAW IS THE FUTURE PROCESS WITH TECHNO
COMMERCIAL EDGE OVER OTHER EXSISTING
PROCESSES

FCAW HAS WIDE RANGE OF PRODUCT
TO MEET INDUSTRIAL NEEDS & ALSO EASE OF
APPLICATION MAKES IT USER FRIENDLY.
SELECTION CRITERIA
Chemical & Mechanical Properties
Commercial Availability of Product
Suitability for Restraint Welds -
Hydrogen Level in Weld Metal
Type of Gas Shielding to be used
Feasibility of Application
Cost Factor

ACID vs BASIC vs METAL CORED vs
RUTILE BASIC
E70T-1 vs E70T-5 vs E70C-6M vs E70T-1
ACID BASIC METALCORED RUTILE BASIC
UTS,Mpa
YS Mpa
%E
585
518
23
535
450
28
575
517
27
585
497
27
IMPACT J
-18 DeG C
-29 Deg C
40-65
20-45
110-160
80-135
75-100
25-55
80-125
65-100
HYDROGEN
Ml/100 GMS
5-10 2-5 3-8 2-5
OPE.CHARAC.
BEAD SHAPE
FLAT CONVEX FLAT FLAT
WETTING
ACTION
VERY GOOD FAIR GOOD VERY GOOD
STORAGE & RECONDITIONING
FOR SMAW /FCAW
SMAW
Low Hydrogen Store 100-150 Deg C
Recondition at 400 Deg
C- 1Hr
Stainless Recondition at 200 Deg C-
1Hr
FCAW
Plastic Recondition at 50 Deg C-
48Hr Min
Coils Store 100-125 Deg C
Recondition at 150 Deg
C- 6-8Hrs
Wire Spool Store 150 Deg C
Basket Recondition at 250 Deg C-
2-3Hrs
Higher Rebake Temperature , Faster
Reconditioning


SHIELDING GASES
Arc Characteristics
Penetration Profile
Mode Of Transfer
Spatter Level
Alloy Recovery
Material Types
SHIELDING GAS COMPARISON
E 81T-1-Ni1 VERTICAL UP @21 KJ/CM
95Ar/5CO2
75Ar/25CO2 50Ar/50CO2
100CO2
TYPICAL
CHEMICAL
ANALYSIS
C
Mn
Si
.059
1.29.
.44
.055
1.29
.44
.042
1.24
.39
.041
1.16
.31
TYPICAL
MECH.
PROP(Mpa)
YS
UTS
540
603
531
586
502
568
457
565
TYPICAL
IMPACT
PROP(J)
0 Deg C
-40Deg C
123
91
125
84
109
48
104
40
BEAD
SHAPE
FLAT FLAT CONVEX CONVEX
PROCESS SHARE FOR VARIOUS
COUNTRIES
INDIA USA
SMAW
80%
SMAW
35%
GMAW
55%
SAW8%
GTAW2%
SAW 8%
GMAW
10%
GTAW 2%
GTAW
SMAW
SAW
GMAW
GTAW
SMAW
SAW
GMAW
EUROPE
JAPAN
GMAW
60%
SMAW
30%
SAW
8%
GTAW 2%
SMAW
20%
GTAW 2%
SAW8%
GMAW
70%
GLOBAL PROCESS SHARE
OF WELD METAL
JAPAN EUROPE USA INDIA
SMAW 20% 30% 35% 80%
SAW 8% 8% 8% 8%
GTAW 2% 2% 2% 2%
GMAW 70% 60% 55% 10%
PROCESS SHARE IN GLOBAL
PERSPECTIVE
Steady Increase in Solid & Core Wire
Consumption
Covered Electrode Consumption will Decline
& Stabilise around 30%
In Developed Countries, CO2 Welding
Accounts for more than 50%
In Developing Countries like China & Korea
CO2 Process Share is already around 15%
ESTIMATING WELD METAL
DEPOSITION COSTS

MATERIAL COST

ELECTRODE

SHIELDING GAS
FIXED COST
Joint Preparation

Fixturing

Tacking
Preheating

Cleaning

Inspection

Rs
COSTING
Power & 2-
5% Equipment

Electrode
Cost 8-
15 %

Labour & 80-
85 %
Overhead Cost
LABOUR &
OVERHEAD
ELECTRODE
COST
POWER &
EQUIP.
INCREASED WELDING PRODUCTIVITY
REDUCED WELDING COST
ELECTRODE EFFICIENCY
& STUB END LOSS
DATA ON EFFECT OF STUB END LOSSES
TYPE -E7018 ELECTRODES

EFFICIENATY AT 50 mm STUB LOSS -70 %
EFFICIENATY AT 75 mm STUB LOSS -64.5%
EFFICIENATY AT 100 mm STUB LOSS -59.1%
EFFICIENATY AT 125 mm STUB LOSS -54.5%
EFFICIENATY AT 150 mm STUB LOSS -49.1%
450
mm
WELD METAL COST FORMULAS
1 Labour & Labour & Overhead Cost/Hr
Overhead = ----------------------------------------
Deposition Operating
Rate (Kg/Hr) X Factor
Electrode Cost / Kg
2 Electrode: = ---------------------------------
Deposition Efficiency
Gas Flow Rate Cu.Meters/
Hr. X Gas Cost / litre
3 Gas = ------------------------------------
Deposition Rate (Kg/Hr)
Flux Cost/kg X 1.4
4 Flux = -------------------------------------
Deposition Efficiency
Cost Rs/KWH x Volts x Amps
5 Power Cost = ----------------------------------
1000 X Deposition Rate
(kg/Hr)
Total Cost per kg = Sum of 1-5 , Above
of Deposited Weld Metal
WELD METAL COST WORKSHEET
FCAW AS COMPARED TO SMAW - WELDING POSITION - FLAT
CALCULATING COST CAL. COST CAL FCAW
COST PER KG FCAW SMAW Vs.
DEP. WELD E 71T-1 / 1.6 DIA. E 7018 / 5mm SMAW
AT 300 A/28 V AT 250 A/28 V * COST RED.-
Labour &
Overhead 150/5X0.45 66.67 150/2.5 X0.30 200 -133.33
Electrode: 150/0.87 172.4 60 /0.65 92.3 80.4
Gas 990 x 0.04 /5 7.92 NA 7.92
Power Cost 4 x 300 x 28 / 4 x 250 x 28 /
1000 x 5 6.72 1000 x 2.5 11.2 -4.48
Sum of Total Variable 253.7 Total Variable 304 -49.29
the Above cost/kgDeposite Cost/kg Deposite :
Rework at 3% at 15%
COST 253.72 /0.97 261.56 303.51 /0.85 357 -95.54
Basic Cost Saving per Kg with FCAW = 49.29
Actual Cost Saving pr Kg with FCAW = 95.54
ONE MINUTE WELD VERTICAL UP
POSITION-6MM FILLET
One Minute Welds made
using SMAW 3.2mm 70mm,
GMAW-0.9mm 105 mm
FCAW 1.2mm 300 mm
Cost aspect based on above
productivity.

FCAW SMAW GMAW
900
1300
2900
DEP. COST PER KG
C
O
S
T

I
N

R
S
.

LABOUR &OVERHEAD-RS.500
SMAW
FCAW
GMAW
FCAW CONSUMABLES AVILABILITY
WITH AWS SPECIFICATION
E70T-1 FOR
E71T-1 BOILER
E70T5 QUALITY
E81T1-W WHEATHERING
E80T1-A1 FOR
E80T1-B2 LOW ALLOY
E80-T1-B3 STEEL
E80T5-G FOR
E90T5-K2 HSLA
E100T5K3 STEELS
E110T5-K4
E308TX-X FOR SS
E316TX-X POSITIONAL
E312TX-X WELDING
E309TX-X
E308.T0-3 FOR
E309T0-3 CLADDING
APPLICATION

FABRICATION INDUSTRIES

CORROSION RESISTANCE OVERLAYS

HARD FACING/REPAIR &
MAINTAINANCE


PROCESS INDUSTRIES
BOILER &PRESSURE VESSELS HEAVY
STRUCTURAL
OFFSHORE FABRICATION
RAIL &ROAD BRIDGES
SHIP BUILDING
ROAD TANKERS
RAIL WAGONS
TRANPORTATION
REPAIR &MAINTAINANCE
SUPER CONDITIONING
HOW WELDING SMARTER SAVED 120,000
MAN-HOURS
Walking Dragline - 12,000 MT Weight
Boom Height : 95 M
Hoist Depth : 55 M
Bucket Load :325 MT
Cylindrical Steel Base
32 M Dia. 2.5 M Wide & 140 MT
Weight
Replacement of the Base
Estimated 160,000 Man- Hour with
SMAW(80 Months)
Estimated 40,000 Man- Hour with
FCAW (20 Months)
32M
2.5M
Wedge Shaped Segments Make Up Dragon Base
150 mm
SS FCAW TO RESCUE OF ASPRIN
MAKERS HEAD ACHE
SS Half Coil Reactor
Found Leaking.
Leak Spots
Identified as likely
restart points in OH
Position.
Small Dia. SS
FCAW made it
possible to reduce
restart points
Better approach
made improved
Fusion Possible.

HALF COIL
REFINARY
Oil is
King!

Tosco, Martinez oil refinery

OFF SHORE APPLICATION
PRESENT STATUS
FCAW ACCEPTED AS FABRICATION PROCESS
AVAILABILITY,COSISTANT QUALITY,EASE OF APPLICATION
WILL HELP IN INCRESING PROCESS SHARE
PRESENT MARKET SHARE OF 12%(GMAW+FCAW)
EXPECTED TO INCESE RAPIDLY TO 20% BY 2010 AS
AGAINST 50% OF ADVANCED COUNTRIES.
INDIAN MANUFACTURES GEARING UPTO CHALLENGE OF
OFFERING IMPROVED QUALITY & QUANTITY AT MOST
COMPETATIVE PRICE.
FCAW PROCESS TO BE CLASSIFIED AS PROCESS CAPABLE
OF PROVIDING HIGHER
PRODUCTIVITY,QUALITY,CONSISTANT
CHEMISTRY,POSITIONAL CAPABILITY & EASE OF
APPLICATION.
CONCLUTION

Industries are adopting FCAW as production process which
can give desired quality.
The availability of CS/LAS,SS & HF consumables in India
has improved.
The present share of GMAW +FCAW which is at present
12% is expected to reach 20% by 2010
As industrial application of SAW has reached 100%
utilisation level ,the FCAW application will have rapid
growth.
The improved availability of FCAW product to AWS
specification &as well as Custom built products will ensure
adoption of FCAW as process where in productivity &
consistant quality are basic requirement

THANK YOU