Transcription of KOBELCO WELDING CONSUMABLES
1 TODAYTODAYKOBELCO WELDING CONSUMABLESKOBELCO WELDING CONSUMABLESFORFOR 2nd Special Editionnd Special Edition MILD STEEL AND 490 MPa HT STEELMILD STEEL AND 490 MPa HT STEELMILD STEEL AND 490 MPa HT STEELMILD STEEL AND 490 MPa HT STEEL KOBELCO WELDING TODAY1 PRODUCTS SPOTLIGHTA Quick Guide to Suitable WELDING Consumablesfor Mild Steel and 490 MPa High Tensile Strength Steel For Shielded Metal Arc WELDING (SMAW)Tips for successful WELDING results1. This guidance is to help users select appropriate WELDING CONSUMABLES . Users are requested to confirm whether the selectedbrand can satisfy the job requirements before use. 2. Suitable electric polarity for SMAW electrodes are as follows: AC, DCEN or DCEP for EXX13, EXX19, and EXX24; AC orDCEP for EXX16, EXX18 and EXX48; DCEP for EXX10. Wires for FCAW and GMAW use DCEP (DW-A51B uses DCEN).
2 ForSAW flux-wire combinations, AC is recommended. Electric polarity can affect the usability of WELDING CONSUMABLES and thechemical composition and mechanical properties of weld metals; therefore, it is recommended to confirm the performance ofthe consumable you selected, using the polarity of a power source available for a particular job. 3. The trade designations with a prefix of G or MF are fused-type fluxes for SAW, whereas those that begin with PF are bonded-type fluxes. The trade designations shown with a prefix of DW or MX are flux-cored wires, whereas those denoted with a prefixof MG or MIX are solid wires. Shielding gas composition can affect the usability of a wire, the chemical composition andmechanical properties of the weld The mechanical properties of weld metals can be affected by preheat and interpass temperatures and WELDING heat , these parameters must be controlled during WELDING to assure the weld quality.
3 5. For details of individual brands, refer to KOBELCO WELDING name*11.[F] designates FAMILIARC . [T] designates TRUSTARC .AWS classificationFeaturesThin to medium plate joints[F] E6013 Capable of vertical downward WELDING .[F] E6013 Lower fume emissions.[F] E6013 Better bead appearance.[F] E6019 Deeper penetration than E6013.[F] E6019 Better X-ray soundness.[F] E6019 Higher resistance to hot plate joints[F] E7016 For mild steel. Higher deposition rates.[F] E7016 For mild steel. Better X-ray soundness.[F] E7016 Typical electrode for 490 MPa HT steel.[F] E7016 Extra-low hydrogen. Harmless fumes.[F] E7016 Extra-low hydrogen. HIgher resistance to cold cracking.[F] E7016 Ultra-low hydrogen. Moisture resistant.[F] E7016 Suitable for 520 MPa HT steel. Extra-low hydrogen.[F] E7016-GSuitable for 520 MPa HT steel.[F] E7016 Suitable for HIC resistant steel.[F] E7018 Higher deposition rates. Better usability with DCEP.
4 [T] E7018-1 Higher deposition rates. Excellent low-temp notch and flat fillets[F] E7018 Typical electrode for 490 MPa HT steel.[F] E7024 Suitable for manual and gravity WELDING .[F] LT-B50-Non-low hydrogen. Not suitable for thick [F] E6010 Suitable for API grades of up to X52.[F] E7010-P1 Suitable for API grades of X52-X60.[F] E8010-P1 Suitable for API grades of X60-X70.[F] E7048 Extra-low hydrogen. Vertical downward WELDING .[F] E8018-GExtra-low hydrogen. Vertical downward WELDING .[F] E9018-GExtra-low hydrogen. Vertical downward passes[F] E7016 Unsurpassed penetration bead k i n g[F] E7048 Excellent re-arcing with a low hydrogen coating. KOBELCO WELDING TODAY2 PRODUCTS SPOTLIGHT For Flux Cored Arc WELDING (FCAW) For Gas Metal Arc WELDING (GMAW) For Gas Tungsten Arc WELDING (GTAW) For Submerged Arc WELDING (SAW)ApplicationsBrand name*11.
5 [F] designates FAMILIARC .AWS classificationFeaturesShielding gasThin plate joints[F] E70C-6C/6 MStable short-circuiting arc. Little or Ar+CO2 Medium plate joints[F] E71T-1 CHigher deposition rates in all position WELDING . CO2[F] E71T-1 CHigher deposition rates in vertical-up WELDING . CO2[F] E71T-9 CSuitable for ship-class E-grade [F] E71T-1C/1M, 9C/9 MSuitable for ship-class E-grade or Ar+CO2[F] E71T-1 MSuperior usability with low +CO2[F] E71T-5M-JBetter crack resistance with DCEN. Basic-type +CO2 Medium to thick plate joints[F] E70T-1 CHigher deposition rates. Little [F] E70C-6 MHigher deposition rates. Little +CO2 Horizontal and flat fillets[F] E70T-1 CLarger legs. Better bead appearance and [F] E70T-1 CHigher resistance to inorganic zinc [F] E70T-1 MHigher resistance to inorganic zinc +CO2[F] E70T-9 CSuitable for ship-class E-grade [F] E70T-1 CHigher speeds on inorganic primer coated name*11.
6 [F] designates FAMILIARC .AWS classificationFeaturesShielding gasThin to medium plate joints[F] ER70S-6 Stable short-circuiting arc. All-position or Ar+CO2[F] MG-50T-Stable short-circuiting arc. All-position or Ar+CO2[F] ER70S-3 Stable arc with lower +CO2[F] ER70S-GStable spray arc with higher +CO2 Thick plate joints[F] ER70S-GStable arc with higher [F] ER70S-GSuperior usability and mechanical +CO2 ApplicationsBrand name*11.[F] designates FAMILIARC .AWS classificationFeaturesShielding gasThin to thick plate joints[F] ER70S-6 Superior properties after long time [F] ER70S-GSuitable for Al-killed steels for low pass in pipe joints[F] ER70S-2 More resistible to rusty name*11.[F] designates FAMILIARC .AWS classificationFeaturesThin plate joints[F] G-50 / [F] F7A2-EH14 Suitable for high speed to medium plate joints[F] G-60 / [F] F7A2-EH14 Suitable for high speed WELDING .[F] PF-H45 / [F] F6A4-EL8 Suitable for single or 4-5 multi-pass to thick plate joints[F] G-80 / [F] F7A2-EH14F6P2-EH14 Good performance in multi-pass WELDING .
7 [F] MF-38 / [F] F7A6-EH14F7P6-EH14 Better porosity resistance and X-ray soundness.[F] MF-300 / [F] F7A6-EH14F7P6-EH14 Better slag detachability.[F] PF-H55E / [F] F7A4-EH14 Double-sided two-pass or multi-pass and flat fillets[F] MF-53 / [F] F7A0-EH14 Better bead appearance and slag detachability. KOBELCO WELDING TODAY3 PRODUCTS SPOTLIGHTAn unsurpassed rutile flux-cored wire for mild steeland 490 MPa high tensile strength steel, which ishighly reputed for solid ultimate performance. Inception of DW-100DW-100 was developed for WELDING mild steel and490 MPa high tensile strength steel and launchedinto the world of arc WELDING nearly 30 years prefix of the trade designation, DW, wascoined from the words, Dual Wire, because thewire consists of steel sheath and cored flux. Thisdevelopment provided the momentum for ship-builders and bridge constructors in particular toemploy semiautomatic and automatic WELDING withDW-100 instead of shielded metal arc weldingwith covered electrodes.
8 This is why DW-100 iscalled an epoch-making flux-cored wire. Outstanding featuresThe most remarkable features of DW-100 whenused with CO2 gas shielding are the following.(1) Adjusting once a certain proper WELDING cur-rent within a wide range of amperage and volt-age for each size of wire shown in Figure 1,there is no need to re-adjust the current posi-tion by position in all-position 1: Proper ranges of WELDING current and arc voltage foreach size of DW-100.(2) Much less spattering improves the weldingenvironment and reduce downtime for remov-ing spatter on the weld Figure 2: A comparison between DW-100 flux cored wire(FCW) and conventional solid wire (SW) on the amount ofspatter in CO2 gas arc WELDING .(3) Convenient self-peeling slag removal andglossy bead appearance reduce postweldcleaning time Figure 3: Convenient self-peeling slag removal and glossybead appearance with DW-100 in horizontal fillet WELDING .
9 (4) Regular bead profiles and smooth fusion withbase metal Figure 4: Regular bead appearance and smooth fusion withthe base metal in horizontal fillet WELDING with DW-100.(5) High deposition rates can save labor costs byreducing WELDING time Figure 5.(6) Consistent mechanical properties of tensilestrength and Charpy impact toughness of theweld metal Table 1.': $:6 $ ( 7 & PP PP PP :HOGLQJ FXUUHQW $PS $UF YROWDJH 9 ROW PP PP :HOGLQJ DPSHUDJH DQG YROWDJH4 XDQWLW\ RI VSDWWHU RI RYHU PHVK VL]H J PLQ KOBELCO WELDING TODAY4 PRODUCTS SPOTLIGHTF igure 5: A comparison on deposition rates between DW-100(FCW), conventional solid wire (SW) and covered electrode(CE) wire extension: 25 mm, shielding gas: leader of flux-cored wireSince DW-100 was launched into the market, pro-duction of flux-core wires has ever increased.)
10 Thisis because of ever increasing consumption of flux-cored wires not only in shipbuilders and bridgeconstructors but also in other various industriesthroughout the world. Nowadays annual produc-tion of flux-cored wires in Japan has reached over125,000 metric tons, accounting for about shown in Figure 6. Among flux-cored wires,DW-100 is one of the leaders. Figure 6: Annual production ratios of WELDING CONSUMABLES inJapan in 2007 (Developed with data from Ref. 1)A variety of applications Nowadays DW-100 is used in various applicationsin such industries as shipbuilding, architecturalstructures, machinery, and bridges. Due to excel-lent usability, even an inexperienced welder canuse DW-100 with satisfactory results. This usabil-ity includes stable wire feeding and tracking ontowelding lines. DW-100 continually earns a highreputation from users in worldwide marketsbecause of the services supported by the slogan, QTQ (Quality Products, Technical Support, andQuick Delivery) launched by Kobe Steel and theKobelco group shines in various applications in such industries asshipbuilding, architectural structures, bridges and things in the traditional During these three decades, DW-100 has seen its features refined, and applications expanded.