Boc Iprm s11-Techdata

643au : IPrM 2007 : sectIon 11 : tecHnIcal data

11Classification Tables 644

Technical Reference Data 656

Deposition Data 657

MMA Electrode Sizes 658

Deposition Rate (GMAW) 659

General Consumable Data 660

Tungsten Electrodes 661

SI Metric System 662

Austenitic SS Classifications 664

Martensitic Ferritic SS Classifications 665

Welding Chart SS 666

Weld Metal Calculator 667

Joint Preparations Summary Chart 670

Effect of Overwelding 671

Technical Data

11 Technical Data

644 au : IPrM 2007 : sectIon 11 : tecHnIcal data

Classification Tables

as/nZs 1553 Part 1-1995 low carbon steel electrodes for Manual Metal arc Welding of carbon steels and carbon Manganese steels

(1) Designates that, for each increase of 1% in the value of elongation over the minimum, a decrease of 10 MPa in tensile and yield strength is allowed to the following minimum values, (e.g. E41XX, tensile: 410 MPa/ yield: 330 MPa and E48XX, tensile: 480 MPa/yield: 400 MPa).

E 4 8 1 8 – 4 H5 R

e

Elec

trod

e

Weld Metal no. tensile strength range (MPa)

Minimum Yield strength (MPa)

Minimum elongation

500-620 (1) 420 (1) 22%

r

Designates the coating is moisture resistant. Tested electrodes

shall exhibit not >10-ml H2/100 g of DWM after exposure to an environment of 27° C and

80%-relative humidity for a period of not less than 9 hours.

18

Welding position, welding current and covering.

see table 1 for details.

Impact energy

grade no.

Minimum average cVn impact-values

2 47J @ -20°C

Z Not required.

a 47J @ + 20°C

0 47J @ 0°C

3 47J @ -30°C

4 47J @ -40°C

5 47J @ -50°C

6 47J @ -60°C

Designates the impact energy grade number. 4

H5 ≤ 5 ml H2/100 g of DWM

H10 ≤ 10 ml H2/100 g of DWM

H5 Designates the diffusible hydrogen content of deposited weld metal

(DWM)

48 Designates approximately 1/10th of the minimum tensile strength in MPa.

41 430-550 (1) 350 (1) 22%

48Optional Indicators for notch toughness,

lower hydrogen status and moisture absorption resistance

11



as/nZs 1553 Part 1-1995 covered electrodes for Welding low carbon steel

AS/NZS 1553.1 Electrode Classification Summary – Table 1

EXX99 As specified by the manufacturer As specified by the manufacturer As described by the manufacturer As specified

electrode classification

Welding Positions

type of current and Polarity

type of flux covering and slag type Penetration

EXX10 F, V, OH, H DC + Fluid Slag High Cellulose Deep

EXX11 F, V, OH, H AC and DC + Fluid Slag High Cellulose Deep

EXX12 F, V, OH, H AC and DC + or – (Viscous) High Titania, Stiff Slag Medium

EXX13 F, V, OH, H AC and DC + or – High Titania, Fluid Slag Medium

EXX14 F, V, OH, H AC and DC + or – Stiff Slag (Viscous) Low Iron Power, Titania Low

EXX15 F, V, OH, H DC + Hydrogen controlled Basic Medium

EXX16 F, V, OH, H AC and DC + Hydrogen controlled Basic Medium

EXX18 F, V, OH, H AC and DC + Low Iron Powder Basic Hydrogen controlled Medium

EXX19 F, V, OH, H AC and DC + or – Potassium Iron Oxide Titania Medium

EXX20 F and H/V-FILLET AC and DC + or – High Iron Oxide Deep

EXX24 F and H/V-FILLET AC and DC + or – Titania High Iron Powder Low

EXX27 F and H/V-FILLET AC and DC + or – Iron Oxide High Iron Powder Deep

EXX28 F and H/V-FILLET AC and DC + High Iron Powder Basic Hydrogen controlled Medium

EXX46 F, V, OH, H, V-DOWN AC and DC + Basic Hydrogen controlled Medium

EXX48 F, V, OH, H, V-DOWN AC and DC + Basic Hydrogen controlled,

Low Iron Powder Medium

11



aWs 5.1-1991 specification for carbon steel electrodes for shielded Metal arc Welding

1) Yield on E6022 electrodes is not specified and E7018M\ may have a range of 53-72 ksi for all diameters other than 3/32< (2.4mm) which is 53-77 ksi.

(2) Minimum elongation for E6012, E6013, E7014 and E7024 types is 17%. Elongation on E6022 electrodes is not specified.

Designates the minimum required tensile strength in ksi.

E 7 0 1 8 – 1 H4 R

e

Elec

trod

e

Weld Metal no. Minimum tensile strength (psi)

Minimum Yield strength (ksi)

Minimum elongation

70,000 58(1) 22%(2)

1 Designates

Welding Positions

1 All Positional

4 Especially good Vertical-Down

2 Flat and H/V Fillets

H4 ≤ 4 mls H2/100g of DWM

H16 ≤ 16mls H2/100g of DWM

r

Designates the coating is moisture resistant. Tested electrodes as

received or conditioned shall exhibit not > 0.3% (by Wt) of moisture

after exposure to an environment of 80% relative humidity for a period

of not less than 9 hours.

8

Designates the flux type and welding current/polarity

to be used. (e.g. hydrogen controlled low iron powder

AC and DC+, medium penetration).


Optional Designators

grade average minimum results cVn impact requirements

e7016-1 20ft Lb @ -50°F (27J @ -46°C)

e7018-1 20ft Lb @ -50° F(27J @ -46°C)

e7024-1 20ft Lb @ 0°F (27J @ -18°C)

1

Applicable to E7016, E7018 and E7024 type electrodes only.

Designates that the electrode meets the requirements for improved impact toughness.

In the case of an E7024 ductility ‘elongation’ is also improved

from 17%.

H4 Designates the diffusible hydrogen content of deposited weld metal

(DWM)

H8 ≤ 8 mls H2/100g of DWM

70

70

60 60,000 48(1) 22%(2)

11



aWs 5.1-1991 specification for carbon steel electrodes for shielded Metal arc Welding

Electrode Classification – Table 2

notes:

b) The term ‘DC +’ refers to direct current electrode positive (dc, reverse polarity). The term ‘DC –’ refers to direct current electrode negative (dc, straight polarity).

c) Electrodes of the E6022 classification are intended for single-pass welds only.

d) Elecrodes with supplemental elongation, notch toughness, absorbed moisture, and diffusible hydrogen requirements may be further identified.

* For electrodes 3/16 in. (4.8mm) and under, except 5/32 in. (4.0mm) and under for classifications E7014, E7015, E7016, E7018, E7018M.

E7048d

E7028d

E7027

E7027 H/V-FILLET

E6010

E6011

E6012

E6013

E6019

E6020

E6022c

E6027

E6027

E7014

E7015d

E7016d

E7018d

E7018M

E7024d F, H/V-FILLET AC, DC + or – Iron Powder,Titania E7024d

F, V, OH, H DC + Low Hydrogen Iron Powder E7018M

F, V, OH, H AC, DC + Low Hydrogen Potassium, Iron Powder E6018d

F, V, OH, H AC, DC + Low Hydrogen Potassium E6016d

F, V, OH, H DC + Low Hydrogen Sodium E6015d

F, V, OH, H AC, DC + or – Iron Powder,Titania E6014

F AC, DC + or – High Iron Oxide, Iron Powder E6027

H/V-FILLET AC or DC – High Iron Oxide, Iron Powder E6027

F, H AC or DC – High Iron Oxide E6022c

F AC, DC + or – High Iron Oxide E6020

F, V, OH, H AC, DC + or – Iron Oxide Titania Potassium E6019

F, V, OH, H AC, DC + or – High Titania Potassium E6013

F, V, OH, H AC or DC – High Titania Sodium E6012

F, V, OH, H AC or DC + High Cellulose Potassium E6011

F, V, OH, H DC + High Cellulose Sodium E6010

AC, DC – High Iron Oxide, Iron Powder E7027

F AC, DC + or – High Iron Oxide, Iron Powder E7027

F, H/V-FILLET AC, DC + Low Hydrogen Potassium, Iron Powder E7028d

F, OH, H V-DOWN AC, DC + Low Hydrogen Potassium,

Iron Powder E7048d

aWs Welding Positionsa type of currentb type of covering aWs classification

11



aWs a5.5-96 specification for low alloy steel electrodes for shielded Metal arc Welding

(1) Yield on E7010-P1 and E7018-W1 is required to be 60ksi (451MPa).

(2) * G classifications require the weld deposit to exhibit only a minimum of one (1) element listed.

(3) # M classification chemical limits can vary widely in the case of Mn, Ni, Cr and Mo. Refer to page 5 of AWS A.5-96 for details. EX018-M electrodes are intended to meet most military requirements and have greater toughness, lower coating moisture content, both as received and after exposure, and also conform to mandatory diffusable hydrogen limits for deposited weld metal.

Electrode

E 8 0 1 8 – C 1

e

60Minimum tensile strength (psi)

Yield strength (ksi)

Weld Metal no:

Minimum tensile strength (psi)

Yield strength (ksi)

Weld Metal no:

70 10018M 100,000 88-10070,000 57

1 Designates

Welding Positions

1 All Positional

4 Especially good Vertical-Down

2 Flat and H/V Fillets

7010-P1 100 100,000 8770,000 60

70xx-B2l 110 100,000 9775,000 57

80 11018M 100,000 98-11080,000 67

80xx-c3 120 120,000 10780,000 68-80

90 12018M 120,000 108-12090,000 77

9018M 12018M1 120,000 108-12090,000 78-90

8 Designates the flux type and welding current/polarity to be

used. (e.g. hydrogen controlled low iron powder AC and DC+, medium penetration). see table 3 for details.

type C Mn Ni Cr Mo V

a1 0.12 0.60-1.00 — — 0.40-0.65 —

nM1 0.10 0.80-1.25 0.80-1.10 0.10 0.40-0.65 0.02

P1 0.20 1.20 1.00 0.30 0.50 0.10

d1d2d3

0.120.150.12

1.00-1.751.65-2.001.00-1.80

0.900.900.90

— — —

0.25-0.450.25-0.450.40-0.65

— — —

g*M#

M1

— 0.100.10

1.0 Min0.60-2.250.80-1.60

0.50 Min1.25-2.503.00-3.80

0.30 min0.15-1.50

0.65

0.20 min0.25-0.550.20-0.30

0.10 min0.050.05

B1B2

B2lB3

B3lB4lB5B6

B6lB7

B7lB8

B8lB9

0.05-0.120.05-0.12

0.050.05-0.12

0.050.05

0.07-0.150.05-0.10

0.050.05-0.10

0.050.05-0.10

0.050.08-0.13

0.900.900.900.900.900.90

0.40-0.701.001.001.001.001.001.001.25

— — — — — — — — — — — — — —

0.4-0.651.00-1.501.00-1.502.00-2.502.00-2.501.75-2.250.40-0.604.00-6.004.00-6.006.00-8.006.00-8.008.00-10.508.00-10.508.00-10.50

0.40-0.650.40-0.650.40-0.650.90-1.200.90-1.200.40-0.651.00-1.250.45-0.650.45-0.650.45-0.650.45-0.650.85-1.200.85-1.200.85-1.20

— — — — — —

0.05— — — — —

0.050.15-0.30

c1c1lc2

c2lc3

c3lc4

c5l

0.120.050.120.050.120.080.100.05

1.251.251.251.25

0.40-1.250.40-1.40

1.250.40-1.00

2.00-2.752.00-2.753.00-3.753.00-3.750.80-1.100.80-1.101.10-2.006.00-7.25

— — — —

0.150.15— —

— — — —

0.350.35— —

— — — —

0.050.05— —

classification suffixes by Major chemical analysis (%)

Carbon-Molybdenum Steel Electrodes

Chromium-Molybdenum Steel Electrodes

Nickel Steel Electrodes

Nickel-Molybdenum Steel Electrodes

Pipeline Electrodes

G=General and M = Military

Manganese-Molybdenum Steel Electrodes

Designates the minimum required tensile strength in ksi. 80

11



aWs a5.5-96 specification for low alloy steel electrodes for shielded metal arc welding

AWS A5.5 Electrode Classification Summary – Table 3

electrode classification Welding Positions type of current

and Polarity type of flux covering and slag type or ‘use’ Penetration

E7010-XE7011-XE7015-XE7016-XE7018-XE7020-XE7027-X

F, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, H

F and H/V-FILLETF and H/V-FILLET

DC +AC and DC +

DC +AC and DC +AC and DC +

AC and DC + or -AC and DC + or -

High Cellulose SodiumHigh Cellulose PotassiumLow Hydrogen Sodium

Low Hydrogen PotassiumIron Powder, Low Hydrogen

High Iron OxideHigh Iron Oxide, Iron Powder

DeepDeep

MediumMediumMedium

Medium to DeepMedium

e70 series, 70,000 psi (480 MPa)

E8010-XE8011-GE8013-GE8015-XE8016-XE8018-X

F, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, H

D. C. +AC and DC +

AC and DC + or –DC +

AC and DC +AC and DC +

High Cellulose SodiumHigh Cellulose Potassium

High Titania PotassiumLow Hydrogen Sodium

Low Hydrogen PotassiumLow Hydrogen, Iron Powder

DeepDeep

MediumMediumMediumMedium


E9010-GE9011-GE9013-GE9015-GE9016-XE9018-XE9018M

F, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, H

DC +AC and DC +



DC +



Low Hydrogen, PotassiumLow Hydrogen, Iron PowderLow Hydrogen, Iron Powder

Deep Deep

MediumMediumMediumMediumMedium


E10010-GE10011-GE10013-GE10015-XE10016-XE10018-XE10018M

F, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, H

DC +AC and DC +



DC +




Deep Deep

MediumMediumMediumMediumMedium

e100 series, 100,000 psi (690 MPa)

E11010-GE11011-GE11013-GE11015-GE11016-GE11018-GE11018ME12010-GE12011-GE12013-GE12015-GE12016-GE12018-GE12016ME12018M1

F, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, HF, V, OH, H

DC +AC and DC +



DC +DC+

AC and DC +AC and DC + or –

DC +AC and DC +AC and DC +AC and DC +AC and DC +








DeepDeep

MediumMediumMediumMediumMediumDeepDeep

MediumMediumMediumMediumMediumMedium

e110 series, 100,000 psi (760 MPa) and e120 series, 120,000 psi (830 MPa)

11



aWs a5.18-2001 specification for carbon steel electrodes and rods for gas shielded arc Welding

Wire class other elements allowable % rangesilicon (si)Manganese (Mn)carbon (c)

er70s-2 0.05-0.15Ti/0.02-0.127r/0.05-0.15Al0.40-0.700.90-1.400.07

er70s-3 0.05Cu*0.45-0.750.90-1.400.06-0.15

er70s-4 0.05Cu*0.60-0.851.00-1.500.06-0.15

er70s-6 0.50Cu*0.80-1.151.40-1.850.06-0.15

er70s-7 0.50Cu*0.50-0.801.50-2.000.07-0.15

er70s-g G = General, composition is not specified and is agreed between the supplier and the customer.

er70c-3X 0.50Cu*0.90*1.75*0.12*

er70c-6X 0.50Cu*0.90*1.75*0.12*

er70c-g(X) G = General, composition is not specified and is agreed between the supplier and the customer.

er70c-gs(X) G = General, Single Pass Only, composition is agreed between the supplier and the customer.

* Single values are maximum. X represents shielding gas indicators (e.g. ‘C’ indicates CO2). (X) is optional for these classifications.

e = electrode, r = rod, s = solid Wire, c = composite Metal cored Wire, followed by a hyphen then a number or letter which defines the chemical composition of the wire.

E R 7 0 S – 6 H4

E 7 0 C – 6 M H4

M Designates ‘Shielding Gas’

M Designates ‘Mixed Gas’ and is classified for use with Argon +

20–25% CO2 gas

cDesignates ‘Carbon Dioxide’ and is

classified for use with 100% CO2 gas or the wire is self shielded

Optional – designates the diffusable hydrogen content of deposited weld metal (DWM)

H4

H4 < 4 mls H2 / 100g of DWM

H8 < 8 mls H2 / 100g of DWM

H16 < 16 mls H2 / 100g of DWM

As Welded Mechanical Properties

aWs class

er70s-2er70s-3er70s-4er70s-6er70s-7er70s-ge70c-3Xe70-6X

e70c-g(X)

e70-gs (X)

Yield strengthtensile strength

Psi% elong. charpy-V-notch (cVn) Impact requirements

70,000

70,000

70,000

70,000

70,000

70,000

70,000

70,000

70,000

Psi

58,000

58,000

58,000

58,000

58,000

58,000

58,000

58,000

58,000

MPa

400

400

400

400

400

400

400

400

400

22

22

22

22

22

22

22

22

22

20ft Lb @ -20°F (27J @ -30°C)

20ft Lb @ 0°F (27J @ -20°C)

Not Required

20ft Lb @ -20°F (27J @ -30°C)

20ft Lb @ -20°F (27J @ -30°C)

As agreed between supplier and purchaser

20ft Lb @ 0°F (27J @ -20°C)

20ft Lb @ -20°F (27J @ -30°C)

As agreed between supplier and purchaser

70,000

MPa

480

480

480

480

480

480

480

480

480

480 Not Specified Not Required

shielding gas

CO2

CO2

CO2

CO2

CO2

*

†

Arg

*

*

*Shielding gas shall be agreed to between purchaser and supplier† 75-80% Ar/balance CO2 or CO2

11



as 2203.1-1990 cored electrodes for arc Welding Part 1: ferritic steel electrodes

g Gas shielding

W40

Properties of the weld metal

Designates approximately 1/10th of the minimum tensile strength in MPa.

W40W50W55W62W69W76W83

c

DC constant potential electrode positivep

n

9a.d3

699P.d2629P.d29a.d19P.ni39a.ni29P.ni29P.ni19a.ni1

43210

Designates Weld Metal-Chemistry

see table 4 for details

Designates the impact energy grade number:

5

ETP – GCP – W50 4 A . CMI H10

Weld Metal no. tensile strength range (MPa)

Min. Proof stress at 0.2% offset (MPa)

Minimum elongation

430-550490-650550-690620-760690-830760-900830-970

310360470540610680750

22%22%19%16%15%14%13%

Impact energy grade no:

Minimum average cVn impact values

Impact energy grade no:

Minimum average cVn impact

valuesNot required. 9a.k1 27J @ -40°C

47J @ + 20°C 508a.k2 27J @ -20°C

47J @ 0°C 509a.k2 27J @ -30°C

47J @ - 20°C 559a.k2 27J @ -30°C

47J @ -40°C 628a.k2 27J @ -20°C

47J @ -60°C 629a.k2 27J @ -50°C

27J @ -30°C 698a.k3 27J @ -20°C

27J @ -50°C 699a.k3 27J @ -50°C

27J @ -60°C 768a.k3 27J @ -20°C

27J @ -40°C 769a.k3 27J @ -50°C

27J @ -73°C 769a.k4 27J @ -50°C

27J @ -40°C 9a.k6 27J @ -30°C

27J @ -50°C 9a.k7 27J @ -50°C

27J @ -40°C 9a.W 27J @ -30°C

27J @ -30°C X.gAgreed between the purchaser and supplier

4

e Electrode

t Tubular

P All Positional

d Flat and H/V Fillets

s Single run only

Shielding requirements and current type

group 2

Carbon dioxide CO2

M Mixed gas

DC constant potential electrode negative

a AC current

Heat treatment condition

a As welded condition

P Post-welded heat treatment

Designates the diffusable hydrogen-content of deposited weld

metal (DWM).H10

H5 ≤ 5 ml H2 / 100 g of DWM

H10 ≤ 10 ml H2 / 100 g of DWM

H15 ≤ 15 ml H2 / 100 g of DWM

n No external shielding gas

construction and recommended

welding position

group 1

group 3

Weld Metal

11



as 2203.1-1990 cored electrodes for arc Welding Part 1: ferritic steel electrodes

AS 2203.1 Weld Metal Chemistry Wt% Summary – Table 4

Single values shown are maximum.

Carbon Steel Cored Wires

Carbon-Molybdenum Steel Cored Wires

Chromium-Molybdenum Steel Cored Wires

Nickel Steel Cored Wires

Manganese-Molybdenum Steel Cored Wires

Other Low Alloy Steel Cored Wires

Weld Metal no.

carbon (c)

Manganese (Mn)

silicon (si)

nickel (ni)

chromium (cr)

Molybdenum (Mo)

other elements

CM1CM2

0.20> 0.20

1.751.75

0.900.90

0.500.50

0.200.20

0.300.30

0.08V/1.8Al0.08V/1.8Al

A1 0.12 1.25 0.80 — — 0.40–0.65 —

Ni1Ni2Ni3

0.120.120.12

1.501.501.50

0.080.080.08

0.80–1.101.75–2.752.75–3.75

0.15— —

0.35— —

0.05V/1.8Al0.05V/1.8A1

—

9X.D19X.D29X.D3

0.120.150.12

1.25–2.001.65–2.251.00–1.75

0.800.800.80

— — —

— — —

0.25–0.550.25–0.550.40–0.65

— — —

9X.K19X.K29X.K39X.K49X.K59X.K69X.K7

G9X.W

0.150.150.150.15

0.10–0.250.150.15—

0.12

0.80–1.400.50–1.750.75–2.251.20–2.250.60–1.600.50–1.501.00–1.751.00 min.0.50–1.30

0.800.800.800.800.800.800.80

0.80 min.0.35–0.80

0.80–1.101.00–2.001.25–2.601.75–2.600.75–2.000.40–1.102.00–2.750.50 min.0.40–0.80

0.150.150.15

0.20–0.600.20–0.70

0.15—

0.30 min.0.45–0.70

0.20–0.650.35

0.25–0.650.30–0.650.15–0.55

0.15—

0.20 min.—

0.05V0.05V/1.8Al

0.05V0.05V0.05V

0.05V/1.8Al—

0.10 min./1.8Al0.30–0.75Cu

B1B2LB2

B2CB3LB3

B3C5Cr7Cr9Cr

0.120.050.12

0.10–0.150.050.12

0.10–0.150.100.100.10

1.251.251.251.251.251.251.251.501.501.50

0.800.800.800.800.800.800.801.001.001.00

— — — — — — —

0.400.400.40

0.40–0.651.00–1.501.00–1.501.00–1.502.00–2.502.00–2.502.00–2.504.00–6.006.00–8.008.00–10.50

0.40–0.650.40–0.650.40–0.650.40–0.650.90–1.200.90–1.200.90–1.200.45–0.650.45–0.650.85–1.20

— — — — — — —

0.50Cu0.50Cu0.50Cu

11



aWs a5.20-95 specification for carbon steel electrodes for flux cored arc Welding

E 7 1 T – 1 M J H4

Position of welding, shielding, polarity,

and application requirements.

1 to 14

g

‘General’ classification and means that the electrode

shielding, polarity and impact properties are not specified.

s ‘Single’ pass welding only.


H4

The second letter and sixth number designates the diffusable hydrogen content of deposited weld metal

(DMW)

H4 ≤ 4 mls H2 / 100g of DWM

H8 ≤ 8 mls H2 / 100g of DWM

H16 ≤ 16 mls H2 / 100g of DWM

M

Designates ’Mixed Gas’ and is classified for use with Argon + 20–25% CO2. If no ‘M’ is shown, then

the electrode is used with either CO2 or the electrode

is self shielded.

J

The fourth letter designates that the electrode meets the following

requirements of improved impact-toughness,

20ft Lb @ -40°F-(27J @ -40°C).


Minimum tensile strength

e ElectrodeOptional

Designators

7 Designates the minimum tensile strength in psi x 10,000.

Weld Metal no. psi (MPa)

(415)60,00067 70,000 (480) 1 Designates the

Welding Positions

0 Flat and Horizontal

1 All Positional

T Designates the Electrode is Flux-cored.

T Tubular

11




Table 5

AWS A5.20 Class Polarity No. of Weld Passes Discernible Features and Applications

T-1 and T-1M DC + Multiple Larger diameters (2 mm [5/64″] and larger) are used for flat and H/V welding only. Very smooth/quiet arc with low spatter loss, flat to slightly convex weld bead contour, full covering easy removed slag, and high deposition rates.

T-2 and T-2M DC + Single Essentially the same as T-1/T-1M types, but with higher manganese or silicon or both. Higher levels of deoxidisers allow welding of heavily oxidised steels such as, rimmed, rusty and mill scaled steels. SINGLE pass only.

T-3* DC + Single # High speed gasless welding in flat and H/V and 20° down inclined positions on sheet metal. Limited mech. props.

T-4* DC + Multiple Very low Sulphur weld deposits (resistant to hot cracking) and very high deposition rates. Bridging of poor fit-up joints.

T-5 and T-5M DC +/- Multiple Larger diameters (>2mm) are used for flat and H/V welding. Good mechanical properties (e.g. impacts 27J @ -29°C/20ft Lb @ -20°F). Slightly convex weld bead contour, easy removed thin slag, resistant to hot and cold cracking.

T-6* DC + Multiple Good low temperature impact properties (e.g. 27J @ -29°C/20ft Lb @ -20°F). Slightly convex weld bead contour, easy removed thin slag, resistant to hot and cold cracking.

T-7* DC - Fluoride

— Dia. (>2mm) used for flat and H/V welding. High deposition rates and very low sulphur weld metal resistant to cracking.

T-8* DC - Multiple Very good low temperature strength, notch toughness and crack resistance (e.g. 27J @ -29°C/20ft Lb @ -20°F).

T-9 and T-9M DC + Multiple Essentially the same as T-1/T-1M types, but deposit weld metal with improved impact properties (e.g. 27J @ -29°C/20ft Lb @ -20°F). To obtain X-Ray quality, joints are to be relatively clean and free of oil, excessive oxide and mil-scale.

T-10* DC - Single High speed gasless welding in flat and H/V and 20° vertical inclined positions on larger thickness than the T-3 class.

T-11* DC - Multiple General purpose wire for use on material less than 20mm (3/4) unless preheat and interpass temp’s are maintained.

T-12 and T-12M DC + Multiple Essentially the same as T-1/T-1M types, but modified to increase impact properties and to meet lower manganese requirements of the ASME Boiler and pressure Vessel code section IX, A-1 analysis group of 1.6% Mn.

T-13* DC - Single Root pass welding only on circumferential pipe welds.

T-14* DC - Single # High speed all positional welding of sheet metal such as, galvanised, zinc and other coated steels < 6mm (1/4)

T-G DC +/- Multiple For electrodes not covered by any present classification. The wire must meet the chemical requirements to ensure a carbon steel deposit and the specified tensile strength.

T-GS DC +/- Single For single pass electrodes not covered by any present classification. The wire must meet the specified tensile strength requirements. No other requirements are specified.

* Self shielded wire types.

11




shielding gas types

e7Xt-1

These electrodes are designed primarily for use with CO2 shielding gas. Argon based gases may be used to improve out-of-position characteristics when recommended by the manufacturer.

Warning: By using Argon-based gas mixtures with these electrode types, the following problems may occur:

1) Deoxidiser levels in weld deposits may increase;

2) Weld deposit hardness levels may increase,

3) Weld deposit manganese and silicon levels will increase, which will raise yield and tensile strength, and may degrade impact properties.

e7Xt-1M

These electrodes are designed primarily for use with Argon + 20–25% CO2 shielding gases.

Warning: Higher levels of CO2 above those recommended, in Ar/CO2 gases or the use of 100% CO2 gas with these types of electrodes may result in the following:

1) Deterioration of arc and out-of-position characteristics;

2) Resultant weld deposits may show decreased levels of manganese and silicon, which will reduce yield and tensile strength and may degrade impact properties.

As Welded Mechanical Properties – Table 6

AWS Class

Tensile Strength Yield Strength% Elong. Charpy-V-Notch (CVN) Impact Requirementsksi MPa ksi MPa

T-1/1m 70 480 58 400 22 20ft lb @ 0°F (27J @ -18°C)

T-2/2m 70 480 n.s. n.s. n.s. not specified

T-3* 70 480 n.s. n.s. n.s. not specified

T-4* 70 480 58 400 22 not specified

T-5/5m 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)

T-6* 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)

T-7* 70 480 58 400 22 not specified

T-8* 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)

T-9/9m 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)


T-11* 70 480 58 400 20 not specified

T-12/12m 70-90 480-620 58 400 22 20ft lb @ 0°F (27J @ -29°C)

E6XT-13* 60 415 n.s. n.s. n.s. not specified

E7XT-13* 70 480 n.s. n.s. n.s. not specified


E6XT-G 60 415 48 330 22 not specified

E7XT-G 70 480 58 400 22 not specified

E6XT-GS 60 415 n.s. n.s. n.s. not specified

E7XT-GS 70 480 n.s. n.s. n.s. not specified

The above designations may be classified with the ‘J’ indicator, provided the lower CVN Impact requirements of 20ft Lb @ -40°F (27J @ -40°C), are met for T-1/1M, T-5/5M, T-6, T-8, T-9/M and T-12/12M types.

* Self shielded wire types.

11 Technical Data


Technical Reference Data

11



deposition ratesWhen welding with a consumable (electrode, wire or rod), it will have a deposition rate at which weld metal is deposited (melted) onto a metal surface. The deposition rate is expressed in kilograms per hour (kg/h).

Deposition rate is based on a 100% duty cycle (continuous operation).

This is not a true reflection on an actual welding workshop, as it does not allow for stops and starts such as electrode change overs, chipping slag, cleaning spatter, machine adjustments or other occurrences, but is used to establish the consumable ability to deposit weld metal.

Therefore it must be noted that, when calculating actual deposition rate for costing of a welded structure, you must take into consideration the duty cycle of equipment and the operator factor.

For example, it is accepted as a general rule that an operator using MMAW will only weld at around 30 percent operator factor (on a good day) and a GMAW will be around 60 percent.

Generally, when welding current is increased, so is the deposition rate. When electrical stick out is increased in the case of GMAW and FCAW, the deposition rate will also increase.

Electrical stick out is the distance from the end of the contact tip to the work piece (ETWD).

Deposition rates are calculated using the following methodology. They show the formula for measuring deposition rates.

deposition rate =

Weight (Test plate before welding - test plate after welding)

Measured period of time (normally 60 seconds)

(e.g. Plate before welding: 4 kg and 4.80 kg after welding = 80 grams, welded in 60 seconds, 80 grams x 60/1000 = 4.8kg/h)

deposition rate example =

4 kg - 4.8 kg=

80 g= 4.8 kg/h

60 sec 60 sec x 60/1000

electrode efficiency (deposition efficiency)Electrode efficiency, to AS/NZS 1553.1: 1995, is the difference between the weight of the weld metal deposited and the weight of the filler metal consumed (not including flux and stub ends) in making the weld. The efficiency of an electrode is calculated by using the following formula by running 5 electrodes in a 1G position:

rn(%) = m2 – m1

m3 – m4

Where:

m1 = mass of test plate before welding m2 = combined mass of test plate and the weld m3 = mass of the core of the wire of the 5 electrodes m4 = mass of the core of the wire in the five stubs after welding

For example, an E6013 type electrode has an approximate efficiency of 91 percent while an E7024 will have around 150 percent efficiency.

Weld Metal recoveryThis should not be confused with an electrode efficiency.

Weld metal recovery measures the amount of weld metal that will be deposited on the work piece.

For example, if you purchase a 5 kg packet of MMAW E6012 electrodes, which will produce a weld metal recovery of around 60 percent, you will end up throwing away 2 kg as slag and stubs.

In a GMAW solid wire at 93 percent you will lose 0.35 kg.

The following are an indication only, as an operator and welding envelope will influence these figures.

Various Process efficienciesWelding processes vary in both the deposition rates and deposition efficiencies. Below are tables that give an indication only of the various processes. The GTAW and Oxy-Acetylene assume that the stubs are joined together to have no waste.

approximate process deposited weld metal recovery (Not electrode efficiency)

Welding Process Average Efficiency

GTAW 100%

Oxy-Acetylene welding 99.99%

GMAW – Pulse Arc 98%

GMAW – Spray Arc 95%

GMAW – Short (Dip) Arc 93%

FCAW – E70C-6M types 92%

FCAW – E70T-5 types 88%


FCAW – Tubular Hard-facing wires 80–85%


MMAW – Hard-facing types 62–72%

MMAW – E7014 types 63%





deposition dataDeposition Rates, Electrode Efficiency

11



AS/NZ 1553.1.1995

Metric (mm) International inches Lengths* (mm) Gauge No.Approximate Fraction inches

— — 200 — —

1.6 0.0625 250 16 1/16

2 0.0787 300 14 5/64

— — 250 — —

2.5 0.0984 300 12 3/32

— — 350 — —

3.2 — 350 10 1/8

4.0 0.1250 380 — —

— 0.1575 450 — —

4.8 0.1576 350 8 5/32

5 0.1969 380 6 3/16

5.6 0.2205 450 — —

6 0.2362 500 4 7/32

6.3 0.2481 600 — 1/4

8 0.3150 700 0 5/16

10 0.3937 900 — 3/8

* Length will depend on manufacture and market preference and not all sizes will be available.

British and United States Electrode Size Comparison Table

Metric (mm) International inches Gauge No. Approximate Fraction inches

2 0.0787 14 5/64

2.5 0.0984 12 3/32

3.15 0.1240 10 1/8

3.25* 0.1280 — —

4 0.1576 8 5/32

5 0.1969 6 3/16

6* 0.2362 4 7/32

6.3 0.2481 — 1/4

8 0.3150 0 5/16

10 0.3937 — 3/8

*The British Standard Institution in the Specifications for Covered Electrodes (BS 639:1969) proposes that, with the exception of the 3.15 and 6 mm sizes, the metric sizes in the first column become standards.

The 3.25 mm diameter is, at present widely, used and will be retained until such a time as it can be dropped through its lesser usage.

The 6 mm diameter is not a preferred size, but it is included because the existing capacities of some welding equipment may make the use of 6.3 mm impractical.

MMa electrode sizes

11



Solid Mild Steel Wire

Wire Size (mm) Welding Current (A) ARC Voltage (V)

Wire Feed Speed (m/min)

Deposition Rate (kg/h)

0.8 60* 16* 3.3 0.7

80* 17* 4.4 1.0

100* 18.5* 5.9 1.3

120* 20* 7.0 1.6

140* 20* 9.9 2.2

160* 22* 12.4 2.8

180 30 14.3 3.2

0.9 70* 15* 3.7 1.1

100* 19* 6.0 1.7

120* 19* 6.9 2.0

150* 20* 8.7 2.5

180* 21* 11.5 3.3

180 29 12.0 3.4

200 31 14.0 4.0

1.2 120* 18* 2.7 1.4

150* 18* 3.5 1.8

170* 19* 3.9 2.0

220 30 6.2 3.2

250 32 9.1 4.7

310 34 11.3 5.8

340 36 12.9 6.6

1.6 140* 19* 1.7 1.6

200* 19* 2.4 2.2

250* 21* 3.1 2.8

300 30 4.9 4.5

350 34 6.2 5.7

400 34 7.5 6.8

* Short arc transfer conditions

Note: Deposition rate data is determined using: • DCEP (reverse polarity) with a conventional constant potential power source • Ar 16–18% CO2 shielding gas • An electrode stick out length of 8–10 mm for short arc transfer conditions and 15 mm for spray transfer conditions • A process efficiency of 96% for both short arc transfer and spray arc transfer conditions.

deposition rate (gMaW)

11



Gas/TIG Rods per kg (approx)

Description

Size (mm)Length (mm)1.6 2.4 3.2 5.0 6.0

Aluminium 196 94 53 — — 915

ProFill Mang Bronze

83 38 21 8 7 750

ProFill Nickel Bronze

— — 20 8 — 750

Cast Iron — — — 9 — 700

Mild Steel 70 29 18 5 — 915

Stainless Steel 69 31 16 — — 915

Low Temperature Alloys Rods per kg (approx)

Description

Size (mm)Length (mm)1.5 2.5 3.0

ProSilver 2 83 31 22 750

ProSilver 5 84 30 18 750

ProSilver 15 80 29 20 750

ProSilver 34 69 31 18 750

ProSilver 40 69 32 18 750

ProSilver 42 67 32 18 750

ProSilver 50 66 24 18 750

ProSilver 55 66 25 18 750

ProSilver 56 64 23 17 750

ProSilver 503 65 24 18 750

Silbralloy 2 83 30 21 750

Copperflo 2 84 31 22 750

BOC ProFill Gas Welding Rods – Applications

BOC CigweldJoining Process

Suitable Materials Features Suitable Flux Comments

Tobin Bronze Tobin Bronze Braze Welding Fusion Welding

Brass & Bronzes Mild Steel Ferrous Materials

Low Fume Tenacity 20 With mild steel, low strength applications only (e.g. car panel filling)

Nickelcoat Nickel Bronze Braze Welding Fusion Welding

Steel Cast Iron Malleable Iron

High Strength Wear Resistant

Self Fluxing Fusion welding of similar copper alloys Brazing of nickel based alloys

Nickel Bronze Nickel Bronze Braze Welding Fusion Welding

Steel Cast Iron Malleable Iron

High Strength Wear Resistant

Tenacity 20 Fusion welding of similar copper alloys Brazing of nickel based alloys Build up of worn ferrous components

Mangcoat Comcoat C Braze Welding Steel Cast Iron Malleable Iron

Low Fume High Strength

Self Fluxing Due to dezincification, not suitable for copper pipes carrying hot water or sea water

Mang Bronze Manganese Bronze

Braze Welding Steel Cast Iron Malleable Iron

Low Fume High Strength

Tenacity 20 Due to dezincification, not suitable for copper pipes carrying hot water or sea water

GMAW Consumable Lengths (m/kg) (approx)

Dia. (mm) Metre

Mild Steel MIG Wire

0.6 525

0.8 277

0.9 204

1.0 164

1.2 123

1.6 64

Flux Cored Wires

1.2 140

1.6 70

2.0 53

2.4 38

Aluminium Welding Wire (5356)

0.8 739

0.9 595

1.2 356

1.6 185

2.4 84

3.2 47

Stainless Steel MIG Wire

0.6 450

0.8 275

0.9 200

1.2 115

1.6 63

general consumable data

11



Tungsten Electrodes are usually identified by a colour on the end of the electrode.

In Australia/NZ, the AWS standard is generally referred to as the compliance standard for this product, although the colour of the tungstens sold by various suppliers may not match that of the standard, due to various manufacturers conforming to European standards.

To help clarify, the charts below show those that are classified under AWS: A5: 12 and those that are sold by BOC.

Note: When sharpening tungstens, they should be sharpened so that the grinding lines travel down the length of the tungsten. This allows the ions to travel down the tungsten without having to cross circumferential lines that would cause them to leave the tip in an erratic manner and affect the weld quality.

Boc tungstens

thoriated

Red Tip DC straight polarity for copper, nickel alloys, titanium, mild steels and stainless steels. This tungsten is usually sharpened to a point. The length of taper should be 2 times the diameter of the tungsten. Thoriated tungsten emits a small amount of radioactivity.

Zirconiated

White Tip AC polarity for the welding of aluminium and magnesium. Tungsten should be used in the ball form.

lanthiated

Gold Tip for AC high frequency and DC Straight Polarity currents. Suitable for automated TIG applications due to its high current carrying capacity and has good multi-strike capability. Lanthiated is radiation free. Lanthiated tungstens are normally sharpened the same as thoriated.

ceriated

Grey Tip for low DCSP on materials that are welded with the thoriated tungstens. Cerium is radiation free. Ceriated tungstens are normally sharpened as per the thoriated tungstens.

tungsten electrodes

AWS: A5:12 Colour Code and Alloying Elements for Various Tungsten Electrode Alloys

AWS Classification Coloura Alloying Element Alloying OxideNominal Weight of Alloying Oxide %

EWP Green — — —

EWCe-2 Orange Cerium CeO2 2

EWLa-1 Black Lanthanum La2O3 1

EWTh-1 Yellow Thorium ThO2 1

EWTh-2 Red Thorium ThO2 2

EWZr-1 Brown Zirconium ZrO2 0.25

EWG Grey Not Specifiedb — —

Note: Colours may varya Colour may be applied in the form of bands, dots etc, at any point on the surface of the electrode.

Recommended Tungsten Electrodes and Gas Cups for Various Welding Currents

Electrode Diameter (mm)

Use Gas Cup (mm)

Direct Current (Amps) Alternating Current (A)

Straight Polarity (DCEN)

Reverse Polarity (DCEP)

Unbalanced Wave

Balanced Wave

0.25 6.4 <15 — <15 <15

0.50 6.4 5–20 — 5–15 10–20

1.00 10 15–80 — 10–60 20–30

1.6 10 70–150 10–20 50–100 30–80

2.4 12 150–250 15–30 100–160 60–10

3.2 12 250–400 25–40 150–210 100–180

4.0 12 400–500 40–55 200–275 160–240

4.8 16 500–750 55–80 250–350 190–300

6.4 20 750–1100 80–125 325–450 325–450

Note: All values are based on the use of argon as the shielding gas.

11



sI Metric systemLength

1 millimetre (mm) — 0.0393 701 inch

1 centimetre (cm) 10 millimetres 0.393 701 inch, 0.032 208 4 feet

1 decimetre (dm) 10 centimetres 3.937 01 inches

1 metre (m) 10 decimetres (100 cm) 39.370.1 inches, 3.280 843 feet, 1.093 614 yards

1 decametre (dam) 10 metres 10.936 14 yards

1 hectometre (hm) 10 decametres (100 m) 109.361 4 yards

1 kilometre (km) 10 hectometres (1,000 m) 3 280.843 feet, 1.093.614 yards, 0.621 371 mile

Area

1 square millimetre (mm2) — 0.001 550 sq. inch

1 square centimetre (cm2) 100 sq. millimetres 0.155 sq. inch, 0.001 076 39 sq. feet

1 square decimetre (dm2) 100 sq. centimetres 15.50 sq. inches

1 square metre (m2) 100 sq. decimetres (10,000 cm2) 10.763 915 sq. feet, 1.195 99 sq. yards

1 are 100 sq. metres (1 sq. decametre) 119.599 sq. yards

1 hectare (ha) 100 ares (10,000 sq. metres) 11 959.9 sq. yards, 2.471 05 acres

1 square kilometre (km2) 100 hectares (1,000,000 sq. metres) 0.386 102 sq. mile

Volume (cubic)

1 cubic millimetre (mm3) — 0.000 061 024 cubic inch

1 cubic centimetre (cm3) 1,000 cubic millimetres 0.061 024 cubic inch

1 cubic decametre (dm3) 1,000 cubic centimetres (1 litres) 61.024 cubic inch

1 cubic metre (m3) 1,000 cubic decimetres (1,000 litres) 35.317 76 cubic feet, 1.307 95 cubic yards

Volume (fluid)

1 millimetre (ml) — 0.035 195 fluid oz

1 centilitre (cl) 10 millilitres 0.351 95 fluid oz

1 decilitre (dl) 10 centilitres 3.519 5 fluid oz, 0.175 975 pint

1 litre (L) 10 decilitres 1.759 75 pints, 0.219 969 gallon, 0.264 18 US gallon

1 decalitre (dal) 10 litres 2.199 69 gallons

1 hectolitre (hl) 10 decalitres (100 litres) 21.996 9 gallons

1 kilolitre (kl) 1,000 litres (1 m3) 219.969 gallons

Mass

1 milligram (mg) (1,000 micrograms) mg 0.015 432 36 grain

1 centigram (cg) 10 milligrams 0.154 323 6 grain

1 decigram (dg) 10 centigrams 1.543 236 grains

1 gram (g) 10 decigrams (1,000 milligrams) 15.432 36 grains, 0.035 274 avoir oz

1 decagram (dag) 10 grams 0.352 74 avoir oz

1 hectogram (hg) 10 decagrams 3.527 4 avoir oz, 15,432.358 grains

1 kilogram (kg) 10 hectograms (1,000 grams) 2.204 622 6 litres, 2.204.622 6 lbs

1 tonne 1,000 kilograms 19.684 1 cwts, 0.984 207 ton, 1.102 311 short tons (2,000 lb ton)

These tables can also be found on page 18 of this manual.

11



°C °F

300 572

290 554

280 536

270 518

260 500

250 482

240 464

230 446

220 428

210 410

200 392

190 374

180 356

170 338

160 320

150 302

140 284

130 266

120 248

110 230

100 212

99 210.2

98 208.4

97 206.6

96 204.8

95 203.0

94 201.2

93 199.4

°C °F

92 197.6

91 195.6

90 194.0

89 192.2

88 190.4

87 188.6

86 186.8

85 185.0

84 183.2

83 181.4

82 179.6

81 177.8

80 176.0

79 174.2

78 172.4

77 170.6

76 168.8

75 167.0

74 165.2

73 163.4

72 161.6

71 159.8

70 158.0

69 156.2

68 154.4

67 152.6

66 150.8

65 149.0

°C °F

64 147.2

63 145.2

62 143.6

61 141.8

60 140.0

59 138.2

58 136.4

57 134.6

56 132.8

55 131.0

54 129.2

53 127.4

52 125.6

51 123.8

50 122.0

49 120.2

48 118.4

47 116.6

46 114.8

45 113.0

44 111.2

43 109.4

42 107.6

41 105.8

40 104.0

39 102.2

38 100.4

37 98.6

°C °F

36 96.8

35 95.0

34 93.2

33 91.4

32 89.6

31 87.8

30 86.0

29 84.2

28 82.4

27 80.6

26 78.8

25 77.0

24 75.2

23 73.4

22 71.6

21 69.8

20 68.0

19 66.2

18 64.4

17 62.6

16 60.8

15 59.0

14 57.2

13 55.4

12 53.6

11 51.8

10 50.0

9 48.2

°C °F

8 46.4

7 44.6

6 42.8

5 41.0

4 39.2

3 37.4

2 35.6

1 33.8

0 32.0

-1 30.2

-2 28.4

-3 26.6

-4 24.8

-5 23.0

-6 21.2

-7 19.4

-8 17.6

-9 15.8

-10 14.0

-11 12.2

-12 10.4

-13 8.6

-14 6.8

-15 5.0

-16 3.2

-17 1.4

-18 -0.4

-19 -2.2

°C °F

-20 -4.0

-21 -5.8

-22 -7.6

-23 -9.4

-24 -11.2

-25 -13.0

-26 -14.8

-27 -16.6

-28 -18.4

-29 -20.2

-30 -22.0

-31 -23.8

-32 -25.6

-33 -27.4

-34 -29.2

-35 -31.0

-36 -32.8

-37 -34.6

-38 -36.4

-39 -38.2

-40 -40.0

-45 -49.0

-50 -58.0

-55 -67.0

sI Metric system (cont.)

Celsius to Fahrenheit

Force

Pounds Force (lbf)

Newtons (N)

Newtons (N)

Pounds Force (lbf)

Tons Force (tonf)

Kilonewtons (kN)

Kilonewtons (kN)

Tons Force (tonf)

1 4.448 22 1 0.224 809 1 9.964 02 1 0.100 361

2 8.896 44 2 0.449 618 2 19.928 04 2 0.200 722

3 13.344 67 3 0.674 427 3 29.892 06 3 0.301 083

4 17.792 89 4 0.899 236 4 39.856 08 4 0.401 444

5 22.241 11 5 1.124 045 5 49.820 10 5 0.501 805

6 26.689 33 6 1.348 854 6 59.784 12 6 0.602 166

7 31.137 55 7 1.573 663 7 69.748 14 7 0.702 527

8 35.585 78 8 1.798 472 8 79.712 16 8 0.802 888

9 40.034 00 9 2.023 281 9 89.676 18 9 0.903 249

10 44.482 22 10 2.248 090 10 99.640 20 10 1.003 610

Note: 1 MPa and 1 N/mm2 are the same. These tables can also be found on page 19 of this manual.

11



austenitic ss classificationsCommon Austenitic stainless steel grades and their applications

AISI No.UNS No. Forms Available

Typical Analysis (%)

Typical ApplicationsC Cr Ni Mo Ti Other

301 S30100 Steel & Coil 0.08 17.0 7.00 — — — General purpose steel with good corrosion resistance for most applications. Employed where the high work-hardening exponent is desirable. Can be supplied cold worked to give high strength and ductility. Used for structural applications such as rail carriages and wagons.

302 S30200 Sheet & Coil, Bars 0.08 18.0 9.0 — — — General purpose steel with good corrosion resistance for most applications. Used for architecture, food processing, domestic sinks and tubs and deep drawing applications.

303 S30300 Bars 0.12 18.0 9.0 — — 0.25 S Free machining steel used where extensive machining is required. Corrosion-resistance and weldability inferior to 302.

304 S30400 Sheet & Coil, Plate & Bars

0.06 18.5 9.0 — — — Similar corrosion resistance to 302. Used where higher resistance to weld decay is needed in brewing, etc.

304L S30403 Sheet & Coil, Plate 0.03 18.5 9.5 — — — Chemical plant and food processing equipment, where freedom from sensitisation is required in plate.

305 S30500 Sheet & Coil, Wire 0.08 18.0 12.0 — — — Spun sheet parts, cold headed screws.

309 S30900 Sheet & Coil, Plate, Bar

0.15 23.0 13.5 — — — High temperature, oxidation resistant. Furnace parts.

309S S30903 Sheet, Plate, Bar, Tube & Pipe

0.08 23.0 13.5 — — — A low carbon version of 309. Used where superior corrosion resistance to 316 is required.

310 S31000 Sheet & Coil, Plate & Bars

0.12 25.0 20.0 Furnace parts and equipment. Resistant to temperature 900–1100°C.

— S30815 Sheet, Plate, Bar, Tube & Pipe

0.10 21.0 11.0 — — 0.15 N 0.4 Ce

Used for furnace parts, radiant shield, fluidised beds. Resistant to temperatures up to 1150°C. Possesses high strength and resistance to sigma-phase formation.

310S S31003 Sheet, Plate, Bar, Tube & Pipe

0.08 25.0 20.0 — — — A low carbon version of 310 used to restrict nitric acid corrosion.

316 S31600 Sheet & Coil, Plate, Seamless welded tube pipe

0.06 17.0 12.0 2.25 — — Used where higher corrosion resistance is required (e.g. marine equipment). Can be welded up to 3mm without subsequent heat treatment.

316L S31603 Sheet & Coil Plate, Seamless welded tube pipe

0.03 17.0 12.0 2.25 — — A low carbon modification of 316 where heavy section weldments are required without the risk of intergranular corrosion.

316Ti S31608 Plate, Pipe, Tube 0.08 17.0 12.0 2.25 0.5 — A titanium stabilised version of 316, used where good resistance to intergranular corrosion and high temperature strength is required.

317 S31700 Sheet & Coil Plate 0.07 19.0 13.0 3.25 — — For chemical plant – has a greater corrosion resistance than 316 in certain applications, notably in contact with brines and halogen salts. Also available in the low carbon ‘L’ grade.

904L N08904 Sheet, Plate, Bar, Pipe, Tube,

0.02 20.0 25.0 4.5 — 1.5 Cu High resistance to: general corrosion (e.g. in sulphuric and acetic acids); crevice corrosion; stress corrosion cracking; pitting in chloride bearing solutions. Good weldability.

— N08028 Sheet, Plate, Tube, Pipe, Bar

0.02 27.0 31.0 3.5 — 1 Cu Used against all types of corrosion under severe conditions. Used in sour oil and gas production pipe, heat exchangers, heat exchangers for acid concentration, piping evaporation.

— 31254 Sheet, Plate, Tube, Pipe, Bar

0.02 20.0 18.0 6.0 — 0.2 N Used where high resistance to chloride pitting and crevice corrosion is required (e.g. seawater heat exchangers, bleach vats and washers in the pulp and paper industry).

321 S32100 Sheet & Coil, Plate & Bar

0.06 18.0 10.0 — 0.5 — Heavy weldments in chemical and other industries. Suitable for heat resisting applications to 800°C. Not suitable for bright polishing.

201 S20100 Sheet & Coil, Plate 0.12 17.0 4.5 — — 6.5 Mn 0.15 N

Lower cost, reduced nickel version of Type 301.

202 S20200 Sheet & Coil, Plate 0.08 18.0 5.0 — — 9.0 Mn 0.15 N

Lower cost, reduced nickel version of Type 302.

11



Martensitic ferritic ss classificationsCommon Martensitic stainless steel grades and their applications

AISI No.

UNS No.

Forms Available


Typical ApplicationsC Cr Ni Mo Other

410 S41000 Bars 0.10 12.5 — — — General purpose grade for use in mildly corrosive environments.

403 S40300 Bars 0.15 13.0 — — — Capable of attaining higher hardness than 410.

416 S41600 Bars 0.10 12.5 — — 0.20 S Free machining variation of 410.

420 S42000 Bars 0.25 12.5 — — — General engineering uses, such as pump and valve shafts.

420C — Sheet & Coil, Plate & Bars

0.30 12.5 — — — Developed for high hardness after heat treatment. Used for cutting tools, surgical knives etc.

431 S43100 Bars 0.18 16.0 2.0 — — Hardenable steel with corrosion resistance approaching 302. Used for pump shafts etc. Should be double tempered after hardening.

440C S44004 Bars 1.10 17.0 — 0.40 — Capable of being hardened to 60Rc. Highest harness and abrasion resistance of all the stainless steels. Corrosion resistance similar to 410.

Common Ferritic stainless steel grades and their applications

AISI No.

UNS No.

Forms Available



405 S40500 Sheet & Coil 0.06 12.0 — — 0.2A1 Welded fabrications for mildly corrosive environments and in heat resistant applications.

409 S40900 Sheet & Coil 0.06 11.5 — 0.5 — Heat resistant steel, easily formed and welded. Mainly used for automotive exhausts or welded applications where superior performance to galvanised steel is required.

446 S44600 Tube, Pipe 0.08 26.0 — — — Used for severe heat resistant applications up to 1200°C. In recuperators, highly resistant to sulphidation and oil ash corrosion.

410S S41008 Sheet & Coil, Plate & Bar

0.06 12.5 — — — Used for heat resistant applications up to 650°C in power plant and oil refineries, where high strength at elevated temperatures is not required.

430 S43000 Sheet & Coil, Plate & Bar

0.08 17.0 — — — Interior architecture component, stove and automotive trim. Welds tend to be brittle.

444 S44400 Sheet & Coil 0.02 18.5 2.0 0.4 — Heat exchanger and hot water tanks, and in chloride containing water. Not prone to cloride stress corrosions. Superior resistance to pitting, crevice and intergranular corrosion. Possesses excellent deep drawing properties.

182 S18200 Bar 0.07 18.25 2.0 – 0.20S Free machining bar variant of 444. Superior machinability to 303.

Common Ferritic-Austenitic stainless steel and their applications

AISI No.

UNS No.

Forms Available



329 S32900 Bars 0.08 26.0 4.5 1.5 — Shafting for pumps, boats. Superior corrosion resistance and strength to 316L, poor weldability.

— S31500 Sheet, Plate Bar, Pipe, Tube, Fitting

0.03 18.0 4.9 2.7 — Superior corrosion resistance to 316L, high resistance to stress corrosion. General fabrication in chemical industry equipment. Suitable for welding in heavy sections without risk of intergranular corrosion.

— S31803 Sheet, Plate Bar, Pipe, Tube, Fitting

0.03 22.0 5.5 3.0 0.14N Superior corrosion resistance to 317L. Excellent stress corrosion resistance. Typically used in heat exchangers, scrubbers, calorifiers, fans, in chemical process tanks, oil and gas and refining industries where outstanding corrosion resistance is required. Suitable for welding heavy sections without risk of intergranular corrosion.

— S32304 Sheet, Plate Bar, Pipe, Tube

0.03 23.0 4.0 — 0.1N Similar corrosion resistance to 316L. High resistance to stress corrosion and erosion, high yield strength. Used where high corrosion resistance is required (e.g. marine, mining, chemical, food, metallurgy and power industries).

11



Welding chart ssConsumables for dissimilar stainless steel

Base Metal ASTM, AISI, UNS

201, 202

304, 304L

309, 309S

310, 310S

317, 316

317L, 316L, 316Ti

321, 347

S30815, (253MA), 904L, (N08904)

409, 430, 446, 5CR12

410, 420

Duplex S31500 S31803 S32304

Carbon and Low Alloy Steels

201, 202

347

308L

347

308L

347

309MoL

347

310

309MoL

318

347

308L

316L

347

347 347

309MoL

309MoL

309L

309MoL

309L

Duplex

309MoL

309MoL

304, 304l

347

308L

347

309MoL

308L

309L

347

310

308L

347

318

308L

347

318

308L

347

308L

347

308L

309MoL

309L

309MoL Duplex

309MoL

309L

309MoL

309L

309, 309s

309MoL

309L

309MoL

309L

310

309MoL

318

316

309L

309L

316L

318

347

309MoL

Match above

309MoL

347

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

310, 310s

310 316L

318

310

316L

318

310

347

310

Match above

309L

310

309MoL

309L

316L

309MoL

309L

310

Duplex

309MoL

309L

309L

309MoL

310

317, 316

318

316L

316L

318

347

316L

Match above

309MoL

316L

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

317l, 316l, 316ti

316L 347

316L

Match above

309MoL

309L

309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

321, 347

347 Match above

309MoL

347

309MoL

309L

309MoL

309L

Duplex

309MoL

347

309MoL

309L

s30815, (253Ma), 904l, (n08904)

Matching 309MoL

309L

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

409, 430, 446, 5cr12

309L

309MoL

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

410, 420

Matching or

309MoL

309L

Duplex

309MoL

309L

309MoL

309L

duplex, s31500, s31803, s32304

Matching Duplex

309MoL

309L

carbon and low alloy steels

Matching

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 your BOC welding process specialist or visit BOC’s Inform website (subscription required) for more detailed information.

This table can also be found on page 383 of this manual.

11



Weights of mild steel weld metal are given in kilograms per metre length of joint, based on joint design.

generalThe following tables have been produced from the product of the joint volume and the density of mild steel. The values are accurate enough to cater for the variations in weld profiles that occur. For most joints, at least two tables must be read in conjunction with each other and the resulting values added together:

Table/s

Fillet welds (down-hand and horizontal/ vertical)

A

Square edge close butts C

Square edge open butts C E

V and double V butts B C D

V close butts (partial penetration) C D

Butt joints with copper backing bard B C D E

U and J groove butt welds F

Multi-pass butt welds F

The following example demonstrates the ease of applying the tables to a complex weld:

Section 1 from Table C

Section 2 from Table D

Section 3 from Table E

Section 4 from Table B

Total weight is the sum of all these four values.

1

2 2

3

4

1

2

3

4

2

These tables can also be used for other materials, but applying factors are proportional to the densities of these materials relative to that of mild steel:

1 Stainless steels: multiply the weights of mild steel weld metal by 1.017, which gives an increase of less than 2%

2 Aluminium alloys: divide the weights of mild steel weld metal by 3

3 Copper alloys: multiply the weights of mild steel weld metal by 1.14, which gives an increase in value of 14%

fillet Welds

Flat Convex Concave

Table A

Leg Length (mm)

Shape of Fillet

Flat Convex Concave

3 .04 .06 .06

5 .10 .13 .12

6 .19 .24 .22

8 .30 .36 .34

9 .43 .52 .49

11 .58 .72 .67

12 .76 .92 .88

14 .96 1.2 1.1

16 1.2 1.4 1.4

19 1.8 2.1 1.9

22 2.4 2.8 2.7

25 3.1 3.7 3.6

note

Values are taken for leg lengths 10% oversize, consistent with normal shop practice. This results in about 20% excess weld metal being required.

underbead Penetration

Table B

Underbead Width (mm) Weld Metal Weights (kg/m)

2 .03

3 .12

5 .28

6 .49

8 .79

9 1.12

11 1.49

12 1.93

notes

1 The underbead width is taken as twice the radius of the penetration bead

2 This table can be used for the radiused section in multi-pass butt joints with U or J preparations

Weld Metal calculator

11



reinforcements

Table C

Bead width (mm)

Height of Reinforcement (mm)

2 3 5 6

5 .04 - - -

6 .05 - - -

8 .065 - - -

9 .07 .16 - -

11 .09 .18 .28 -

12 .10 .21 .31 -

14 .12 .24 .36 -

16 .13 .27 .40 -

18 .15 .30 .43 .58

19 .16 .33 .48 .63

22 .18 .37 .55 .71

25 .21 .42 .63 .85

29 .24 .48 .71 .95

32 .27 .52 .79 1.06

35 .30 .58 .88 1.2

38 .31 .64 .95 1.3

41 .34 .68 1.03 1.4

45 .37 .74 1.1 1.5

50 .42 .85 1.3 1.6

notes

1 See Table E for square edge butts with a gap between faces

2 These weights must be doubled for 2-pass butts

3 Normal shop practice would give reinforcements of 2 mm for thicknesses up to 20 mm, and 3 mm on thicker plates except for 2-pass square edge close butts, where the reinforcement can be greater

4 Bead width is usually the same as plate thicknesses ±3 mm, depending upon preparation, except in multi-pass welding where the bead width is approximately the maximum weld preparation width plus 6 mm

V section

A B

Table D

Depth of V (mm)

Included Angle of V

14° 20° 60° 70° 90° 45°

3 .01 .013 .04 .055 .08 .04

5 .022 .031 .10 .125 .18 .09

6 .04 .06 .18 .22 .32 .16

8 .06 .09 .28 .34 .50 .25

9 .09 .12 .42 .49 .72 .36

11 .12 .18 .57 .68 .98 .49

12 .15 .22 .73 .89 1.3 .64

14 .19 .28 .92 1.12 1.6 .80

16 .24 .34 1.15 1.4 2.0 .98

18 .30 .42 1.4 1.6 2.4 1.2

19 .34 .51 1.6 1.9 2.9 1.4

21 .42 .60 1.9 2.4 3.3 1.6

22 .48 .68 2.2 2.7 3.9 1.9

25 .63 .89 3.0 3.6 5.1 2.5

29 .79 1.13 3.7 4.5 6.6 3.3

32 .97 1.4 4.6 5.5 8.0 4.0

35 1.2 1.6 5.5 6.7 9.6 4.8

38 1.4 2.1 6.5 8.0 11.4 5.7

45 1.9 2.7 8.9 10.9 15.4 7.7

50 2.5 3.6 11.8 14.1 20.2 10.1

notes

1 This table should be read in conjunction with Tables B, C and E and the weights added together

2 This table can be used for V butt joints with gaps, the gap value being obtained from Table E

3 The final column (45°) only applies to Figure B , the figures being half those applicable to the 90° V

11



square edge open Butts

Table E

Plate thickness (mm)

Width of Separation (mm)

2 3 5 6 10 12

3 .04 .07 .12 .16 .24 .31

5 .06 .12 .18 .24 .36 .48

6 .07 .16 .24 .31 .48 .64

8 .10 .19 .30 .40 .58 .79

9 .12 .24 .36 .48 .71 .95

11 .13 .28 .42 .55 .83 1.1

12 .16 .31 .48 .64 .95 1.3

14 .18 .36 .54 .71 1.1 1.4

16 .19 .40 .60 .79 1.2 1.6

18 .22 .43 .65 .86 1.3 1.8

19 .24 .48 .71 .95 1.4 1.9

22 .28 .55 .83 1.1 1.6 2.2

25 .31 .64 .94 1.3 1.9 2.5

29 .36 .71 1.1 1.4 2.1 2.8

32 .40 .79 1.2 1.6 2.4 3.1

35 .43 .86 1.3 1.8 2.7 3.4

38 .48 .95 1.4 1.9 2.8 3.9

41 .52 1.03 1.5 2.1 3.1 4.2

45 .55 1.10 1.6 2.2 3.3 4.5

48 .58 1.2 1.8 2.4 3.6 4.8

50 .64 1.3 1.9 2.5 3.9 5.1

note

This table should be read in conjunction with Table C (reinforcement) and the weights added together.

Multi-Pass groove Butt Joints

Table F

Groove Depth (mm) Weight of Weld Metal (Kg/m)

11 1.34

12 1.5

16 1.8

19 2.1

22 2.4

25 2.7

32 3.6

38 4.5

45 5.4

50 6.6

57 7.9

63 9.2

70 10.7

76 12.4

note

This table is compiled from Tables B, C, D and E.

11



Joint Preparations summary chartTypical preparations for a range of material thicknesses

Material Thickness

Process

Manual Metal ArcManual MIG-MAG Dip Transfer

Manual MIG-MAG Spray Transfer

Mechanised MIG-MAG Submerged Arc

20 SWG

10 SWG

3 mm2mm 2mm

sin

gle

V p

rep

arat

ion

4 mm

6 mm

10 mm

12 mm

20 mm

do

ubl

e V

pre

par

atio

n

25 mm

38 mm

75 mm

6mm

30°

30°

12mm r

11



effect of overweldingIf a 6 mm filletweld is specified and it is over-welded by 1.5 mm, it will add 56 percent volume to the joint. Overwelding this by 3 mm will add 125 percent weld volume.

15

8

3

13

6 11

24

22

20

18

35

33

31

29

27

16

9

4

1

14

7

2

12

5 10

25

23

21

19

17

36

34

32

30

28

26

6 mm Fillet 7.5 mm Fillet 9 mm Fillet

16 Triangles= 100%

25 Triangles25/16 = 156%

36 Triangles36/16 = 225%

Excess 56% Excess 125%

NotRequiredNot

Required

15

8

3

13

6 11

24

22

20

18

35

33

31

29

27

16

9

4

1

14

7

2

12

5 10

25

23

21

19

17

36

34

32

30

28

26


16 Triangles= 100%

25 Triangles25/16 = 156%

36 Triangles36/16 = 225%


NotRequiredNot

Required

15

8

3

13

6 11

24

22

20

18

35

33

31

29

27

16

9

4

1

14

7

2

12

5 10

25

23

21

19

17

36

34

32

30

28

26


16 Triangles= 100%

25 Triangles25/16 = 156%

36 Triangles36/16 = 225%


NotRequiredNot

Required

Boc Iprm s11-Techdata

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