Flux Cored

Flux cored wireIdeal combination of high quality and high

efficiency

Dipl.-Ing. IWE Michael ReimannProduct Manager

OERLIKON SwitzerlandWelding conference Lima, Peru 25.11.2005

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Arrangement of flux cored wires

Seamless flux cored wire

Metal cored wire

Rutil flux cored wire

Basic flux cored wire

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Flux cored wire classification Fluxofil 14 HD

DIN EN 758 T 46 2 P M 1 H5T : Flux cored wire46 : Yield and tensile Strenght2 : ToughnessP : Slag fast freezing slagM : Mixed gas 82% Ar 18% CO21 : All welding positionH5 : Diffusible hydrogen H2

ASME Code Sec.II/CAWS SFA 5.20 E 71T-1 M H4

E : Electrode7 : Yield, tensile Strenght and toughness1 : welding position H,F,VU,OHT-1M : Slag characteristic, shielding gasH4 : Diffusible hydrogen H2

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Welding project with Fluxofil 14 HD

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Welding project with Fluxofil 14 HD

WPS Fluxofil 14 HD with weldycar

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Root pass on ceramic backing

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Front view on round ceramic backing

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Fixation the weldycar

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Root pass on ceramic backing

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CurrentI=225AVoltageU=24VWelding speedVs=13cm/minWire speed8,0m/minWeld deposit3,5 Kg/h

Cap welding

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Nahtvorbereitung Lagenaufbau

Schweißparameter

Joint preparation

Welding parameters

Layers set up

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Weldycar fixed in transver position

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WPS Fluxofil 14 HD with weldycarTransver welding on ceramic in action

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WPS Fluxofil 14 HD with weldycarNahtvorbereitung Lagenaufbau

Schweißparameter

Joint preparation

Welding parameters in transver position

Layers set up

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Fluxofil 14 HD in project operation

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Flux cored wire application tank building

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Flux cored wire application tank building

Joint preparationVessel

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Fluxofil 14 HD Application pipe junction

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Flux cored wire application hall truss

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Flux cored wire application exhibition hall

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Fluxofil 14 HD in all welding position

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Calculation comparison between solid and flux coredwire

Schweißverfahren MAG- FülldrahtMAG- MassivdrahtSchweißzusatz Fluxofil 14 HD

Ausführungen HalbmechanisiertNahtvorbereitungLagenaufbau

Lagenzahl/RaupenzahlSchweißpositionDrahtdurchmesser (mm)Schweißstrom I (mm)Schweißspannung U (V)Schweißgeschwindigkeit Vs (cm/min)Abschmelzleistung SG (Kg/h)Schweißzeitfaktor ED (%)Lohnsatz LS (Euro/h)Schweißzusatzpreis SZP (Euro/Kg)Schutzgaspreis SP (Euro/l)Schutzgasmenge SM (l/min)Gemeinkostenfaktor GKF (%)

Carbofil 1

1,545

Halbmechanisiert

PF1,2140

300

3L/3R

130,930.0115

1813

3L/3RPF1,221023263,045133,30.0115300

12 90°

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Calculation comparison between solid and flux coredwire

Schweißverfahren MAG- Fülldraht MAG- MassivdrahtSchweißzusatz Fluxofil 14 HDAusführungen HalbmechanisiertNahtvorbereitungLagenaufbau

Lagenzahl/RaupenzahlSchweißnahtgewicht SNG (Kg/m)

Hauptzeit Th ( min/m )Hauptzeit + Nebenzeit T ( min / m )

Schweißzusatzkosten KZ (Euro/m)Schutzgaskosten KS(Euro/m)

Lohnkosten KL (Euro/m)Gemeinkosten KG (Euro/m)Fertigungskosten KF (Euro/m)

Gesamtkosten KGe (Euro/m)

Ersparnis Euro/m

Ersparnis %

Carbofil 1halbmechanisiert

3L/3R1,20

48,00106,67

1,12

94,43

0,87

23,1169,3392,44

3L/3R1,20

24,0053,33

3,960,87

11,56

45,94

34,6746,22

51,05

43,38

12 90°

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Fluxofil 14 HD - Data sheet -

Standards: DIN EN 758 T 46 2 P C 1 H5 / T 46 2 P M 1 H5AWS/ASME SFA-5.20 E71T-1 H4 / E71T-1M H4

Applications and properties:The higher fil ling degree of FLUXOFIL 14 HD results in higher current carrying capacity and deposition rate. Weldingspeed is thereby essentially increased which leads to a saving of time and reduction of costs. It can be used in allpositions with only one setting of welding parameters (24 volts, wire feed = 9m/min, wire dia. 1,2 mm). FLUXOFIL 14HD is employed in manual welding, as well as in fully mechanized welding by means of the orbital welding unit CI-TOTRACK OSG-O1 or the vert ical welding set CITOTRACK VSG-O1. It is preferably used under mixed shield ing gasand is characterized by low spatter loss, good slag removal and finely rippled, pore-free welds without undercuttinginto the base metal.Materials:

EN-Designation DIN-Designation EN-Designation DIN-/AWS-DesignationS185 St 33 S235 to S355 St 37.0 to St 52.0S235 to S355 St 37-2 to St 52-3 P235 to P355 St 37.4 to St 52.4P235 St 35.8 P265 St 45.8L210 to L415 StE 210.7 to StE 415.7 L360 to L485 StE 360.7 TM-StE 480.7 TML290, L320 StE 290.7TM, StE 320.7TM P235GH, P265GH HI, HII

X42 to X65 P295GH 17 Mn 4StE 255 S(P)275 to S(P)460 StE 285to StE 460A, B, D, E AH 32 to EH 36GS-38 GP240R GS-45

Please observe admissible operating temperature for welding consumable and base material.Qualification tests: TÜVApprovals: DB, ABS, DNV, GL, LRSIndications as to approvals, see appendix.Analysis of all-weld metal (typical values in %):

C Si Mn0,05 0,55 1,2

Mechanical properties of all-weld metal (single values are typical values):Impact energy ISO-V [Joule]Heat treatment Yield strength

[N/mm²]Tensile strength

[N/mm²]Elongation

A5 [%] -20 °CAW >460 550 650 >22 >80

AW = as-weldedChemical composition and mechanical properties apply to the use of shielding gas:

DIN EN 439 - M21 (82 Vol. % Ar + 18 Vol. % CO2)Shielding gas as to DIN EN 439: M21 (ARCAL 21), C1 (carbon dioxide)Consumption: 12 15 l/min for Ø £1,6 mmWelding parameters and deposition rate, see: B 131

Form of delivery:Wire cage reel K300 (16 kg)

Wire diameters [mm] 1,0 1,2 1,6Further forms of delivery on request.

Type of current/Polarity/Welding positions:

Rutile tubular cored electrode for MAG-welding, with fast-freezing slag

FLUXOFIL 14 HD

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Fluxofil 14 HD - advantages -

Easy handling in all welding position

- High deposition rate in all welding position

- To use in fully mechanized welding processes

- One side welding on ceramic backing

- Less spatter during the welding process

- Easy slag removal

- Very good penetration

- Seamless wire

- Less fume and less hydrogen content

- High efficiency

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Application Metal cored wire Fluxofil M8

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Metal cored wire Fluxofil M8 - advantages -

- Easy handling in H and F welding position

- Seamless wire

- Less fume and less hydrogen content

- High deposition rate in H and F welding position

- To use in fully mechanized welding processes

- One side welding on ceramic backing

- Less spatter during the welding process

- Very good penetration

- High efficiency

- Very good ristriking

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Variable applications with flux cored wires

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Flux Cored

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