The Australian Welding Guide 2012

THE AUSTRALIAN

WELDING GUIDE The Ultimate Welding Reference Guide 2012

welding.com.au

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FOR OVER 50 YEARS With a proven history of over 50 years in the Australian market, WIA has built a reputation for delivering high quality filler metal products for the industrial user. Known for their quality, consistency and performance, WIA filler metal products are preferred by operators across a wide range of industry sectors. WIA offers an extensive range of consumables for various welding processes and applications. Choose from mild steel and low hydrogen electrodes to specialised flux cored wires and hardfacing products. Backed by a team of technical professionals who understand our customers’ needs, we are committed to delivering welding products that offer peak performance in operability, mechanical properties and productivity, and backed by the delivery of technical expertise and support. WIA is ISO 9001 certified. It’s your guarantee of the highest levels of quality, satisfaction and efficiency when you choose WIA products.

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welding.com.au 1300 300 884

WELDING INDUSTRIES OF AUSTRALIA AN ITW COMPANY

USING THIS GUIDE PRODUCT SECTION The front section of this guide contains comprehensive product information on the range of WIA consumables. Access the latest information on WIA filler metal products, including technical data sheets at welding.com.au. TECHNICAL REFERENCE SECTION Designed as a portable reference tool for welding engineers, design and costing personnel, workshop supervisors, welding specialists and students, the Technical Reference Section incorporates the information welding professionals need to have on hand. VIEWING THIS GUIDE AS AN INTERACTIVE PDF Depending on the device or computer you are viewing this PDF in, all CONTENTS pages contain ‘clickable’ links to help you navigate easily through the document. DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products, and does not operate as a provider of consultancy or other technical services or advice related to welding. The information provided in this document is offered as a guide only. Every effort has been made to ensure the information contained in this booklet was correct at the time of printing. WIA does not accept responsibility for errors or information which is found to be misleading. Prior to using WIA products, it is the purchasers’ responsibility to ensure the products selected are suitable for the application.

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CONTENTS Introduction



ELECTRODES

5

WIRES

33

HARDFACING PRODUCTS

65

General Purpose Electrodes - Mild Steel Hydrogen Controlled Electrodes Iron Powder Electrodes Cellulose Electrodes Stainless Steel Electrodes Cast Iron Electrodes Gouging and Cutting Electrodes



Solid MIG Wires – Mild Steel Solid MIG Wires – Low Alloy Steel Solid MIG Wires – Aluminium Metal Cored Gas Shielded Wires Flux Cored Gas Shielded Wires Flux Cored Self Shielded Wires



Hardfacing Electrodes Hardfacing Solid MIG Wires Hardfacing Self Shielded Flux Cored Wires



1

Hardfacing Gas Shielded Flux Cored Wires

TECHNICAL INFORMATION

86

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CONTENTS

ELECTRODES General Purpose Electrodes - Mild Steel

Austarc 12P................................................................. 6-7 Austarc 13S................................................................. 8-9 Hydrogen Controlled Electrodes

Austarc 16TC............................................................10-11

Austarc 18TC........................................................... 12-13 Austarc 77................................................................ 14-15 Iron Powder Electrodes

Austarc 24................................................................ 16-17 Cellulose Electrodes

Austarc 11................................................................ 18-19 Stainless Steel Electrodes

Staincord 309Mo-16................................................. 20-21 Staincord 316L-16.................................................... 22-23 Unicord 312............................................................. 24-25 Cast Iron Electrodes

Supercast Ni............................................................ 26-27 Suercast Ni/Fe......................................................... 28-29 GOUGING AND CUTTING ELECTRODES

Austarc C&G............................................................ 30-31

5 CONTENTS

AUSTARC 12P SUMMARY

• General Purpose Rutile Type Electrode • Versatile/All Positional Capabilities Including Vertical Down • Smooth Performance on Low OCV AC Welding Machines IDENTIFICATION

Coating - Brown Tip - Red Imprint - WIA 4313A CLASSIFICATION

• AS/NZS 4855-B - E43 13 A • AWS A5.1: E6013 DESCRIPTION AND APPLICATION

Austarc 12P is a smooth running, rutile type electrode for all positional welding of mild steel. It is characterised by a moderately forceful and extremely stable arc. Superb arc starting and restriking on low voltage AC welding machines. A stiff fast freezing slag for all positional (especially vertical down) fillet welding capabilities. Typical applications include, the all positional welding of galvanised gates/fences, steel furniture, trailers and wrought iron. OPERATIONAL DATA ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.0 2.5 3.2 4.0 5.0

300 300 380 380 450

40-60 60-85 90-130 130-180 180-230

ARC VOLTAGE RANGE **(V)

*Recommended for DC +/- or AC (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.

6 CONTENTS

19 20 21 22 23

4G

3G

1F

2F

SHIPPING APPROVALS LR 2Ym ABS 2 DNV 2 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS C

0.07

Mn

Si

0.5

Fe

0.3

Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS Yield Stress Tensile Strength Elongation CVN Impact Values

In as welded condition.

450 MPa 500 MPa 26% 70J @ 0°C

PACKAGING DATA ELECTRODE SIZE (mm) 2.0 2.5 3.2 4.0 5.0

PACKAGING (KG) Packet

Carton

2.5 2.5 5.0 5.0 5.0

12.5 12.5 15 15 15

APPROX NO. OF RODS PER KG 103 67 31 20 11

PART NUMBER 12P20 12P25 12P32 12P40 12P50

4F

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

3G

2G

1G

7 CONTENTS

AUSTARC 13S SUMMARY

• • • •

General Purpose/Rutile Type Electrode Versatile/All Positional (especially vertical up) Capabilities Ideal for Down Hand Fillet Welding of Mild Steel Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATION

Coating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A CLASSIFICATION

• AS/NZS 4855-B - E43 13 A • AWS A5.1: E6013 DESCRIPTION AND APPLICATION

Austarc 13S is the popular “blue and white striped” general purpose electrode for smooth mitre fillet welding applications. 13S has a soft and stable arc and produces flat, uniform fillet welds with ease and a self peeling slag action. Austarc 13S is formulated primarily for fillet welding in all down hand positions. It is ideal for the general purpose and structural welding of sheet and plate steels (galvanised or otherwise) and tubular components, including trailers, duct work, hoppers and storage tanks, etc. OPERATIONAL DATA ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.0 2.5 3.2 4.0 5.0 6.0

8 CONTENTS

300 300 380 380 450 450

40-60 60-85 100-130 140-180 180-230 230-290

ARC VOLTAGE RANGE **(V)

*Recommended for DC +/- or AC (minimum 45 OCV) operation. **Voltage is determined by arc current and electrode arc length. Arc voltage shown is typical and is only to be used as a guide.

19 20 21 22 23 24

3G

1F

4G

2F

4F

SHIPPING APPROVALS LR 2m ABS 2 DNV 2 TYPICAL ALL WELD METAL CHEMICAL ANALYSIS C

0.07

Mn

Si

0.55

Fe

0.45

Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS Yield Stress Tensile Strength Elongation CVN Impact Values

In as welded condition.

450 MPa 520 MPa 26% 60J @ 0°C

PACKAGING DATA ELECTRODE SIZE (mm) 2.0 2.5 3.2 4.0 5.0 6.0

PACKAGING (KG) Packet

Carton

2.5 2.5 5.0 5.0 5.0 5.0

12.5 12.5 15 15 15 15

APPROX NO. OF RODS PER KG 99 63 29 10 6 6

PART NUMBER 13S20 13S25 13S32 13S40 13S50 13S60

ELECTRODES - GENERAL PURPOSE ELECTRODES - MILD STEEL

2G

1G

9 CONTENTS

AUSTARC 16TC SUMMARY

• • • • • •

Basic/Twin Coated (TC) Manual Arc Electrode Low Hydrogen, “H10” Status Versatile/All Positional (Especially Vertical Up) Capabilities Reliable, Low Temperature Impact Toughness Easy to Strike and Re-Strike Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATION

Coating - Light Grey Tip - Bronze Imprint - WIA 4916A CLASSIFICATION

• AS/NZS 4855-B - E49 16-A U H10 • AWS A5.1: E7116-1 H8 DESCRIPTION AND APPLICATION

Austarc 16TC is a smooth running, basic low hydrogen electrode, developed for all positional (except vertical down) welding, using AC or DC power sources. The electrode gives exceptional arc stability and weldability for its class and produces high quality weld deposits with reliable notch toughness to -40°C. Austarc 16TC is manufactured using a unique twin coating extrusion process, which produces electrodes with two concentric flux coatings. Arc stabilising elements are concentrated in the inner coating of the electrode for significantly improved arc stability on AC welding machines. Other features of 16TC include, a smooth rippled weld profile with excellent edge wetting and a fluid, easily removed glassy slag. Austarc 16TC deposits X-ray quality weld metal with typical diffusible hydrogen levels of 5-8 mls of hydrogen per 100 gms of deposited weld metal, for “as manufactured” product, thus satisfying the “H10” low hydrogen category of AS/NZS 4855 and “H8” of AWS A5.1. OPERATIONAL DATA

10 CONTENTS

ELECTRODE ELECTRODE WELDING CURRENT *Please note, 2.5 and 3.2 Austarc 16TC are SIZE (mm) LENGTH (mm) RANGE *(A) recommended for 2.5 300 60-90 DC+ or AC (minimum 45 OCV) operation, 3.2 380 90-135 whereas 4.0, 5.0 and 4.0 380 140-190 6.0mm sizes require a 5.0 450 190-240 minimum of 55 OCV for stable AC operation. 6.0 450 250-310

3G

1F

4G

SHIPPING APPROVALS

LRS 4Ym H10

4F

2F

ABS 3 H10

DNV 3Y H10

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS C

0.06

Mn

Si

1.2

P

0.4

0.015

S

0.010

Fe

Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS Yield Stress Tensile Strength Elongation CVN Impact Values

460 MPa 560 MPa 28% 130J @ -20°C 110J @ -40°C

PACKAGING DATA ELECTRODE SIZE (mm) 2.5 3.2 4.0 5.0 6.0

PACKAGING (KG) Packet

Carton

2.5 5.0 5.0 5.0 5.0

12.5 15 15 15 15

APPROX NO. OF RODS PER KG 61 29 19 10 7

PART NUMBER 16TC25 16TC32 16TC40 16TC50 16TC60

MATERIALS TO BE WELDED CODE

AS 1163

Structural Steel

Pressure Equipment Steel

TYPE

C250, C350, C450

AS 1397 AS 1450 AS/NZS 3679.1 AS/NZS 3678.1 AS/NZS 3679.2

G250, G300, G350, G450 C/H200, C/H250, C/H350, C/H450, 250, 300, 350, 400 200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

AS 1548

7-430, 7-460, 5-590, 7-490

Fine Grain Steel

AS/NZS 1594

Cast Steel Pipe Material

AS2074 API 5LX

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

2G

1G

HAI, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016, HA350, HA400 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2 X42, X46, X52, X60

11 CONTENTS

AUSTARC 18TC SUMMARY

• • • • • •

Basic Twin-Coated (TC) Iron Powder Electrode Very Low Hydrogen H5 Status Suitable for all Positional Welding Except Vertical Down Excellent Low Temperature Fracture Toughness Easy to Strike and Re-Strike Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATION

Coating - Light Grey Tip - Blue Imprint - WIA 4918-1A CLASSIFICATION

• AS/NZS 4855-B - E49 18-A U H5 • AWS A5. 1: E7018-1 DESCRIPTION AND APPLICATION

Austarc 18TC is a basic iron powder electrode used primarily on C-Mn and low alloy structural steels. The unique twin-coat design for 18 type low hydrogen electrode offers excellent AC arc stability and superb DC+ arc transfer, excellent re-strike, reduced spatter level and extraordinary ease of use for out-of-position welding. Typical applications include oil and gas, pipe welding, structural steel construction, off-shore where Ni-alloying is prohibited, mining equipment, heavy girders and earth moving plant repair and maintenance. OPERATIONAL DATA ELECTRODE ELECTRODE WELDING CURRENT SIZE (mm) LENGTH (mm) RANGE *(A) 2.5 3.2 4.0

300 380 380

60-90 90-135 140-190

*Please note, the recommended welding polarity for Austarc 18TC is DC + or AC (Min. 50 OCV).

SHIPPING APPROVALS

LRS/Pending

12 CONTENTS

DNV/Pending

3G

1F

4G

2F

4F

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS C

0.06

Mn

Si

1.55

P

0.54

S

0.010

0.02

Fe

Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS Yield Stress Tensile Strength Elongation CVN Impact Values

530 MPa 602 MPa 24% 87J @ -50°C

PACKAGING DATA ELECTRODE SIZE (mm) 2.5 3.2 4.0

PACKAGING (KG) Packet

Carton

2.5 5.0 5.0

12.5 15 15

APPROX NO. OF RODS PER KG 45 26 17

PART NUMBER 18TC25 18TC32 18TC40

MATERIALS TO BE WELDED CODE

AS 1163

Structural Steel

Pressure Equipment Steel Fine Grain Steel

TYPE

C250, C350, C450

AS 1397 AS 1450 AS 1450 C/H200, C/ H250,

G250, G300, G350, G450 C/H200, C/H250, C/H350, C450 250, 300, 350, 400 200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

AS/NZS 3679.1

250, 300, 350, 400

AS/NZS 3678.1 AS/NZS 3679.2

200, 250, 300, 350, 400, 450, A1006, XK1016, WR350

AS 1548

7-430, 7-460, 5-590, 7-490

AS/NZS 1594

Cast Steel

AS2074

Pipe Material

API 5LX

ELECTRODES - HYDROGEN CONTROLLED ELECTRODES

2G

1G

HA1, HA3, HA4N, HA200, HA250, HA300, HA1006, HA1010, HA1016, HA350, HA400 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2 X42, X46, X52, X60

13 CONTENTS

AUSTARC 77 SUMMARY

• • • •

Basic Coated Iron Powder Electrode Low Hydrogen Status Suitable for All Positional Welding Except Vertical Down Excellent Low Temperature Fracture Toughness

IDENTIFICATION

Coating - Light Grey Tip - Black Imprint - WIA 4918-1A CLASSIFICATION

• AS/NZS 4855-B - E49 18-1 U H5 • AWS A5.1: E7018-1 DESCRIPTION AND APPLICATION

The Austarc is a smooth running basic type of low hydrogen iron powder electrode used for all positional welding except vertical down. The arc is very quiet with little spatter and the welds are exceptionally smooth with excellent wash in at the toes of the weld, thus giving minimum undercut. This electrode is used where the highest restrained work pieces are fabricated for mining equipment, pressure vessels, heavy girders, earth moving plant, repair and maintenance etc. For the highest weld quality with low hydrogen levels, Austarc 77 electrodes should be baked at 400˚C for one hour to obtain