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  • Fcaw

    Transféré par

    Asaad Mohamed
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    welding process

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    57019100-FCAW

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    69 vues34 pages

    Fcaw

    Transféré par

    Asaad Mohamed
    welding process

    Droits d'auteur :

    © All Rights Reserved
    Téléchargez comme PDF ou lisez en ligne sur Scribd
    Signaler comme contenu inapproprié
    sur 34
    AWS WHB-2 90 mm 0784265 0020939 3 mm Nae) PREPARED BY A ‘COMMITTEE CONSISTING OF: G.C. Barnes, Chairman Alloy Rods FLUX CORED |" Consultant G.H. MacShane Consultant M, T, Merlo ‘Tri-Mark Incorporated LL. Soisson Walding Consultants, Incorporated ‘WELDING HANDBOOK COMMITTEE MEMBER: RM, Walkosale Westinghouse Hlectrie Conporation Fundamentals of the Process 158 Equipment 162 Materials - 7 168 Process Conta 175 Joint Design and ‘Welding Procedures 181 Weld Quality . 136 Safety 190 Supplementary Reading List 190 Copia by the Ameian Nellng Soci Sot 05 10-1723 997 188 FLUX CORED ARC WELOING areata) FLUX CORED ARC WELDING FUNDAMENTALS OF THE PROCESS FLux coxep anc welding (PCAW) isan arc welding process that uses an arc between a continuous filler metal elec- trode and the weld pool. The process is used with shielding froma flux contained within the tubular electrode, with or without additional shielding feom an externally supplied ‘85, and without the application of pressure. The flux cored electrode is a composite tubular filler metal electrode consisting of a metal sheath and a core of various powdered materials, During welding an extensive slag cover is produced on the face of a weld bead. ‘The feature that distinguishes the FCAW process from ‘other arc welding processes isthe enclosure of Faxing ingre- dents within a continnously fed electrode. The remarkable ‘operating characteristics of the process and the resulting weld propertics are attributable to this electrode development. ‘Note that metal cored electrodes are not covered inthis chapter, because their powdered core materials produce ‘no more than slag islands on the face ofa weld bead. Thus, they do not match the definition of flax cored electrodes. ‘Metal cored electrodes are covered in Chapter 4 - Gas Metal Are Welding. FCAW offers two major process variations that differ in their method of shielding the arc and weld pool from at- mospheric contamination (oxygen and nitrogen). One type, self-shielded FCAW, protects the molten metal through the decomposition and vaporization of the flux core by the heat of the arc. The other type, gas shielded FCAW, makes use of a protective gas flow in addition to the fi core action, With both methods the electrode core material provides a substantial slag covering to pro- tect the solidiving weld meta Flux cored electrodes are also used in electrogas welding (EGW), That process isa single pass, vertical-up welding process described in Chapter 7 - Electrogas Welding, Flux cored are weldingis normally a semiautomatic pro- cess, The process is also used in machine and automatic welding. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 HISTORY GAS StFLDED METAL are welding processes have been in use since the early 1920's. Experiments at that time showed a significant improvement of weld metal proper- ties when the arc and molten weld metal were protected from atmospheric contamination, However, the develop- ‘ment of coated electrodes in the late 1920's reduced the interest in gas shielded methods. Nort until che easly 1940's, with the introduction of the commercially-accepted gas tungsten arc welding process, did there become a renewed interest in these gas-shiclded methods, Later in that same decade, the gas metal are weld- ing process was successfully commercialized. Argon and he- Tinm were the two primary shielding gases at that time. Research work conducted on manual coated electrode ‘welds dealt with an analysis ofthe gas produced inthe disin- tegration of electrode coatings. Results of this analysis showed that the predominant gas given off by electrode coatings was CO2, This discovery led quickly to the use of CO: for shielding ofthe gas metal are process when used on carbon steels. Although early experiments with COz as a shielding gas were unsuccessful, techniques were finally de- ‘veloped which permitted its use, Carbon dioxide shielded GMAW became commercially available in the mid-1950's. ‘About that same time, the CO shielding was combined with a flux-containing tubular electrode which overcame many of the problems encountered previously. Operating characteristics were improved by the addition of the core material and weld quality was improved by eliminating at- mospheric contamination. The process was introduced publicly at the AWS Exposition held at Buffalo, New York, in May 1954, The electrodes and equipment were refined and introduced in essentially the present form in 1957. The process is being continually improved, Power sources and wire feeders are now greatly simplified and ‘more dependable than their predecessors. The new guns are lightweight and rugged. Electrodes are undergoin continuous improvement, Alloy electrodes and small di ameter clectrodes down to 0.035 in. (0.9 mm) are some of the later advances. PRINCIPAL FEATURES "THE BENEFITS OF FCAW are achieved by combining thice general features: (1) The productivity of continuous wire welding (2) ‘The metallurgical benefits that can be derived froma flux (G) A slag that supports and shapes the weld bead ECAW combines characteristics of shielded metal are welding (SMAW), gas metal arc welding (GMAW), and submerged arc welding (SAW). ‘The FCAW features, as well as those that distinguish the two major versions of the process, are shown in Figure 5.1, illustrating the gas-shiclded version, and Figure 5.2, illus- {tating the selfshielded type. Both figures emphasize the melting and deposition of filler metal and flux, together with the formation of a slag covering the weld meral. In the gas shielded method, shown in Figure 5.1, the shielding gas (usually carbon dioxide or a mixture of argon and carbon dioxide) protects the molten metal from the WELD METAL, Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 AUS WHB-2 90 MM 0784265 OOLOS4) 1 mm FLUX CORED ARC WELDING 189 oxygen and nitcogen of the air by forming an envelope around the are and over the weld pool. Little need exists for denitrification of the weld metal because air with its nitrogen is mostly excluded. However, some oxygen may be generated from dissociation of COz to form carbon monoxide and oxygen, The compositions of the elec- trodes are formulated to provide deoxidizers to combine ‘with small amounts of oxygen in the gas shield. In the self-shielded method shown in Figure 5.2, shield- ing is obtained from vaporized flux ingredients which dis- place the air, and by slag compositions that cover the mol- ten metal droplets, to protect the molten weld pool during, welding, Production of CO and introduction of deoxidiz- ing and denitriding agents feom flux ingredients rightat the surface of the weld pool explain why selfshielded elec- trodes can tolerate stronger aie currents than gas shielded clectrodes. Thus self-shielded FCAW is the usual choice for ficld work such as that shown in Figure 5.3. ‘One characteristic of some self-shielded electrodes is the use of long clectrode extensions. Electrode extension is the length of unmeeed electrode extending beyond the nd of the contact tube during welding. Sel-shielded elee- trode extensions of 1/2 to 3-3/4 in. (19 to 95 mm) are generally used, depending on the application. Increasing the electrode extension increases the resis tance heating of the electrode. This preheats the electrode and lowers the voltage drop across the are. At the same GAS NOZZLE WIRE GUIDE & CONTACT TUBE [SHIELDING GAS TUBULAR ELECTRODE POWDERED METAL, FLUX, & SLAG FORMING MATERIALS ARC & METAL TRANSFER Figure 6.1~Gas Shielded Flux Cored Arc Welding 160 FLUX CORED ARG WELDING AUS WHB-2 90 mm O784265 OOL0942 3 mm WIRE GUIDE AND CONTACT TUBE SOLIDIFIED SLAG —_wouTeN stag igure 6. time, the welding current decreases, which Lowers the heat available for melting the base metal. The resulting weld bead is narrow and shallow. This makes the process suit- able for welding light gage material and for bridging gaps caused by poor fit-up. Ifthe arc length (voltage) and weld! ing current are maintained (by higher voltage settings at the power supply and higher electrode feed rates), longer elec- trode extension will increase the deposition rate. (On certain types of self-shilding flux cored electrodes, the polarity should be DCEN (straight polarity). This polar- ity results in less base metal penetration. As a result, small diameter electrodes such as 0.030 in, (0.8 mm), 0.035 in. (0.9 mm), and 0.045 in, (1.2 mm) have proven to be quite successful for work on thin gage materials. Some self shiclded electrodes have been developed specifically to weld the zinc-coated and aluminized steels which are now commonly used in antomobile production. In contrast, the gas-shielded method is suited to the pro- duction of narrow, deeply penetrating welds, Short electrode extensions and high welding currents aro used for all wire siameters, For fillet welding, compared to SMAW, FCAW ‘welds are narrower with larger throat lengths. The electrode extension principle cannot be equally applied to the gas shielded method because of adverse effects on the shielding. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 - TUBULAR ELECTRODE /; POWDERED METAL, VAPOR [ FORMING MATERIALS, (/ DEOXIDIZERS AND SCAVENGERS ARC SHIELD COMPOSED OF VAPORIZED AND SLAG FORMING COMPOUNDS >: ARC & METAL TRANSFER PRINCIPAL APPLICATIONS APPLICATION OP THE two methods of the FCAW process overlap. However, the specific characteristics of each method make each one suitable for different operating conditions. The process is used to weld carbon and low alloy steels, stainless steels, and cast irons. [is also used for are spot welding of lap joints in shect and plate, as well as for cladding and hardfacing. ‘The type of FCAW used depends on the type of elec- trodes available, the mechanical property requirements of the welded joints, and the joint designs and fit-up. Gener- ally, the self-sielded method can often be used for appli- cations that are normally done by shielded metal arc weld- ing, The gas shielded method can be used for some applications that are welded by the gas metal arc welding process, The advantages and disadvantages of the FCAW process must be compared to those of other processes when it is evaluated for a specific application. Higher productivity, compared to shielded metal are welding, is the chief appeal of lux cored arc welding for many applications. This generally translates into lower overall costs per pound of metal deposited in joints chat petmit continuous weldingand easy FCAW gun and equip- AUS WHB-2 90 Mm O7842b5 0010943 5 mm FLUX CORED ANC WELDING 161 ment accessibility. The advantages are higher deposition zates, higher operating factors, and higher deposition effi- ciency (no stub loss). CAW has found wide application in shop fabrication, maintenance, and field erection work. It has been used to produce weldments conforming to the ASME Boiler and Prossure Vessel Code, the rules of the American Bureau of Shipping, ancl ANSI/AWS D1.1, Structural Welding Code~ Steel. CAW enjoys prequalified status in ANSI/AWS DI. Stainless stecl, self-shielded, and gas shielded flux cored dlectrodes have been used in general fabrication, surfacing, joining dissimilar metals, and maintenance and repair. Copia by the Ameian Nellng Soci Sot 05 10-1723 997 Figure 5.3~Self-Shielded Flux Cored Arc Wel The major disadvantages, compared to the SMAW pto- cess, are the higher cast ofthe equipment, the relative com- plexity of the equipment in setup and control, and the re- striction on operating distance fom the electrode wire feeder. FCAW may generate large volumes of welding fumes, which, except in field work, require suitable exhaust equipment. Compared to the slag-free GMAW process, che need for removing slag between passes is an added labor cost. This is especially truc in making root pass welds. 162 FLUX CORED ARC WELDING AUS WHE-2 40 Wm 0784265 OOLOW44 7 mm ————_—_—— EQUIPMENT SEMIAUTOMATIC EQUIPMENT AAs sHOWN IN Figure 5.4, the basic equipment for self- shielded and gas shielded flax cored arc welding is similar, ‘The major difference is the provision for supplying and me- tering gas to the arc of the gas shielded electrode. The rec- ‘ommended power source is the de constant-voltage type, similar to sources used for gas metal aze welding, The power supply should be capable of operating atthe maximum cur- d for the specific application. Most semiauto- thatic applications use les than $00 A. The voltage contol should be capable of adjustments in increments of one volt ot less. Constant-current (de) power sources of adequate capacity with appropriate controls and wire feeders are also used, but these applications are rate. ‘The purpose of the wire feed control is to supply the continuous electrode to the welding ate ata constant pre- set rate. The rate at which the electrode is fed into the are determines the welding amperage that a constant-voltage power source will supply. If the electrode feed rate is changed, the welding machine automatically adjusts to ‘maintain the presct arc voltage. Electrode feed rate may be controlled by mechanical or electronic means. DIRECT CURRENT CONSTANT VOLTAGE POWER SOURCE VOLTAGE CONTROL CONTACTOR CONTROL eee 116 V SUPPLY ELECTRODE POWER CABLE WELDING. GUN WORK WORKPIECE CABLE VOLTMETER AND > AMMETER 1 ' TO SOLENOID VALVE 1 SHIELDING GAS SOURCE WIRE FEED (CURRENT) CONTROL. GAS IN WIRE DRIVE MOTOR NOTE: GAS SHIELDING IS USED ONLY WITH FLUX CORED ELECTRODES THAT REQUIRE IT. igure 5.4—Typical for S Are Welding Equipment Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 This process requires the use of drive rolls that will not flatten or otherwise distort the tubular electrode. Various ‘grooved and knurled feed roll surfaces are used to advance the electrode. Some wire feeders have a single pair of drive rolls, while others have two pairs with at east one roll of each pair being driven, When al rolls are driven, the wire can be advanced with less pressure on the rolls ‘Typical guns for semiautomatic welding are shown in Figures 5.5 and 5.6. They are designed for handling com- fort, ease of manipulation, and durability. The guns pro- vide internal contact with the electrode to conduct the welding current, Welding current and electrode feed are actuated by a switch mounted on the gun. ‘Welding guns may be either air cooled ot water cooled, Air-cooled guns are favored because there is no require- ment to deliver water, However, water-cooled guns are ‘more compact, lighter in weight, and require less mainte- nance than air-cooled guns. Water-cooled guns generally have higher current ratings. Capacity ratings range up to 6600 A, continuous duty. Guns may have either straight or AUS WHB-2 40 mm O7842b5 OOLO4S 9 mm FLUX CORED ARC WELDING 163 curved nozzles. The curved nozzle can vary from 40°to 60°. In some applications, the curved nozzle enhances flexibility and ease of electrode manipulation, Some self-shielded flux cored electrodes require a spe- cific minimum electrode extension to develop proper shielding. Welding guns for these electrodes generally have guide tubes with an insulated extension guide to support the electrode and assure a minimum electrode extension, Details of a self-shielded electrode nozzle showing the in- sulated guide tube are illustrated in Figure 5.7. AUTOMATIC EQUIPMENT “FiauRE 5.8 sHOWs the equipment layout for an automatic flux cored acc welding installation, For automatic opera- tion, a de constant-voltage power source designed for 100 percent duty cycles recommended. The size ofthe power source is determined by the current requited for the work ELECTRODE GUIDE TUBE Lie CONTACT TUBE IZ EB \V INSULATED N EXTENSION GUE N \ ELECTRODE Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 CONDUIT POWER CABLE ST yy 7 ELECTRODE F GUIDE TUBE 3} WELDING MACHINE CONTACTOR LEADS SWITCH PROTECTIVE HAND SHIELD AUS UHB-2 40 M™ 0784265 COLOTUL O mm 164 FLUX CORED ARC WELDING ARROWS INDICATE GAS FLOW ‘CONTACT TUBE ‘WATER COOLED CHAMBER POWER CABLE, ARROWS INDICATE <— Water IN GAS INLET, SWitcH WATER IN AND OUT —> water our cas HAND SHIELD—»\ \ Figure 6.6~Typical Guns for Gas-Shielded Flux Gored Are Welding Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 ELECTRODE GUIDE TUBE INSULATED. Guive Tuse~L| ELECTRODE EXTENSION FLUX CORED | visi t EXTENSION ELECTRODE, Figure to be performed, Because large electrodes, high electrode feed rates, and long welding times may be required, elec- trode feeders neceseaily hae higher capacity drive motors and heavier duty components than similar equipment for semiautomatic operation. Figure 5.9 shows two typical nozzle assemblies for au- tomatic gas-shielded flux cored are welding. Nozzle as- semblies may be designed for side shielding or for con- centric shiclding of the electrode. Side shielding permits welding in narrow, deep grooves, and minimizes spatter buildup in the nozzle, Nozzle assemblies may be air or water cooled. In general, air-cooled nozzle assemblies are preferred for operation up to 600 A. Water-cooled noz- le assemblies are recommended for welding currents above 600 A. For higher deposition rates with gas shielded electrodes, tandem welding guns may be used, as shown in Figure 5.10. For large-scale surfacing, increased productivity can be obtained from automatic multiple-clectrode oscillating Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 ‘AUS WHB-2 90 M™O78U2L5 OOLOWN7 2 mm FLUX CORED ARG WELDING 165 equipment, Such installations may include a track- mounted manipulator supporting a multiple-clectrode os- cillating welding head with individual electrode feeders, and a track-mounted, power driven turning roll, in addi- tion to power supply, electronic controls, and electrode supply system, Figure 5.11 illstrates the operating details of a six-electrode oscillating system for self-shiclded sur- facing of a vessel shell with stainless steel FUME EXTRACTORS As A RESULT of safety and health requirements for control- ling air pollution, several manufacturers have introduced welding guns equipped with integral fume extractors, A fame extractor usually consists of an exhaust nozzle that encircles the gun nozzle. Itcan be adapted to gas-shielded and self shielded guns. The nozzle is ducted to filter can ister and an exhaust pump. The aperture of the fume ex- tracting nozzlcislocated ata sufficient distance behind the top of the gun nozzle to draw in che fumes rising from the arc without disturbing the shielding gas flow. The chief advantage of this fume extraction system is that itis in close proximity to the fume source wherever the welding gun is used. In contrast, a portable furne ex- haust may not generally be positioned so close to the fume source. It would also requiee repositioning of the exhaust hood for each significant change in welding location, One disadvantage of the fume extractor system is that the added weight and bulk make semiautomatic welding more cumbersome for the welder. Ifnot properly installed and maintained, fume extractors may cause welding, problems by disturbing the gas shiclding. In a well-vent lated welding area, a fume-extractor welding gun com nation may not be necessary. GAS SHIELDING APPARATUS Like GMAW EtecrRoDES, the gas shielded FCAW elec- {trodes require gas shielding in addition to the internal flux. This involves a gas source, a pressure regulator, a flow me- tering device, and necessary hoses and connectors. Shield- ing gases are dispensed from cylinders, manifolded cylin- der groups, or from bulk tanks which are piped to individual welding stations, Regulators and flowmeters are used to control pressure and flow rates. Since regulators can freeze during rapid withdrawal of CO2 gas from stor age tanks, heaters are available to prevent that complica- tion, Welding grade gas purity is required because small amounts of moisture can resilt in porosity or hydrogen absorption in the weld metal. The dew point of shielding, gases should be below -40°F (-40°C), AUS UHB-2 90 MH 0784265 OOLOG4S 4 mm 166 FLUX ConED ARC WELDING DIRECT CURRENT CONSTANT VOLTAGE POWER SOURCE VoLTMETER AND AMMETER MoLteGe SHIELOING 7 CONTROL GAS SOURCE contactor Coen ware Fee CONTROL. (cuRRENT CONTROL a > —_—_____—4 a risveurew _|{CJ S Gas IN WIRE DRIVE ELECTRODE POWER CABLE WELDING GUIDE TUBE AND CONTACT TUBE L___ WORK NOTE: GAS SHIELDING IS USED ONLY WORKPIECE WITH ELECTRODES REQUIRING IT J—Typloal Flux Cored Automatic Are Welding Equipment Copia by the Ameian Nellng Soci Sot 05 10-1723 997 AUS WHB-2 90 MH 0784265 OOLOG45 & mm FLUX CORED ARC WELDING 167 SHIELDING SS SHIELDING GAS GAS \ ‘CIRCULATING POWER! a ORCUL LEAD / POWER LEAD ° o 0 7 AIR-COOLED, WATER-COOLED, SIDE-SHIELDED CONCENTRIC-SHIELDED NOZZLE ASSEMBLY NOZZLE ASSEMBLY [ELECTRODE — ELECTRODE Figure 6.9-Typical Nozzle Assemblies for Automatic Gas-Shielded FCAW TRAIL LEAD ELECTRODE ELECTRODE WELDING DIRECTION Figure 6.10—Automatic Tandem Are Welding _With Two Gas Shielded Flux Cored Electrodes Copia by the Ameian Nellng Soci Sot 05 10-1723 997 “AWS UHB-2 90 168 FLUX coneo anc weLoINe ELECTRODE FEEDER AND OSCILLATOR ASSEMBLY 2. CONTACT TUBE ASSEMBLY ‘A. CONTACT TUBE B, PNEUMATIC CONTROL PANEL 3, ELECTRONIC CONTROL SYSTEM A. CABINET B. OPERATOR STATION WELDING POWER SUPPLY AUXILIARY ELECTRODE HANDLING SYSTEM WELDING HEAD MANIPULATOR WORK TURNING ROLLS soos ‘wm o784265 0020550 2 a Figure 6.11—Typi MATERIALS SHIELDING GASES Carbon Dioxide CARBON DIOXIDE (CO2) is the most widely used shielding gas for flux cored arc welding, Two advantages of this gas are its low cost and deep weld penetration. Although it usually gives a globular metal transfer, some flux formula- tions produce a spray-like metal transfer in COz Carbon dioxide is relatively inactive at room tempera- ture, When i is heated to high temperature by the welding arc, COz dissociates to form carbon monoxide (CO) and ‘oxygen (O), as indicated by the chemical equation 200; = 2C0 +02 (5) ‘Thus the arc atmosphere contains a considerable amount ‘of oxygen to react with elements in the molten metal. The oxidizing tendency of COp shielding gas has been recog- Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 AUS WHB-2 90 M™ O784265 001095) 4 mm ized in developing flax cored electrodes. Deoxicizing ma- terials are added to the core of the electrode to compen- sate for the oxidizing effect of the CO, In addition, molten iron reacts with CO2, producing iron oxide and carbon monoxide in a reversible reaction: Fe+CO2=RO-+CO (5.2) Atred heat temperatures, some of the carbon monoxide dissociates to carbon and oxygen: 200 26 + Or (5.3) ‘The effect of COa shielding on the carbon content of mild and low alloy steel weld metal is unique, Depending ‘upon the original catbon contents of the base metal and the electrode, the COz atmosphere can behave as either a carbutizing or decarburizing medium, Whether the carbon content of the weld metal will be inereased or decreased depends upon the carbon present in the electrode and the base metal. Ifthe carbon content of the weld meta is be- low approximately 0.05 percent, the molten weld pool will tend to pick up carbon from the COz shielding atmo- sphere. On the other hand, if the carbon content of the weld metal is greater than approximately 0.10 percent, the ‘molten weld pool may lose carbon. The loss of carbon is attributed to the formation of carbon monoxide (CO), be- cause of the oxidizing characteristics of CO2 shielding gas at high temperatures, When this reaction occurs, the carbon monoxide can be trapped in the weld metal as porosity. This tendency is minimized by providing an adequate level of deoxidizing clements in the core of the electrode. Oxygen will react with the deoxidizing elements rather than the carbon in the stecl. That reaction results in formation of solid oxide compounds that float to the surface of the molten weld pool, where they form part of the slg covering. Gas Mixtures Gas MoxtuRes UseD in flux cored are welding may com- bine the separate advantages of two or more gases. The higher the percentage of inert gas in mixtures with CO2 ot ‘oxygen, the higher will be the transfer efficiencies of the deoxidizers contained in the core. Angon is capable of pro- tecting the molten weld pool at all welding temperatures. Its presence in sufficient quantities in a shielding gas mix- ture results in ess oxidation than oceurs with 100 percent CO2 shielding. ‘The mixture commonly used in gas shielded FCAW is 75 percent argon - 25 percent carbon dioxide, Weld metal eposized with this mixture generally has higher tensile and yield strengths than weld metal deposited with 100 percent CO2 shielding, When welding with this mixture, spray tcansfer-type arc is achieved, The Ar-COp mixture is primatily used for out-of-position welding; i has greater Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 FLUX CORED ARC WELDING 169 ‘operator appeal and better arc characteristics than 100 percent COz. ‘The use of shiclding gas mixtures with high percentages of inert gas for electrodes designed for COz shielding may cause an excessive buildap of manganese, silicon, and other deoxidizing clements in the weld metal. Such higher alloy content of the weld metal will change its mechanical properties. Therefore, electrode manufacturers should be consulted for the mechanical properties of weld metal ob- tained with specific shielding gas mixtures, If data are not available, ets should be made to determine the mechani- cal properties forthe particular application, Gas mixtures high in argon content, such as 95 percent argon - 5 percent oxygen, generally are not used with flux. cored clectrodes because the slag cover is lost BASE METALS WELDED Most sreeis THAT ate weldable with the SMAW, GMAW, ‘ot SAW processes are readily welded using the FCAW pro- cess. Examples of these steels include the following: (1) Mild steel, structural, and pressure vessel grades, such as ASTM A36, ASIS, and AS16 2) High-strength, low alloy structural grades, such as ASTM A440, A441, A572, and AS88 (3) Highsstrength quenched and tempered alloy steels, such as ASTM A514, ASI7, and AS33 4) Chromium-molybdentum steels, such as 1-1/4 per- scent Cr-1/2 percent Mo and 2-1/4 percent Cr-1 percent ‘Mo (5) Corrosion-resistant wrought stainless steels, such as AISI Types 304, 309, 316, 347, 410, 430, and 5023 also cast stainless steels such as ACI Types CF3 and CF8 (6) Nickel steels, such as ASTM A203 (7) Abrasion-resistant alloy steels when welded with filler metal having.a yield strength less than that of the steel being welded ELECTRODES FLUX CORED ARC welding owes much of its versatility to the wide variety of ingredients that can be included in the cote of a tubular electrode. The electrode usually consists of a low carbon steel or alloy steel sheath surrounding a core of fluxing and alloying materials. The composition of the flax core will vty according tothe electrode clasifica- tion and the particular manufacturer of the electrode. ‘Most flux cored electrodes are made by passing steel strip through rolls that form it into a U-shaped cross sec- tion, The formed strip i filled with a measured amount of granular core material (alloys and flax). The filled shape is then closed by closing rolls that round it and tightly com press the core material. The round tube is next pulled through drawing dies or rolls that reduce its diameter and farther compress the core. The electrode is drawn to final 470 FLUX conED ANC WELDING size, and then wound on spools or in coils, Other methods of mannfacture are also used. ‘Manufacturers generally consider the precise composi- tion of their cored electrodes to be proprietary informa- tion. By proper selection of the ingredients in the core (in combination with the composition of the sheath), the fol- lowing is possible: (1) Produce welding characteristics ranging from high deposition rates in the flat position to proper fusion and bbcad shape in the overhead position. (@) Produce electrodes for various gas shiclding mix- tures and for self shielding. (3) Vary alloy content of the weld metal from mild stecl for certain electrodes to high alloy stainless steel for others, The primary functions ofthe flax core ingredients are to do the following: (1) Provide the mechanical, metallurgical, and corco- sion resistant properties ofthe weld metal by adjusting the chemical composition, (2) Promote weld metal soundness by shielding the mol- ten metal from oxygen and nitrogen in the air. ld Seven impurities rom che molten metal by we of luxing reactions. (4) Produce a slag cover to protect the solidifying weld ‘metal from the air, and to control the shape and appear- AUS WHB-2 0 MM O764265 OO109S2 & mm ance of the bead in the different welding positions for hich the electrode is suited, (5) Stabilize the are by providing a smooth electrical path to reduce spatter and facilitate the deposition of uni- formly smooth, properly sized beads. Table 5.1 lists most of the elements commonly found in the flux core, their sources, and the purposes for which they are used. In mild and low alloy stecl electrodes, a proper balance of dcoxidizers and denitrifiers (in the case of sel-shiclded electrodes) must be maintained to provide a sound weld deposit with adequate ductility and toughness. Deoxidiz- cers, such as silicon and manganese, combine with oxygen to form stable oxides. This helps to control the loss of alloying elements through oxidation, and the formation of carbon monoxide which otherwise could cause porosity. ‘The denitrifers, such as aluminum, combine with nitrogen and tie it up as stable nitrides. This prevents nitrogen po- rosity and the formation of other nitrides which might be harmful. CLASSIFICATIONS OF ELECTRODES Mild Steel Electrodes Mosr mito steel. FCAW electrodes are classified accord- ing to the requirements of the latest edition of ANSI/AWS A5.20, Specification for Carbon Steel Electrodes for Plux Tal Common Gore Elements in Flux Cored Electrodes Eloment| Usually Present As Purpose in Weld Aun Yalow Deoxiie and donitify Colca Minras such as fuorspar(CaF2) and limestone (CaCO) Provide stating and form slag Carbon Elamant in feroaloys suchas feromenganese Increase harness and strength Chromium —Ferraloy or metal powder ‘Alloying to improve creep resistanc, hardness, strength and corasion resistance ron Ferroaloys and iron powder ‘Aly matic inion base deposits, alloy in nck base and other ‘onfrrous deposits Manganese Fareloy such as feromenganese or as metal powder Deoxiie; prevent hot shortness by combining with sur to form MS; ineess hardnass and strength; frm sig Molybdenum — Feratoy Alloying to increase hardness strength, and in austenitic ‘stilass stas to increase resistance to pitng-ype corasion Nickel Metal Ponder Alloying to inprove harness, strength, toughness and corrosion resistence Potassium Minas such as potassium bearing feldpars and siicates and Stabile the arc and frm slog in fits Siicon Farroaoy such as ferosiicon o silicomangaese; mineral Deoxiie and form slag slates such as feldspar Sodium Minerals such as sodiu-beatingfespas ae sizates in fits Stabile tho rc and form slg Titanium Faroaoy such as ferotitanium in mineral, rutile Deoxiiew and deny form slog; stebize carbon in some sails teas Zrconiun Oxide oF metal ponder Deoxicie acl dent form slog Vanadium Oxide or metal powder Inerase trongth Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 AUS WHB-2 90 mm 0784265 0010953 6 mm FLUX CORED ARC WELDING DESIGNATES AN ELECTRODE, INDICATES THE MINIMUM TENSILE STRENGTH OF THE DEPOSITED WELD METAL IN A TEST WELD MADE WITH THE ELECTRODE AND IN ACCORDANCE WITH SPECIFIED. WELDING CONDITIONS. INDICATES THE PRIMARY WELDING POSITION FOR WHICH im [Te ELECTRODE IS DESIGNED: — x x Tx (0 - FLAT AND HORIZONTAL POSITIONS 1~ ALL POSITIONS INDICATES USABILITY AND PERFORMANCE CAPABILITIES, INDICATES A FLUX CORED ELECTRODE. Cored Arc Welding. The identification system follows the ‘general pattern for electrode classification and is illus- trated in Figure 5.12, It may be explained by considering typical designation, E7OT-1 ‘The prefix “E” indicates an electrode, as in other elec- trode classification systems. The first number efers to the minimum as-welded tensile strength in 10 000 psi units. In this example, the number “7” indicates that the electrode has a minimum tensile strength of 72.000 psi. The second number indicates the welding positions for which the elec- trode is designed. Here the “zero” means that the clec- twode is designed for flat groove and filet welds, and hori- zontal groove and fillet welds However, some classifications may be suitable for vertical or ovethcad positions, or both. In those cases, a “I” would beused instead of the “0” to indicateall-position capability. ‘The letter “T” indicates thatthe electrode is of tubular con. struction (a flux cored electrode). The suffix number (inthis ‘example “1”) places the electrode in a particular grouping buile around the chemical composition of deposited weld ‘metal, method of shiclding, and suitability of the electrode for single or multiple pass welds. Table 5.2 explains the sig- nificance of the last digit of the FCAW designations, Mild steel FCAW electrodes are classified on the basis of whether they ate self shielded or whether carbon dioxide is required as a separate shielding gas, the type of current, and their usability for welding out of position, The classifi- cation also specifies whether the clectrode is «single-pass ‘or multiple-pass electrode, and the chemical composition and as-welded mechanical properties of deposited weld metal. Electrodes are designed to produce weld metals Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 intification System for Mild Steel FCAW trodes having specified chemical compositions and mechanical properties when the welding and testing are done accord- ing to the specification requirements. lectrodes are produced in standard sizes ranging from 0.045 to 5/32 in. (1.2 to 4.0 mm) diameter. Special sizes may also be available. Weld properties may vary appreci bly depending on: clectrode size, welding amperage, plate thickness, joint geometry, preheat and interpass tempera- tures, surface conditions, base metal composition and ad- mixture with the deposited metal, and shielding gas {if re- Table 5.2 Shielding and Polarity Requirements for Steel FCAW Electrodes Current and Polarity de, eect postive EXXT-2 (She as] A, deco postive EXT (Signs) None lero posite EQC-4 (Multipass) ‘None letodepositne ‘EXXT-5 (Multiple-pass) coe dc, electrode positive ‘EXXT-6 (Muitiple-pass) None de, electrode positive ‘EXXT-7 (Multile-pass) None de, alectroda negative EQXTS (Matisse) ‘None, tod gate EQC-10(Snjeess) None bt nogtve ‘EXXT-11 (Multiple-pess) None de, electrode negative EXT (Maiplpss) : e EXXT-63 (Slee) : * As aqred upon btween supplier ane user. 172 FLUX CORED ARC WELDING quired). Many electrodes are designed primarily for ‘welding inthe flat and horizontal positions. They may also be suitable for use in other positions if the proper choice of welding current and electrode diameter is made. Selected electrodes with diameters below 3/32 in, (2.4 mm) may be used for out-of-position welding at welding currents on the low side of the manufacturer's recommended range. ‘There are twelve different classifications of mild steel FCAW electrodes designated in ANSI/AWS AS.20. Theie descriptions and intended uses ar listed below. EXXT-1, Electrodes of the T-1 group ate designated for CO2 shielding gas by this specification and are used with DCEP. However, gas mixtures of argon and CO2 are also used to improve usability, especially for out-of-posi- tion applications, Decreasing amounts of COa in he gon-COz mixture will increase manganese and silicon in the deposit and may improve the impact properties. These electrodes are designed for single- or multiple pass weld: ing, The T-1 electrodes are characterized by a spray trans- fer, low spatter los, flat to slightly convex bead configuea- tion, and.a moderate volume of slag which completely covers the weld bead. EXXT-2, Electrodes of this classification are used with DCER, are essentially T-1 electrodes with higher manga- nese oF silicon or both, and are designed primarily for sin sle-pass welding in the flat position and for horizontal fil lets. The higher amounts of deoxidizersin these electrodes allow single-pass welding over scaled or rimmed steel. 7-2 electrodes that use manganese as the principal deoxidizing clement give good mechanical properties in both single- and multiple-pass applications. However, the manganese content and tensile strength will be high in maltiple-pass applications. These electrodes can be used for welding ma- terial which has heavier mill sale, rust, or other foreign ‘materials on its surface than can be tolerated by some elec- teodes of the T- classification, and wil still produce welds of radiographic quality. The arc characteristics and deposi- tion rates are similar to those of the T-1 electrodes. EXXT-3. Electrodes of this classification are self- shielded, are used with DCER, and have a spray-type tran fer. The slag system is designed to give characters which make possible very high welding speeds. ‘The elec- trodes are used to make single-pass welds in the flat, hori zontal, and (up to 20°) downhill positions on sheet metal up to 3/16 in, (4.8 mm). They are not recommended for ‘welding of materials greater than 3/16 in, (48 mm), nor for making multiple-pass welds. EXXT-4, Electrodes of the T-4 classification are self- shielded, operate on DCEP, and have a globular-type trans- designed to give characteristics which permit high deposition rates while desulfurizing the weld metal to a low level, which makes the weld deposit AUS UHB-2 90 Mm 0784265 COLOGS4 T mm resistant to cracking. These electrodes are designed for low penetration, adapting them for use on joints with poor fi-up, and for single- and multiple-pass welding in the flat and horizontal positions. EXXT-5. Electrodes of the T-5 group are designed to bbe used with CO2 shielding gas (argon-CO mixtures may beused, as with the T-1 types) for single-and maltiple-pass ‘welding in the flat position and for horizontal filles. These electrodes are characterized by a globular transfer, slightly convex bead configurations, and a thin slag which may not completely cover the weld bead. Weld deposits produced by electrodes of this group have improved impact proper- ties and crack resistance in comparison to the rutile types (EXXT-1 and EXXT-2), EXXT-6. Electrodes of the I-6 classification are self- shielded, operate on DCEP, and have a spray-type transfer. ‘The slag system is designed to give very good, low-tempet- ature impact properties, deep penetration, and excellent deep groove slag removal. The electrodes are used for sin- gle- and multiple-pass welding in the flat and horizontal positions. EXXT-7. Electrodes of the T-7 classification are self- shielded and operate on DCEN. The slag system is de- signed to give characteristics which allow the larger sized clectrodes to be used at high deposition rates and the smaller sizes to be used for all-position welding, The slag system is also designed to desulfurize the weld metal thor- oughly, which helps to make the weld deposit resistant to cracking. The electrodes are used for single- and multiple- pass welding, EXXT-8. Electrodes of the T-8 classification are self- shielded and operate on DCEN. The slag system has char- acteristics which make it possible to use these electrodes for all-position welding. The slag system also achieves good, low-temperature impact properties in the weld metal and desulfurizes the weld metal to alow level, which helps resist weld cracking. The clectrodes are used for both single- and multiple-pass applications. EXXT-10. Electrodes of the T-10 classification are selfshielded and operate on DCEN. The slag system en- ables welds to be made at high travel speeds. The elec: trodes are used for making single-pass welds on material of any thickness in the flat, horizontal, and (up to 20°) down- hil positions. EXXT-11. Electrodes of the T-11 classification are sclf-shielded and operate on DCEN, and have a smooth spray-type arc. The slag system permits welding in all posi- tions and at high travel speeds. These are gencral purpose electrodes for single- and multiple-pass welding in all positions. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 EXXT-G._ The EXXT-G classification is for new multi- ple-pass electrodes which are not covered under any of the presently defined clasifications. The slag system, are char- acteristics, weld appearance, and polarity are not defined. EXXT-GS._The EXXI-GS classification is for new sle-pass electrodes not covered by any other presently de- fined classification, The slag system, arc characteristics, weld appearance, and polarity are not defined. Low Alloy Steel Electrodes FLUX CORED ELECTRODES are commercially available for welding low alloy stecls. They are described and classified in the latest edition of ANSI/AWS A5.29, Specification for Low Alloy Steel Electrodes for Flux Cored Are Welding. The electrodes are designed to produce deposited weld metals having chemical compositions and mechanical properties similar to those produced by low alloy steel SMAW clec- trodes. They are generally used to weld low alloy stecls of similar chemical composition. Some electrode classifica tions ate designed for welding in all positions while others AUS UHB-2 90 mm 0784265 COLOT5S 4 mw FLUX CORED ARC WELDING 173 are limited to flat and horizontal fillet positions only. Like the mild steel electrodes, there is an identification system used by AWS to describe the various classifications. Figure 5.13 illustrates the components of these designations. ANSI/AWS AS.29 lists five different classifications of low alloy steel FCAW electrodes, ‘Their descriptions and intended uses are summarized below. EXXT1-X. Electrodes of the TIX group are classified fot use with CO2 shielding eas. However, gas mixtuces of argon and COz may be used where recommended by the ‘manufacturer to improve usability, especially for out-of- position applications. These electrodes are designed for single-and multiple-pass welding, The T1-X electrodes are characterized by a spray transfer, low spatter loss, flat to slightly convex bead configurations, and a moderate vol- ume of slag, which completely covers the weld bead. EXXT4-X, Electrodes of the T4-X classification are self-shielded, operate on DCEP, and have a globular type transfer, The slag system is designed to give characteristics that make possible high deposition rates and to desulfurize = x Xt x-x LL DESIGNATES AN ELECTRODE. INDICATES THE MINIMUM TENSILE STRENGTH OF THE DE- POSITED WELD METAL IN A TEST WELD MADE WITH THE ELECTRODE AND IN ACCORDANCE WITH SPECIFIED. ‘WELDING CONDITIONS. INDICATES THE PRIMARY WELDING POSITION FOR WHICH ‘THE ELECTRODE IS DESIGNED: (0 ~ FLAT AND HORIZONTAL POSITIONS 1 ~ ALL POSITIONS. DESIGNATES THE CHEMICAL COMPOSITION OF THE DEPOS- ITED WELD METAL. SPECIFIC CHEMICAL COMPOSITIONS ARE NOT ALWAYS IDENTIFIED WITH SPECIFIC MECHANICAL PROPERTIES IN THE SPECIFICATION. A SUPPLIER IS RE- ‘QUIRED BY THE SPECIFICATION TO INCLUDE THE MECHANI- CAL PROPERTIES APPROPRIATE FOR A PARTICULAR ELEC- ‘TRODE IN CLASSIFICATION OF THAT ELECTRODE, THUS, FOR EXAMPLE, A COMPLETE DESIGNATION IS E80T5-Ni3; EXXT5-Ni3 IS NOT A COMPLETE CLASSIFICATION, INDICATES USABILITY AND PERFORMANCE CAPABILITIES, INDICATES A FLUX CORED ELECTRODE, Figure 5.13-1 Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 ication System for Low Alloy Steel FCAW Electrodes: AUS WHB-2 90 MM 0784265 OOL05S6 3 mm 174 FLUX CORED ARC WELDING the weld metal o a low level, which helps make the weld deposit resistant to cracking. These electrodes are de- signed for low penetration, enabling them to be used on weld joints with poor fit-up and for single- and rultiple- pass welding in the flat and horizontal positions. EXXTS-X. Electrodes of the T-X group are designed for use with DCEP and COz shielding gas (angon-CO mix- tures may be used where recommended by the manufac- turer like the T1 types) for single- and multiple-pass weld- ingin the flat postion, and for horizontal fillets. Certain X electrodes are designed to weld on DCEN with argonand (CO2 mixtures for out-of-position welding, These electrodes are characterized by a globular transfer, slightly convex bead configuration, and a thin slag, which may not com- pletely cover the weld bead, Weld deposits produced by electrodes of this group have improved impact properties and crack-resistance in comparison with the TLX types. EXXT-8X _Plectrodes of the T8-x classification are self shielded and operate on DCEN. The slag system has chae- acteristics that make it possible to use these clectrodes for all-position welding, The slag system also produces good, low-temperature impact properties in the weld metal and desulfurizes the weld metal thoroughly, which helps resist weld cracking. The electrodes are used for single-and mul- tiple-pass welding. EXXTX-G, EXXTX.G classification is for new multi- ple-pass electrodes that are not covered under any of the presently defined classifications. The slag system, arc char- acteristics, weld appearance, and polarity are not defined. Most low alloy steel FCAW electrodes are designed for ts shielded welding using ether a T1-X or a TSX flox core formulation! and CO2 shielding gas. However, the use of special formulations designed for shielding with 75 per- cent argon/25 pereent CO2 shielding gases is becoming in- gresngy common, They generally produce weld metal having Charpy V-notch impact strengths of 20 ft-lb (27 J) at O°F (18°C) or below. A few nickel steel electrodes with - ‘TAX or -T8-X formulations are available for self-shiclded FCAW. Charpy V-notch impact requirements for weld metal de- posited with the -T4 formulation will generally meet 20 fe- Ib (27 J) at 0°F (18°C), Weld metal deposited with -T8 clectrodes will generally mect 20 ft-lb (27 J) at -20°F (29°C), A complete series of low alloy flux cored welding electrodes comparable to the variety of low alloy shielded ‘metal ac electrodes described in ANSI/AWS AS.5, Speci- fication for Low Alloy Steel Covered ‘Arc Welding Elec- trodes, is described in the latest edition of ANSI/AWS Specification A5.29, Specification for Low Alloy Steel Elec- trodes for Flux Cored Arc Welding. As a result of the issu- ance of this specification, low alloy flux cored electrodes 1. Toran expnaton of ux core designations, sc thefts edon of ANSI/AWS A529, Speciation fr Lo Alloy Stel Elecrodes for Fhe (Goede Welding ae fom the American Walling Soci. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 have gained widespread acceptance in welding high- strength, low alloy stecls. Electrodes for Surfacing FLUX CORED ELECTRODES are produced for certain types of surfacing applications, such as restoring usable service parts and hardfacing, Such electrodes possess many of the advantages of the electrodes used for joining, but there is less standardization of weld metal analysis and perfor- mance characteristics. Literature from various mamufac- turers should be consulted for details on flux cored surfac- ing electrodes, Flux cored surfacing electrodes deposit iron base alloys which may be ferrtic, martensitic, or austenitic. They may deposit weld metal that is high in carbides. The electrodes are variously designed to produce surfaces with corrosion resistance, wear resistance, toughness, or antigalling prop- erties. They may be used to restore worn parts to original dimensions. Stainless Steel Electrodes ‘THE CLASSIFICATION SYSTEM of ANSI/AWS AS.22, Speci- fication for Plux Cored Corrosion-Resisting Chromium ‘and Chromiur-Nickel Steel Electrodes, prescribes require- iments for flux cored corrosion resisting chromium and chromium-nickel steel electrodes. These electrodes are classified on the basis of the chemical composition of the deposited weld metal and the shielding medium to be em- ployed during welding. Table 5.3 identifies the shielding designations used for classification, and indicates the re- spective current and polarity characteristics. Electrodes classified EXXX-1 that use CO2 shielding suffer some minor loss of oxidizable elements and some increase in carbon content. Electrodes with the EXXXT-3 classifications, which are used without external shielditg, suffer some loss of oxidizable elements and a pickup of nitrogen which may be significant. Low welding currents TT Table 5.3 id Welding Current 3s Steel Flux Cored BOOT co? ‘enh (ee post) BOOT 2 Ar 2%0 dip (lectiod poste) BOTS None dip (ood pasitve) BOT None Speed Not Specie 2. The dassifications are given in AWS AS.22, Speifetions for Fux Cored Corrosion Resisting Chromium and Chromium-Nickel Steal Elec- ‘woes, The latrs "XXX" stand forthe chemical composition (AIS! Type) suth as 308, 316, 410, and 502. Direct carrntreverso polarity. coupled with long arc lengths (high arc voltages) increase the nitrogen pickup. Nitrogen stabilizes austenite and may therefore reduce the ferrite content of the weld metal. ‘The requirements of the EXXXT-3 classifications are different from those of the EXXXT-1 classifications be- cause shielding with a flux system alone is not as effective as shielding with both a flux system and a separately ap- plied external shielding gas. The EXXXT-3 deposits, therefore, usually have 2 higher nitrogen content than the EXXXT-i deposits, This means that to control the ferrite content of the weld metal the chemical compositions of the EXXXT-3 deposits must have different Cr/Ni ratios than those of the EXXXT-1 deposits, In contrast to self- shielded mild steel or low alloy steel electrodes, EXXXT-3 stainless steel electrodes generally do not contain strong denitriding elements such as aluminum. The technology of the EXXXT-1 types has now been developed to the point that all-position stainless steal flux cored wires have become available, These wires have higher deposition rates than solid stainless wire when used out-of-position; they are easier to use than solid wire in the dip transfer mode; and they produce consistently sound welds with standard constant-potential power sources, ‘These wires are available in sizes as small as 0.035 in. {0.9 mmm) in diameter. ‘The mechanical properties of deposited weld metal are specified for each classification, including.a minimum ten- sile strength and minimum ductility, Radiographic sound- ness requirements are also specified. Although welds made with electrodes meeting AWS specifications are commonly used in corrosion ot heat re AUS UHB-2 90 MM 784265 0009S? 5 mm FLUX CORED ARC WELDING 175 sisting applications, i is not practical to require electrode ‘qualification tests for corrosion or scale resistance on welds or weld metal specimens. Special tests which are per- tinent to an intended application should be established by agreement between the electrode manufacturer and the Flux Cored Nickel Base Electrodes AT THE TIME of this writing, a new AWS specification, 5.34, is being drafted to classify flux cored nickel base electrodes. Such electrodes have appeared commercially fora few nickel-base alloys. Their slag systems and operat- ing characteristics have much in common with the stain- less steel electrodes classified by ANSI/AWS AS.22. Con- sult AWS A5.34 as soon as it is published, for helpful, additional information, Protection from Moisture PROTECTION FROM MOISTURE pickup is essential with most flux cored electrodes. Moisture pickup can result in “worm tracks,” or porosity in the weld bead. A retuen to the original package is recommended for overnight storage. Reconditioning of exposed wire by baking at 300 to 600°F (150 to 315°C) is recommended by certain mant- facturers. This assumes that the wire is spooled or coiled ona metal device. PROCESS CONTROL WELDING CURRENT WELDING CURRENT Is proportional to electrode feed rate for a specific electrode diameter, composition, and elec- trode extension. The relationship between electrode feed rate and welding current for typical mild steel gas shielded electrodes, self-shiclded mild steel electrodes, and self- shielded stainless steel electrodes are presented in Figures 5.14, 5.15, and 5.16 respectively. A constant voltage power source of the proper size is used to melt the electrode at a rate that maintains the preset output voleage arc length). If the other welding variables are held constant for a given dinmeter of electrode, changing the welding cursent will have the following major effects: (1) Increasing current increases electrode deposition rate, (@) Increasing current increases penetration, G) Excessive current produces convex weld beads with oor appearance. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 (4) Insufficient current produces large droplet transfer and excessive spatter. (6) Insufficient current can result in pickup of excessive nitrogen and also porosity in the weld metal when welding with self-shielded flux cored electrodes. ‘As welding current is increased or decreased by chang- ing electrode feed rate, power supply output voltage should be changed to maintain the optimum relationship of arc voltage to current. For a given electrode feed rate, measured welding current varies with the clectrode exten. sion, As the electrode extension increases, welding current will decrease, and vice versa. ARC VOLTAGE ARG VOLTAGE AND atc length are closely related. The volt- age shown on the meter ofthe welding power supply isthe sum of the voltage drops throughout the welding circuit. This includes the drop through the welding cable, the elec- AUS WHB-2 40 MM O784265 0010956 7 mm 176 FLUX CORED ARC WELDING 1000 00 0046 in, coo a aso z ao gor 116 in 260 3 (1.6 mm) DIAM, 2 fi 200 $ w 5/64 in, & 3 aook (20mm Dia, z s/32in 180 u %24 mn) IAM, 7/64 i, a (28mm) dIAM. J 109 ny Se SS 50 (3.2 mm) DIAM. ° a a a a WELDING CURRENT, A Ttosl Eloctodes with "_€02 Shielding trode extension, the arc, the workpiece and the worklead cable. Therefore, arc voltage will be proportional. to the ‘meter, reading provided all other circuit elements (includ- ing theic temperatures) remain constant. “The appearance, soundness, and properties of welds made with flux cored electrodes can be affected by the arc voltage, Too high an arc voltage (too long an arc) can result in excessive spatter and wide, irregularly shaped weld beads. With self-shielded electrodes, too high an are volt- age will result in excessive nitrogen pickup. With mild steel electrodes, this may cause porosity. With stainless stec] electrodes, it will reduce the ferrite content of the weld ‘metal, and this in turn may result in cracking. Too low an are voltage (too short an atc) will result in narrow convex beads with excessive spatter and reduced penetration. ELECTRODE EXTENSION ‘THe UNMELTED ELECTRODE that extends beyond the con- tact tube duving welding (electrode extension) is resistance heated in proportion to its length, assuming other variables remain constant, As explained earlier, electrode tempera- ture affects arc energy, electrode deposition rate, and weld penetration, It also can affect weld soundness and arc fect of electrode extension as an operating factor in FCAW introduces a new variable that must be held in balance with the shielding conditions and the related weld- ing variables. For example, the melting and activation of the core ingredients must be consistent with that of the containment tube, as well as with arc characteristics. Other things being equal, too long an extension produces an unstable arc with excessive spatter. Too short an exten- sion may cause excessive arc length at a particular voltage setting. With gas shielded electrodes, it may result in ex- cessive spatter buildup in the nozzle that can interfere with the gas flow. Poor shielding gas coverage may cause weld metal porosity and excessive oxidation. Most manufacturers tecommend an extension of 3/4 to 1.1/2 in, (19 to 38 mm) for gas shielded electrodes and from approximately 3/4 to 3-3/4 in (19 to 95 mm) for self-shielded types, depending on the application. For opti- imum settings in these ranges, the electrode manufacturer should be consulted. Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 TRAVEL SPEED ‘TRAVEL SPEED INFLUENCES weld bead penetration and contour, Other factors remaining constant, penetration at low travel speeds is greater than that at high travel speeds, Low travel speeds at high cureents ean result in overheat- ing of the weld metal. This will canse a rough appearing well with the possibilty of mechanically trapping slag, or melting through the base metal. High travel speeds tend to result in an ieregular, ropy bead. AUS WHB-2 90 Mm 0784265 0010959 9 mm FLUX CORED ARC WELOING 177 ‘SHIELDING GAS FLOW For GAS SHIELDED electrodes, the gas flow rate isa vatiable affecting weld quality. Inadequate flow will result in poor shielding of the molten pool, resulting in weld porosity and oxidation. Excessive gs flow can result in turbulence and mixing with air. The effect on the weld quality will be the same as inadequate flow. Either extreme will inercase weld metal impurities. Correct gas flow will depend on the type and the diameter of the gun nozzle, distance of the (© E71T-7, 1 in. (25 mm) EXTENSION x E7OT-4, 2-3/4 in, (70 mm) EXTENSION © E70T-4, 3-3/4 in, (95 mm) EXTENSION ‘A ETOT-G, 1-1/4 in. (82 mm) EXTENSION 400 360 5/64 in, 8 8 160 ELECTRODE FEED RATE, in./MIN 100 200 400 (2.0 mm) DIAM. 18 in, (3.2 mm) DIAM. x 1Bin. (8.2 mm) DIAM. A r, /3/32 in, (2.4 mm) DIAM. mm/s 600) 800 1000 WELDING CURRENT, A —<—<—<—<—————_$§£J@ _ _Figure 5.15-Electrode Feed Rate Versus Welding Current for Self-Shielded Mild Steel Electrodes Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 AUS UHB-2 90 M™ O7842L5 OOLO[G0 S mm 178 FLUX CORED ARC WELDING 600 | 260 © 1 in, (28 mm) EXTENSION X 8/4 in, (19 mm) EXTENSION poole 1/16 ir in 5/64 in, (1.6 mm) eon + 200 o1AM “omen 2 2 400 + # 150 é 2 § 0b $ w 3.32 . 4 in, 8 (2.4 mm) e DIAM F100 3 200 | + 50 100 + ° L 1 1 t ° ° 100 200 300 “400 500 600 WELDING CURRENT, A nozzle from the work, and air movements in the immediate region of the welding operation. DEPOSITION RATE AND EFFICIENCY DRPOStION RATE IN any welding process is the weight of ‘material deposited per unit of time, Deposition rate is de- pendent on welding variables such as electrode diameter, electrode composition, electrode extension, and welding current, Deposition rates versus welding current for vari- ous diameters of gas shielded and self-shiclded mild stec! electrodes and self-shielded stainless steel electrodes are presented in Figures 5.17, 5.18, and 5,19 respectively Deposition efficiencies of FCAW electrodes will range from 80 to 90 percent for those used with gas shielding, Versus Welding Current for Self-Shielding ES08T-3 and from 78 to 87 percent forself-shielded electrodes. De- position efficiency is the ratio of weight of metal deposited to the weight of electrode consumed. ELECTRODE ANGLE ‘THE ANGLE AT which the electrode is held during welding determines the direction in which the arc force is applied to the molten weld pool. When welding variables are prop- erly adjusted for the application involved, the arc force can be used to oppose the effects of gravity. in the FCAW and SMAW processes, the arc force is used not only to help shape the desired weld bead, but also to prevent the slag from running abead of and becoming entrapped in the weld metal Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 5/64 in. (2.0 mm) DEPOSITION RATE, Ib/h 0784265 OOLO5L1 7 FLUX CORED ARC WELDING 179 (2.4 mm} DIAM. “LAT POSITION ‘SEMIAUTOMATIC HORIZONTAL POSITION 400 00 WELDING CURRENT, A Figure 5.17—Deposition Rate Versus Welding Current for E70T-1 Mild Steel Electrodes, _with C02 Shielding ‘When making groove and filet welds in the flat posi tion, gravity tends to cause the molten weld pool to run ahead of the weld, To counteract this, the electrode is held at an angle to the vertical with the electrode tip pointing backwards toward the weld, ie, away from the direction of travel, This travel angle, defined as the drag angle, is measured froma vertical ine in the plane ofthe weld axis, as shown in Figure 5.20(A). ‘The proper drag angle depends on the FCAW method used, the base metal thickness, and the position of weld- ing, For the self-shielded method, drag angles should be about the same as those used with shielded metal arc weld- ing electrodes. For flat and horizontal positions, drag an- ales will vty from approximately 20 to 45 degrees. Larger Angles are uted for thin sections, As materi thickness in creases, the drag angle is decreased to increase penetration. For vertical-up welding, the drag angle should be $ to 10 degrees. ‘With the gas shielded method, the drag angle should be small, usually 2 to 15 degrees, but not more than 25 de- agrees. Ifthe drag angle is too large, the effectiveness of the shielding gas will be lost. ‘When fillet welds are made in the horizontal position, the weld poo! tends to flow both in the direction of travel and at right angles to it. To counteract the side-fiow, the electrode should point at the bottom plate close to the comer of the joint. In addition to its drag angle, the elec- trode should have a work angle of 40° to $0” from the vertical member. Figure 5.20(B) shows the electrode offset and the work angle used for horizontal fillets For vrtialup welding a smal lading electrode ange Copia by the Ameian Nellng Soci Satu 05 10.1725 1997 AUS WHB-2 50 mm 0764265 0020962 9 mm \ 180 FLUX conED anc weLoING Dt 1D 1/16 in. (1.6 mm) DIA. © 8/68 in. (2.0 mm) DIA x 3/32 in. (24 mm) DIA © 1/8 in G2 mm o1s ‘_6/32'n. (40 mm) DIA 40 18.0 ic a6 h 14 20h iz

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