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General benefits
32
30
28
26
24
34
Voltage (V)
The wire enters the spray transfer mode typically from appr.
125 Amps. 22 Volts (for .045/1.2 mm wire, Ar/CO2 gas
mixture and at 100 A, 23 V for .035/0.9 mm wire) and
produces a powerful penetrating arc that deposits a smooth
spatter free weld metal.
Spatter formation
36
22
20
80
100
BHLER stainless flux cored wires like our well known rutile coated electrodes produce weld metal with
excellent bead appearance. The weld deposit is radiographically sound and spatter free with good wetting
characteristics. The slag protects the weld pool from oxidation and is easily removed to reveal a smooth
weld profile that requires minimum post weld cleaning.
150
200
Amperage (A)
250
300
Cored wires have a wider arc column than solid wires. Therefore they operate with very safe penetration. The risk of lack of side wall
fusion is minimized compared to solid wire welding even when the torch is slightly misdirected due to lack of welder concentration.
4
Cost comparisons
Although solid wires cost less than flux cored wires it is the
overall total welding costs of the finished component that
should be taken into consideration. Flux cored wires offer
benefits that greatly reduce the overall welding costs, particularly in such areas as postweld cleaning, pickling, etc. which
are often overlooked.
FCAW offers
100 % faster travel speed = half welding time
8,16
18
flux cored wire .035 (0.9 mm)
16
7,26
6,35
coated electrode
5,44
12
Welding position 1G PA
10
4,54
3,63
3/16 (5 mm)
2,72
6
5/32 (4 mm)
1,81
0,91
2
100
200
Ampere
300
14
7/minute
(180 mm/minute)
4
3.5/minute
(90 mm/minute)
2
FCAW wire .045
400
Shielding Gas
Wire Stick-Out
Argon + 18 % CO2
Argon + 18 % CO2
Argon + 18 % CO2
Argon + 12 % CO2
FCAW
GMAW
SMAW
Special features
Sheet metal fabrication using BHLER .035 (0.9 mm) FCAW wires
Butt weld
Fillet weld
Lap joint
Corner joint
Welding joints on
5/64 (2 mm) sheet metal
Metal droplet
on a flux cored electrode
Welding position
0.9 mm
.045
1.2 mm
fillet weld
2F (horizontal)
1/16
1.5
1/8
3.0
fillet weld
3F (vertical down)
1/16
1.5
1/8
3.0
fillet weld
3F (vertical up)
3/16
5.0
3/16*
5.0*
butt weld
1G (flat)
1/16
1.5
1/8
3.0
butt weld
3G (vertical down)
5/64
2.0
1/8
3.0
butt weld
3G (vertical up)
3/16
5.0
3/16*
5.0*
Sizes
inch
(mm)
Classification
EN
AWS
E 308 H-FD
Mechanical properties
ksi
MPa
C
Si
Mn
Cr
Ni
0.05
0.6
1.2
19.4
10.1
YS
TS
EL
CVN
56.5
84
42 %
59 ft lbf
390
585
80 J
C
Si
Mn
Cr
Ni
0.03
0.7
1.5
19.8
10.2
YS
TS
EL
CVN
55
380
81
560
40 %
44 ft lbf
60 J
24 ft lbf -184 F
32 J -196 C
SAS 2-FD
C
Si
Mn
Cr
Ni
Nb
0.03
0.6
1.4
19.0
10.4
+
YS
TS
EL
CVN
61
420
87
600
35 %
55 ft lbf
75 J
24 ft lbf -184 F
32 J -196 C
C
Si
Mn
Cr
Mo
Ni
0.03
0.7
1.5
19.0
2.7
12.0
YS
TS
EL
CVN
58
400
81
560
38 %
37 ft lbf
50 J
24 ft lbf -184 F
32 J -120 C
SAS 4-FD
C
Si
Mn
Cr
Mo
Ni
Nb
0.03
0.6
1.3
18.8
2.6
12.2
+
YS
TS
EL
CVN
65
430
87
570
35 %
48 ft lbf
65 J
24 ft lbf -184 F
32 J
-120 C
E 317 L-FD
C
Si
Mn
Cr
Mo
Ni
0.035
0.7
1.3
18.8
3.4
13.1
YS
TS
EL
CVN
71
420
98,5
570
32 %
37 ft lbf
50 J
24 ft lbf -76 F
32 J
-60 C
CN 22/9 N-FD
C
0.03
Si
0.8
Mn
0.9
Cr
22.7
Mo
3.2
Ni
9.0
N
0.13
PREN 35
YS
TS
EL
CVN
87
600
116
800
27 %
44 ft lbf
60 J
24 ft lbf -40 F
32 J
-40 C
A 7-FD
C
Si
Mn
Cr
Ni
0.1
0.8
6.8
18.8
9.0
YS
TS
EL
CVN
61
420
91
630
39 %
44 ft lbf
60 J
24 ft lbf -148 F
32 J
-100 C
Hardness 200 HB, Coldworkhardened up to 400 HV.
CN 23/12-FD
C
Si
Mn
Cr
Ni
0.03
0.7
1.4
22.8
12.5
YS
TS
EL
CVN
61
400
82
540
35 %
44 ft lbf
60 J
24 ft lbf -76 F
32 J
-60 C
C
Si
Mn
Cr
Mo
Ni
0.03
0.6
1.4
22.7
2.7
12.3
YS
TS
EL
CVN
72.5
500
101.5
700
30 %
40 ft lbf
55 J
24 ft lbf -76 F
32 J
-60 C
C
Si
Mn
Cr
Nb
Fe
Ni
Ti
0.03
0.4
3.2
19.6
2.5
2.0
bal.
+
YS
TS
EL
CVN
58
94
39 %
100 ft lbf
81 ft lbf
110 J
C
Si
Mn
Cr
Ni
Mo
0.025
0.7
0.9
12.0
4.6
0.6
EAS 2-FD
TV-D, SEPROZ, CE
EAS 4 M-FD
TV-D, TV-A, CWB, GL, DB, SEPROZ,
BB, CE
CN 23/12 Mo-FD
TV-D, TV-A, ABS, GL, DNV, DB,
BB, RINA, SEPROZ, CE
NIBAS 70/20-FD
TV-D
CN 13/4-MC
SEPROZ
Chemical
composition %
.045 (1.2) T 13 4 M M 2
1/16 (1.6) EC410NiMo (mod.)
400
650
135 J
-320 F
-196 C
Sizes
inch
(mm)
Chemical
composition %
Mechanical properties
ksi
MPa
E 308 H PW-FD
C
Si
Mn
Cr
Ni
0.05
0.6
1.2
19.4
10.1
YS
TS
EL
CVN
56.5
84
42 %
66 ft lbf
C
Si
Mn
Cr
Ni
0.03
0.7
1.5
19.8
10.2
YS
TS
EL
CVN
55
380
81
560
40 %
51 ft lbf
70 J
24 ft lbf-320 F
32 J -196 C
C
Si
Mn
Cr
Ni
Nb
0.03
0.7
1.4
19.0
10.4
+
YS
TS
EL
CVN
61
87
35 %
48 ft lbf
24 ft lbf
32 J
C
Si
Mn
Cr
Mo
Ni
0.03
0.7
1.5
19.0
2.7
12.0
YS
TS
EL
CVN
58
400
81
560
38 %
48 ft lbf
65 J
24 ft lbf -184 F
32 J -120 C
TV-D, CE
C
Si
Mn
Cr
Mo
Ni
Nb
0.03
0.6
1.3
18.8
2.6
12.2
+
YS
TS
EL
CVN
62
430
83
570
35 %
48 ft lbf
65 J
24 ft lbf -184 F
32 J -120 C
E 317 L PW-FD
C
Si
Mn
Cr
Mo
Ni
0.035
0.7
1.3
18.8
3.4
13.1
YS
TS
EL
CVN
55
81
39 %
43 ft lbf
24 ft lbf
32 J
58 J
-76 F
-60 C
EAS 2 PW-FD
Classification
EN
AWS
SAS 2 PW-FD
TV-D, SEPROZ, CE
EAS 4 PW-FD
TV-D, CWB, DB, SEPROZ, BB, CE
SAS 4 PW-FD
BV
390
585
90 J
420
600
75 J
-184 F
-120 C
380
560
C
0.03
Si
0.8
Mn
0.9
Cr
22.7
Mo
3.2
Ni
9.0
N
0.13
PREN 35
YS
TS
EL
CVN
87
600
116
800
27 %
59 ft lbf
80 J
33 ft lbf -50 F
45 J
-46 C
A 7 PW-FD
C
Si
Mn
Cr
Ni
0.1
0.8
6.8
19.0
9.0
YS
TS
EL
CVN
61
420
91
630
39 %
44 ft lbf
60 J
24 ft lbf -148 F
32 J -100 C
CN 23/12 PW-FD
C
Si
Mn
Cr
Ni
0.03
0.7
1.4
22.8
12.5
YS
TS
EL
CVN
58
400
78
540
35 %
48 ft lbf
65 J
37 ft lbf -76 F
50 J
-60 C
Dissimilar joints between high alloyed Crand CrNi-steels to un- and low alloyed
steels. Also for weld cladding. For service
temperatures from -76 F (-60 C)
to +570 F (+300 C).
C
Si
Mn
Cr
Mo
Ni
0.03
0.7
1.4
22.7
2.7
12.3
YS
TS
EL
CVN
72.5
530
101.5
720
32 %
48 ft lbf
65 J
37 ft lbf -76 F
50 J
-60 C
Dissimilar joints between high alloyed Crand CrNi(Mo)-steels to un- and low alloyed
steels. Also for Mo containing weld cladding.
For service temperatures from -76 F
(-60 C) to +570 F (+300 C).
CN 22/9 PW-FD
TV-D, ABS, CWB, DNV, GL, RINA,
SEPROZ, CE
CN 23/12 Mo PW-FD
TV-D, SEPROZ, BV, CE
BHLER offers an outstanding range of products for high quality welds and considerable cost savings when positional welding.
Operating Parameters
Flat and horizontal welding positions
Welding
position
downhand
and
horizontal
Type of joint
Wall thicknesses
inch
mm
1/16 - 5/32 1.5 - 4
1/8 - 3/16
3- 5
3/16 - 19/32 5 - 15
3/16 - 19/32 5 - 15
3/8 - 25/32 10 - 20
1/16 - 3/16 1.5 - 5
1/8 - 9/32
3- 7
9/32 - 19/32 7 - 15
5/16 - 25/32 8 -20
Wire
inch
mm
.035
.045
.045
.045
1/16
.035
.045
.045
1/16
Amperage
A
0.9
1.2
1.2
1.2
1.6
0.9
1.2
1.2
1.6
100
130
130
200
200
100
130
200
200
Voltage
V
160
150
150
280
350
160
220
280
350
22
23
22
26
25
23
22
26
25
28
24
24
30
33
28
28
30
33
591
236
236
571
374
591
394
571
374
8.0
4.5
4.5
8.5
4.5
8.0
4.5
8,5
4.5
15.0
6.0
6.0
14.5
9.5
15.0
10.0
14.5
9.5
Limit the length of arc to 1/8 (3 mm) with .035 (0.9 mm) wire
3/16 (5 mm) with .045 (1.2 mm) wire
The trailing torch angle permits good weld pool control while
at the same time promoting defect free sidewall fusion, despite
high deposition rates.
Torch positioning, flat and horizontal welding positions
Positional welding
Optimum parameter settings for .045 (1.2 mm) wire
Welding
position
vertical up
3G, 3F
overhead
4G, 4F
horizontal 2G
flat postion 1G
Type of joint
Amperage
A
130
150
150
140
180
180
140
170
140
180
180
170
200
200
150
190
26
28
28
28
29
29
25
28
256
354
354
354
433
433
275
394
6
7
7
6.5
9
9
6.5
8
6.5
9
9
9
11
11
7
10
Amperage
A
Voltage
V
130 - 200
22 - 30
236 - 433
6 - 11
130 - 200
22 - 30
236 - 433
6 - 11
130 - 250
22 - 32
236 - 512
6 - 13
Limit the length of arc to 1/8 (3 mm) with .045 (1.2 mm) postional welding wire
General
Dependent on the characteristics of the welding machine optimum parameter setting can vary accordingly. Recommended shielding
gases are Argon +15 - 25 % CO2 or 100 % CO2. (When using 100 % CO2 it is necessary to increase the welding voltage by 2 Volts!).
The gas flow rate should be 32 - 38 cubic feet/hr (15 - 18 l/min). The wire stick-out should be 19/32 - 1 (15 - 25 mm) when welding
.045 - 1/16 (1.2 - 1.6 mm) wires and 1/2 - 25/32 (12 - 20 mm) when welding .035 (0.9 mm) wires. Adequate fume extraction is
recommended as always when welding stainless steels. Rebaking: 300 F (150 C), if necessary!
10
All wires are vacuum packaged in moisture resistant aluminized bags for maximum protection.
BHLER Weldings flux cored wires are precision layer
wound and have excellent feeding characteristics.
Some applications
Dewatering-filter for the pulp industrie,
base metal 1.4306 / AISI 304 L, welded with BHLER EAS 2-FD
11
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