Filler Metals

Filler Metals
Filler Metals
Section 7 Filler Metals
GMAW (MIG) Solutions - Steel
GMAW (MIG) Solutions - Steel - Robotic
1-6
FCAW Solutions - Steel
GTAW (TIG) Solutions - Tungsten Electrodes
Tungsten Electrode Grinder
SMAW (Stick) Solutions - Electrodes
16-17
Stainless Steel Wire and Rods
18-19
Aluminum Wi re (GMAW and GTAW )
Brazing and Soldering Alloys and Fluxes
22-24
Maintenance and Repair Electrodes
25-26
3-6
7-14
15
15
21
Filler Metals
7 1
Gas Metal Arc Welding

(GMAW or MIG) Wire Solutions
MIG Welding Wire
PROSTAR Premium Quality MIG welding wires are designed
to meet the requirements of the metal fabrication industry,
featuring excellent tolerance to rust and scale, excellent wetting characteristics, and superior arc stability.
Applications
Heavy equipment
Structural
General carbon steel fabrication
Packaging
PROSTAR Premium Quality MIG welding wires are available in several packaging sizes 2 lb, 12 lb, 33 lb, 44 lb
and 60 lb spools, and in various diameters conveniently
designed to fit all needs.
It is also available in twist-free robotic containers of

330 lb (150 kg), 660 lb (300 kg), 990 lb (450 kg) and
1,200 lb (550 kg), designed to enhance the robot welding
p e rf o rmance and reduce operating costs. See the
following pages for details.
Wire Specifications
ER70S-6 Designed for superior perf o rmance
in carbon steel.
Wi re Dia.
USA
Package
PROSTAR
.023"
2 lb
PRSS6RN06B001
.023"
12 lb
PRSS6RN06P006
.023"
33 lb
PRSS6RN06P015
.030"
2 lb
PRSS6RN08B001
.030"
12 lb
PRSS6RN08P006
.030"
33 lb
PRSS6RN08P015
.030"
330 lb
PRSS6RW08Q150
Minimum Mechanical Pro p e rties with CO2
.030"
660 lb
PRSS6RW08Q300
Tensile Strength
.035"
2 lb
PRSS6RN09B001
.035"
12 lb
PRSS6RN09P006
.035"
44 lb
PRSS6RN09P020
.035"
60 lb
PRSS6RN09P027
.035"
330 lb
PRSS6RW09Q150
.035"
660 lb
PRSS6RW09Q300
.035"
990 lb
PRSS6RW09Q450
.035"
1200 lb
PRSS6RW09Q550
Canada
AWS 5.18-93
ER480S-6
Class ER70S-6
CWB-CSA W48.4-95
ASME SFA-5.18
CWB-A5.18
Yield Strength
85,000 psi (590 MPa)

68,000 psi (470 MPa)
Elongation in 2"
29 %
Charpy V-Notch
60 ft/lb @ -20 oF
(81 J @ -29 oC)
Typical Wi re Chemistry (%)

C
0.06 - 0.12
Mo *
0.15 max.
.040"
44 lb
PRSS6RN10P020
Mn
1.45 - 1.65
Ni *
0.15 max.
.045"
2 lb
PRSS6RN11B001
Si
0.80 - 1.00
Ti+Zr *
0.15 max.
.045"
12 lb
PRSS6RN11P006
0.020 max.
.045"
44 lb
PRSS6RN11P020
Bal
.045"
60 lb
PRSS6RN11P027
.045"
330 lb
PRSS6RW11Q150
.045"
660 lb
PRSS6RW11Q300
.045"
990 lb
PRSS6RW11Q450
.045"
1200 lb
PRSS6RW11Q550
.052"
60 lb
PRSS6RN13P027
.052"
330 lb
PRSS6RW13Q150
.052"
660 lb
PRSS6RW13Q300
.052"
990 lb
PRSS6RW13Q450
.052"
1200 lb
PRSS6RW13Q550
P
S
Cu
0.025 max.
0.025 max.
Al *
Fe
0.30 max.
* Total of Cr + Ni + Mo + V shall not exceed 0.50%
Filler Metals
7 2

ER70S-3 Designed for killed or semi-killed steel.

USA
Canada
AWS 5.18-93
ER480S-3
USA
Canada
Class ER70S-3
CWB-CSA W48.4-95
AWS A5.28-93
ER80S-D2
CWB-A5.18
Class ER80S-D2
CWB-CSA W48.4-95
ASME SFA-5.28
CWB-A5.28
ASME SFA-5.18
ER80S-D2 Designed for higher strength

low alloy steel.
Tensile Strength
76,000 psi (520 MPa)
Yield Strength
63,000 psi (435 MPa)
Tensile Strength
100,000 psi (690 MPa)
Elongation in 2"
29%
Yield Strength
85,000 psi (590 MPa)
Charpy V-Notch
50 ft/lb @ -20 oF
(67 J @ -29 oC)
Elongation in 2"
29 %
Charpy V-Notch
100 ft/lb @ -20 oF

(136 J @ -29 oC)
Typical Wire Chemistry (%)
0.06 - 0.12
Mo *
0.15 max.
Typical Wire Chemistry (%)
Mn
1.00 - 1.30
Ni *
0.15 max.
0.06 - 0.12
Mo
0.40 - 0.60
Si
0.50 - 0.70
Ti+Zr *
0.15 max.
Mn
1.70 - 1.95
Ni
0.15 max.
0.50 - 0.80
Ti + Z r
0.15 max.
0.025 max.
Al *
0.020 max.
Si
0.025 max.
Fe
Bal
0.025 max.
Al
0.020 max.
0.025 max.
Fe
Bal
* Total of Cr + Ni + Mo + V shall not exceed 0.50%
Cu
0.30 max.
Wi re Diameter
Package
Part Number
Wi re Diameter
Package
Part Number
0.035"
44 lb
PRSS3RN09P020
0.035"
12 lb spool
PRSD2RN09P006
0.035"
60 lb
PRSS3RN09P027
0.040"
44 lb
PRSS3RN10P020
0.045"
44 lb
PRSS3RN11P020
0.045"
60 lb
PRSS3RN11P027
Cu
0.30 max.
PROSTAR Select MIG Welding Wire

PROSTAR Select MIG Welding Wire features level layer
winding on the spool to help ensure smooth wire feeding
characteristics.
Class
Wi re Diameter
Package
Part Number
ER70S-6
.030"
33 lb
PRSS6RS08P015
ER70S-6
.035"
44 lb
PRSS6RS09P020
ER70S-6
.045"
44 lb
PRSS6RS11P020
ER80S-D2
.035"
44 lb
PRSD2RS09P020
ER80S-D2
.045"
44 lb
PRSD2RS11P020
Filler Metals

7 3
Premium Quality Tw i s t - F ree Robotic Welding Wire

PROSTAR Twist-Free Robotic Welding Wire provides the best
and most logical solution for heavy fabricators who need to
achieve the highest productivity and efficiency in their robotic
and automatic welding operations.
Due to its excellent feedability, PROSTAR Twist-Free Robotic
Welding Wire minimizes burnbacks and bird-nesting, and helps
eliminate arc wander. It also minimizes weld defects due to offseam tracking, and improves weld consistency.
7
Side by Side Performance
Characteristics
PROSTAR Twist-Free Robotic Welding

Wi re aids in controlling an ideal weld bead
size, reducing excess metal, indirect labor
and grinding.
Conventional Welding Wi re
Three dimensional flip and
rotation at the arc
Arc and weld will be at the

tool point of the MIG torch
Oversized
welds
Ideal sized
weld beads
Rough weld surface conditions which

may re q u i re grinding or shot blasting
A smoother
weld
An electrically hot and exposed wire ,

with possible electric shock hazard
An electrically
safer pro d u c t
An accumulation of shop dust

and dirt on the wire
Clean wire
no shop dust and dirt
Package disposal
problems
A completely recyclable and

easy to dispose of package
Typical contact tip wear after

using conventional wire fro m
standard spools. Tip wear is
irregular and contact unreliable,
producing costly spatter (after
100 pounds of wire).
Typical contact tip wear after

using PROSTAR Twist-Free
Robotic Welding Wi re. Tip
wear is uniform, with reliable
p e rf o rmance and longer tip life
(after 300 pounds of wire).
PROSTARs Superior Three-Dimensional Stability from Start to Finish

Demonstrate for yourself:
Bend four inches of the wire at 90
degrees (as shown in the picture).
Firmly hold the wire with your
fingers. Pull out 30 feet of wire,
release the bent wire end and
check the rotation.
Observe the following:
The wire should not rotate more
than 360 degrees in 30 feet. This
will remain the same whether you
test at the beginning, middle or
end of the PROSTAR PAC.
PROSTAR Tw i s t - F ree Robotic Welding Wi re
Filler Metals
7 4

Performance Comparison Between Conventional Welding Wire on Spools

and PROSTAR Tw i s t - F ree Robotic Wire Twist, Helix and Cast
S t a n d a rd spools with twist, helix and 25" (600 mm) cast on the wire
S t a n d a rd spools with twist, helix and 50" (1200 mm) cast on the wire
PROSTAR Twist-Free Robotic Welding Wi re:

no twist, helix or cast per 30 feet tested
Accessory Ordering
Information
A Plastic Dome
(330/660 lb)
Part Number
GPLWPT2X
E
C
Plastic Dome
(990 lb)
Part Number
GPLWPT2
D
C
D Wi re Liner
(order by the foot)
Part Number
PIPWPT5
B Dome Quick
Disconnect Adapter
Part Number
PIPWPT3
C Male Quick
Disconnect Adapter
Part Number
PIPWPT4
E Wi re Feeder
Adapter
Part Number
PIPWPT6
Filler Metals

7 5
Tw i s t - F ree Robotic Wire

Available Packaging
PAC 660
PAC 330
PAC 990
PAC 1200
ER70S-6 PAC 330

(330 lb/150 kg)
ER70S-6 PAC 660

(660 lb/300 kg)
ER70S-6 PAC 990

(990 lb/450 kg)
ER70S-6 PAC 1200

(1200 lb/550 kg)
Wi re Dia.
Part Number
Wi re Dia.
Part Number
Wi re Dia.
Part Number
Wire Dia.
P a rt Number
.030"
PRSS6RW08Q150
.030"
PRSS6RW08Q300
.035"
PRSS6RW09Q450
.035"
PRSS6RW09Q550
.035"
PRSS6RW09Q150
.035"
PRSS6RW09Q300
.040"
PRSS6RW10Q450
.040"
PRSS6RW10Q550
.040"
PRSS6RW10Q150
.040"
PRSS6RW10Q300
.045"
PRSS6RW11Q450
.045"
PRSS6RW11Q550
.045"
PRSS6RW11Q150
.045"
PRSS6RW11Q300
.052"
PRSS6RW13Q450
.052"
PRSS6RW13Q550
.052"
PRSS6RW13Q300
.062"
PRSS6RW16Q450
.062"
PRSS6RW16Q550
ER70S-3 PAC 660 (660 lb/300 kg)
ER70S-3 PAC 990 (990 lb/450 kg)
Wi re Dia.
Part Number
Wi re Dia.
Part Number
.035"
PRSS3RW09Q300
.035"
PRSS3RW09Q450
.045"
PRSS3RW11Q300
.045"
PRSS3RW11Q450
.052"
PRSS3RW13Q300
.052"
PRSS3RW13Q450
.062"
PRSS3RW16Q450
ER80S-D2 PAC 330

(330 lb/150 kg)
ER80S-D2 PAC 660

(660 lb/300 kg)
ER80S-D2 PAC 990

(990 lb/450 kg)
ER80S-D2 PAC 1200

(1200 lb/550 kg)
Wi re Dia.
Part Number
Wi re Dia.
Part Number
Wi re Dia.
Part Number
Wi re Dia.
Part Number
.035"
PRSD2RW09Q150
.045"
PRSD2RW11Q300
.045"
PRSD2RW11Q450
.045"
.052"
PRSD2RW11Q550
PRSD2RW13Q550
Filler Metals
7 6
24/7 Robotic Welding Wire
24/7 Non-Stop Welding Wi re Feeding System
How It Works
The new 24/7 Non-Stop Welding Wire Feeding System is

an automatic switch-over device that provides continuous
supply of welding wire for the robotic operation. Developed
exclusively for the ProStar 1200 lb Welding Wire PACs, this
patent pending system improves efficiency and maximizes
profitability.
A butt-welding machine joins the wire-end of the primary wire

pack to the wire - s t a rt of the next full pack - this process only
takes a few seconds. When the primary pack is empty, the
boom automatically switches from the primary pack to the
reserve pack, without operator intervention. After replacing
the original pack with a new full pack, this operation is then
repeated again and again, allowing a continuous, uninterru p ted supply.
The 24/7 system helps you:
Increase Productivity - eliminate wire pack changeover

downtime (labor and equipment), and repairs caused by
out-of-wire interruptions.
Improve Profitability - allows 24/7 utilization of robots and
automatic setups.
Maximize Savings - particularly useful and convenient in
multi-robot cell operations.
Save Floor Space - wire pack can be located up to 150
feet from the robot cell.
J u s t - I n - Time Inventory - receive your new pack of wire only
when you need it.
Dont Run Out Of Wi re - Just In Ti m e

Praxair offers the convenience and savings of receiving new
packs of wire just before you are running out. A Low Wire
Level Sensor can be installed on the side of the wire packs
and sends a signal to the robot control panel, indicating the
wire is running low. This automatically triggers an e-mail to
Praxairs Customer Service, alerting the need of a new shipment. No hassle, just in time.
Ordering Inform a t i o n
Description
24/7 Boom
24/7 Butt Welder
Low Wi re Level Proximity Sensor
Wi re Liner (plastic)
Wi re Conduit (flat wire mono coil)
Part Number
SID24/7BOOM
SID24/7WELDER
SID24/7SENSOR
PIPWPT5 (order by the foot)
SIDPRSCONDUIT-Y (order by the foot - USA)
(order by the metre - Canada)
Conduit To Robot
Swinging Arm
Butt-Welded Wire Joint
Welding
Wire
Welding
Wire
Filler Metals
Flux-Cored Arc Welding

(FCAW) Wire Solutions
7 7
PROSTAR Premium Quality Tubular Wires

PROSTAR flux-cored and metal-cored wires represent
the latest in tubular wire design and perf o rmance. These
products offer one of the highest levels of consistency, quality
and perf o rmance in todays marketplace. Rigorous inspection
systems ensure that PROSTAR tubular wires exhibit the
same high quality standards on an everyday basis. New
manufacturing technologies provide the ultimate in feedability,
weldability and overall perf o rm a n c e .
Diameters and Packaging
PROSTAR Premium Quality Tubular Wi res are available in a
broad range of diameters (from .030" to 1/8") and in a wide
variety of packages.
PROSTAR Premium Quality Metal-Cored Wi re
The continuing search for improvements has led to the

development of PROSTAR metal-cored tubular welding wire s .
Cleaner strip material with improved surface characteristics,
more accurate filling of the wire core, and tighter controls on
wire sizing all contribute to making PROSTAR tubular wire
the best of class.
These factors also help to provide exceptional feedability with
reduced contact tip wear and superior arc characteristics.
Higher Deposition Efficiency

Higher Productivity
Lower Fume Generation
Improved Sidewall Fusion
Improved Metal Transfer
Better Bead Profile
PROSTAR Premium Quality Flux Cored Wires

Flux-cored arc welding offers many advantages over solid
wires and covered electrodes. Higher deposition rates, better
penetration, improved sidewall fusion, and an enhanced ability
to weld over some mill scale or rust on the plate surface, with
less operator skill, are important advantages of these wires.
Gas-Shielded Flux-Cored Wires
PROSTAR tubular flux-cored wires are used in applications
where the base metal thickness is greater than 1/4" and
where the parts to be welded have poor fit-up or contain
some amount of dirt, oil, rust or mill scale.
Self-Shielded Flux-Cored Wires
Designed for a work environment subject to crosswinds
(i.e. outdoor construction) or for areas where it is difficult to
provide cylinders of shielding gas. PROSTAR self-shielded
cored wires are formulated to produce their own shielding
environment as a result of the decomposition of components
present in the core of the wire and neutralization of the
nitrogen gas.
Product Selection Guidelines

Advantages of Flux-Cored vs.
Solid Electrodes
1. Higher deposition rates in all position welds
2. Better penetration
3. Elimination of cold lap or lack of fusion
4. Vi rtually free from subsurface porosity when welded on
scaled material
Advantages of Flux-Cored vs.
Covered Electrodes
1. Higher deposition rates
2. Higher duty cycles
Advantages of Metal-Cored vs.
Solid Electrodes
1. More productivity
2. Less spatter and rework
3. Improved sidewall fusion and penetration
Advantages of Metal-Cored vs.
Flux-Cored
1. Less spatter and no slag to clean up
2. Higher deposition efficiencies
Filler Metals
7 8
Flux-Cored Arc Welding

(FCAW) Wire Solutions
Premium Quality Tubular Wires
Most Popular Products
Gas-Shielded
Flux-Cored Wi res
AWS Class
Performance
Characteristics
PROSTAR FC-70
E70T-1, E70T-9
Smooth arc, flat bead profile and

wide operating range.
PROSTAR FC-70LF
E70T-1
Less fume and spatter than FC-70.

Bead is slightly more convex.
PROSTAR FC-71LF
E71T-1, E71T-1M
E71T-9, E71T-9M
Smooth arc, low spatter, good allposition characteristics and low

fume with Ar/CO2.
PROSTAR FC71-C
E71T-1, E71T-9
All-position capability with CO2.
PROSTAR FC-71
Supreme
E71T-1, E71T-1M
E71T-12,
E71T-12M
Best welding characteristics,

mechanical pro p e rties and low
fume with Ar/CO2.
Self-Shielded
Flux-Cored Wi res
AWS Class
Performance
Characteristics
PROSTAR FC-SS-11 E71T-11
All-position, for carbon steel

weldments.
PROSTAR FC-SS-GS E71T-GS
All-position, for single pass

welding of coated steels.
M e t a l - C o red
Wi res
AWS Class
Performance
Characteristics
PROSTAR
STARCORE 6
E70C-6M
For general-purpose
application and low fume.
Product Regulatory Approvals
PROSTAR
STARCORE 6LF
E70C-6M
Lower fume and spatter; best

operator appeal and bead shape.
PROSTAR
STARCORE 6LS
E70C-6M
Enhanced mechanical pro p e rties

with 20 ft. lb. at -50 oF achievable.
PROSTAR Tubular Wi res are approved to various worldwide

standards including the American Welding Society (AWS), the
Canadian Welding Bureau (CWB), ABS, DnV and Lloyds.
Filler Metals
Flux-Cored Arc Welding (FCAW) Wire Solutions
7 9
Tubular Wire Comparison Chart

AWS Class
Corex
Dual Shield
H o b a rt
Lincoln
Tri-Mark
C o re
Pre f e rred Gas
FC 7
DS R70
RXR
OS70
TM-72
Flux-Cored
Praxair Mig Mix Gold, C-25
DS R70 Ultra
TR70
Flux-Cored
Praxair Carbon Dioxide
DS 7000
825
OS 71
TM-711M
Flux-Cored
Praxair StarGold C-25
71
OS 71M
TM777
Flux-Cored
Flux-Cored
Praxair Carbon Dioxide
Flux-Cored
Flux-Cored Steel
E70T-1
PROSTAR FC-70
E70T-1
PROSTAR FC-70LF
E71T-1,1M
PROSTAR FC-71M
E71T-1,1M
PROSTAR FC-71LF
DS 7100 Ultra
E71T-1
PROSTAR FC-71C
DS 7100 Ultra
E71T-1,1M
PROSTAR FC-71
SUPREME
DS 7100 Ultra LC
VC 1
AWS Class
OS 71M
Corex
Dual Shield
Hobart
Lincoln
Tri-Mark
Core
Preferred Gas
86R
OS MC710
Met 76
Metal-Cored
Met 70X
Metal-Cored
Metal-Cored Steel
E70C-6M
PROSTAR
STARCORE 6
MC 6
CW 70
E70C-6M
PROSTAR
STARCORE 6LF
MC 6L
CW Ultra
Flux-Cored Gasless Steel

E71T-11
PROSTAR FC-SS-11
SS 11
Coreshield 11
FS 21B
IS NR 211MP TM-121
Flux-Cored
Gasless
E71T-GS
PROSTAR FC-SS-GS
SS 11GS
Coreshield 15
FS 23
IS NR 151
Flux-Cored
Gasless
TM-123
Filler Metals
7 10
Flux-Cored Wires
PROSTAR FC-70
PROSTAR FC-70LF
Specification
E70T-1/1M, E70T-9/9M per AWS A5.20, ASME SFA 5.20,
CWB E492T-9 H8, E492T-9M H8
Specification
E70T-1 H8,E70T-9 H8 per AWS A5.20, ASME SFA 5.20,
CWB E492T-9 H8
Description
ProStar FC-70 offers excellent arc stability over the complete
recommended welding range. Spatter losses are very low,
the slag removes easily and cleanly, and bead appearance is
excellent. High deoxidization enables Pro S t a r FC-70 to weld
over mill scale, rust and other contaminants better than most
T-1 wires. However, this level of deoxidization will also cause
increased hardening as multiple layers are welded, and caution should be exercised in welding thick or highly restrained
joints. ProStar FC-70 is used for single and multiple-pass
welding in the flat and horizontal positions using 100% CO2
or 75% AR/25% CO2 shielding gas.
Description
ProStar FC-70LF is designed for general purpose welding
with minimized fume generation rates utilizing 100% CO2 gas.
ProStar FC-70LF is specially formulated with added deoxidizers to allow you to weld through rust, mill scale and light oil
with minimal need for pre-cleaning. Primarily designed for single or multi-pass welding in the flat and horizontal positions,
ProStar FC-70LF welds mild steel and low allow steels with
very light spatter and particulate fume generation.
Characteristics
Good perf o rmance over the entire range of amperage
More deoxidization than the usual E70T-1 for improved
perf o rmance on rusted and scaled plate
Excellent weld bead configuration on horizontal fillets
An outstanding general purpose E70T-1
Caution should be exercised on heavy multiple-pass
weldments
Typical Mechanical Properties

Tensile Strength
87,000 psi (662 MPa)
Yield Strength
81,000 psi (579 MPa)
Elongation
24%
CV-N @ -20OF
36 ft/lb (49J)
Typical Deposit Composition (%)
C
Mn
Si
P
0.07
1.37
0.61
0.010
Recommended Welding Parameter
Diameter (in)
1/16"
Operating Range
Amp (DCEP)
200-375
Volts
25-29
WFS (in/min)
138-311
ESO
1/2" - 1
Optimum Parameters
Amps
Volts
WFS (in/min)
Diameter
1/16"
3/32"
375
29
311
Weight
60 lb Coil
60 lb Coil
S
0.011
3/32"
350-550
26-36
120-235
3/4" - 1-1/4
550
36
235
P a rt Number
PRSS272019-702
PRSS272029-702
Characteristics
Low Fumes
Flat bead profile with multi-pass fillet welds
Easy slag removal
Resists weld cracking on heavy plate and restrained joints
Very flexible amperage/voltage range

Tensile Strength
86,900 psi (599 MPa)
Yield Strength
78,000 psi (538 MPa)
Elongation
24%
CVN @ 0OF (-18OC)
61 ft/lbs (82J)
CVN @ -20OF (-29OC)
53 ft/lbs (72J)
C
Mn
Si
P
0.24
1.34
0.49
0.013
S
0.10
Recommended Welding Parameters DCEP

Diameter (in)
1/16"
5/64
Operating Range
Amp (DCEP)
170-350
250-550
Volts
25-32
26-32
WFS (in/min)
140-345
110-345
ESO
1/2 - 1"
1/2 - 1"
Optimum Parameters
Amps
Volts
WFS (in/min)
Diameter
1/16"
5/64"
3/32"
350
32
345
Weight
60 lb Coil
60 lb Coil
60 lb Coil
550
32
345
3/32"
350-550
26-36
120-235
3/4 - 1-1/4
550
36
235
P a rt Number
PRSS247019-702
PRSS247025-702
PRSS247029-702
Filler Metals
7 11
Flux-Cored Wires
PROSTAR FC-71M
PROSTAR FC-71LF
Specification
AWS E7QT-1 H8, E71T-1M, H8, per AWS A5.20, ASME SFA
5.20
Specification
E71T-1, E71T-1M, E71T-9, E71T-9M per AWS A5.20, ASME
SFA 5.20, E491T-9-H8, E491T-9M-H8 per CSA W48-01
Description
ProStar FC-71M is a gas shielded flux-cored wire for semiautomatic welding of carbon steels. It can also be used for
welding higher strength steels in applications where E71T-1
filler metal pro p e rties are deemed adequate. The wire is re commended for single and multiple-pass welding in all positions. Its stiff arc action enhances deep penetration and arc
control for out-of-position welding. Arc characteristics are
superior with 75% Ar/25% CO2 gas shielding. ProStar FC71M has a quick-freezing slag which facilitates welding and
the attainment of good bead contour in the vertical up and
o v e rhead positions. Typical applications include shipbuilding
and repair, and general structural and fabrication work.
Description
ProStar FC-71LF is a flux-cored wire that is designed for general purpose fabrication, welding in all positions. It can be
used with either 100% CO2 or 75% AR/25% CO2 shielding
gas, offering a spray type transfer of weld metal. ProStar FC71LF provides good impact strength at low temperatures. It
also has low fume and spatter levels and the slag is easy to
remove.
Characteristics
Eliminates lack of fusion problems in all-position weldments
Higher deposition rates than GMAW wires in out-ofposition welding
Stiff arc transfer for overhead welding
Can be used with straight CO2 or 75% Ar/25% CO2

Tensile Strength
94,000 psi (649 MPa)
Yield Strength
81,000 psi (559 MPa)
Elongation % in 2
28%
Avg. @ 0OF (-18OF)
39 ft/lb (53J)
C
Mn
Si
P
0.10
1.18
0.69
0.010
S
0.006
Typical Welding Parameter

Optimum Parameters
Diameter Position
Amps WFS Volts
0.045"
Flat
320
784
30
Overhead
225
435
26
Ve rtical up
225
435
26
Operating Range
Amps
Volts
200-320
24-30
175-225
24-26
175-225
24-26
Diameter
.045"
Part Number
PRSS248812-729
Weight
33 lb Spool
Characteristics
Low fumes and low spatter
Easy slag removal
Ve ry good out-of-position capabilities

Tensile Strength
87,700 psi (605 MPa)
Yield Strength
79,100 psi (546 MPa)
Elongation % in 2
28%
CVN @ 0OF (-18OC)
70 ft/lb (95J)
CVN @ -20OF (-29OC)
39 ft/lb (53J)
C
Mn
Si
P
0.021
1.30
0.69
0.015
S
0.011

Optimum Parameters
Diameter Position
Amps WFS Volts
0.045"
Flat
320
784
30
Overhead
225
435
26
Ve rtical up
225
435
26
0.052"
Flat
350
565
31
Overhead
250
320
26
Ve rtical up
250
320
26
1/16"
Flat
400
440
31
Overhead
250
310
26
Ve rtical up
250
310
26
Operating Range
Amps
Volts
200-320
24-30
175-225
24-26
175-225
24-26
275-350
26-31
200-250
24-26
200-250
24-26
300-400
27-31
200-250
24-26
200-250
24-26
Diameter
0.045"
0.045"
0.045"
0.052"
1/16"
1/16"
Part Number
PRSS247112-729
PRSS247112-744
PRSS247112-702
PRSS247115-729
PRSS247119-729
PRSS247119-702
Weight
33 lb Spool
44 lb Spool
60 lb Coil
33 lb Spool
33 lb Spool
60 lb Coil
Filler Metals
7 12
PROSTAR FC-71 Supreme

Specification
E71T-1M H8, E71T-12MJ H8 per AWS A5.20, ASME SFA
5.20, CWB E491T-9M-H8
Description
ProStar FC-71 Supreme combines superior welding perf o rmance with outstanding mechanical pro p e rties. ProStar
FC-71 Supreme has exceptional operator appeal for a wire
with superb physical pro p e rties, an arc that is soft and stable,
and low fume levels with virtually no spatter. Even in the
vertical up position, the welds produced with Pro S t a r FC-71
Supreme will have a flat bead profile. This wire is designed for
both single and multiple-pass welding in all positions, using a
shielding gas of 75-85% Ar/15-25% CO2. Typical applications
include shipbuilding, off s h o re stru c t u res and general fabrication where high impact pro p e rties, ease of operation and high
productivity are required.
Characteristics
Low fume levels with virtually no spatter
Good CVN toughness at sub-zero temperatures
No to be used with 100% CO2
Flux-Cored Wires

Tensile Strength
80,000 psi (522 MPa)
Yield Strength
71,000 psi (490 MPa)
Elongation % in 2
29%
CVN @ 0OF (-18OC)
99 ft/lb (134J)
CVN @ -40OF (-40OC)
55 ft/lb (75J)
C
Mn
Si
P
0.06
1.04
0.26
0.011
S
0.014

Optimum Parameters
Diameter Position
Amps WFS Volts
0.035"
Flat
225
784
28
Overhead
175
545
25
Ve rtical Up 175
545
25
0.045"
Flat
320
784
30
Overhead
225
435
26
Ve rtical Up 225
435
26
0.052"
Flat
350
565
31
Overhead
250
320
26
Ve rtical Up 250
320
26
1/16"
Flat
400
440
31
Overhead
250
210
26
Ve rtical Up 250
210
26
Diameter
0.035"
0.045"
0.045"
0.045"
0.045"
0.045"
0.052"
0.052"
0.052"
0.052"
1/16"
1/16"
1/16"
1/16"
Weight
33 lb Spool
10 lb Spool
33 lb Spool
44 lb Spool
60 lb Coil
500 lb Drum
10 lb Spool
33 lb Spool
44 lb Spool
60 lb Coil
33 lb Spool
44 lb Spool
60 lb Coil
500 lb Drum
Ni
0.38
Operating Range
Amps
Volts
175-255
25-28
125-175
23-25
125-175
23-25
200-320
24-30
175-225
24-26
175-225
24-26
275-350
26-31
200-250
24-26
200-250
24-26
300-400
27-31
200-250
24-26
200-250
24-26
Part Number
PRSS283206-729
PRSS283212-722
PRSS283212-729
PRSS283212-744
PRSS283212-702
PRSS283212-713
PRSS283215-722
PRSS283215-729
PRSS283215-744
PRSS283215-702
PRSS283219-729
PRSS283219-744
PRSS283219-702
PRSS283219-703
Filler Metals
7 13
Metal-Cored Wires
PROSTAR STARCORE 6
PROSTAR STARCORE 6LF
Specification
E70C-6M H4 per AWS A5.18, ASME SFA 5.18, CWB E491C6M H4
Specification
E70C-6M H4 per AWS A5.18, ASME SFA 5.18, CWB E492C6M H4
Description
ProStar STARCORE 6 has higher manganese and silicon
levels than solid S-6 wires with slightly lower spatter and
higher strength. The increased deoxidization level allows for
more tolerance of mill scale with fewer root pores. ProStar
STARCORE 6 is recommended for single-pass and multi-pass
welding in flat and horizontal positions with 75 - 92% Ar/CO2
with no detrimental effects at the higher argon levels. The
wetting action is better than solid wire, minimizing cold lap on
heavier sections of steel.
Description
ProStar STARCORE 6LF is a metal-cored wire with lower
fume generation rates than other metal-cored wires. The fume
generation rates are comparable to solid wires while offering
the higher deposition rates of a metal-cored wire. The wire is
recommended for single-pass and multiple-pass welding in
both the flat and horizontal positions. The recommended
shielding is a mixture of argon and carbon dioxide with a minimum of 75% argon and a maximum of 92% argon. Arc characteristics improve with the richer argon gases while fume levels decrease. Pro S t a r STARCORE 6LF has the lowest spatter level of all the ProStar metal-cored wire s .
Characteristics
Higher deoxidizer level than solid wires to improve
perf o rmance on mill scale plate
Better wetting action than solid wire, minimizing cold lap
Superb operator appeal
Good choice to use for short - c i rcuit or pulse applications
Tensile Strength
91,000 psi (628 MPa)
Yield Strength
81,000 psi (559 MPa)
Elongation
27%
CVN @ -20OF (-29OC)
53 ft/lb (72J)
C
Mn
Si
P
0.06
1.64
0.75
0.012
Operating Range
Dia.
Amps
WFS
Volts
0.035" 200-260 550-800 26-30
0.045" 250-350 395-650 29-34
0.052" 300-400 355-640 30-33
1/16" 275-450 185-380 30-33
Diameter
0.035"
0.045"
0.045"
0.045"
0.045"
0.052"
0.052"
0.052"
0.052"
1/16"
1/16"
1/16"
3/32"
Weight
33 lb Spool
33 lb Spool
44 lb Spool
60 lb Coil
500 lb Drum
33 lb Spool
44 lb Spool
60 lb Coil
500 lb Drum
44 lb Spool
60 lb Coil
500 lb Drum
60 lb Coil
S
0.019
Optimum Parameters
ESO
Amps WFS Volts
3/8-5/8 260
800
30
3/8-1/2 350
650
34
3/8-3/4 400
640
33
3/8-3/4 450
380
33
Part Number
PRSS249408-729
PRSS249412-729
PRSS249412-744
PRSS249412-702
PRSS249412-713
PRSS249415-729
PRSS249415-744
PRSS249415-702
PRSS249415-713
PRSS249419-744
PRSS249419-702
PRSS249419-713
PRSS280629-702
Characteristics
Lowest fume level of our cored products
Exceptionally clear arc
Better wetting action than solid wire, minimizing cold lap
Vi rtually slag-free welds reduce clean-up time
Tensile Strength
82,000 psi (566 MPa)
Yield Strength
70,000 psi (483 MPa)
Elongation
29%
CVN @ OF (-18OC)
47 ft/lb (64J)
C
Mn
Si
P
0.04
1.50
0.70
0.008
Operating Range
Dia.
Amps
WFS
Volts
0.035" 200-260 550-800 26-30
0.045" 250-350 395-650 29-34
0.052" 300-400 355-640 30-33
1/16" 275-450 185-380 30-33
Diameter
0.035"
0.035"
0.045"
0.045"
0.045"
0.045"
0.052"
0.052"
1/16"
Weight
33 lb Spool
44 lb Spool
33 lb Spool
44 lb Spool
60 lb Coil
500 lb Dru m
44 lb Spool
60 lb Coil
60 lb Coil
S
0.013
Optimum Parameters
ESO
Amps WFS Volts
3/8-5/8 260
800
30
3/8-1/2 350
650
34
3/8-3/4 400
640
33
3/8-3/4 450
380
33
P a rt Number
PRSS280808-729
PRSS280808-744
PRSS280812-729
PRSS280812-744
PRSS280812-702
PRSS280812-713
PRSS280815-744
PRSS280815-702
PRSS280819-702
Filler Metals
7 14
Flux-Cored Wires Self-Shielded
PROSTAR FC-SS-GS
PROSTAR FC-SS-11
Specification
E71T-GS per AWS A5.20, ASME SFA 5.20
Specification
E71T-11 per AWS A5.20, ASME SFA 5.20
Description
ProStar FC-SS-GS offers extremely high operator appeal in
applications involving thin gauge galvanized or carbon steels.
Arc action is smooth and stable, excellent at low welding currents. DCEN (straight polarity) operation facilitates the welding
of sections as thin as 18 gauge with little tendency for burn
through. Good wetting action makes ProStar FC-SS-GS well
suited for the lap and butt welds encountered in body panel
and sheet metal ductwork. With vertical down welding, bead
g e o m e t ry and appearance are excellent; spatter levels are low.
ProStar FC-SS-GS is outstanding for use in portable welding
systems, as the small diameters perf o rm well on port a b l e
110-volt input welding machines. It is recommended only for
single-pass welding and can be used in all positions using no
shielding gas.
Description
ProStar FC-SS-11 is a versatile wire with excellent operator
appeal because of its smooth arc, low spatter emission and
overall ease of handling. With no shielding gas needed, it is a
good choice for welding in hard-to-reach locations or where
the provision of gas cylinders is not practical. It is a good wire
for applications where windy or other adverse conditions prevail and where mechanical pro p e rties are of less concern.
ProStar FC-SS-11 has little tendency to burn through and is
well suited for butt, fillet and lap joints on steel thicknesses
from 16 gauge to 3/8. It is not recommended for welding
steel thicknesses greater than 3/4. When welding on steels
in the 3/8 to 3/4 thickness range, a preheat temperature of
325OF is advisable. This wire is recommended for single-pass
and limited multiple-pass welding in all positions using no
shielding gas.
Characteristics
Use DCEN (straight polarity), minimizing burn-through
Designed specifically for welding thin gauge galvanized
steels
Single-pass weldments on galvanized and carbon steel
sheet metal from 18 gauge up to 3/16
Ve ry smooth arc, minimal spatter when applied to carbon
steel
Typical Mechanical Pro p e rties
Transverse
87,000 psi (600 MPa)
Tensile Strength
Base metal fracture
Longitudinal Guided
Satisfactory
Bend
Optimum Parameters
Diameter Position
Amps WFS Volts
0.030"
Flat
200
565
18
Overhead
150
300
17
Ve rtical Up
150
300
17
0.035"
Flat
225
450
19
Overhead
175
300
19
Ve rtical Up
175
300
19
0.045"
Flat
250
280
19
Overhead
200
190
19
Ve rtical Up
200
190
19
Diameter
0.030"
0.030"
0.035"
0.035"
0.045"
0.045"
Weight
2 lb Spool
10 lb Spool
2 lb Spool
10 lb Spool
10 lb Spool
33 lb Spool
Operating Range
Amps
Volts
75-200
14-18
75-150
14-17
75-150
14-17
75-225
13-19
75-175
13-19
75-175
13-19
75-250
15-19
100-200
16-19
100-200
16-19
Part Number
PRSS222306-719
PRSS222306-722
PRSS222308-719
PRSS222308-722
PRSS222312-722
PRSS222312-729
Characteristics
Limited multi-pass, all-position wire
Can be used on up to 3/4 thick steel
Can be used with CC power sources, provided that the
power source can produce a low voltage range between
14-19 volts and voltage sensing wire feeders
Uses DCEN polarity
Smooth arc and low spatter emission
Tensile Strength
91,000 psi (628 MPa)
Yield Strength
64,000 psi (442 MPa)
Elongation
21%
C
Mn
Si
P
0.30
0.49
0.15
0.009
Optimum Parameters
Diameter Position
Amps WFS Volts
0.035"
Flat
225
450
19
Overhead
175
300
19
Ve rtical
175
300
19
0.045"
Flat
250
280
19
Overhead
200
190
19
Ve rtical
200
190
19
Diameter
0.035"
0.035"
0.035"
0.045"
0.045"
Weight
2 lb Spool
10 lb Spool
33 lb Spool
10 lb Spool
33 lb Spool
S
0.003
Al
1.18
Operating Range
Amps
Volts
75-225
13-19
75-175
13-19
75-175
13-19
75-250
15-19
100-200
16-19
100-200
16-19
Part Number
PRSS222108-719
PRSS222108-722
PRSS222108-729
PRSS222112-722
PRSS222112-729
Filler Metals
7 15
GTAW (TIG) Solutions

Tungsten Electrodes
Tungsten Operating Range
Air Cooled TIG To rc h
Water Cooled TIG To rc h
Electrode Diameter in (mm)
1/16 (1.60)
3/32 (2.40)
1/8 (3.20)
5/32 (4.00)
1/16 (1.60)
3/32 (2.40)
1/8 (3.20)
5/32 (4.00)
Pure Tungsten AC Curre n t
50
100
150
200
100
160
210
275
Alloyed Tungsten AC Current
70
140
225
300
150
235
325
400
Alloyed Tungsten DEN

or Straight Polarity
70
150
250
400
150
250
400
Alloyed Tungsten DCEP

or Reverse Polarity
10
15
25
40
20
30
40
55
PROSTAR Tungsten Electrodes
Lanthanated Tungsten
Color Code: Gold
Lanthanated tungsten is a non-radioactive substitute for 2% thoriated tungsten. They provide similar perf o rm a n c e
with minimum amount of adjustment of
operating conditions.
Ground finished tungsten electrodes are

cleaned of impurities by centerless
grinding, which is done to produce a
uniform size, to remove surface imperfections, and a more stable arc .
Grade
Color code
Size
1/16
3/32
1/8
5/32
AWS
spec
Pure
Green
PRS40203
PRS40207
PRS40200
Thoria 2%
Red
PRS40204
PRS40208
PRS40201
PRS40210
EWTh-2
Lanthanated 1.5%
Gold
PRS40205
PRS40209
PRS40202
PRS40211
EWLa-1
Ceria 2%
Orange
PRS40216
PRS40218
PRS40212
Zirconia 2%
Brown
SYL1167GZ
SYL3327GZ
SYL187GZ
Pure Tungsten
Color Code: Green
These electrodes are used mainly with
a l t e rnating current (AC) for welding of
aluminum and magnesium alloys. With
this type of current, the tip of the pure
tungsten electrode forms a clean, balled
end, which provides good arc stability.
Pure tungsten is more prone to contamination of the weld than the other types
of tungsten electrodes.
EWP
EWCe-2
SYL5327GZ
EWZi-2
Thoriated Tungsten
Color Code: Red
2% Thoriated tungsten electrodes, are
designed for direct current electrode
negative (DEN) or straight polarity applications. They maintain a sharpened tip
configuration during welding, which is
desirable for the welding of steel, nickel
alloys, and most alloys other than aluminum and magnesium. Thoriated tungsten electrodes are not normally used
with AC welding because it is
difficult to maintain the balled end.
Ceriated Tungsten
Color Code: Orange
Ceriated tungsten is characterized
by ease of starting, good arc stability,
long life, high current capacity and
non-radioactivity. Ceriated electrodes will
operate successfully with AC or DC.
Zirconiated Tungsten
Color Code: Brown
Zirconiated tungsten electrodes have
characteristics that lay between pure
and thoriated electrodes. They are commonly the electrode of choice for AC
welding of aluminum and magnesium
alloys. Zirconiated tungsten combines
the desirable arc stability characteristics
and balled end typical of pure tungsten
along with the higher current capacity
and better arc starting characteristics
of thoriated tungsten electro d e s .
Tungsten Electrode Grinder

TURBO-SHARP III is an enclosed electrode grinder, which
eliminates grinding dust exposure to both the user and the
environment. TURBO-SHARP III comes with a metal carrying
case containing:
Standard head for diameters: .040 (1.0mm), 1/16

(1.6mm), 3/32 (2.4mm) and 1/8 (3.2mm)
Accessory for stationary mounting
Adapter for vacuum cleaning
Pen-style electrode holder
Multi-functional cover
Tools for assembling and replacement of grinding wheel
User instructions
Grinding tungsten electrodes produces dust and can be

radioactive (2% thoriated). TURBO-SHARP III is therefore an
enclosed grinder. The dust is captured and cannot be inhaled
or blown into the environment.
TURBO-SHARP III advantages:
Dust cannot be inhaled
No environmental damage
Can be connected to vacuum system (accessory included
with unit)
Filler Metals
7 16
SMAW (Stick) Solutions Electrodes
Mild Steel Covered Electrode
E
-601 0

Electrode
Tensile Strength in KSI
Position
1 All Position
2 Flat and Horizontal
Coating
Type of Coating
Cellulose Sodium
Cellulose Potassium
Titania Potassium
Iron Powder Titania
Iron Powder Low Hydro g e n
Iron Powder Titania
Coating Code
0
1
3
4
8
4
DCEP Direct Current Electrode Positive
Curre n t
DCEP
ALL
DEN, AC
ALL
DCEP, AC
DCEP, AC
AWS Spec
E6010
E6011
E6013
E7014
E7018
E7024
Lincoln
5P and 5P+
Fleetweld 180
Fleetweld 37
Fleetweld 47
LH70, 73, 75, 78
Jetweld 1, 3
DEN D i rect Current Electrode Negative
Hobart
Pipemaster 60
335A
447A
14A
418, 18AC, 718MC
24
Murex
Pipecraft
6011C
6013 & 6013D
7014
7018MR
7024
PROSTAR
PROSTAR 6011
PROSTAR 6013
PROSTAR 7014
PROSTAR 7018 & 7018 AC
AC Alternating Current
PROSTAR Stick Electrodes
Brand
(AWS Spec)
Diameter
(in)
MS6011
(E6011)
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
MS6013
(E6013)
MS7014
(E7014)
MS7018AC
(E7018)
MS7018
(E7018)
U.S.
5 lb (2.3 kg) boxes
Part Number
PRSED031156
PRSED031157
PRSED031158
PRSED031159
PRSED031160
PRSED031161
PRSED031162
PRSED031163
PRSED031164
PRSED031168
PRSED031169
PRSED031170
PRSED031165
PRSED031166
PRSED031167
Canada
11 lb (5 kg) boxes
Part Number
PRS612-8313
PRS612-8314
PRS612-8315
PRS612-8623
PRS612-8624
PRS612-8625
PRS612-8823
PRS612-8824
PRS612-8825
PRS615-8423
PRS615-8424
PRS615-8425
PRS615-8323
PRS615-8324
PRS615-8325
Lincoln Stick Electrodes 10 Pound Boxes

Brand (AWS Spec)
5P (E6010)
5P+ (E6010)
Fleetweld 180 (E6011)
Low Hydrogen LH70 (E7018)
Diameter (in)
3/32"
1/8"
5/32
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/32
1/8"
3/32"
1/8"
5/32"
Part Number
LINED010210
LINED010202
LINED010215
LINED010282
LINED010277
LINED010284
LINED010108
LINED010103
LINED010113
LINED010159
LINED010151
LINED010164
LINED010188
LINED010182
LINED010566
LINED010560
LINED010574
Lincoln Stick Electrodes 50 Pound Boxes

Brand (AWS Spec)
5P (E6010)
5P+ (E6010)

Jetweld 1 (E7024)
Jetweld 3 (E7024)
Diameter (in)
3/32"
1/8"
5/32"
3/16"
3/32"
1/8"
5/32"
3/16"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/16"
3/32"
1/8"
5/32"
3/16"
3/32"
1/8"
5/32"
3/16"
7/32"
1/4"
1/8"
3/32"
1/8"
5/32"
3/32"
1/8"
5/32"
3/16"
7/32"
1/4"
Part Number
LINED010211
LINED010203
LINED010216
LINED010207
LINED010283
LINED010278
LINED010285
LINED010281
LINED010105
LINED010110
LINED010114
LINED010161
LINED010153
LINED010165
LINED010156
LINED010189
LINED010183
LINED010193
LINED010186
LINED010568
LINED010561
LINED010575
LINED010564
LINED010577
LINED010558
LINED010711
LINED010362
LINED010372
LINED010366
LINED010529
LINED010521
LINED010533
LINED010525
LINED010536
LINED010518
Filler Metals
7 17
SMAW (Stick) Solutions Electrodes

Low Alloy Steel Covered Electrode
E
-801
8-B2

Electrode
Tensile Strength in KSI
Position
1 All Position
Type of Coating
Chemical Composition of
Weld Metal Deposited
AWS Spec
Lincoln
Hobart
Murex
E7018-A1
LH7018-A1
7018-A1
7018-A1
E8018-B2
LH90
8018-B2
E8018-C1
LH8018-C1
8018-C1
E8018-C2
E8018-C3
8018-C2
LH8018-C3
8018-C3
8018-C3 MR
E9018-B3
9018-B3
E9018-B3L
9018-B3L
9018-B3L MR
E9018-M
9018-M
9018-M MR
E10018-D2
10018-D2
E10018-M
10018-M
E11018-M
LH-110M
E12018-M
11018-M
11018-MR
12018-M
AWS Low Alloy Suffix Code

Suffix
Mn
Si
Ni
Cr
Mo
Va
A1
0.12
0.6-1.0*
0.4-0.8*
N/A
N/A
0.4-0.65
N/A
B1
0.12
0.9
0.6-0.8*
N/A
0.4-0.65
0.4-0.65
N/A
B2L
0.05
0.9
0.8-1.0*
N/A
1.0-1.5
0.4-0.65
N/A
B2
0.12
0.9
0.6-0.8*
N/A
1.0-1.5
0.4-0.65
N/A
B3L
0.05
0.9
0.8-1.0*
N/A
2.0-2.5
0.9-1.2
N/A
B3
0.12
0.9
0.6-0.8*
N/A
2.0-2.5
0.9-1.2
N/A
B4L
0.05
0.9
1.0
N/A
1.75-2.25
0.4-0.65
0.05
B5
.07-.15
0.4-0.7
0.3-0.6
N/A
0.5-0.6
1.0-1.25
N/A
C1
0.12
1.20
0.6-0.8*
1.0-2.75
N/A
N/A
N/A
C2
0.12
1.20
0.4-0.8*
3.0-3.75
N/A
N/A
N/A
C3
0.12
0.4-1.25
0.8
0.80-1.10
0.15
0.35
0.05
D1
0.12
1.25-1.75
0.6-0.8*
N/A
N/A
0.25-0.45
N/A
D2
0.15
1.65-2.0
0.6-0.8*
N/A
N/A
0.25-0.45
N/A
N/A
1.0 Min
0.80 Min
0.5 Min
0.3 Min
0.2 Min
0.1 Min
0.10
0.6-2.25*
0.60-0.80*
1.4-2.5*
0.15-1.5*
0.25-0.55*
0.05
* Note: Amount depends on electrode classification. Single values indicate maximum.

Check AWS A5.5 for the different electrode classes.
Filler Metals
7 18
Stainless Steel Wire
Sandvik Stainless Steel Welding Wi res

Specifications
U.S.A.
Canada
AWS 5.9
ASME SFA 5.9
CWB AWS 5.9 - 93
C h e m i s t ry (%)
Filler Metal
308L/308LSi
309L/309LSi
316L/316LSi
C
.025
.025
.025
Mn
1.8
2.0
1.8
Si
0.4-0.8
0.4-0.8
0.4-0.8
Cr
20
24
19
Ni
10
13
12
Mo
2.5
Mechanical Properties
Filler Metal
308L/308LSi
309L/309LSi
316L/316LSi
Yield (psi)
55,000
58,000
60,000
Tensile (psi)
85,000
87,000
88,000
Elongation (%)
37
34
35
Classifications MIG and TIG

Filler Metal
308L, 308LSi
309L, 309LSi
316L, 316LSi
Base Material
302, 304, 304L, 308, 308L
Dissimilar base metals (i.e. mild steel to stainless steel)
304, 304L, 316, 316L
GMAW (MIG) Welding Conditions

S h o rt Arc
Wi re Diameter
.035"
.045"
Wi re Speed (ipm)
150-300
140-280
Amps
60-150
100-210
Voltage
14-21
17-22
Gas Flow (cfh)

30-40
30-40
Gas Recommended
Praxair HeliStar A-1025, HeliStar SS
Praxair HeliStar A-1025, HeliStar SS
Spray Arc
Wi re Diameter
.035"
.045"
Wi re Speed (ipm)
240-470
190-360
Amps
140-250
180-270
Voltage
22-28
24-30
Gas Flow (cfh)

30-40
30-40
Gas Recommended
Praxair StarGold C-2 and O-2
Praxair HeliStar SS
Stainless Steel GMAW (MIG) Wire

308L
Wi re Size
.023"
.030"
.035"
.045"
308LSi
Wi re Size
.023"
.030"
.035"
.039"
.045"
309L
Wi re Size
.035"
.045"
2 lb (1 kg)
SAN308L0232
SAN308L0302
SAN308L0352
SAN308L0452
10 lb (4.5 kg)
SAN308L02310
SAN308L03010
SAN308L03510
SAN308L04510
15 lb (6.8 kg)
SAN308L02315
2 lb (1 kg)
SAN308LSI0232
SAN308LSI0302
SAN308LSI0352
10 lb (4.5 kg)
SAN308LSI02310
SAN308LSI03010
SAN308LSI03510
15 lb (6.8 kg)
SAN308LSI02315
SAN308LSI0452
SAN308LSI04510
33 lb (15 kg)
SAN309L03533
SAN309L04533
309LSi
Wi re Size
.035"
.039"
.045"
33 lb (15 kg)
600 lb Drum (272 kg)
SAN308L03033
SAN308L03533
SAN308L04533
SAN308L045DM
33 lb (15 kg)
SAN308LSI03033
PRS05021
PRS06309
PRS05022
33 lb (15 kg)
PRS05023
PRS06310
PRS05024

SAN309LSI035D
SAN308LSI035D
312
Wi re Size
.035"
.045"
33 lb (15 kg)
SAN31203533
SAN31204533
Filler Metals
7 19
Stainless Steel Wire

Stainless Steel GMAW (MIG) Wire, continued
316L
Wi re Size
.023"
.030"
.035"
.045"
316LSi
Wi re Size
.023"
.030"
.035"
.039"
.045"
2 lb (1 kg)
SAN316L0232
SAN316L0302
SAN316L0352
SAN316L0452
10 lb (4.5 kg)
SAN316L02310
SAN316L03010
SAN316L03510
SAN316L04510
15 lb (6.8 kg)
SAN316L02315
2 lb (1 kg)
SAN316LSI0232
SAN316LSI0302
SAN316LSI0352
10 lb (4.5 kg)
SAN316LSI02310
SAN316LSI03010
SAN316LSI03510
15 lb (6.8 kg)
SAN316LSI02315
SAN316LSI0452
SAN316LSI04510
33 lb (15 kg)
SAN316L03033
SAN316L03533
SAN316L04533
SAN316L045DM
33 lb (15 kg)
SAN316LSI03033
PRS05025
PRS06311
PRS05026
SAN316LSI035D2
Stainless Steel FCAW (Flux-Cored) Wire

308L Series
Wi re Size
.035"
.045"
1/16"
308LT0-4*
33 lb (15 kg)
SAN308LT003533
SAN308LT004533
SAN308LT006333
308LT1-4**
33 lb (15 kg)
316L Series
Wi re Size
.035"
.045"
1/16"
316LT0-4*
33 lb (15 kg)
SAN316LT003533
SAN316LT004533
SAN316LT006333
316LT1-4**
33 lb (15 kg)
309L Series
Wi re Size (in)
.035"
.045"
1/16"
SAN308LT104533
SAN308LT106333
309LT0-4*
33 lb (15 kg)
SAN309LT003533
SAN309LT004533
SAN309LT006333
309LT1-4**
33 lb (15 kg)
SAN309LT104533
SAN309LT106333
Welding Position
* Flat/horizontal
** All position
SAN316LT104533
SAN316LT106333
Stainless Steel GTAW (TIG) Rods 10 lb packs

.035"
.045"
1/16"
3/32"
1/8"
308L
SAN308L035T
SAN308L045T
PRS05012
PRS05013
PRS05014
309L
SAN309L035T
SAN309L045T
PRS05015
PRS05016
PRS05017
312
SAN312035T
SAN312045T
SAN312063T
SAN312093T
SAN312125T
316L
SAN316L035T
SAN316L045T
PRS05018
PRS05019
PRS05020
Stainless Steel SMAW (Stick) Electrodes 10 lb packs

3/32"
1/8"
5/32"
3/16"
308L-16
SAN308L16098
SAN308L16128
SAN308L16157
SAN308L1616
308L-17
SAN308L17098
SAN308L17128
SAN308L17157
SAN308L17187
309L-16
SAN309L16098
SAN309L16128
SAN309L16157
SAN309L16196
309L-17
SAN309L17098
SAN309L17128
SAN309L17157
SAN309L17196
312-16
SAN31216098
SAN31216128
SAN31216157
SAN31216187
316L-16
SAN316L16098
SAN316L16128
SAN316L16157
SAN316L16196
316L-17
SAN316L17098
SAN316L17128
SAN316L17157
SAN316L17196
Hints
Lower carbon in stainless steel
promotes corrosion resistance
The 16 coating is for all positions
while the 17 is for flat
312-16 electrode is an excellent
maintenance electrode for almost
all steel and stainless steel
309 or 312 series can be used to
weld steel to stainless. Never use
the 308 or 316 series for this
application
High silicon reduces grinding requirements but may not be suitable
for some military applications or
when the welds are highly polished
Filler Metals
7 20
Aluminum MIG Welding
AWS Spec E4043 ProStar MIG Wi re

USA
Canada
Wi re Size (in)
1 lb (.45 kg)
14 lb (6.4 kg)/16 lb (7 kg)
0.030
PRS404301030243
0.035
PRS404301035243
3/64
PRS404301047243
20 lb (9 kg)
1 lb (.45 kg)
20 lb (9 kg)
PRS404315030243 (14 lb)
PRSED702608
PRSED702609
PRS404315035243 (16 lb)
PRSED702610
PRSED702611
PRSED702612
PRSED702613
PRS404320047243
1/16
PRS404320062243
PRSED702614
3/32
PRSED702615
AWS Spec E5356 ProStar MIG Wire

USA
Canada
Wi re Size (in)
1 lb (.45 kg)
14 lb (6.4 kg)/16 lb (7 kg)
1 lb (.45 kg)
20 lb (9 kg)
0.030
PRS535601030243
PRS535615030243 (14 lb)
20 lb (9 kg)
PRSED702616
PRSED702617
0.035
PRS535601035243
PRS535615035243 (16 lb)
PRSED702618
PRSED702619
3/64
PRS535601047243
PRSED702620
PRSED702621
PRS535620047243
1/16
PRS535620062243
PRSED702622
3/32
PRSED702623
Typical GMAW Parameters

Wi re Diameter
(in)
Suggested
Amperage (amp)
Suggested
Voltage (volts)
Base Metal
Thickness (in)
Wi re Speed
(ipm)
Consumption
100 ft of weld (lb)
Gas Flow (cfh)
0.030
90
22
0.062
260
1.5
25
0.030
110
23
0.094
320
1.8
25
0.030
130
23
0.125
380
25
0.030
150
24
0.187
430
25
0.035
90
23
0.062
250
1.5
35
0.035
130
24
0.125
360
35
0.035
170
25
0.250
470
35
0.047
110
25
0.094
215
1.8
45
0.047
150
26
0.125
290
45
0.047
190
26
0.250
370
45
0.047
220
27
0.375
430
16
45
0.062
200
26
0.250
190
55
0.062
230
27
0.375
215
16
55
0.062
260
28
0.500
240
30
55
Filler Metals
7 21
Aluminum TIG Welding
AWS Spec R4043 ProStar Tig Rod

USA
CANADA
Wi re Dia.
1 lb
10 lb
10 lb
1/16
PRS404331062243
PRS404336062243
PRSED702631
3/32
PRS404331094243
PRS404336094243
PRSED702633
1/8
PRS404331125243
PRS404336125243
PRSED702632
AWS Spec R5356 ProStar Tig Rod

USA
CANADA
Wi re Dia.
1 lb
10 lb
10 lb
1/16
PRS535631062243
PRS535636062243
PRSED702628
3/32
PRS535631094243
PRS535636094243
PRSED702630
1/8
PRS535631125243
PRS535636125243
PRSED702629
TIG Welding Parameters for Aluminum Tee Joints

Metal
Thickness
(in)
Position
Passes
Required
Travel
Speed
(ipm)
AC Amps
(amp)
Cup
Diameter
(in)
Argon
Flowrate
(cfh)
Volume
used/100 ft
weld
Tungsten
Diameter
(in)
Filler Rod
Diameter
(in)
lbs.
deposited/
100 ft weld
1/16
Flat
80
3/8
20
50
1/16
3/32
1/2
1/16
H&V
80
3/8
20
50
1/16
3/32
1/2
1/16
Overhead
70
3/8
25
62
1/16
3/32
1/2
1/8
Flat
10
150
7/16
20
40
1/8
1/8
1/8
H&V
120
3/8
20
50
3/32
1/8
1/8
Overhead
135
3/8
25
62
3/32
1/8
3/16
Flat
215
1/2
25
62
5/32
5/32
4.5
3/16
H&V
180
7/16
25
62
1/8
5/32
4.5
3/16
Overhead
190
7/16
30
75
5/32
5/32
4.5
1/4
Flat
260
1/2
30
75
3/16
3/16
1/4
H&V
235
1/2
30
75
3/16
3/16
1/4
Overhead
240
1/2
35
87
3/16
3/16
Filler Metals
7 22
Brazing
Brazing Selection Chart
The melting temperature of the filler

metal is greater than 800 oF but less
than the melting temperature of the
base metal. For example: Silver brazing,
depending on the alloy, has a range of
1045 oF to 1700 oF. The alloy bonds the
two metals together when flux, alloy and
adequate heat are applied to a clean
joint with the proper fit-up. Some alloys
require 0.001-0.003 gap in the base
metals, while some work best with a
gap of 0.005. The alloy is drawn into the
joint by capillary action. This requires
more attention to be paid to fit-up, flux,
and heat in order for this process to
be successful.
Base
Metal 1
Base
Metal 2
Brazing Alloy
Flux
Temperature
Copper
Copper
15
None
1190-1475 oF (640-800 oC)
Note: The exception to the flux requirement is Copper-Phosphorus Brazing

Alloys. In copper to copper applications,
no flux is required but you should back
purge the part with nitrogen for an
oxide-free surf a c e .
Soldering
The melting temperature of the filler
metal is less than 800 oF. Caution: Silver
soldering is a term that is commonly
misused to discuss silver brazing. Silver
solders usually consist of Tin and Silver
with a silver content of less than 6%.
To rc h
Air/FG-2
Copper
Brass
15
None
1190-1475 F (640-800 C)
Air/FG-2
Copper
Steel
A56T
Black
1145-1205 oF (620-650 oC)
Oxy/FG-2
Copper
Stainless
50N
Black
1290-1375 F (700-750 C)
Oxy/FG-2
Copper
Cast Iro n
50N
White
1290-1375 oF (700-750 oC)
Oxy/FG-2
Copper
Tool Steel
50N
White
Oxy/FG-2
1290-1375 F (700-750 C)
Brass
Brass
15
White
1190-1475 F (640-800 C)
Air/FG-2
Brass
Steel
A56T
White
1145-1205 oF (620-650 oC)
Oxy/FG-2
Brass
Stainless
50N
Black
1290-1375 F (700-750 C)
Oxy/FG-2
Brass
Cast Iro n
50N
Black
1290-1375 oF (700-750 oC)
Oxy/FG-2
Steel
Steel
17
Nickel Silver
HW 17
1690-1715 F (920-940 C)
Oxy/FG-2
Steel
Stainless
50N
Black
1290-1375 oF (700-750 oC)
Oxy/FG-2
Steel
Cast Iro n
17
Nickel Silver
HW 17
1690-1715 F (920-940 C)
Oxy/FG-2
Stainless
Stainless
50N
Black
1290-1375 oF (700-750 oC)
Oxy/FG-2
Stainless
Cast Iro n
50N
Black
1290-1375 F (700-750 C)
Oxy/FG-2
Cast Iro n
Cast Iro n
17
Nickel Silver
HW 17
1690-1715 oF (920-940 oC)
Oxy/FG-2
Soldering Selection Chart

Base Metal 1
Stainless
Stainless
Copper
Base Metal 2
Stainless
Copper
Brass
Soldering Alloy
Flux
Temperature
o
To rc h
Tin Silver
Acid
430 F (220 C)
Air/FG-2
Tin Antimony
Acid
475 oF (245 oC)
Air/FG-2
Tin Silver
Acid
430 F (220 C)
Air/FG-2
Tin Antimony
Acid
475 oF (245 oC)
Air/FG-2
Tin Silver
Acid
430 F (220 C)
Air/FG-2
Tin Antimony
Acid
475 oF (245 oC)
Air/FG-2
Flame adjustment
For soldering and brazing, use a
carburizing flame. Solders have tensile
strengths of 3,000 to 10,000 psi.
Brazing alloys have tensile strengths
of 50,000 to 90,000 psi.
Caution
Never solder an oxygen line. OSHA
and NFPA require brazing. If the line
is copper, use PROSTAR 15 with a
nitrogen backup at 30 cfh and zero
back pressure.
Filler Metals
7 23

Brazing Alloys and Fluxes
Cadmium-Free Silver Brazing Alloys
PROSTAR Premium Quality Brazing

Alloys and Fluxes are specifically
designed and engineered to meet
the most demanding operations.
Part Number
Brazing Alloy
Packaging
Solidus
Liquidus
WJT59685
A35 Silver
3/64" x 1 T oz. Canister
1150 oF (620 oC)
1350 oF (730 oC)
WJT59687
A45 Silver
1/16" x 50 T oz. Coil
1225 oF (660 oC)
1370 oF (740 oC)
Its extensive product line includes

Copper- P h o s p h o rus and Cadmium-Free
Silver Brazing Alloys and Brazing Fluxes.
WJT59693
A50N Silver
1/16" x 50 T oz. Coil
1220 F (660 C)
1305 oF (710 oC)
PRS59697
PROSTAR A56T Silver
1/16" x 1 T oz. Canister
1145 oF (620 oC)
1205 oF (650 oC)
WJT55043
A56T Silver
1/16" x 50 T oz. Coil
1145 oF (620 oC)
1205 oF (650 oC)
WJT59699
A56T Silver
1/32" x 50 T oz. Coil
1145 F (620 C)
1205 oF (650 oC)
Liquidus
Copper- P h o s p h o rus Brazing Alloys

Part Number
Brazing Alloy
Packaging
Solidus
WJT30979
.050 X 1/8" X 20" 1 lb Tube
1310 oF (710 oC)

o
1460 oF (790 oC)
WJT31221
.050 X 1/8" X 20" 1 lb Tube
1190 F (640 C)
1490 oF (810 oC)
PRS31223
PROSTAR 15
.050 X 1/8" X 20" 1 lb Tube
1190 oF (640 oC)
1475 oF (800 oC)
Silver Brazing Flux and Black Flux

Part Number
Flux
Packaging
PRS75061
PROSTAR Silver Brazing Flux (White)
7 oz. Jar
WJT75062
Silver Brazing Flux (White)
1/2 lb Jar
PRS75063
PROSTAR Silver Brazing Flux (White)
1 lb Jar
WJT75060
Black Flux
1 lb Jar
PROSTAR C a d m i u m - F ree
Silver Brazing Alloys
PROSTAR Copper-Phosphorus
Brazing Alloys
PROSTAR Silver Brazing Flux

and Black Flux
Praxair Tip
A45 is Cadmium free. However, it is a

very sluggish alloy and may not produce
your desired results.
50N is Cadmium-free.
This alloy contains nickel to make it
resistant to inter-granular corrosion
caused by acids leaching out the
zinc content of the brazing alloy.
PROSTAR Cadmium-Free A56T presents equal to or better results than cadium bearing alloys. It is also approved by
the National Sanitary Foundation (NSF)
for parts used in food service.
Filler Metals
7 24
Brazing Alloys
PROSTAR Bronze Brazing Alloys (15 and 15FC)

PROSTAR 15
R-CuZn-C
1 lb (.45 kg)
1/16
PRS61300
3/32
PRS61310
1/8
PRS61320
3 lb (1.2 kg)
PRS61303
PRS61313
PRS61323
5 lb (2.3 kg)
PRS61305
PRS61315
PRS61325
PROSTAR 15FC (Flux Coated)

R-CuZn-C
1 lb (.45 kg)
3 lb (1.2 kg)
1/16
PRS61400
PRS61403
3/32
PRS61410
PRS61413
1/8
PRS61420
PRS61423
No flux is needed for gas welding with R-45 or R-60
PROSTAR Steel Gas Welding Rods
R45 is a general purpose oxy/acetylene rod

for welding mild steels
PROSTAR 45
R-45
1 lb (.45 kg)
1/16
PRS61302
3/32
PRS61312
1/8
PRS61322
3 lb (1.2 kg)
PRS61308
PRS61318
PRS61328
5 lb (2.3 kg)
PRS61309
PRS61319
PRS61329
PROSTAR 60
R-60
1 lb (.45 kg)
1/16
PRS61503
3/32
PRS61513
1/8
PRS61523
3 lb (1.2 kg)
PRS61506
PRS61516
PRS61526
5 lb (2.3 kg)
PRS61507
PRS61517
PRS61527
R60 provides additional strength and ductility

for a variety of steels
Recommended shielding gas: argon or

helium/argon mixtures
E70S-2 is a triple deoxidized filler metal which can

produce x-ray quality when it is used on killed steels
E70S-6 is a silicon manganese deoxidized filler metal that

produces very clean TIG deposits
Recommended shielding gas: argon or

helium/argon mixtures
ERCuSi-A is a silicon deoxidized copper-based filler metal

which is used to attach two pieces of metal together where
strength is secondary and cosmetics are primary.
PROSTAR Steel TIG Welding Rods

E70S-2
1/16"
3/32"
1/8"
1 lb (.45 kg)
PRS61304
PRS61314
PRS61324
3 lb (1.2 kg)
PRS61306
PRS61316
PRS61326
5 lb (2.3 kg)
PRS61307
PRS61317
PRS61327
E70S-6
1/16"
3/32"
1/8"
1 lb (.45 kg)
PRS61404
PRS61414
PRS61424
3 lb (1.2 kg)
PRS61406
PRS61416
PRS61426
5 lb (2.3 kg)
PRS61407
PROSTAR Silicon Bronze TIG Welding Rods

Silicon Bronze
1/16"
3/32"
1/8"
1 lb (.45 kg)
PRS61801
PRS61811
PRS61821
3 lb (1.2 kg)
PRS61803
PRS61813
PRS61823
5 lb (2.3 kg)
PRS61805
PRS61815
PRS61825
Filler Metals
7 25
Maintenance and Repair (M&R) MG Alloys

MG 200 - AC or DC straight polarity (electrode negative)
Recommended for low temperature welding
of cast iron in all positions.
Tensile Strength
Diameter
3/32"
1/8"
5/32"
Amperage
30-70
55-110
75-135
Up to 50,000 psi (35 kg/mm2)

5 lb (2.3 kg)
MGI093425811238
MGI093425811337
MGI093425811436
10 lb (4.5 kg)
MGI093425811344
MGI093425811443
Pro c e d u res Clean weld area if possible. Bevel joint to form a

U groove. A bead hole must be welded at right angles to each
end of all cracks to prevent spreading during welding. Select lowest possible amperage. Maintain a medium long arc with electrode tilted slightly in the direction of travel. Short stringer beads
or narrow weave beads should be used to prevent excessive
heat build-up. When breaking the arc, always fill the crater and
drag rod back over the weld deposit. Peening while still hot will
help to reduce stress. When restriking the arc, start on pre v i o u s l y
deposited weld metal, not on the base material. Allow part to
cool slowly.
MG 210 - AC or DC straight polarity (electrode negative)

Commonly used to weld ductile iron, Ni-Resist and Meehanite
to themselves or to steel. Also suitable for joining nickel alloys to
gray cast iron, malleable cast iron and cast steel.
Tensile Strength
Diameter
3/32"
1/8"
5/32"
Amperage
35-80
65-120
75-140
Up to 80,000 psi (56 kg/mm2)

5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425814239
MGI093425814338
MGI093425814437
MGI093425814345
MGI093425814444
Pro c e d u res Clean weld area if possible. Bevel joint to form a

U groove. A bead hole must be welded at right angles to each
end of all cracks to prevent spreading during welding. Select lowest possible amperage. Maintain a medium long arc with electrode tilted slightly in the direction of travel. Short stringer beads
or narrow weave beads should be used to prevent excessive
heat build-up. When breaking the arc, always fill the crater and
drag rod back over the weld deposit. Peening while still hot will
help to reduce stress. When restriking the arc, start on previously
deposited weld metal, not on the base material. Allow part to
cool slowly.
MG 250 - AC or DC reverse polarity (electrode positive)

Welds can be satisfactorily produced on light and medium-size
casting if there is no severe stress or high phosphorus content
encountered in the parent material.
Specifications
Diameter
3/32
1/8
5/32
Amperage
40-75
65-115
100-150
AWS A5.15 Class ENi-Cl

5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425817230
MGI093425817339
MGI093425817438
MGI093425817346
MGI093425817445
Pro c e d u res In most cases, preheating or postheating will

not be necessary, but in cold weather or when special machining
qualities are desired, the part should be preheated to 400 oF
(204 oC). Stringer beads and intermittent welds should be
employed to reduce stress and cracks; peening while still hot
also helps reduce these problems. Allow part to cool slowly.

Commonly used to weld high-position irons and steels, ductile
iron and high-nickel alloy cast iron.
Specifications
Diameter
3/32
1/8
5/32
Amperage
40-95
70-125
110-160
AWS A5.15 Class ENiFe-Cl

5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425818237
MGI093425818336
MGI093425818435
MGI093425818244
MGI093425818343
MGI093425818442
Procedures
Preheat cast iron parts to 600 oF (326 oC). Steels and other materials usually do not re q u i re preheat unless they are complicated
and contain excessive stresses. Use stringer beads or narro w
weave beads. Remove slag between passes when making multiple layers. Maintain preheat temperature during entire welding
operation; when completed, allow part to cool slowly.

For use on dirty cast iron like sewer pipe, machine bases, transmission or gear housings, sprockets, repair of build-up on gears
and any repair of cast iron to steel.
Tensile Strength
Diameter
3/32"
1/8"
5/32"
Amperage
40-70
70-110
90-130
Up to 75,000 psi (53 kg/mm2)

5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425819234
MGI093425819333
MGI093425819432
MGI093425819241
MGI093425819340
MGI093425819449
Pro c e d u res On heavy sections remove worn, cracked metal

and bevel joint using MG 570 or a grinding wheel. When repairing cracks, drill stop hole at either end to prevent crack travel
while welding. On very heavy sections, preheat to approximately
400 oF. Use short stringer beads for root pass and peen lightly
after removing slag. Use a short to medium arc and the lowest
amperage possible to minimize base metal overheating. When
breaking arc, always back-whip into weld crater. Weaving two
times rod diameter is acceptable for cover beads on multi-pass
work. Weld joints should be allowed to slowly cool for maximum
strength and machinability.
Filler Metals
7 26
Maintenance and Repair (M&R) MG Alloys (cont.)

Used extensively on construction grades, for shipbuilding,
pipelines, boiler plate and cast steel.
Tensile Strength
Yield Strength
Elongation %
Diameter
3/32"
1/8"
5/32"
MG 400 - DC reverse polarity (electrode positive)

Repair of aluminum machining errors and build-up of
missing sections of castings, extrusions, plates, etc.
Tensile Strength
Elongation %
Diameter
3/32"
1/8"
5/32"
Amperage
50-80
80-130
100-160
Up to 34,000 psi (24 kg/mm2)

15-25
5 lb (2.3 kg)
MGI093425834237
MGI093425834336
MGI093425834435
Pro c e d u res Clean weld area. Parts 1/8" or heavier should

be beveled 70o-90o. No preheat is necessary on thin gauges but
faster, flatter, smoother welds are produced on heavier sections if
they are preheated to approximately 400 oF (205 oC). Hold electrode vertical to workpiece, maintain a short arc and fast travel
speed. Use either stringer beads or weaving technique. Remove
slag between passes. Restart arc on existing weld deposits. Allow
p a rt to cool slowly. Chip off all slag before quenching. For complete slag removal use a wire brush with a 10% sulfuric acid and
hot water solution. Rinse with clean hot water.
MG 500 - AC or DC either polarity

Commonly used on applications requiring short, intermittent and
spot welds because of the outstanding re s t a rting characteristics.
Tensile Strength
Yield Strength
Elongation %
Diameter
3/32"
1/8"
5/32"
Amperage
35-80
65-125
90-160
Up to 80,000 psi (56 kg/mm2)

Up to 68,000 psi (47 kg/mm2)
Approx. 24
5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425842232
MGI093425842331
MGI093425842430
MGI093425842249
MGI093425842348
MGI093425842447
Pro c e d u res
Remove as much foreign material as practical from the weld area.
DC reverse polarity (electrode +) produces deep penetration; DC
straight polarity (electrode -) will have limited penetration and a
flatter bead. AC prevents arc blow. A medium arc length should
be maintained with either stringer or weave beads. Slag is easily
removed with a light chipping hammer.
Amperage
60-100
110-150
140-200
76,000 psi (54 kg/mm2)

69,000 psi (49 kg/mm2)
31-33
5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425847237
MGI093425847336
MGI093425847435
MGI093425847244
MGI093425847343
MGI093425847442
Pro c e d u res Area to be welded should be clean and free of

surface contamination such as rust, scale, grease, etc. On DC,
use reverse polarity (electrode +). Preheat of 300 o-450 o should
be employed with heavy sections and hardenable grades of base
metal. For highest x-ray quality, maintain a short arc gap. On vert ical welds, start at bottom and weave slightly while pausing at the
edges. For root passes, set a minimum gap (3/32" for 1/6" electrodes), and run stringer beads. For fill and cover passes, a weaving technique is best employed.
MG 540 - AC or DC reverse polarity (electrode negative)

For tramp and problem steels high in sulphur, phosphorus or
other elements added to improve the machinability of the steel.
Tensile Strength
Diameter
3/32"
1/8"
5/32"
Amperage
60-100
110-150
140-200
Up to 80,000 psi (56 kg/mm2)

5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425849231
MGI093425849248
MGI093425849347
MGI093425849446
Pro c e d u res Area to be welded should be cleaned thoroughly.

Surface contamination must be removed and bevel or chamfer
where required. Maintain close arc length. Vertical joints should
be welded from bottom up, using rapid weave technique. Do not
whip. Use drag technique to make horizontal fillet welds. Slag is
easily removed.
MG Super 600 - AC or DC reverse

polarity (electrode positive)
Due to its exceptional strength and crack resistance, it is ideal for
repairing tools, spring steel, and any dissimilar metal combinations.
Tensile Strength
Yield Strength
Elongation %
Diameter
3/32"
1/8"
5/32"
Amperage
35-70
60-110
75-140
Up to 1,280,000 psi (88 kg/mm2)

(as welded)
Up to 90,000 (63 kg/mm2)
Approx. 32
5 lb (2.3 kg)
10 lb (4.5 kg)
MGI093425857236
MGI093425857335
MGI093425857434
MGI093425857342
MGI093425857441
Pro c e d u res The area in which the weld is to be made should

be free of rust, grease, paint and other materials which cause
weld contamination. A 90o V joint should be used when joining
heavy sections. Preheat is necessary only for high carbon steels,
which should be preheated to 350 oF (204 oC). The interpass
temperature should be kept below 500 oF (260 oC). Alignment
should be maintained by the use of fixtures, tack welds or other
types of mechanical support. Maintain a short arc length and use
stringer beads. Avoid weaving whenever possible.

Filler Metals

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Filler Metals

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Filler Metals

Section 7 Filler Metals

GMAW (MIG) Solutions - Steel

GMAW (MIG) Solutions - Steel - Robotic

FCAW Solutions - Steel

GTAW (TIG) Solutions - Tungsten Electrodes

Tungsten Electrode Grinder

SMAW (Stick) Solutions - Electrodes

Stainless Steel Wire and Rods

Aluminum Wi re (GMAW and GTAW )

Brazing and Soldering Alloys and Fluxes

Maintenance and Repair Electrodes

Gas Metal Arc Welding

It is also available in twist-free robotic containers of

Minimum Mechanical Pro p e rties with CO2

85,000 psi (590 MPa)

Typical Wi re Chemistry (%)

* Total of Cr + Ni + Mo + V shall not exceed 0.50%

Gas Metal Arc Welding

ER70S-3 Designed for killed or semi-killed steel.

Minimum Mechanical Pro p e rties with CO2

ER80S-D2 Designed for higher strength

76,000 psi (520 MPa)

Minimum Mechanical Pro p e rties with CO2

63,000 psi (435 MPa)

100,000 psi (690 MPa)

85,000 psi (590 MPa)

100 ft/lb @ -20 oF

Typical Wire Chemistry (%)

Typical Wire Chemistry (%)

* Total of Cr + Ni + Mo + V shall not exceed 0.50%

PROSTAR Select MIG Welding Wire

Gas Metal Arc Welding

Premium Quality Tw i s t - F ree Robotic Welding Wire

PROSTAR Twist-Free Robotic Welding

Arc and weld will be at the

Rough weld surface conditions which

An electrically hot and exposed wire ,

An accumulation of shop dust

A completely recyclable and

Typical contact tip wear after

Typical contact tip wear after

PROSTARs Superior Three-Dimensional Stability from Start to Finish

PROSTAR Tw i s t - F ree Robotic Welding Wi re

Gas Metal Arc Welding

Performance Comparison Between Conventional Welding Wire on Spools

PROSTAR Twist-Free Robotic Welding Wi re:

Gas Metal Arc Welding

Tw i s t - F ree Robotic Wire

ER70S-6 PAC 330

ER70S-6 PAC 660

ER70S-6 PAC 990

ER70S-6 PAC 1200

ER70S-3 PAC 660 (660 lb/300 kg)

ER70S-3 PAC 990 (990 lb/450 kg)

ER80S-D2 PAC 330

ER80S-D2 PAC 660

ER80S-D2 PAC 990

ER80S-D2 PAC 1200

24/7 Robotic Welding Wire

24/7 Non-Stop Welding Wi re Feeding System

The new 24/7 Non-Stop Welding Wire Feeding System is

A butt-welding machine joins the wire-end of the primary wire

The 24/7 system helps you: