Page 1


ASKAYNAK

Shielded Metal Arc Welding (SMAW) Electrodes Gas Metal Arc Welding (GMAW) Wires and Submerged Arc Welding (SAW) Wires


1th Edition 1998 2nd Edition 2001 3rd Edition 2003 4th Edition 2005 5th Edition 2006

6th Edition 2009


Eczacıbaşı GROUP Eczacıbaşı is an internationally active, health-based Turkish group of companies with a history dating back to the 1940s. Eczacıbaşı is a prominent Turkish industrial group with a combined net turnover of close to $ 3 billion, 40 companies and more than 9,500 employees in 2008. The Eczacıbaşı Group operates in three core divisions ; pharmaceuticals, building materials and consumer products. Increasingly, it is also active in finance, information technology and welding technology.

www.eczacibasi.com.tr


ASKAYNAK Kaynak TekniÄ&#x;i Sanayi ve Ticaret A.Ĺž. Established in 1970, ASKAYNAK become the exclusive distributor of Lincoln Electric's welding machinery and equipment in 1992. In 1998, this relationship become a fully-fledged partnership with the acquisition of a 50 % shareholding in the Company by Lincoln Electric. Lincoln Electric is the world leader in the design, development and manufacture of arc welding products, robotic welding systems, plasma and oxy-fuel cutting equipment. Lincoln Electric has manufacturing operations, joint-ventures and alliances in 20 countries, and a worldwide network of distributors and sales offices covering more than 160 countries. ASKAYNAK produces a wide variety of high-quality welding wires and electrodes under its own brand names of "Askaynak" and "Kobatek". ASKAYNAK line of welding electrodes and wires are mainly used in the manufacturing industry. KOBATEK line primarily consists of welding consumables for maintenance and repair welding applications.


Company Profile ASKAYNAK has constructed a new plant and head office in Gebze, an industry-intensive area of Kocaeli. The new plant encompasses 40 thousand square meters total erea.

ASKAYNAK has an annual capacity of 36,000 tons of stick electrodes, 3,500 tons of submerged arc welding wire and 24,000 tons of MIG/MAG welding wire. As a result, Askaynak's overall capacity is almost 65 thousand tons. ASKAYNAK distributes these products through a network of 600 authorized dealerships throughout Turkey. It has also built up a substantial export network, with exports to more than 40 countries around the world. ASKAYNAK expanded its exports to markets in the Balkans, Caucasus, North Africa, Russia, Ukraine and CIS..


Company Values Customer-Focused Culture : In ASKAYNAK, we have adopted quality as a way of life. In every operation we perform, in every product we produce, and in every service we offer. Our target is the highest quality level and our approach to quality is shaped by our concern for the customer. Continuous Improvement : The pioneering spirit which we have never lost is open to change and globalization. Being innovative in our operations is a long standing tradition. Participation : Our management philosophy rests on the principal of employee participation. We all believe that we have the right to get involved in issues that interest us. We believe that we should continuously improve our personal capabilities to reach the highest levels possible.


Quality Assurance System ASKAYNAK was the first manufacturer of welding consumables in Turkey to recieve ISO 9001 certification, one of the most comprehensive and prestigious international standards for quality systems from RWTÜV in June 1995. This certification was a significant corporate milestone illustrating ASKAYNAK's overall commitment to superior quality and to enhance her operational productivity and efficiency.

ASKAYNAK's strong position in the Turkish market is underpinned by its strong reputation for quality. In 1999, the Company received the prestigious "TÜSİAD-KalDer Quality Award" for Small and Medium-sized Enterprises. International standards including EN, AWS and ISO are used in the production and testing of ASKAYNAK products.


Lloyd Approvals and Certificates ASKAYNAK products have been approved by leading international certification bodies including ; - European Conformity (CE) - Deutsche Bahn (DB) - Rheinish-Westfalischer Technischen Überwachungs Vereine (RWTÜV) - Federal Agency on Technical Regulating and Metrology (GOST) - National Association of Control and Welding (NAKS) - UkrSEPRO Quality Sertificate (SEPRO) - American Bureau of Shipping (ABS) - Bureau Veritas (BV) - Det Norske Veritas (DNV) - Germanischer Lloyd (GL) - Lloyd's Register of Shipping (LRS) - Russian Maritime Register of Shipping (RMRS)

For more information, see page 7 and 8.


AS R-143

AS B-248

AS SG2

AS S1 AS S2 AS S2Mo


"ASKAYNAK" Coated Electrodes ASKAYNAK offers complete solutions by providing a broad range of high performance, superior quality and costeffective coated electrodes specially designed to meet different welding requirement.


"ASKAYNAK" Coated Electrodes ASKAYNAK line of welding products include ; - Rutile coated electrodes for mild steels - Basic coated electrodes for mild steels - Cellulosic coated electrodes - High recovery, iron powder electrodes - Electrodes for high strength, low alloy steels - Electrodes for stainless steels - Electrodes for heat and corrosion resistant steels - Electrodes for non-ferrous metals - Electrodes for cast irons - Electrodes for cutting and gouging - Electrodes for hardfacing


"ASKAYNAK" Welding Wires ASKAYNAK welding wires provide excellent weldability and superior mechanical properties due to a consistent chemical composition, optimum feedability and a smooth, stable arc. - Gas Metal Arc Welding (GMAW) Wires for Mild Steels - Submerged Arc Welding (SAW) Wires


"ASKAYNAK" Welding Wires


Wires Packaging Options Gas Metal Arc (GMA) Welding wires are available in 1 and 5 kg plastic spools, 15 kg basket rims, basket spools and plastic spools and 250 kg ASFIL速 drums. Submerged Arc (SA) Welding wires are available in 30 kg basket rims and 320-350 kg ASFIL速 drums. ASFIL速 drums decrease downtime due to spool changeover and provide a higher degree of accuracy in wire placement at arc start. They are the right answer for fast, efficient and profitable automated welding.

For our standard pallets, see pages 120, 121 and 122. Upon request, any kind packaging can be applicable.


Wires Packaging Options for GMAW

B 300 (15 kg)

BS 300 (15 kg)

S 100 (1 kg)

S 200 (5 kg)

S 300 (15 kg)

ASFIL速 (250 kg) for GMAW


"KOBATEK" Products KOBATEK products provide the customer with a most complete and advanced product range available. By increasing the wear resistance, KOBATEK products help to reduce maintenance periods and spare part inventories. By providing total solutions with an outstanding welding performance, KOBATEK product range minimizes production loses and increases plant efficiency.


"KOBATEK" Products - Electrodes for Cast Irons - Electrodes for High Alloyed Steels - Electrodes for Non-Ferrous Metals - Electrodes for Hardfacing Applications - Flux-cored Wires for Hardfacing Applications - MIG Wires and TIG Rods for Stainless Steels - MIG Wires and TIG Rods for Aluminium Alloys - Silver Brazing Alloys - Hot and Cold System Metal Spraying Powders


COATED ELECTRODES


GMA and SA WELDING WIRES


Table of Contents Electrodes for Unalloyed and Low-Alloyed Steels AWS A5.1 AWS A5.5 *

EN ISO 2560-A

Page

E 7014 E 6013 E 6013 E 6013 E 6013

E 42 0 RR 12 E 42 0 RR 12 E 42 0 RR 12 E 42 0 RC 11 E 38 0 R 12

17 18 19 20 21

E 7018 E 7048 E 7018 E 7018 E 7018-1 E 7016-1

E 46 4 B 32 H10 E 42 2 B 11 E 42 3 B 42 H10 E 42 3 B 42 H5 E 46 5 B 32 H5 E 46 6 B 22

25 26 27 28 29 30

E 6010 E 6011 E 7010-A1 * E 8010-G *

E 42 2 C 21 E 42 2 C 11 E 46 2 Mo C 21 E 46 3 Z C 21

33 34 35 36

E 7024 E 7024

E 46 0 RR 74 E 46 0 RR 74

39 40

Rutile Coated Electrodes AS R-116 AS R-132 AS R-143 AS R-144 AS R-146

Basic Coated Electrodes AS B-204 AS B-235 AS B-248 AS B-248 H5 AS B-255 AS B-268

Cellulosic Coated Electrodes AS S-6010 AS S-6011 AS S-7010 Mo AS S-8010 Ni

High Efficiency Iron Powder Electrodes AS DT-165 AS DT-180

3


Electrodes for Welding High Strength Low Alloyed Steels EN 1599 EN ISO 2560-A ** EN 757 ***

AWS A5.5 AWS A5.4 * AS DA-708 AS DA-710 AS DA-715 AS DA-731 AS DA-735 AS DA-737 AS DA-753 AS DA-771 AS DA-774 AS DA-777 AS DA-778

E 8018-G E 8018-C1 E 8018-C3 H4 E 8013-G E 7018-A1 E 9018-D1 E 11018-G (E 8013-B2) E 8018-B2 E 9018-B3 E 502-15 *

E 42 2 Z B 42 ** E 46 6 2Ni B 42 ** E 50 6 1Ni B 42 H5 ** E Mo R 22 E Mo B 22 E Mo B 22 E 69 5 Mn 2 NiCrMo BT 42 ***

(E CrMo 1 R 12) E CrMo 1 B 22 E CrMo 2 B 22 E CrMo 5 B 42

Page 44 45 46 47 48 49 50 51 52 53 54

Electrodes for Welding Stainless and Heat - Corrosion Resistant Steels AWS A5.4 AS P-307 AS P-308 L AS P-308 Mn AS P-308 Mo AS P-309 L AS P-309 Mo AS P-310 R AS P-312 AS P-316 L AS P-316 S AS P-318 Super AS P-347

E 307-15 E 308 L-16 (E 307-15) E 308 Mo-15 E 309 L-16 E 309 MoL-16 E 310-16 E 312-16 E 316 L-16 (E 316-16) (E 318-16) (E 347-16)

EN 1600

Page

E 18 9 MnMo B 22 E 19 9 LR 12 E 18 8 Mn B 22 E 20 10 3 B 22 E 23 12 LR 12 E 23 12 2 LR 32 E 25 20 R 12 E 29 9 R 12 E 19 12 3 LR 12 E 19 12 3 R 73 E 19 12 3 Nb R 12 E 19 9 Nb R 12

61 62 63 64 65 66 67 68 69 70 71 72

Electrodes for Non-Ferrous Metals AWS A5.3 AS AlSi 5 AS AlSi 12

DIN 1732

E 4043 -

EL-AlSi 5 EL-AlSi 12

AWS A5.6 AS Bronz

DIN 1733

E CuSn-C

EL-CuSn 7

4

Page 77 78 Page 79


Electrodes for Welding Cast Irons Electrodes for Cutting and Gouging AWS A5.15

EN ISO 1071

Page

AS Pik 55 AS Pik 65 AS Pik 98 Super

E NiFe-CI E NiCu-B E Ni-CI

E C NiFe-1 3 E C NiCu-B 3 E Ni-C1 2

84 85 86

AS Oluk Aรงma AS Kesme STARWELD KARBON

-

-

87 88 89

Electrodes for Overlay Welding and Hardfacing

AS SD-CR 10 AS SD-CR 13 AS SD-60 AS SD-65 AS SD-300 AS SD-350 AS SD-HSS AS SD-MANGAN AS SD-MANGAN 165 AS SD-ABRA Nb AS SD-ABRA Cr

EN 14700

DIN 8555

Page

E Fe8 E Fe7 E Fe4 E Fe4 E Fe1 E Fe1 E Fe4 E Fe9 E Fe9 E Fe15 E Fe15

E6-UM-55 R E5-UM-45 R E6-UM-60 E2-UM-60 Z E1-UM-300 E1-UM-350 E4-UM-60 (65) S E7-UM-200 K E7-UM-200 K (E10-UM-60 GR) E10-UM-60 G

93 94 95 96 97 98 99 100 101 102 103

*) hardness after double tempering **) hardness after cold working

5


Gas Metal Arc (GMA) Welding Wires

AS SG2 / ASFİL 250 AS SG3

AWS A5.18

EN 440

Page

ER 70 S-6 ER 70 S-6

G42 3CM G3Si 1 G42 3CM G4Si 1

108 109

Submerged Arc (SA) Welding Wires

AS S1 / ASFİL S1 AS S2 / ASFİL S2 AS EM12K AS S2 Si AS S2 Mo

AWS A5.17 AWS A5.23 *

EN 756

Page

EL 12 EM 12 EM 12 K EM 12 K EA 2 *

S1 S2 S2 Si S2 Si S2 Mo

113 114 115 116 117

6


7

AS R-116 AS R-143 AS R-146 AS B-204 AS B-248 AS B-248 H5 AS B-255 AS S-6010 AS DT-165 AS DT-180 AS DA-735 AS DA-753 AS P-308L - AS P-309L - AS P-316L AS P-308Mn - AS SD-350 AS SG2 (CO 2) AS SG2 (Ar+CO 2) AS S1 (+L860 flux) AS S2 (+L761 flux) AS S2 (+L780 flux) AS S2 (+L860 flux)

Product Name

2 2 3H10, 3Y 3H10, 3Y 3H5, 3Y 3H5, 3Y 3 2 2 X 3SA, 3YSA 3YSA 3M 3M, 3YM 3M, 3YM

ABS

2 2 3YH 3YHH 3YHHH 3YHHH 3 2 2 X 3YM A3M A3YM

BV 2 2 3YH10 3YH5 3YH5 3 2 X III YMS III YMS III M III YM

DNV

Lloyds Approvals for ASKAYNAK Welding Electrodes and Wires

2 3YH15 3YH10 3YH5 3YH5 3 X X 3YS 3YS 3M 3YM 3YM

GL 2m 2m 3m 3Ym H15 3m 3Ym H10 3m 3Ym H5 3m 3Ym H5 3m 2m 3S 3YS H15 3M 3M 3YM

LRS 2 3YH10 3YH5 2 X 3Y42 3Y42

RINA 3Y40HH 3YHHH 3Y -

RMRS


8

All products (except B-248 H5 and Starweld Karbon)

All products (except B-248 H5)

GOST

SEPRO

R-143 ; B-248 ; SG2

DB

B-248 ; B-255 ; B-268 ; SG2

R-143 ; B-248 ; SG2 ; S1 ; S2 ; S2Mo ; P-308L ; P-308Mn

RWTÜV

NAKS

R-116 ; R-143 ; R-146 ; B-204 ; B-248 ; B-248 H5 ; B-255 ; DT-165 ; DT-180 ; S-6010 ; P-308L ; P-308Mn ; P-309L ; P-316L ; SG2 ; S1 ; S2

CE


CONTENTS Rutile Coated Electrodes

1

Basic Coated Electrodes

2

Cellulosic Coated Electrodes

3

High Efficiency Iron Powder Electrodes

4

Electrodes for Welding High Strength Low Alloyed Steels

5

Electrodes for Welding Stainless and Heat - Corrosion Resistant Steels

6

Electrodes for Non-Ferrous Metals Aluminium and its alloys - Copper and its alloys

7

Electrodes for Welding Cast Irons Electrodes for Cutting and Gouging

8

Electrodes for Overlay Welding and Hardfacing

9

GMA Welding Wires

10

SA Welding Wires

11 9


AS R

1

Rutile Coated Electrodes

Product Name

EN ISO 2560-A

AWS A5.1

AS AS AS AS AS

E 42 0 RR 12 E 42 0 RR 12 E 42 0 RR 12 E 42 0 RC 11 E 38 0 R 12

E 7014 E 6013 E 6013 E 6013 E 6013

R - 116 R - 132 R - 143 R - 144 R - 146

11

Page 17 18 19 20 21


C

0.08

0.08

0.08

0.08

0.07

Product Name

AS R - 116

AS R - 132

AS R - 143

AS R - 144

AS R - 146

0.20

0.45

0.35

0.40

0.40

Si

Rutile Coated Electrodes

0.40

0.55

0.65

0.60

0.60

Mn

E 6013

E 6013

E 6013

E 6013

E 7014

AWS A5.1

E 38 0 R 12

E 42 0 RC 11

E 42 0 RR 12

E 42 0 RR 12

E 42 0 RR 12

EN ISO 2560-A

1

12


Electrode Selection

( E CrMo1 R 12 ) *

E CrMo1 B 22 * E CrMo2 B 22 *

E 69 5 Mn 2 NiCrMo BT 42 **

AS DA-771 AS DA-774 AS DA-777

E Mo B 22 *

AS DA-753

E 46 5 B 32 H5 E 46 0 RR 74 E 46 6 2Ni B 42

E 42 3 B 42 H10

E 42 0 RC 11 E 46 4 B 32 H10

E 42 0 RR 12 E 42 0 RR 12

EN ISO 2560-A EN 1599 * EN 757 **

1

Unalloyed Steels High Strength Low Alloyed Steels

St 37-2 St 37-3 St 44-2 St 44-3 St 52-3

1.0308 1.0309 1.0408 1.0418 1.0580 1.0581 1.0507 1.0509

St 35 St 35-4 St-45 St 45-4 St 52 St 52-4 St 55 St 55-4

1.0305 1.0405

St 35-8 St 45-8

1.0484 1.0409 1.0582 1.8970 1.8972 1.8975

St E 290-7 (TM); X42 St E 320-7 (TM); X46 St E 360-7 (TM); X52 St E 385-7 (TM); X56 St E 415-7 (TM); X60 St E 445-7 (TM); X65

AS DA-710 AS DA-735

AS B-248 AS B-255 AS DT-180

AS S series stick electrodes

1.0037 1.0116 1.0040 1.0144 1.0570

AS B-204

BASE METAL

AS R-143 AS R-144

AS R-116

PRODUCT

) No restriction. ) Preheating and mechanical properties should be considered.

13

1


( E CrMo1 R 12 ) *

E CrMo1 B 22 * E CrMo2 B 22 *

E 69 5 Mn 2 NiCrMo BT 42 **

AS DA-771 AS DA-774 AS DA-777

E Mo B 22 *

AS DA-753

E 46 5 B 32 H5 E 46 0 RR 74 E 46 6 2Ni B 42

E 42 3 B 42 H10

EN ISO 2560-A EN 1599 * EN 757 **

E 42 0 RC 11 E 46 4 B 32 H10

1

E 42 0 RR 12 E 42 0 RR 12

2

Unalloyed Steels High Strength Low Alloyed Steels

1.0345 1.0425 1.0481 1.0473 1.0473 1.5415 1.7335 1.7225 1.7380

HI H II H III (St E 255) 17 Mn 4 19 Mn 6 15 Mo 3 13 CrMo 4 4 42 CrMo 4 10 CrMo 9 10

1.0619 1.7354 1.7357 1.7380 1.7218

GS-C 25 GS-22 CrMo 5 4 GS-17 CrMo 5 5 GS-12 CrMo 9 10 GS-25 CrMo 4 A- ; BA- .......... DA- .......... E-

1.0416 1.0443 1.0551 1.0553

GS 38 GS 45 GS 52 GS 60

) No restriction. ) Preheating and mechanical properties should be considered. ) Up to 20 mm. thickness.

14

AS DA-710 AS DA-735

AS B-248 AS B-255 AS DT-180

AS B-204

BASE METAL

AS R-143 AS R-144

AS R-116

PRODUCT


( E CrMo1 R 12 ) *

E CrMo1 B 22 * E CrMo2 B 22 *

E 69 5 Mn 2 NiCrMo BT 42 **

AS DA-771 AS DA-774 AS DA-777

E Mo B 22 *

AS DA-753

E 46 5 B 32 H5 E 46 0 RR 74 E 46 6 2Ni B 42

E 42 3 B 42 H10

E 42 0 RC 11 E 46 4 B 32 H10

EN ISO 2560-A EN 1599 * EN 757 **

E 42 0 RR 12 E 42 0 RR 12

3

Unalloyed Steels High Strength Low Alloyed Steels

1.0301 1.0401 1.0402 1.0406 1.0501 1.0503

C 10 - Ck 10 C 15 - Ck 15 C 22 - Ck 22 C 25 - Ck 25 C 35 - Ck 35 C 45 - Ck 45

1.0461 1.0486 1.0562 1.8902 1.8905 1.8907 1.8926 1.8927 1.8928

St E 255 / St E 26 St E 285 / St E 29 St E 355 / St E 36 St E 420 / St E 43 St E 460 / St E 47 St E 500 / St E 51 St E 550 / St E 56 St E 620 / St E 63 St E 690 / St E 70

1.0462 1.0487 1.0565 1.8930 1.8932 1.8935 1.8937

WSt E 255 / WSt E 26 WSt E 285 / WSt E 29 WSt E 355 / WSt E 36 WSt E 380 / WSt E 39 WSt E 420 / WSt E 43 WSt E 460 / WSt E 47 WSt E 500 / WSt E 51

) No restriction. ) Preheating and mechanical properties should be considered.

15

AS DA-710 AS DA-735

AS B-248 AS B-255 AS DT-180

AS B-204

BASE METAL

AS R-143 AS R-144

AS R-116

PRODUCT

1


( E CrMo1 R 12 ) *

E CrMo1 B 22 * E CrMo2 B 22 *

E 69 5 Mn 2 NiCrMo BT 42 **

AS DA-771 AS DA-774 AS DA-777

E Mo B 22 *

AS DA-753

E 46 5 B 32 H5 E 46 0 RR 74 E 46 6 2Ni B 42

E 42 3 B 42 H10

EN ISO 2560-A EN 1599 * EN 757 **

E 42 0 RC 11 E 46 4 B 32 H10

1

E 42 0 RR 12 E 42 0 RR 12

4

Unalloyed Steels High Strength Low Alloyed Steels

1.0463 1.0488 1.0566 1.8910 1.8912 1.8915 1.8917

TSt E 255 / TTSt E 26 TSt E 285 / TTSt E 29 TSt E 355 / TTSt E 36 TSt E 380 / TTSt E 39 TSt E 420 / TTSt E 43 TSt E 460 / TTSt E 47 TSt E 500 / TTSt E 51

1.6212 1.6217 1.6228

11 MnNi 5 3 13 MnNi 6 3 14 NiMn 6

1.5421 1.6341 1.6343 1.8807 1.6368 1.6780 1.6782 1.6919 1.7279

20 MnMo 3 5 11 NiMoV 5 3 12 MnNiMo 5 5 13 MnNiMo 5 4 15 NiCuMoNb 5 15 NiCrMo 10 6 16 NiCrMo 12 6 11 NiMnCrMo 5 5 16 MnCrMo 3 3

) No restriction. ) Preheating and mechanical properties should be considered.

16

AS DA-710 AS DA-735

AS B-248 AS B-255 AS DT-180

AS B-204

BASE METAL

AS R-143 AS R-144

AS R-116

PRODUCT


AS

R - 116

AS R-116 is a heavily coated rutile electrode. Weld metal has a high resistance to cracking in multipass applications. The slag is easy to remove and it gives high quality, smooth weld beads. It is easy to strike and re-strike and thus an ideal electrode for tacking . It is an easy to use electrode. It has about 100 % metal recovery due to high iron powder content in its coating.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 0 RR 12 AWS A5.1 : E 7014

C

Si

Mn

0.08

0.4

0.6

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

470 550 25 60 @ 0°C 40 @ - 20°C

ABS BV DNV GL LRS

: : : : :

2 2 2 2 2m

CE , GOST , SEPRO

Applications AS R-116 is a general purpose electrode for welding mild steels. Bridging over fairly large gaps that can occur in site welding where preheating is not possible, galvanized plates, rusty or dirty surfaces, ordinary ship's plate of A- and D- quality, automotive bodies and general structural steels are among its application areas. General Structural Steels

: St 33, St 37, St 37-4, St 44, St 44-4, St 52, St 52-4

Fine Grained Steels

: St E 255, St E 420

Elevated Temperature Steels

: St 35.8, St 45.8

Boiler and Pressure Vessel Steels : HI, HII, HIII, 17 Mn 4 Ship Plates

: A-, D- *

Cast Steels

: GS-38, GS-45, GS-52

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 350 350

60 - 100 95 - 145 140 - 190 180 - 245

2120 3190 4830 7410

17

1


AS

R - 132

AS R-132 is a heavily coated rutile electrode. Weld metal has a high resistance to cracking. The slag is easy to remove, and it gives high quality, excellent smooth weld beads. It is easy to strike and re-strike and thus an ideal and easy to use electrode. Basic component quantity is less than AS R-116.

1

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 0 RR 12 : E 6013 AWS A5.1

C

Si

Mn

0.08

0.4

0.6

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

450 550 25 50 @ 0°C

Applications AS R-132 is a general purpose electrode especially used for the welding of medium carbon steels and particularly suitable for butt welding of thin plates and sheet steels. It is also useful for welding mild structural steels and pressure and boiler vessel steels having a tensile strength up to 500 N/mm². Ship's plate of A- quality, automotive bodies and welding of thin plates are among its application areas.

General Structural Steels

: St 33, St 37, St 37-4, St 44, St 44-4, St 52, St 52-4

Fine Grained Steels

: St E 255, St E 420

Elevated Temperature Steels

: St 35.8, St 45.8

Boiler and Pressure Vessel Steels : HI, HII, HIII, 17 Mn 4, 19 Mn 6 Ship Plates

: A-, D-

Cast Steels

: GS-38, GS-45, GS-52

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 450

50 - 110 90 - 140 140 - 190

2140 3450 6670

18


AS

R - 143

AS R-143 is a heavily coated rutile electrode. As its basic component quantity is higher than AS R-116, weld metal properties are superior accordingly. Weld metal has a high resistance to cracking. The slag is easy to remove, and it gives high quality, smooth and excellent weld beads. It is easy to strike and restrike and thus an ideal, easy to use electrode.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 0 RR 12 : E 6013 AWS A5.1

C

Si

Mn

0.08

0.35

0.65

Approvals ABS BV DNV LRS RINA

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

480 550 25 60 @ 0°C 40 @ - 20°C

: : : : :

2 2 2 2m 2

CE , DB , GOST SEPRO , TÜV

Applications AS R-143 is a general purpose electrode especially used for the welding of low and medium carbon structural steels ranging between St 33 and St 52.3. Machinery fabrications, bridge constructions; welding of boiler vessels, automotive bodies, steel furnitures, metal plate works, thin plates and small repairs are among its application areas. General Structural Steels

: St 33, St 37, St 37-4, St 44, St 44-4, St 52, St 52-4

Fine Grained Steels

: St E 255, St E 420

Elevated Temperature Steels

: St 35.8, St 45.8

Boiler and Pressure Vessel Steels : HI, HII, HIII, 17 Mn 4, 19 Mn 6 Ship Plates

: A -, D -

Cast Steels

: GS-38, GS-45, GS-52

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00 4.00 5.00 5.00

300 350 350 350 450 350 450

50 - 70 65 - 90 90 - 140 140 - 200 140 - 190 180 - 240 180 - 230

1050 2070 3230 4770 6690 7550 9910

19

1


AS

1

R - 144

AS R-144 is a rutile-cellulosic coated electrode. It can be used in all positions including verticaldownwards travel. As it is an easy to bend electrode, it brings great convenience to reach in difficult-toreach areas. It has a good penetration respectively. The slag is easy to remove and it is very easy to strike and re-strike.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 0 RC 11 : E 6013 AWS A5.1

C

Si

Mn

0.08

0.45

0.55

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

440 550 25 50 @ 0°C

Applications Welding of boiler vessels, steel constructions, automotive bodies, steel plate works, ordinary ship's plates, some assembly processes, machinery fabrication and welds required in tubular structures are among its application areas. General Structural Steels

: St 33, St 37, St 37-4, St 44, St 44-4, St 52, St 52-4

Fine Grained Steels

: St E 255, St E 420

Elevated Temperature Steels

: St 35.8, St 45.8

Boiler and Pressure Vessel Steels : HI, HII, HIII, 17 Mn 4, 19 Mn 6 Ship Plates

: A-, D-*

Cast Steels

: GS-38, GS-45, GS-52

* It is recommended to use a basic coated electrode in the root pass.

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 350 350

70 - 100 90 - 150 140 - 200 160 - 230

1830 3040 4320 6700

20


AS

R - 146

AS R-146 is a medium coated general purpose rutile electrode. It is a very easy to use electrode. The slag is easy to remove and it gives high quality, smooth weld beads. It is easy to strike and re-strike and thus it is an ideal electrode for tacking .

1

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 38 0 R 12 : E 6013 AWS A5.1

C

Si

Mn

0.07

0.2

0.4

Approvals CE , GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

400 480 25 60 @ 0°C

Applications Welding of structures in thin and medium thick plates in all positions, bridging over the large gaps in steel constructions, welding of galvanized plates are among its application areas. AS R-146 is relatively insensitive to rust and other surface impurities and recommended especially for welding ordinary ship steels and for structural steels having similar mechanical strength and quality.

General Structural Steels

: St 33, St 37, St 37-4, St 44, St 44-4

Elevated Temperature Steels

: St 35.8, St 45.8

Boiler and Pressure Vessel Steels : HI, HII, HIII* Ship Plates

: A-, B-

Cast Steels

: GS-38, GS-45, GS-52*

* It is recommended to use a basic coated electrode in the root pass.

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 350

60 - 100 110 - 140 140 - 200

1990 3190 4790

21


AS B Basic Coated Electrodes

2

Product Name

EN ISO 2560-A

AWS A5.1

Page

AS AS AS AS AS AS

E 46 4 B 32 H10 E 42 2 B 11 E 42 3 B 42 H10 E 42 3 B 42 H5 E 46 5 B 32 H5 E 46 6 B 22

E 7018 E 7048 E 7018 E 7018 E 7018-1 E 7016-1

25 26 27 28 29 30

B - 204 B - 235 B - 248 B - 248 H5 B - 255 B - 268

23


0.06

0.08

0.07

0.07

0.07

0.07

AS B - 235

AS B - 248

AS B - 248 H5

AS B - 255

AS B - 268

C

AS B - 204

Product Name

24

0.50

0.50

0.50

0.50

0.60

0.50

Si

Basic Coated Electrodes

1.10

1.20

0.90

0.90

1.00

1.20

Mn

-

-

-

-

-

P

< 0.03 < 0.03

-

-

-

-

-

S

E 7016-1

E 7018-1

E 7018

E 7018

E 7048

E 7018

AWS A5.1

E 46 6 B 22

E 46 5 B 32 H5

E 42 3 B 42 H5

E 42 3 B 42 H10

E 42 2 B 11

E 46 4 B 32 H10

EN ISO 2560-A

2


AS

B - 204

AS B-204 is a basic coated electrode. It is used particularly to weld rigidly restrained mass structures where high welding stresses are unavoidable. Weld metal has a high resistance to cracking. The slag is easy to remove and it gives very high quality, smooth weld beads. It has 125 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 4 B 32 H10 : E 7018 AWS A5.1

2

C

Si

Mn

0.06

0.5

1.2

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

480 560 30 110 @ - 20°C 80 @ - 40°C

ABS BV GL LRS

: : : :

3H10, 3Y 3Y H 3YH15 3m 3Ym H15

CE , GOST , SEPRO Redrying Temp : 250-400°C / 2-3 hrs

Applications AS B-204 is suitable for steel constructions and machines operating under dynamic forces. Ship building, boiler and pressure vessel manufacturing and pipe connections are among its application areas. It is recommended for the welding of high carbon steels having high P and S content; welding of high strength ship's plate of A-, D- and E- quality and vessel plates of 17 Mn 4 and 19 Mn 5 type. AS B-204 is also suitable for welding thin plates in the small diameters. General Structural Steels

: St 33, St 34, St 37, St 42, St 44, St 52

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00 5.00

300 350 350 450 450

50 - 80 75 - 110 110 - 150 150 - 190 170 - 240

1500 2390 3860 7260 10440

25


AS

B - 235

AS B-235 is a basic coated electrode especially designed for welding in vertical downwards position, with a relatively large diameter electrode, at a very high travelling speed and high current. Thus, it can replace cellulosic coated electrodes in some circumstances. Weld metal has a high resistance to cracking.

Classification and Typical Weld Metal Composition (%)

2

EN ISO 2560-A : E 42 2 B 11 AWS A5.1 : E 7048

C

Si

Mn

0.08

0.6

1.0

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

460 560 30 80 @ - 20°C

Redrying Temp : 250-400°C / 2-3 hrs

Applications AS B-235 is especially suitable for steel constructions and machines operating under dynamic forces. Ship building, boiler and pressure vessel manufacturing and pipe connections are among its application areas. It is recommended for the welding of high carbon steels having high (P) and (S) content; high strength ship's plate of A-, D- and E- quality and also for low alloyed and structural steels of similar strength with the electrode. General Structural Steels

: St 33, St 34, St 37, St 42, St 44, St 52

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00

350 350

110 - 150 140 - 200

3020 4480

26


AS

B - 248

AS B-248 is a basic coated electrode. It is used particularly to weld rigidly restrained mass structures where high welding stresses are unavoidable. Weld metal has a high resistance to cracking. The slag is easy to remove and it gives excellent quality, smooth weld beads. It is also suitable for welding in vertical upwards position at a high welding speed. It has 125 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 3 B 42 H10 : E 7018 AWS A5.1

2

C

Si

Mn

0.07

0.5

0.9

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] [ Joule ] Impact (ISO-V)

: : : :

460 530 28 110 @ - 30°C 80 @ - 40°C

ABS BV DNV GL LRS RINA RMRS

: : : : : : :

3H10, 3Y 3Y HH 3 YH10 3YH10 3m 3Ym H10 3YH10 3Y40HH

CE , DB , GOST , NAKS SEPRO , TÜV

Applications

Redrying Temp : 250-400°C / 2-3 hrs

AS B-248 is suitable for steel constructions and machines operating under dynamic forces. Ship building, boiler and pressure vessel manufacturing and pipe connections are among its application areas. It is recommended for the welding of high carbon, high strength low alloyed steels having high (P) and (S) content; high strength ship's plate of A-, D- and E- quality and vessel plates of 17 Mn 4 and 19 Mn 5 type. AS B-248 can join steel parts to steel casts and can be used in welding of thick parts. It is suitable for the root pass and welding in difficult positions. It gives excellent weld beads with high impact strength values at subzero temperatures. It is also very suitable for welding of GALVANIZED plates. General Structural Steels

: St 34, St 37, St 42, St 44, St 52, C 55, Ck 55

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52, GS-60, GS-62

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00 5.00

300 350 350 450 450

50 - 80 80 - 110 110 - 145 130 - 190 190 - 245

1400 2420 3800 7230 10700

27


AS

B - 248 H5

AS B-248 H5 is a basic coated electrode. It is used particularly to weld rigidly restrained mass structures where high welding stresses are unavoidable. Weld metal has a high resistance to cracking. The slag is easy to remove and it gives excellent quality, smooth weld beads. It is also suitable for welding in vertical upwards position at a high welding speed. It has 125 % metal recovery.

Classification and Typical Weld Metal Composition (%)

2

EN ISO 2560-A : E 42 3 B 42 H5 : E 7018 AWS A5.1

C

Si

Mn

0.07

0.5

0.9

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] [ Joule ] Impact (ISO-V)

: : : :

460 530 28 110 @ - 30°C 80 @ - 40°C

ABS BV DNV GL LRS

: : : : :

3H5, 3Y 3Y HHH 3 YH5 3YH5 3m 3Ym H5

CE Redrying Temp : 350-400°C / 2-3 hrs

Applications AS B-248 H5 is suitable for steel constructions and machines operating under dynamic forces. Ship building, boiler and pressure vessel manufacturing and pipe connections are among its application areas. It is recommended for the welding of high carbon, high strength low alloyed steels having high (P) and (S) content; high strength ship's plate of A-, D- and E- quality and vessel plates of 17 Mn 4 and 19 Mn 5 type. AS B-248 H5 can join steel parts to steel casts and can be used in welding of thick parts. It is suitable for the root pass and welding in difficult positions. It gives excellent weld beads with high impact strength values at subzero temperatures. It is also very suitable for welding of GALVANIZED plates. General Structural Steels

: St 34, St 37, St 42, St 44, St 52, C 55, Ck 55

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52, GS-60, GS-62

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00 5.00

300 350 350 450 450

50 - 80 80 - 110 110 - 145 130 - 190 190 - 245

1400 2420 3800 7230 10700

28


AS

B - 255

AS B-255 is a basic coated electrode. Weld metal has high impact strength at low temperatures. As the weld metal is very resistant to hot cracking, it is used particularly to weld rigidly restrained mass structures where high welding stresses are unavoidable. The slag is easy to remove and it gives very high quality, smooth weld beads. It has 125 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 5 B 32 H5 AWS A5.1 : E 7018-1 H4

2

C

Si

Mn

0.07

0.5

1.2

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

480 580 30 180 @ - 20°C 120 @ - 40°C

ABS BV DNV GL LRS RINA RMRS

: : : : : : :

3H5, 3Y 3Y HHH 3 YH5 3YH5 3m 3Ym H5 3YH5 3YHHH

CE , GOST , NAKS , SEPRO Redrying Temp : 300-400°C / 2-3 hrs

Applications AS B-255 is especially suitable for fine grained structural steels having high yield strength values. It is designed for steel constructions and machines operating under dynamic forces at low temperatures. Welding of ship's plate of A-, D- and E- quality, boiler and pressure vessel manufacturing and pipe connections are among its application areas. AS B-255 can join steel parts to steel casts and can be used in the welding of thick parts. It is suitable for the root pass and welding in difficult positions. It gives excellent weld beads with high impact strength values at subzero temperatures. General Structural Steels

: St 34, St 37, St 42, St 44, St 52, St 70, C 60, Ck 60

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52, GS-60, GS-70

Current Type : [ DC (+) / AC min. 65 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

80 - 110 110 - 145 140 - 190 180 - 240

2460 3890 7310 10640

29


AS

B - 268

AS B-268 is a basic coated electrode. It gives excellent quality, smooth and homogeneous weld beads with a very low impurity (like P and S) content. It guarantees a yield strength value up to 430 N/mm² for medium and high strength steels. ø 2.5 or ø 3.25 mm electrode selection in the root pass brings homogeneous weld beads due to full penetration, which brings great advantage in special welding applications.

Classification and Typical Weld Metal Composition (%)

2

EN ISO 2560-A : E 46 6 B 22 AWS A5.1 : E 7016-1

C

Si

Mn

S

P

0.07

0.5

1.1

< 0.03

< 0.03

Approvals GOST , NAKS , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

460 550 30 240 @ 0°C 240 @ - 20°C

180 @ - 40°C 120 @ - 60°C

Redrying Temp : 250-400°C / 2-3 hrs

Applications AS B-268 is designed for steel constructions and machines operating under dynamic forces. Ship building, boiler and pressure vessel manufacturing and pipe connections are among its application areas. It is recommended for the welding of high carbon, high strength low alloyed steels having high (P) and (S) content; high strength ship's plate of A-, D- and E- quality and vessel plates of 17 Mn 4 and 19 Mn 5 type. AS B-268 can join steel parts to steel casts and can be used in the welding of thick parts. It is suitable in the root pass and recommended especially in applications where high impact values are required at -30 or -40 °C. General Structural Steels

: St 33, St 34, St 37, St 42, St 44, St 52

Fine Grained Steels

: St E 255 - St E 420 ; WSt E 255 - WSt E 420 : TSt E 255 - TSt E 420

Pipe Materials Boiler and Pressure Vessel Steels Elevated Temperature Steels Ship Plates Cast Steels

: : : : :

St E 240-7, St E 290-7, St E 360-7 ; 5LX42 - 5LX60 HI, HII, HIII, 17 Mn 4, 19 Mn 6 St 35.8, St 45.8 A-, D-, E-, AH-, DH-, EH GS-38, GS-45, GS-52

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 450

70 - 110 100 - 140 140 - 180

2080 3250 5940

30


AS S Cellulosic Coated Electrodes

3

Product Name

EN ISO 2560-A

AWS A5.1 AWS A5.5 *

Page

AS AS AS AS

E 42 2 C 21 E 42 2 C 11 E 46 2 Mo C 21 E 46 3 Z C 21

E 6010 E 6011 E 7010-A1 * E 8010-G *

33 34 35 36

S - 6010 S - 6011 S - 7010 Mo S - 8010 Ni

31


C

0.08

0.09

0.08

0.10

Product Name

AS S - 6010

AS S - 6011

AS S - 7010 Mo

AS S - 8010 Ni

0.30

0.10

0.30

0.20

Si

Cellulosic Coated Electrodes

1.10

0.70

0.60

0.60

Mn

-

0.50

-

-

Mo

0.20

-

-

-

Ni

-

-

-

-

Cr

-

-

-

-

V

E 8010-G *

E 7010-A1 *

E 6011

E 6010

AWS A5.1 AWS A5.5 *

3

32

E 46 3 Z C 21

E 46 2 Mo C 21

E 42 2 C 11

E 42 2 C 21

EN ISO 2560-A


AS

S - 6010

AS S-6010 is an easy to strike cellulosic coated electrode. Excellent molten pool control due to easilyremovable, low-volume slag and gaseous arc shielding eliminates porosity problems in weld beads. In all positions, it enables weld beads of high penetration and it minimizes problems that frequently occur in the welding of rusty or oily steels.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 2 C 21 : E 6010 AWS A5.1

C

Si

Mn

0.08

0.2

0.6

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

420 530 25 45 @ - 29°C

ABS BV DNV GL LRS

: : : : :

3 3 3 3 3m

CE , GOST , SEPRO

Applications Site welding of pipe and pipelines carrying natural gas, crude petroleum or alike; ship building; storage tanks, boiler and pressure vessel manufacturing, steel and bridge constructions are among its application areas. AS S-6010 can be used in applications requiring high penetration . It can be used for root and deposition pass and also for pipe connections of 5LX46 grade line pipes. AS S-6010 is an ideal electrode for welding in vertical downwards position. General Structural Steels Pipe Materials

Pressure Vessel Steels Ship Plates Cast Steels

: St 33, St 34, St 37, St 42, St 44, St 52 : St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52 St E 210-7, St E 240-7, St E 290-7, St E 360-7 5LX42, 5LX46, 5LX52 : HI, HII, HIII, 17 Mn 4 : A-, B-, C-, D-, E: GS-38, GS-45

Current Type : [ DC (+) ] Diameter/Length [ mm ] 2.50 x 350 3.25 x 350 4.00 x 350 5.00 x 350

Welding Positions

[ Root Pass ]

Current [ A ] [ Hot Pass ] [ Cover Pass ]

40 - 80 80 - 100 110 - 130 -

100 - 125 115 - 140 160 - 185

33

80 - 100 110 - 130 140 - 160

3


AS

S - 6011

AS S-6011 is an easy to strike cellulosic coated electrode. Arc welding may be done with either AC or DC current. Excellent molten pool control due to easily-removable, low-volume slag and gaseous arc shielding eliminates porosity problems in weld beads. In all positions, it enables notch-free, smooth weld beads of high penetration. It also minimizes problems that frequently occur in the welding of rusty or oily steels.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 2 C 11 AWS A5.1 : E 6011

3

C

Si

Mn

0.09

0.3

0.6

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

420 540 25 45 @ - 29°C

Applications Site welding of pipe and pipelines made particularly from unalloyed structural steels; ship building; storage tanks, boiler and pressure vessel manufacturing and steel constructions are among its application areas. AS S-6011 can be used in applications requiring high penetration . It can also be used for the root and deposit pass. As it is an easy to bend electrode, it brings great convenience to reach in difficult-to-reach areas. AS S-6011 is an ideal electrode for welding in vertical downwards position. General Structural Steels Pipe Materials

Pressure Vessel Steels Ship Plates Cast Steels

: St 33, St 34, St 37, St 42, St 44, St 52 : St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52 St E 240-7, St E 290-7, St E 310-7, St E 360-7 5LX42, 5LX46, 5LX52 : HI, HII, HIII, 17 Mn 4 : A-, B-, C-, D-, E: GS-38, GS-45

Current Type : [ AC min. 50 V / DC (+) ] Diameter/Length [ mm ] 2.50 x 350 3.25 x 350 4.00 x 350

Welding Positions

[ Root Pass ]

Current [ A ] [ Hot Pass ] [ Cover Pass ]

40 - 80 80 - 100 110 - 130

100 - 125 115 - 140

34

80 - 100 110 - 130


AS

S - 7010 Mo

AS S-7010 Mo is a cellulosic coated electrode. It has 0.5 % Mo content. Excellent molten pool control due to easily-removable slag and gaseous arc shielding eliminates porosity problems in weld beads which have good mechanical properties. In all positions, it enables notch-free, smooth weld beads of high penetration.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 2 Mo C 21 AWS A5.5 : E 7010-A1

C

Si

Mn

Mo

0.08

0.1

0.7

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

480 600 25 50 @ - 20°C 40 @ - 30°C

Applications It is especially designed for the site welding of higher strength pipe and pipelines with 0.5 % Mo, that carry content carrying natural gas, crude petroleum or alike. It is particularly used on pipe steels in the 5LX52 - 5LX56 range. Ship building; storage tanks, and boiler and pressure vessel manufacturing are among its application areas. AS S-7010 Mo is an ideal electrode for welding in vertical downwards position. General Structural Steels Fine Grained Steels Pipe Materials

Pressure Vessel Steels Ship Plates Cast Steels

: St 33, St 34, St 37, St 42, St 44, St 52-3 : St E 255 - St E 355, WSt E 255 - WSt E 355 : St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52 St E 290-7, St E 360-7, St E 385-7, St E 415-7 5LX42, 5LX46, 5LX52, 5LX56, 5LX60 : HI, HII, HIII, HIV, 17 Mn 4, 19 Mn 5, 15 Mo 3 : A-, B-, C-, D-, E: GS-38, GS-45

Current Type : [ DC (+) ] Diameter/Length [ mm ] 3.25 x 350 4.00 x 350

Welding Positions

[ Root Pass ]

Current [ A ] [ Hot Pass ] [ Cover Pass ]

80 - 100 110 - 130

100 - 125 115 - 140

35

80 - 100 110 - 130

3


AS

S - 8010 Ni

AS S-8010 Ni is an easy to strike cellulosic coated electrode that provide the highest impact notch toughness values among our range of cellulosic coated electrodes. Due to its higher mechanical properties, it is useful for the root and deposit pass of large diameter pipe connections having high yield strength. In all positions, it enables notch-free, smooth weld beads of high penetration. It enables excellent molten pool control due to easily-removable, low-volume slag.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 3 Z C 21 : E 8010-G AWS A5.5

3

C

Si

Mn

Ni

0.1

0.3

1.1

0.2

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

480 600 24 60 @ - 20°C 50 @ - 30°C

Applications AS S-8010 Ni can be used in the site welding of pipe and pipelines made particularly from low alloyed high strength steels. Site welding of pipe steels in the 5LX60 - 5LX70 range is a good example to application areas. AS S-8010 Ni is an ideal electrode for welding in vertical downwards position.

Generally used for pipe materials welding. Pipe Materials

: St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52-4 St E 360-7, St E 385-7, St E 415-7, St E 445-7, St E 480-7 5LX46, 5LX52, 5LX56, 5LX60, 5LX65, 5LX70

Current Type : [ DC (+) ] Diameter/Length [ mm ] 2.50 x 350 3.25 x 350 4.00 x 350 5.00 x 350

Welding Positions

[ Root Pass ]

Current [ A ] [ Hot Pass ] [ Cover Pass ]

40 - 80 80 - 100 110 - 130 -

90 - 120 120 - 140 140 - 170

36

80 - 100 110 - 130 140 - 160


AS DT High Efficiency Iron Powder Electrodes

4

Product Name

EN ISO 2560-A

AWS A5.1

AS DT - 165 AS DT - 180

E 46 0 RR 74 E 46 0 RR 74

E 7024 E 7024

37

Page 39 40


0.08

0.08

AS DT-180

C

AS DT-165

Product Name

0.45

0.40

Si

0.90

0.70

Mn

High Efficiency Iron Powder Electrodes

E 7024

E 7024

AWS A5.1

4

38

E 46 0 RR 74

E 46 0 RR 74

EN ISO 2560-A


AS

DT - 165

AS DT-165 is a heavily coated, high efficiency rutile iron powder electrode. It gives a metal recovery of about 165 % due to high iron powder content in its coating. It is particularly suitable for fillet welding of thick plates. It gives smooth weld bead appearance with a soft arc. The slag is easy to remove.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 0 RR 74 : E 7024 AWS A5.1

C

Si

Mn

0.08

0.4

0.7

Approvals

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

ABS : 2 BV : 2 RINA : 2 CE , GOST , SEPRO

500 580 24 60 @ 0°C

4

Applications It is used for the welding of medium carbon and mild steels. AS DT-165 is an ideal electrode particularly used for welding vertical-horizontal fillets. Weld metal goes well up the vertical plate giving a good transition to the base metal without undercutting, even at high currents. Machinery fabrication and ship building where smooth weld beads are required; boiler and pressure vessel manufacturing; automotive bodies and steel and bridge constructions are among some application areas where AS DT-165 is extensively used as it brings high efficiency in terms of welding cost. General Structural Steels Fine Grained Steels Pipe Materials Pressure Vessel Steels Ship Plates Cast Steels

: St 34, St 37, St 42, St 44, St 52 *, C 10 - C 22 : St E 255 - St E 420, WSt E 255 - WSt E 420 : St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52 St E 290-7, St E 360-7, 5LX42, 5LX46, 5LX52 : HI, HII, HIII *, 17 Mn 4, 19 Mn 6 : A-, B-, C-, D- * : GS-38, GS-45, GS-52 *

*) It is recommended to use a basic coated electrode in the root pass.

Current Type : [ AC min. 70 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 450 450 450

85 - 125 130 - 155 170 - 240 250 - 310

3000 6540 10050 14920

39


AS

DT - 180

AS DT-180 is a heavily coated, high efficiency rutile iron powder electrode. It gives a metal recovery of about 180 % due to high iron powder content in its coating. It is particularly suitable for GRAVITY WELDING of thick plates. It gives smooth weld bead appearance with a soft arc. The slag is easy to remove. As the electrode length is 700 mm, it enables uninterrupted welding with large and long welding beads.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 0 RR 74 : E 7024 AWS A5.1

4

C

Si

Mn

0.08

0.45

0.9

Approvals ABS BV DNV LRS

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

500 560 25 60 @ 0°C

: : : :

2 2 2 2m

CE , GOST , SEPRO

Applications It is used for the welding of mild steels having a maximum tensile strength of 440 N/mm², and for ordinary ship's plate of A- and D- quality. AS DT-180 is an ideal electrode particularly used for fillet and butt joints in flat and horizontal positions. Machinery fabrication and ship building where smooth weld beads are required; boiler and pressure vessel manufacturing; automotive bodies and steel and bridge constructions are among some application areas where AS DT-180 is extensively used. It brings high efficiency as it is a very fast electrode with a very high deposition rate. General Structural Steels Fine Grained Steels Pipe Materials Pressure Vessel Steels Ship Plates Cast Steels

: St 34, St 37, St 42, St 44, C 10 - C 22 : St E 255 - St E 420 : St 35, St 35-4, St 35-8, St 45, St 45-4, St 45-8, St 52 * St E 290-7, 5LX42, 5LX46 : HI, HII, 17 Mn 4, 19 Mn 6 : A-, B-, C-, D- * : GS-38, GS-45, GS-52 *

*) It is recommended to use a basic coated electrode in the root pass.

Current Type : [ AC min. 70 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

4.00 5.00

700 700

180 - 230 250 - 320

16900 25530

40


AS DA Electrodes for Welding High Strength Low Alloyed Steels

5

Product Name

EN 1599 EN ISO 2560-A * EN 757 **

AWS A5.5 AWS A5.4 *

AS AS AS AS AS AS AS AS AS AS AS

E 42 2 Z B 42 * E 46 6 2Ni B 42 * E 50 6 1Ni B 42 H5 * E Mo R 22 E Mo B 22 E Mo B 22 E 69 5 Mn 2 NiCrMo BT 42 ** (E CrMo 1 R 12) E CrMo 1 B 22 E CrMo 2 B 22 E CrMo 5 B 42

E 8018-G E 8018-C1 E 8018-C3 H4 E 8013-G E 7018-A1 E 9018-D1 E 11018-G (E 8013-B2) E 8018-B2 E 9018-B3 E 502-15 *

DA - 708 DA - 710 DA - 715 DA - 731 DA - 735 DA - 737 DA - 753 DA - 771 DA - 774 DA - 777 DA - 778

41

Page

44 45 46 47 48 49 50 51 52 53 54


42

0.40

0.40

0.30

0.50

0.40

0.50

0.05

0.06

0.06

0.05

0.05

AS DA - 753

AS DA - 771

AS DA - 774

AS DA - 777

AS DA - 778

0.30

0.06

0.08

AS DA - 731

0.35

AS DA - 737

0.05

AS DA - 715

0.30

0.30

0.06

AS DA - 710

0.30

0.08

0.05

AS DA - 708

Si

AS DA - 735

C

Product Name

0.70

0.80

0.80

0.80

1.50

1.30

0.80

0.70

1.30

0.90

1.00

Mn

5.00

2.40

1.20

1.20

0.35

-

-

-

-

-

-

Cr

-

-

-

-

1.80

-

-

-

1.00

2.40

0.60

Ni

0.50

1.10

0.50

0.40

0.45

0.40

0.50

0.50

-

-

-

Mo

-

-

-

-

-

-

-

-

-

-

0.45

Cu

-

P

-

-

-

-

-

-

-

-

0.02

0.02

Electrodes for Welding High Strength Low Alloyed Steels

5 -

-

-

-

-

-

-

-

0.02

0.02

-

S

E 502-15 *

E 9018-B3

E 8018-B2

(E 8013-B2)

E 11018-G

E 9018-D1

E 7018-A1

E 8013-G

E 8018-C3 H4

E 8018-C1

E 8018-G

AWS A5.5 AWS A5.4 *

E CrMo 5 B 42

E CrMo 2 B 22

E CrMo 1 B 22

(E CrMo 1 R 12)

E 69 5 Mn 2 NiCrMo BT 42 **

E Mo B 22

E Mo B 22

E Mo R 22

E 50 6 1 Ni B 42 H5 *

E 46 6 2 Ni B 42 *

E 42 2 Z B 42 *

EN 1599 EN ISO 2560-A * EN 757 **


Heat Treatment of High Strength Low Alloyed Steels The mechanical properties gained by the coated electrodes that are used for welding high strength low alloyed steels and high temperature creep resistant steels varies with respect to the amount of preheating, interpass temperature and heat treatment after welding.

According to EN ISO 2560-A, EN 1599, EN 757 Product Name

Preheating Temp. (°C)

Interpass 1 Temp. (°C)

AS DA-708 AS DA-710 AS DA-731 AS DA-735 AS DA-737 AS DA-753 AS DA-771 AS DA-774 AS DA-777 AS DA-778

max. 200 max. 200 max. 200 150 - 250 150 - 250 200 - 300 200 - 300

max. 250 max. 250 max. 200 max. 200 max. 200 125 - 175 150 - 250 150 - 250 200 - 300 200 - 300

Heat Treatment 2 Time of Heat After Weld. (°C) Treatment (min.)

250 250 570 - 620 570 - 620 570 - 620 560 - 600 660 - 700 660 - 700 690 - 750 730 - 760

12 hours 12 hours 60 60 60 60 60 60 60 60

1) Measured 30-40 mm away from the center of weld bead 2) Air cooling According to AWS A5.5 and AWS A5.4 1

Product Name

Preheating and Interpass Temperature (°C)

Heat Treatment After Weld. (°C)

AS DA-710

93 - 107

620 + 14

60

AS DA-735

93 - 107

620 + 14

60

AS DA-737

93 - 107

620 + 14

60

AS DA-753

93 - 107

620 + 14

60

AS DA-771

163 - 191

690 + 14

60

AS DA-774

163 - 191

690 + 14

60

AS DA-777

163 - 191

690 + 14

60

AS DA-778

150 - 260

b

840 - 870

a

1) Work piece heated at 65-280°C/hour up to heat treating temperature. Held 1 hour at that temperature. Cooled at max. 190°C/hour. Fournace leaving at 320 °C. a) Cooled at max. 55°C/hour to 595°C at furnace. Afterwards, air cooling. b) No preheating.

43

Time of Heat Treatment (min.)

120

5


AS

DA - 708

AS DA-708 is a heavily coated, Ni-Cu alloyed basic electrode. It gives a weld metal that has an excellent corrosion resistance to sea water and to flue gases. Weld metal has good mechanical properties. AS DA-708 welds with a quite, stable arc giving very little spatter.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 42 2 Z B 42 AWS A5.5 : E 8018-G

C

Si

Mn

Ni

Cu

0.05

0.3

1.0

0.6

0.45

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

5

: : : :

470 570 28 120 @ - 20°C

Applications The electrode can be used in all positions for the welding of all types of joints. AS DA-708 is particularly designed for welding the shell platings of ships where the protective paint coating wears severely. Ship steels of A-, D- and E- quality and slow corrosion steels (due to its copper content) of the CORTEN-A and CORTEN-B type are among other application areas. It can be used in the welding of parts that work under dynamic loads at elevated temperatures; in all construction applications including bridges, boiler and pressure vessels, and shipbuilding. AS DA-708 can also be used in the root pass.

General Structural Steels Fine Grained Steels

Pipe Materials

: St 44, St 44-2, St 44-3, St 45-4, St 52-3 : from St E 255 to St E 420 from E 255 to WSt E 420 from TSt E 255 to TSt E 420 : from St E 240-7 to St E 360-7

Pressure Vessel Steels and Ship Plates Elevated Temperature Steels

: HI, HII, HIII, 17 Mn 4, 19 Mn 5, A-, D-, E: St 35.8, St 45.8

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 450

80 - 115 100 - 140 150 - 190

2320 3700 7040

44


AS

DA - 710

AS DA-710 is a heavily coated, Ni alloyed basic electrode. It is particularly useful for the welding of finegrained steels and low alloy steels which have high impact resistance at low temperatures down to - 60°C. It is used for the welding of joints which need to have high toughness values at low temperatures. It gives a weld metal that has an excellent corrosion resistance to sea water and to sulphuric acid fumes. It has about 120 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 46 6 2Ni B 42 : E 8018-C1 AWS A5.5

C

Si

Mn

Ni

P

S

0.06

0.3

0.9

2.4

< 0.02

< 0.02

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

500 600 28 150 @ - 20°C 110 @ - 60°C

5

Applications AS DA-710 is particularly designed for the welding of high strength low alloyed steels. It is suitable for the root pass and welding of pipelines and storage tanks that are frequently used in the chemical industry and cold storage areas.

Fine Grained Steels

: from St E 255 to St E 500 from ESt E 255 to ESt E 500 from TSt E 255 to TSt E 500

Low Temperature Steels : 14 Ni 6, 10 Ni 14, 16 Ni 14, 12 Ni 19 TT St 35 N, TT St 45 N, TT St 35 V, TT St 45 V 11 MnNi 5 3, 13 MnNi 6 3, 14 NiMn 6 Pipe Materials

: 5LX52, 5LX 56, 5LX 60

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 450

80 - 115 100 - 140 140 - 190

2500 3740 7510

45


AS

DA - 715

AS DA-715 is a thick coated basic electrode. The weld metal contains 1 % Ni. It is particularly used for the welding of fine-grained steels and steels which maintain their toughness at low temperatures down to - 60°C. Weldability is very good at all positions except vertical down. The weld metal diffusible hydrogen level is below 5 ml/100 g. Recovery is 120 %.

Classification and Typical Weld Metal Composition (%) EN ISO 2560-A : E 50 6 1Ni B 42 H5 : E 8018-C3 H4 AWS A5.5

C

Si

Mn

Ni

P

S

0.05

0.35

1.3

1.0

< 0.02

< 0.02

Approvals ---

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

5

: : : :

540 620 27 80 @ - 50°C 60 @ - 60°C

Applications It is especially suitable for high strength low alloy steels used at low temperatures and at weld joints which require high impact strength. It is used at root and other passes for chemical industry, cold air warehouses, pressure and boiler vessels, piping/tubing and offshore platforms. General Structural Steels : from S 275 to S 355 Ship Plates

: A-, B-, C-, D-, Efrom A(H) 32 to A(H) 36

Fine Grained Steels

: from St E 255 to St E 500 from WSt E 255 to WSt E 500 from TSt E 255 to TSt E 500

Low Temperature Steels : from S 275 NL to S 420 NL from P 275 NL2 to P 355 NL2 11 MnNi 53, 13 MnNi 63, 15 MnNi 63 Pipe Materials

: from 5LX42 to 5LX 65

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

80 - 115 100 - 150 140 - 190 180 - 240

2380 3700 7300 10850

46


AS

DA - 731

AS DA-731 is a rutile coated electrode. It gives a Mo alloyed weld metal that is used in the welding of boiler and pressure vessels operating under high temperatures.

Classification and Typical Weld Metal Composition (%) EN 1599 : E Mo R 22 AWS A5.5 : E 8013-G

C

Si

Mn

Mo

0.08

0.3

0.7

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

500 600 24 50 @ +20°C

Applications AS DA-731 is used for the welding of low alloyed and pressure vessel steels with a tensile strength up to 540 N/mm². It is ideal for the welding of boiler and pressure vessel steels and pipe connections that operate under temperatures up to 525°C. AS DA-735, a basic coated electrode, should be preferred in multipass applications of thick sectioned or rigidly restrained mass structures.

Fine Grained Steels

: from St E 255 to St E 420 from WSt E 255 to WSt E 420 : from St E 320-7 to St E 420-7 5LX52, 5LX 56, 5LX 60

Pipe Materials Pressure Vessel Steels Elevated Temperature Steels Cast Steels

: HI, HII, HIII, 15 Mo 3, 17 Mn 4, 19 Mn 5 : St 35.8, St 45.8 : GS-45, GS-22 Mo 4, GS-C 25

Current Type : [ AC min. 70 V / DC (+/-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25

350 350

75 - 110 100 - 140

2020 3380

47

5


AS

DA - 735

AS DA-735 is a basic coated electrode. It gives a Mo alloyed weld metal that is used in the welding of boiler and pressure vessels operating under high temperatures. Ductile weld metal has a particular creep resistance. It is ideal in multipass applications that is required in the welding of thick and rigidly restrained mass structures. It gives high quality weld beads with good mechanical properties.

Classification and Typical Weld Metal Composition (%) EN 1599 : E Mo B 22 AWS A5.5 : E 7018-A1

C

Si

Mn

Mo

0.08

0.3

0.8

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

5

: : : :

510 620 24 150 @ +20°C

Applications AS DA-735 is used for the welding of 15 Mo 3 grade steels operating under temperatures up to 550°C. It is also ideal for the welding of fine grained steels (up to St E480-7 TM). It is ideal for the welding of boiler and pressure vessel steels and pipe connections that operate under temperatures up to 525°C. The stable arc enables proper welding in the root pass and in difficult positions. Fine Grained Steels

: from St E 255 to St E 500 from WSt E 255 to WSt E 500 : from St E 320-7 to St E 480-7 TM 5LX52, 5LX 56, 5LX 60, 5LX65

Pipe Materials Pressure Vessel Steels Elevated Temperature Steels Cast Steels Steels resistant to Aging

: : : :

HI, HII, HIII, 15 Mo 3, 17 Mn 4, 19 Mn 5 St 35.8, St 45.8 GS-45, GS-52, GS-60, GS-22 Mo 4, GS-C 25 17 MnMoV 64, 15 NiCuMoNb 5 20 MnMoNi 45

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 450

80 - 110 110 - 140 150 - 190

2490 3840 7330

48


AS

DA - 737

AS DA-737 is a basic coated, AC/DC electrode for the welding of high tensile strength steels. It gives a weld metal that has good notch toughness down to - 60°C. Grain boundary cracking risk is very low.

Classification and Typical Weld Metal Composition (%) EN 1599 : E Mo B 22 AWS A5.5 : E 9018-D1

C

Si

Mn

Mo

0.06

0.4

1.3

0.4

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

580 660 24 170 @ +20°C 50 @ - 50°C 40 @ - 60°C

5

Applications Due to the weld metal's good notch toughness properties down to - 60°C, it is used for welding unalloyed and low alloyed steel structures exposing to low temperatures like LPG holders. Welding of low alloyed high tensile steels when preheating cannot be applied and enclosed joint welding and cladding of rails when a hardness of about 250 HV is required are among its application areas.

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

110 - 140 150 - 190 190 - 250

3790 7300 10500

49


AS

DA - 753

AS DA-753 is a basic coated electrode. It is used for the welding of fine-grained, heat treatable high strength steels with a yield strength up to 760 N/mm². It can also be used in the welding of fine grained structural steels having a yield strength value greater than 760 N/mm². It gives a weld metal that has a high toughness value and resistant to cracking at low temperatures down to - 50°C.

Classification and Typical Weld Metal Composition (%) EN 757 : E 69 5 Mn 2 NiCrMo B T 42 AWS A5.5 : E 11018-G

C

Si

Mn

Cr

Ni

Mo

0.05

0.4

1.5

0.35

1.8

0.45

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

5

: : : :

700 800 20 115 @ +20°C 85 @ - 20°C

70 @ - 40°C 55 @ - 50°C

40 @ - 60°C

Applications It is used for welding fine grained, low alloyed high strength structural steels at room temperature or with moderate preheat. It is used in the welding of steel structures, boiler and pressure vessels, and for construction of heavy machinery. It is particularly used in the root pass of high strength steels (790 N/mm²). 1) If possible, each joint should be welded continuously, except electrode change and slag removal. 2) In multi-pass welding applications, interpass temperature should be maintained at 100-150°C. 3) Use only dry electrodes. Fine Grained Steels

: from St E 500 to St E 690 from TSt E 500 to TSt E 690 from WSt E 500 to WSt E 690 : 15 NiCrMo 10 6, 16 NiCrMo 12 6, 11 NiMoV 5 3 11 NiMnCrMo 5 5, 17 MnCrMo 3 3, 12 MnNiMo 5 5

Pipe Materials

: 5LX70, 5LX 75

Heat Treated Fine Grained Structural Steels

: N-A-XTRA 65, N-A-XTRA 70, N-A-XTRA 75 HSB 77V, T1, T1A, T1B

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

75 - 110 100 - 145 130 - 190 180 - 250

2290 3800 7390 11550

50


AS

DA - 771

AS DA-771 is a rutile coated electrode. It gives a Cr-Mo alloyed weld metal that is used in the welding of creep resistant pressure vessels and pipe steels operating under high temperatures. AS DA-771 is especially used for 13 CrMo 44 type steels that are frequently used in operating temperatures up to 570°C. It gives a root pass free of porosity with a minimum amount of spatter.

Classification and Typical Weld Metal Composition (%) EN 1599 : (E CrMo 1 R 12) AWS A5.5 : (E 8013-B2)

C

Si

Mn

Cr

Mo

0.06

0.3

0.8

1.2

0.4

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

520 600 22 60 @ +20°C

5

Applications AS DA-771 is used for the welding of vapor pipes and boiler and pressure vessels that are manufactured from Cr-Mo steels. AS DA-774, a basic coated electrode, should be preferred in the multi-pass welding of thick sectioned and rigidly restrained mass structures. Heat Resistant High Strength Pipe Materials and Pressure Vessel Steels : 13 CrMo 4 4 22 CrMo 4 4 15 CrMo 5 25 CrMo 4 42 CrMo 4 *

GS-17 CrMo 5 5 GS-22 CrMo 5 4 GS-25 CrMo 4

*) Mechanical properties should be considered.

Current Type : [ AC min. 50 V / DC (-) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25

350 350

70 - 95 100 - 140

2200 3050

51


AS

DA - 774

AS DA-774 is a basic coated electrode. It gives a Cr-Mo alloyed weld metal that is used in the welding of creep resistant pressure vessels and pipe steels operating under high temperatures. AS DA-774 is especially used for 13 CrMo 44 type steels that are frequently used in operating temperatures up to 570°C. It gives a root pass free of porosity with a minimum amount of spatter. It is recommended to use the electrode in DC (+).

Classification and Typical Weld Metal Composition (%) EN 1599 : E CrMo 1 B 22 AWS A5.5 : E 8018-B2

C

Si

Mn

Cr

Mo

0.06

0.5

0.8

1.2

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical

5

Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: : : :

540 620 22 90 @ +20°C

Applications AS DA-774 is used for the welding of vapor pipes and boiler and pressure vessels that are manufactured from Cr-Mo steels. It can also be used in welding similarly alloyed cementation steels, heat treatable steels and cast steels. It is an ideal electrode in the multi-pass welding of thick sectioned and rigidly restrained mass structures. Heat Resistant Steels : 13 CrMo 4 4 13 CrMoV 4 2 22 CrMo 4 4 15 CrMo 3 15 CrMo 5 25 CrMo 4 42 CrMo 4 *

Cast Steels : GS-17 CrMo 5 5 GS-22 CrMo 5 GS-22 CrMo 5 4 GS-25 CrMo 4

Cementation Steels : 15 Cr 3 16 MnCr 5 20 MnCr 5 25 MnCr 4

*) Mechanical properties should be considered.

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

80 - 100 90 - 140 130 - 190 150 - 240

2030 3270 6420 10000

52


AS

DA - 777

AS DA-777 is a basic coated electrode for joining and welding of heat and creep resistant steels containing 2.2 % Cr + 1 % Mo that are exposed to operating temperatures up to 600°C. The weld metal has a high resistance to cracking. AS DA-777 runs with a quite, stable arc giving a minimum amount of spatter and smooth weld beads. It is recommended to use the electrode in DC (+).

Classification and Typical Weld Metal Composition (%) EN 1599 : E CrMo 2 B 22 AWS A5.5 : E 9018-B3

C

Si

Mn

Cr

Mo

0.05

0.4

0.8

2.4

1.1

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

560 650 22 80 @ +20°C

5

Applications Power plant constructions; flange pipes used in petrochemical plants; forged cast parts, vapor production plants, preheaters and heaters, boiler and pressure vessels and pipe connections are among some application areas where AS DA-777 is used. It can also be used in welding similarly alloyed cementation steels, heat treatable steels and cast steels. Part should be preheated before welding to avoid the cracking risk and operating temperature during welding should not exceed 300°C. Heat Resistant Steels : 10 CrMo 9 10 10 CrSiMoV 7 26 CrMo 7 24 CrMo 10 10 CrMo 11 16 CrMo 9 3

Cast Steels : GS-12 CrMo 9 10 GS-18 CrMo 9 10

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

80 - 110 90 - 140 130 - 190 150 - 240

2160 3420 6450 10000

53


AS

DA - 778

AS DA-778 is a basic coated electrode particularly used for the welding of steels containing 5 % Cr and 0.5 % Mo. The weld metal has a crack resistance to operating temperatures up to 550°C. Since it is a low hydrogen electrode, the weld metal has a high creep resistance. It has about 110 % metal recovery. It is recommended to use the electrode in DC (+).

Classification and Typical Weld Metal Composition (%) EN 1599 : E CrMo 5 B 42 AWS A5.4 : E 502-15

C

Si

Mn

Cr

Mo

0.05

0.5

0.7

5.0

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

5

: : : :

400 580 22 80 @ +20°C

Applications Power plant constructions; flange pipes used in petrochemical plants; forged cast parts, vapor production plants, preheaters and heaters, boiler and pressure vessels and pipe connections are among some application areas where AS DA-778 is used. It can also be used in welding similarly alloyed cementation steels, heat treatable steels and cast steels. Part should be preheated to 300°C before welding and operating temperature during welding should not exceed 350°C. Heat Resistant Steels : 12 CrMo 19 5 22 CrMo 4 4 15 CrMo 3 15 CrMo 5 25 CrMo 4

Cast Steels : GS-17 CrMo 5 5 GS-22 CrMo 5 GS-22 CrMo 5 4 GS-25 CrMo 4

Current Type : [ DC (+) / AC min. 70 V ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [ Amp ]

Weight (100 pcs) [g]

2.50 3.25

350 350

75 - 100 90 - 140

2300 3640

54

Cementation Steels : 15 Cr 3 16 MnCr 5 20 MnCr 5 25 MnCr 4


AS P Electrodes for Welding Stainless & Heat-Corrosion Resistant Steels

6 Product Name

EN 1600

AWS A5.4

AS AS AS AS AS AS AS AS AS AS AS AS

E 18 9 Mn Mo B 22) E 19 9 LR 12 E 18 8 Mn B 22 E 20 10 3 B 22 E 23 12 LR 12 E 23 12 2 LR 32 E 25 20 R 12 E 29 9 R 12 E 19 12 3 LR 12 E 19 12 3 R 73 E 19 12 3 Nb R 12 E 19 9 Nb R 12

E 307-15 E 308L-16 (E 307-15) E 308Mo-15 E 309L-16 E 309MoL-16 E 310-16 E 312-16 E 316L-16 (E 316-16) (E 318-16) (E 347-16)

P - 307 P - 308 L P - 308 Mn P - 308 Mo P - 309 L P - 309 Mo P - 310 R P - 312 P - 316 L P - 316 S P - 318 Super P - 347

55

Page 61 62 63 64 65 66 67 68 69 70 71 72


0.10

0.03

0.10

0.05

0.03

0.03

0.10

0.10

0.03

0.06

0.04

0.03

AS P - 308 L

AS P - 308 Mn

AS P - 308 Mo

AS P - 309 L

AS P - 309 Mo

AS P - 310 R

AS P - 312

AS P - 316 L

AS P - 316 S

AS P - 318 Super

AS P - 347

C

AS P - 307

Product Name

56

0.90

0.90

0.70

0.70

0.90

0.60

0.80

0.80

0.35

0.50

0.80

0.40

Si

0.70

0.80

0.60

0.80

0.80

1.70

0.80

0.70

2.50

6.00

0.70

4.50

Mn

19

18

17

17

29

26

23

23

19

18

19

20

Cr

9.5

12

11

11

9

21

12.5

13

10

9

10

10

Ni

-

2.5

2.9

2.9

-

-

2.7

-

2.5

-

-

1.0

Mo

0.5

0.5

-

-

-

-

-

-

-

-

-

-

Nb

(E 347-16)

(E 318-16)

(E 316-16)

E 316L-16

E 312-16

E 310-16

E 309MoL-16

E 309L-16

E 308Mo-15

(E 307-15)

E 308L-16

E 307-15

AWS A5.4

Electrodes for Welding Stainless and Heat-Corrosion Resistant Steels

6 E 19 9 Nb R 12

E 19 12 3 Nb R 12

E 19 12 3 R 73

E 19 12 3 LR 12

E 29 9 R 12

E 25 20 R 12

E 23 12 2 LR 32

E 23 12 LR 12

E 20 10 3 B 22

E 18 8 Mn B 22

E 19 9 LR 12

E 18 9 Mn Mo B 22

EN 1600


Electrode Selection Rutile coated electrode Basic coated electrode

1 x x

x x x

x x x x x x x

1.3401

X120 Mn 12

1.4000 1.4001 1.4002 1.4006 1.4008 1.4013 1.4016 1.4021 1.4024 1.4027

X6 Cr 13 X7 Cr 14 X6 CrAl 13 X10 Cr 13 G-X8 CrNi 13 X8 Cr 16 X6 Cr 17 X20 Cr 13 X15 Cr 13 G-X20 Cr 14

1.4710 1.4712 1.4713 1.4724 1.4729 1.4740 1.4741 1.4742 1.4745 1.4762 1.4776

G-X30 CrSi 6 X10 CrSi 6 X10 CrAl 7 X10 CrAl 13 G-X40 CrSi 13 G-X40 CrSi 17 X10 CrSi 18 X10 CrAl 18 G-X40 CrSi 23 X10 CrAl 24 G-X40 CrSi 29

1.4510 1.4511 1.4512 1.4523

X6 CrTi 17 X6 CrNb 17 X5 CrTi 12 X8 CrMoTi 17

AS P - 347

AS P - 316Â S AS P - 318 Super

AS P - 316 L

AS P - 310 R AS P - 312

AS AS AS AS

BASE METAL

AS P - 309 L AS P - 310 B

PRODUCT

P - 307 P - 308 L P - 308 Mn P - 308 Mo

Stainless & Heat-Corrosion Resistant Steels

6

) Can be welded. Gives same weld metal as the base metal. ) Can be welded. Gives similar weld metal as the base metal. ) Refer page 59.

57


2 Rutile coated electrode Basic coated electrode

x x

x x x

x x x x x x x

6

1.4541 1.4543 1.4550 1.4552 1.4878 1.6903 1.6905

X6 CrNiTi 18 10 X5 CrNiNb 18 9 X6 CrNiNb 18 10 G-X5 CrNiNb 18 9 X12 CrNiTi 18 9 X10 CrNiTi 18 10 G-X5 CrNiNb 18 10

1.4571 1.4573 1.4580 1.4583

X6 CrNiMoTi 17 12 2 X10 CrNiMoTi 18 12 X6 CrNiMoNb 17 12 2 X10 CrNiMoNb 18 12

1.4057 1.4059 1.4107 1.4301 1.4303 1.4306 1.4308 1.4311 1.4312 1.4339 1.4340 1.4347 1.4822 1.4845 1.6900 1.6906

X20 CrNi 17 2 G-X22 CrNi 17 G-X8 CrNi 12 X5 CrNi 18 10 X5 CrNi 18 12 X2 CrNi 19 11 G-X6 CrNi 18 9 X2 CrNiN 18 10 G-X10 CrNi 18 8 G-X32 CrNi 28 10 G-X40 CrNi 27 4 G-X8 CrNi 26 7 G-X40 CrNi 24 5 X12 CrNi 25 21 X12 CrNi 18 9 X5 CrNi 18 10

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1 2 2

1 2 2

1 2 2

2 2

AS P - 347

AS P - 316 S AS P - 318 Super

AS P - 316 L

2

) Can be welded. Gives same weld metal as the base metal. ) Can be welded. Gives similar weld metal as the base metal. ) Refer page 59.

58

AS P - 310 R AS P - 312

AS AS AS AS

BASE METAL

AS P - 309 L AS P - 310 B

PRODUCT

P - 307 P - 308 L P - 308 Mn P - 308 Mo

Stainless & Heat-Corrosion Resistant Steels

1


3 Rutile coated electrode Basic coated electrode

x x

x x x

x x x x x x x

1.4106 1.4113 1.4120

X10 CrMo 13 X6 CrMo 17 1 X20 CrMo 13

1.4401 1.4404 1.4406 1.4408 1.4410 1.4429 1.4435 1.4436 1.4437

X5 CrNiMo 17 12 2 X2 CrNiMo 17 12 2 X2 CrNiMoN 17 12 2 G-X6 CrNiMo 18 10 G-X10 CrNiMo 18 9 X2 CrNiMoN 17 13 3 X2 CrNiMo 18 14 3 X5 CrNiMo 17 13 3 G-X6 CrNiMo 18 12

1.4821 1.4823 1.4825 1.4826 1.4828 1.4832 1.4837 1.4841 1.4848 1.4417

X20 CrNiSi 24 4 G-X40 CrNiSi 27 4 G-X25 CrNiSi 18 9 G-X40 CrNiSi 22 9 X15 CrNiSi 20 12 G-X25 CrNiSi 20 14 G-X40 CrNiSi 25 12 X15 CrNiSi 25 20 G-X40 CrNiSi 25 20 X2 CrNiMoSi 19 5

1

1

1

1

1

1

) Can be welded. Gives same weld metal as the base metal. ) Can be welded. Gives similar weld metal as the base metal. ) Gives an austenitic type, high alloyed, tougher weld metal. It is reductive as compared to Cr alloyed base materials; whereas has lower resistance in Sulphur containing environments. 1 ) No heat treatment. 2 ) As it has lower resistance in strong oxidizing environments like nitric acid, Mo-free electrodes should be considered.

59

AS P - 347

AS P - 316 L AS P - 316 S AS P - 318 Süper

AS P - 310 R AS P - 312

BASE METAL

AS P - 310 B

AS P - 307 AS P - 308 L

PRODUCT

AS P - 308 Mn AS P - 308 Mo AS P - 309 L

Stainless & Heat-Corrosion Resistant Steels

6


Schaeffler Diagram 30 28

10 ferrite

Austenite

24

Nickel Equivalent = % Ni + 30 x % C + 0.5 x % Mn

5 ferrite

4

26

22

3

20

20 ferrite

18

40 ferrite

16

A+M

14

A+F 80 ferrite

12 10 8

2

6

A+M+F

1

Martensite M+F

4

Ferrite

2 2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

Chromium Equivalent = % Cr + % Mo + 1.5 x % Si + 0.5 x % Nb

Schaeffler Diagram and Askaynak Electrodes Nickel Equivalent = % Ni + 30 x % C + 0.5 x % Mn

6

26 24

310R / 310B 5 ferrite

22 20

10 ferrite

18 16

20 ferrite

308 Mn

307

309L

14

316L 318

12

308L 308 Mo

10 8 16

309Mo 312 40 ferrite

80 ferrite

347

18

20

22

24

26

28

30

32

Chromium Equivalent = % Cr + % Mo + 1.5 x % Si + 0.5 x % Nb

60

38

40


AS

P - 307

AS P-307 is a basic coated electrode. It gives a filler metal of the Cr-Ni-Mo type that is high (4.5 %) in Mn content. Weld beads are highly resistant to impact, wearing and cracking due to heat effects. It gives a fully austenitic, nonmagnetic weld metal.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 18 9 MnMo B 22 AWS A5.4 : E 307-15

C

Si

Mn

Cr

Ni

Mo

0.10

0.40

4.5

20

10

1.0

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

420 690 35 80 @ +20°C

Hardness : 150 HB (as welded) 250 HB (after cold working)

Applications AS P-307 is used for forming a buffer layer for hardfacing and joining of armour steel plates, steel welds that are low hardenable and work-hardening austenitic Mn steels. It can also be used for dissimilar weld joints of C-Mn steels with austenitic and ferritic stainless steels. There is no need to apply heat treatment to armour steel plates before or after the welding. Interpass temperature during welding should not exceed 120°C.

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25

300

80 - 110

2950

61

6


AS

P - 308 L

AS P-308 L is an extra low carbon rutile coated electrode. It gives a filler metal of the Cr-Ni type. Excellent quality smooth weld beads are highly resistant to acids, intergranular corrosion at operating temperatures up to 350°C, and to oxidation up to 800°C. It gives a stable arc and the slag is easy to remove.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 19 9 LR 12 AWS A5.4 : E 308L-16

Werkstoff-Nr : 1.4306

C

Si

Mn

Cr

Ni

0.03

0.8

0.7

19

10

Approvals ABS BV DNV GL

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

420 570 45 80 @ +20°C

CE , GOST , SEPRO , TÜV

Applications

6

In addition to the welding of steels corresponding to AISI 301, 302, 304, 304L, 308 and 308L; AS P-308 L can also be used in the welding of niobium or titanium stabilized austenitic stainless steels. Welding of vapor and pressure fittings, storage tanks and equipment that are used in milk and other food industries, stainless steel or stainless steel plated steels operating under chemical attack are among its application areas. It is an ideal electrode for the joining of stainless steel parts (having similar chemical composition with the electrode) with steel cast pieces. Up to and including 3.25 mm diameter electrodes can be used in all positions; whereas 4 mm and 5 mm electrodes should be used in the flat position. EN 10088-1/-2 Extra low carbon C < 0.03 %

X2 CrNi 19 11 X2 CrNiN 18 10

Medium carbon C > 0.03 %

X4 CrNi 18 10

Ti , Nb stabilized

X6 CrNiTi 18 10 X6 CrNiNb 18 10

EN 10213-4

W. Nr. 1.4306 1.4311

G-X5 CrNi 19 10

1.4301 1.4308

G-X5 CrNiNb 19 10

1.4541 1.4450 1.4552

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00

250 250 300 350

45 - 60 60 - 80 75 - 115 115 - 150

990 1660 3230 5420

62


AS

P - 308 Mn

AS P-308 Mn is a basic coated electrode. It gives an austenitic filler metal of the Cr-Ni type that is high (6.0 %) in Mn content. Weld beads are highly resistant to oxidation at operating temperatures up to 850°C and also to acids.

Classification and Typical Weld Metal Composition (%) Werkstoff-Nr : 1.4370

EN 1600 : E 18 8 Mn B 22 AWS A5.4 : (E 307-15)

C

Si

Mn

Cr

Ni

0.1

0.5

6.0

18

9

Approvals GL CE , GOST , SEPRO , TÜV

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

420 640 35 100 @ +20°C 75 @ - 60°C

Hardness : 200 HB (as welded) 350 - 400 HB (after cold working)

Applications AS P-308 Mn can be used for welding hardenable steels (alloyed or unalloyed), Mn steels, armour plates, rail steels, stainless chromium steels, tool steels and steels with poor weldability. Building up of parts operating under impact, high pressure and cavitation; surface build up of water turbine vanes; build up of valve seats and joining and building up of rail switches are among its usage areas. AS P- 308 Mn can also be used for forming buffer layer passes before hardfacing applications having a chromium carbide structure. The lowest possible welding current should be selected to avoid the overheating of the electrode during welding. For hard Mn steels, weld beads should be forged.

Note : Weal beads can not be cut with oxy-acetylene flame.

Welding Positions

Current Type : [ DC (+) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

250 300 350 350

50 - 80 80 - 110 100 - 140 140 - 160

1590 3030 5100 7060

63

6


AS

P - 308 Mo

AS P-308 Mo is a basic coated electrode. It gives a filler metal of the Cr-Ni-Mo type that is high (2.5 %) in Mn content. Weld beads are highly resistant to sudden impact and cracking due to heat effect.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 20 10 3 B 22 AWS A5.4 : E 308 Mo-15

Werkstoff-Nr : 1.4431

C

Si

Mn

Cr

Ni

Mo

0.05

0.35

2.5

19

10

2.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

420 620 38 100 @ +20°C

Applications AS P-308 Mo is used for forming a buffer layer for hardfacing and joining of armour steel plates, heat treatable steels, different type steels and for steels with poor weldability.

6

There is no need to apply heat treatment to armour steel plates before or after the welding. Interpass temperature during welding should not exceed 120°C. It is also used to form a buffer layer for stress relief before hardfacing applications.

Welding Positions

Current Type : [ DC (+) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00

300 350

80 - 110 110 - 140

2855 5095

64


AS

P - 309 L

AS P-309L is a low carbon rutile coated electrode. It gives a filler metal of the Cr-Ni type. Weld beads are highly resistant to oxidation at operating temperatures up to 1000°C. It can be used in all positions. The weld metal has a high resistance to cracking. Ferrite content is 12 %.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 23 12 LR 12 AWS A5.4 : E 309L-16

Werkstoff-Nr : 1.4332

C

Si

Mn

Cr

Ni

0.03

0.8

0.7

23

13

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

460 590 40 70 @ +20°C 35 @ - 80°C

Approvals ABS BV DNV GL RINA CE , GOST , SEPRO

Applications AS P-309 L is used for welding of Cr and Cr-Ni alloyed steels that are highly resistant to operating conditions up to 1000°C. It is particularly used for joining stainless steels with low and medium alloyed steels and for root pass applications before welding of surface plated steels. It can also be used for cladding of mild steels and to form a buffer layer for hardfacing before welding with AS P-308 L. AS P-309 L is an ideal electrode especially designed for welding pipes, plates and tanks that are used in chemical, petrochemical, food and paper industries; forged and cast pieces and industrial furnaces that are exposed to high temperatures. EN 10088-1/-2

EN 10213-4

W. Nr.

Corrosion resistant steels

X2 CrNiN 18 10

1.4311

Stainless steel claddings

X2 CrNi 19 11 X4 CrNi 18 10

1.4306 1.4301

Welding Positions

Current Type : [ AC min. 50 V / DC (+) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

250 300 350

50 - 80 80 - 120 120 - 150

1580 3100 5490

65

6


AS

P - 309 Mo

A high Cr-Ni-Mo alloyed all position rutile-basic electrode. It gives high corrosion resistant deposit. Weldable on AC and DC (+) polarity.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 23 12 2 LR 32 AWS A5.4 : E 309MoL-16

C

Si

Mn

Cr

Ni

Mo

0.03

0.8

0.8

23

12.5

2.7

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

575 720 30 60 @ +20°C

Applications

6

Specially developed for welding stainless steel to mild steel and root runs in cladding. It is also suitable for repair welding in dissimilar joints and steels difficult to weld. Maximum plate thickness in butt welds is ~ 12 mm. Build-up welding on mild or low alloyed steels. EN 10088-1/-2 First layer in CrNiMo claddings

EN 10213-4

W. Nr.

G-X5 CrNiMo 19 11

1.4404 1.4435 1.4406 1.4429 1.4401 1.4436 1.4571 1.4573 1.4580 1.4408

X2 CrNiMo 17 12 2 X2 CrNiMo 18 14 3 X2 CrNiMoN 17 11 2 X2 CrNiMoN 17 13 3 X4 CrNiMo 17 12 2 X4 CrNiMo 17 13 3 X6 CrNiMoTi 17 12 2 X10 CrNiMoTi 17 13 3 X6 CrNiMoNb 17 12 2

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

250 300 350 350

60 - 85 90 - 125 125 - 160 150 - 190

1755 3355 5550 8660

66


AS

P - 310 R

AS P-310 R is a rutile coated fully austenitic electrode. It gives a fully austenitic filler metal of the Cr-Ni type. Weld beads are highly resistant to oxidation at operating temperatures up to 1200°C.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 25 20 R 12 AWS A5.4 : E 310-16

Werkstoff-Nr : 1.4842

C

Si

Mn

Cr

Ni

0.1

0.6

1.7

26

21

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

480 600 35 60 @ +20°C

Applications It is an ideal electrode for welding heat resistant stainless steels of the AISI 309 and AISI 310 type. It is used for welding unalloyed steels to stainless steels and to air hardening steels like armour plates. AS P-310 R can be used in the welding of chimneys, boilers and heating plates and also for industrial furnaces operating at high temperatures (that are frequently made from ferritic steels of Cr-Si-Al type). During the welding of high carbon steels to stainless steels, it gives a weld bead that has a better machinability as compared to beads of electrodes with 18 % Cr and 8 % Ni. EN 10088-1/-2 Heat resistant steels

EN 10213-4

W. Nr.

X10 CrAl 24 G-X25 CrNiSi 18 9 G-X40 CrNiSi 22 9 X15 CrNiSi 20 12 G-X25 CrNiSi 20 14 X15 CrNiSi 25 20 X12 CrNi 25 21 G-X40 CrNiSi 25 20

Current Type : [ AC min. 70 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

250 300 350 350

45 - 75 80 - 120 100 - 140 130 - 160

1650 3280 5740 8810

67

1.4762 1.4825 1.4826 1.4828 1.4832 1.4841 1.4845 1.4848

6


AS

P - 312

AS P-312 is a rutile coated electrode. It gives a filler metal of the Cr-Ni type. Due to its high tensile and impact resistance, it is used for the joining and build up welding of steels with a high tendency to cracking. It is especially developed for maintenance and repair welding.

Classification and Typical Weld Metal Composition (%) Werkstoff-Nr : 1.4337

EN 1600 : E 29 9 R 12 AWS A5.4 : E 312-16

C

Si

Mn

Cr

Ni

0.1

0.9

0.8

29

9

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

600 800 25 50 @ +20°C

Hardness : 200 HB (as welded) 350 - 400 HB (after cold working)

Applications

6

Unalloyed steels, high carbon steels (1.4085 : G-X 70 Cr 29), high alloyed steels, tool steels, spring steels, high speed steels, cast pieces and air hardenable armour steel plates that have poor weldability can be welded with AS P-312. Joining of unalloyed or low alloyed steels with stainless steels and build up welding of gears and shafts are among its application areas. Generally, there is no preheating requirement before welding. If preheating is necessary, preheating temperature might be less than that required for other electrodes. AS P-312 should not be used for the welding of parts that are continuously operating at temperatures exceeding 450°C. Interpass temperature should be controlled in multipass applications.

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

250 300 350 350

55 - 85 80 - 120 110 - 160 150 - 180

1540 3180 5450 9130

68


AS

P - 316 L

AS P-316 L is a low carbon rutile coated electrode. It gives a filler metal of the Cr-Ni-Mo type. Excellent quality smooth weld beads are highly resistant to acids and to intergranular corrosion at operating temperatures up to 350°C. It gives a stable arc and the slag is easy to remove.

Classification and Typical Weld Metal Composition (%) Werkstoff-Nr : 1.4430

EN 1600 : E 19 12 3 LR 12 AWS A5.4 : E 316L-16

C

Si

Mn

Cr

Ni

Mo

0.03

0.7

0.8

17

11

2.9

Approvals ABS BV DNV GL RINA

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

490 600 35 60 @ +20°C

CE , GOST , SEPRO

Applications In addition to the welding of austenitic steels and acid resistant AISI 316 type steels, it is an ideal electrode for the welding of niobium or titanium stabilized 18/12 steels. AS P-316 L can be used in the welding of pipes, tanks and vessels that are used in chemical, paint and paper industries. Cr-Ni-Mo steels, steel cast parts and pipes that are used for acid, gas and vapor transmission can also be welded with this electrode. AS P-316 L can also be used in the build up welding of leakproof surfaces. Electrode diameters up to 3.25 mm can be used in all positions; whereas 4 and 5 mm electrodes should be used in flat and nearly flat positions only. EN 10088-1/-2 Extra low carbon C < 0.03 %

EN 10213-4

Medium carbon C > 0.03 %

X2 CrNiMo 17 12 2 X2 CrNiMo 18 14 3 X2 CrNiMoN 17 11 2 X4 CrNiMo 17 12 2 X4 CrNiMo 17 13 3

Ti , Nb stabilized

X6 CrNiMoTi 17 12 2 X6 CrNiNb 18 10

W. Nr.

G-X5 CrNiMo 19 11

G-X5 CrNiNb 19 10

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.00 2.50 3.25 4.00

250 250 300 350

40 - 60 50 - 80 80 - 120 100 - 145

930 1620 2940 4920

69

1.4404 1.4435 1.4406 1.4401 1.4436 1.4408 1.4571 1.4550 1.4552

6


AS

P - 316 S

AS P-316 S is a rutile coated electrode with an unalloyed core. Therefore it can tolerate higher currents than AS P-316 L. It has 160 % metal recovery. It gives a filler metal of the Cr-Ni-Mo type. Excellent quality smooth weld beads are highly resistant to acids and to intergranular corrosion at operating temperatures up to 350°C. It gives a stable arc and the slag is easy to remove.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 19 12 3 R 73 AWS A5.4 : (E 316-16)

Werkstoff-Nr : 1.4430

C

Si

Mn

Cr

Ni

Mo

0.06

0.7

0.6

17

11

2.9

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

440 565 30 70 @ +20°C

Applications

6

It is an ideal electrode for the welding of austenitic steels and acid resistant steels of the AISI 316 type. It is used for welding mild and low alloyed steels to stainless steels or austenitic manganese steels. It can also be used for stainless cladding of carbon and manganese steels. AS P-316 S can be used in the welding of pipes, tanks and vessels that are used in chemical, paint and paper industries. Cr-Ni-Mo steels, steel cast parts and pipes that are used for acid, gas and vapor transmission can also be welded with this electrode. AS P-316 S can also be used in the build up welding of leakproof surfaces. Electrode diameters up to 3.25 mm can be used in all positions; whereas 4 and 5 mm electrodes should be used in flat and nearly flat position only. EN 10088-1/-2

EN 10213-4

Extra low carbon C < 0.03 %

X2 CrNiMo 17 12 2 X2 CrNiMo 18 14 3 X2 CrNiMoN 17 11 2

Medium carbon C > 0.03 %

X4 CrNiMo 17 12 2

W. Nr. 1.4404 1.4435 1.4406

G-X5 CrNiMo 19 11

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 350 350

80 - 120 100 - 140 110 - 180 200 - 240

3190 5520 8500 12500

70

1.4401 1.4408


AS

P - 318 Süper

AS P-318 Super is a low carbon rutile coated electrode. It gives a filler metal of the Cr-Ni-Mo type. AS P-318 Super can also be used in the welding of niobium or titanium stabilized AISI 318 or similar quality stainless steels. Excellent quality smooth weld beads are highly resistant to acids and to intergranular corrosion at operating temperatures up to 350°C. It gives a stable arc and the slag is easy to remove.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 19 12 3 Nb R 12 AWS A5.4 : (E 318-16)

Werkstoff-Nr : 1.4576

C

Si

Mn

Cr

Ni

Mo

Nb

0.04

0.9

0.8

18

12

2.5

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ Joule ] Impact (ISO-V)

: : : :

500 620 35 65 @ +20°C

Applications AS P-318 Süper can be used in the welding of corrosion resistant pipes, tanks and vessels that are made of Cr-Ni-Mo type stainless steel. It is also an ideal electrode for the welding of parts that are used in chemical, food and paint industries for acid, salt, gas, vapor and water transmission. EN 10088-1/-2

EN 10213-4

W. Nr.

Extra low carbon C < 0.03 %

X2 CrNiMo 17 12 2 X2 CrNiMo 18 14 3 X2 CrNiMoN 17 11 2 X2 CrNiMoN 17 13 3

1.4404 1.4435 1.4406 1.4429

Medium carbon C > 0.03 %

X4 CrNiMo 17 12 2 X4 CrNiMo 17 13 3

Ti , Nb stabilized

X6 CrNiMoTi 17 12 2 X6 CrNiMoNb 17 12 2 X6 CrNiNb 18 10

1.4401 1.4436 1.4408 1.4571 1.4580 1.4550 1.4552

G-X5 CrNiMo 19 11

G-X5 CrNiNb 19 10

Current Type : [ AC min. 70 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

250 300 350

50 - 80 70 - 120 100 - 150

1570 3140 5870

71

6


AS

P - 347

AS P-347 is a low carbon rutile coated electrode. It gives a niobium stabilized, Cr-Ni type filler metal of AISI 304 or similar quality. It has an excellent strength especially in oxidizing environments like nitric acid. Smooth weld beads are highly resistant to acids and to intergranular corrosion at operating temperatures up to 350°C.

Classification and Typical Weld Metal Composition (%) EN 1600 : E 19 9 Nb R 12 AWS A5.4 : (E 347-16)

Werkstoff-Nr : 1.4551

C

Si

Mn

Cr

Ni

Nb

0.03

0.9

0.7

19

9.5

0.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] Impact (ISO-V) [ Joule ]

: : : :

520 600 35 55 @ +20°C

Applications

6

AS P-347 can be used particularly in the welding of austenitic stainless steels of AISI 321 and 347 type. It can also be used for Cr-Ni steels and for steel cast parts having same or similar analysis results with the electrode. Tanks and vessels that are used in chemical and food industries; parts exposing to the effects of acid, gas and vapor; and water fittings are among some application areas. AS P-308 L can be used for 18 % Cr - 8 % Ni, Nb stabilized steel parts that are working under low operating temperatures. EN 10088-1/-2 Non stabilized

EN 10213-4

W. Nr.

G-X5 CrNi 19 10 G-X10 CrNi 18 8

1.4301 1.4306 1.4308 1.4312

G-X5 CrNiNb 19 10

1.4541 1.4550 1.4552

X4 CrNi 18 10 X2 CrNi 19 11

Ti , Nb stabilized

X6 CrNiTi 18 10 X6 CrNiNb 18 10

1.4006 - X10 Cr 13 ; 1.4016 - X8 Cr 17 ; 1.4021 - X20 Cr 13 ; 1.4511 X8 CrNb 17

Current Type : [ AC min. 50 V / DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

250 300 350

50 - 80 75 - 115 110 - 150

1620 3110 5730

72


AS Electrodes for Non-Ferrous Metals

Electrodes for Aluminium and its alloys Electrodes for Copper and its alloys

Product Name

AWS A5.3

DIN 1732

Page

AS AlSi - 5 AS AlSi - 12

E 4043 -

EL-AlSi 5 EL-AlSi 12

77 78

Product Name

AWS A5.6

DIN 1733

Page

AS Bronz

E CuSn-C

EL-CuSn 7

79

73

7


balance

balance

AS AlSi - 5

AS AlSi - 12

11.0 - 12.0

4.7 - 5.3

Si

74

AS Bronz

Product Name

balance

Cu

0.5

Si

Electrodes for Copper and Its Alloys

Al

Product Name

1.0

Mn

max 0.1

max 0.05

Mn

Electrodes for Aluminium and Its Alloys

7 0.2

Fe

max 0.4

max 0.2

Fe

7.0

Sn

max 0.05

max 0.05

Mg

E CuSn-C

AWS A5.6

-

E 4043

AWS A5.3

EL CuSn 7

DIN 1733

EL-AlSi 12

EL-AlSi 5

DIN 1732


Electrode Selection

1 x x

DC (+) DC (_)

Aluminium & Its Alloys

AS AlSi - 5 AS AlSi - 12

PRODUCT BASE METAL 3.1325 3.1355

AlCuMg 1 AlCuMg 2

3.2151 3.2161 3.2315 3.2341 3.2381 3.2383 3.2581 3.2583

G-AlSi 6 Cu 4 G-AlSi 8 Cu 3 AlMgSi 1 G-AlSi 5 Mg G-AlSi 10 Mg G-AlSi 10 Mg (Cu) G-AlSi 12 G-AlSi 12 (Cu)

3.3241 3.3261 3.3206

G-AlMg 3 Si G-AlMg 5 Si G-AlMg Si 0.5

3.4345 3.4365

AlZnMgCu 0.5 AlZnMgCu 1.5

7

) No restriction. ) Mechanical properties should be considered. ) Can be used if corrosion resistance is considerable.

75


Electrode Selection

2 x

DC (+) DC ( )

Copper & Its Alloys (Bronze)

AS Bronz

PRODUCT BASE METAL

7

2.1016 2.1020 2.1030

CuSn 4 CuSn 6 CuSn 8

2.0220 2.0240 2.0250 2.0265 2.0360 2.0460 2.0510 2.0530 2.0540 2.0550 2.0572

CuZn 5 CuZn 15 CuZn 20 CuZn 30 CuZn 40 CuZn 20 Al 2 CuZn 37 Al 1 CuZn 38 Sn 1 CuZn 35 Ni 2 CuZn 40 Al 2 CuZn 40 Mn 2

2.1090 2.1093

G-CuSn 7 ZnPb G-CuSn 6 ZnNi

) No restriction. ) Mechanical properties should be considered. ) Corrosion resistance should be considered.

76


AS

AlSi - 5

AS AlSi-5 is an aluminium electrode with 5 % Si. It is used for joining and repair welding of 5 % Si containing rolled aluminium and cast aluminium parts. It is used on DC positive pole.

Classification and Typical Weld Metal Composition (%) DIN 1732 : EL-AlSi 5 AWS A5.3 : E 4043

Al

Si

Mn

Fe

Mg

balance

4.7 - 5.3

max 0.05

max 0.2

max 0.05

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] : 90 Yield Strength [ N/mm² ] : 160 Tensile Strength [%] : 15 Elongation (L=5d)

Applications It is an ideal electrode particularly used for the welding of 5 % Si containing rolled aluminium parts and for aluminium pipes and plates. It should not be used in the welding of aluminium alloys having high magnesium, copper or zinc content. As the weld pool metal is very fluid, parts should be welded in horizontal position. During welding, electrode should be vertical to the work piece and it should not be oscillated. Arc length should be short. Preheating to 100-300°C should be applied with respect to the thickness of the part to be welded. The slag should be removed completely after welding, since it is corrosive (the slag might be removed with water as the piece cools).

Rolled Aluminium :

Cast Aluminium :

AlMgSi 0.5 AlMgSi 0.7 AlMgSi 0.8 AlMgSi 1 AlMg 1 Si Cu

Current Type : [ DC (+) ]

G-AlSi 5 G-AlSi 6 Cu 4

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 350

60 - 90 90 - 110 100 - 140

900 1320 2040

77

7


AS

AlSi - 12

AS AlSi-12 is an aluminium electrode with 12 % Si. It is particularly used for joining and repair welding of cast aluminium and Si-alloyed aluminium parts. It is also an ideal electrode for the removal of cast defects and for the fill up of cast cavities. It is used only on DC positive pole.

Classification and Typical Weld Metal Composition (%) DIN 1732 : EL-AlSi 12

Al

Si

Mn

Fe

Mg

balance

11 - 12

max 0.1

max 0.4

max 0.05

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ HB ] Hardness

: : : :

80 180 5 160

Applications It is an ideal electrode for the welding of 12 % Si containing cast aluminium parts. It should not be used in the welding of aluminium alloys having high magnesium, copper or zinc content. The special covering removes oxide layer on the surface during welding and enables a stable arc. As the weld pool metal is very fluid, parts should be welded in horizontal position. During welding, electrode should be vertical to the work piece and it should not be oscillated.

7

Arc length should be short. Preheating to 100-300°C should be applied with respect to the thickness of the part to be welded. The slag should be removed completely after welding, since it is corrosive (the slag might be removed with water as the piece cools).

Cast Aluminium :

G-AlSi 11 G-AlSi 12 G-AlSi 12 (Cu) G-AlSi 6 Cu 4 G-AlSi 7 Mg

G-AlSi 9 Mg G-AlSi 10 Mg G-AlSi 10 Mg (Cu) G-AlSi 9 Cu 3 G-AlMg 3 Si

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 350

60 - 90 80 - 110 110 - 140

980 1320 1960

78


AS

Bronz

AS Bronz is especially designed for the welding of bronze and brass materials. It gives a filler metal of the tin-bronze type. It is possible to weld in all positions except overhead and vertical upwards.

Classification and Typical Weld Metal Composition (%) DIN 1733 : EL CuSn 7 Werkstoff-Nr : 2.1025 AWS A5.6 : E CuSn-C

Mn

P

Sn

Cu

0.5

0.10

7

balance

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ HB ] Hardness

: : : :

160 260 20 90

Applications It is used for the joining and build up welding of copper and its alloys; for the joining of copper and bronze materials with steels and joining of steel casts with cast irons. It is ideal for the copper plating of cast iron and steel parts. If machinability is not considered after welding, it should also be used for the welding of cast iron parts. It is suitable for the build up welding and joining of machine parts; especially turbine and centrifugal vanes, ship propellers, valve seats, couplings, piston arms and gears. Electrode should be nearly vertical to the work piece and the arc length should be short. To attain the best possible joining, a preheating of 300°C should be applied to copper and bronze parts.

2.1016 - CuSn 4 2.1020 - CuSn 6 2.1030 - CuSn 8

2.0220 - CuZn 5 2.0240 - CuZn 15 2.0250 - CuZn 20 2.0265 - CuZn 30 2.0360 - CuZn 40

2.0460 - CuZn 20 Al 2 2.0510 - CuZn 37 Al 1 2.0530 - CuZn 38 Sn 1 2.0540 - CuZn 35 Ni 2 2.0572 - CuZn 40 Mn 2

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

300 350 350 350

60 - 90 90 - 130 130 - 160 160 - 240

1460 2910 5180 6600

79

7


AS Pik Electrodes for Welding Cast Irons Electrodes for Cutting and Gouging

Product Name

AWS A5.15

EN ISO 1071

Page

AS Pik - 55 AS Pik - 65 AS Pik - 98 Super

E NiFe-CI E NiCu-B E Ni-CI

E C NiFe-1 3 E C NiCu-B 3 E Ni-C1 2

84 85 86

Product Name

-

-

Page

AS Oluk Aรงma AS Kesme STARWELD KARBON

-

-

87 88 89

81

8


1

0.5

1

AS Pik - 65

AS Pik - 98 Super

C

AS Pik - 55

Product Name

-

0.4

-

Si

-

1

-

Mn

Electrodes for Welding Cast Irons

-

3

43

Fe

8

82

balance

balance

balance

Ni

-

30

-

Cu

E Ni-CI

E NiCu-B

E NiFe-CI

AWS A5.15

E Ni-C1 2

E C NiCu-B 3

E C NiFe-1 3

EN ISO 1071


Electrode Selection

1 x x

AC / DC (+) _ AC / DC ( )

x

BASE METAL 0.6010 0.6015 0.6020 0.6025 0.6030 0.6035

GG-10 GG-15 GG-20 GG-25 GG-30 GG-35

0.7033 0.7040 0.7043 0.7050 0.7060 0.7070 0.7080

GGG-35.3 GGG-40 GGG-40.3 GGG-50 GGG-60 GGG-70 GGG-80

0.8035 0.8040 0.8045

GTW-35-04 GTW-40-05 GTW-45-07

0.8135 0.8145 0.8155 0.8165 0.8170

GTS-35-10 GTS-45.06 GTS-55.04 GTS-65.02 GTS-70-02

AS Pik - 65

PRODUCT

AS Pik - 98 Super AS Pik - 55

Cast Irons

8

) No restriction. ) Mechanical properties should be considered. ) Welding applications for cast irons should be considered.

83


AS

Pik - 55

AS Pik-55 is a nickel cored electrode. It is used for the welding of all types of cast irons and particularly for the joining of austenitic alloyed cast irons; called Ni-resist. It gives a very stable arc and a negligible amount of slag that can easily be removed. Weld metal can be easily machined and it has the same color with that of the cast iron. It has excellent mechanical properties and it is very resistant to cracking.

Classification and Typical Weld Metal Composition (%) EN ISO 1071 : E C NiFe-1 3 AWS A5.15 : E NiFe-CI

C

Fe

Ni

1

43

balance

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ HB ] Hardness

: : : :

320 - 360 430 - 470 10 160 - 200

Applications AS Pik-55 is particularly used for the joining and build up welding of gray cast iron, nodular cast iron and malleable cast iron parts. It is an ideal electrode for the joining of cast iron pieces to stainless steel or steel parts. On the other hand, it can also be used for filling up cavities in castings, or cavities that might form after machining. It is also an ideal electrode for the welding of parts, exposing to high dynamic forces, that are found in heavy machinery base and body.

8

When welding cast iron without preheat, the smallest possible electrode diameter and the lowest possible welding current should be selected to limit the width of the heat effected zone that might occur due to excess heating. When welding thick pieces, a preheating to 150-200°C and slow cooling is recommended. 0.8135 0.8145 0.8155 0.8165 0.8170

-

GTS 35-10 GTS 45-06 GTS 55-04 GTS 65-02 GTS 70-02

0.7040 0.7050 0.7060 0.7070 0.7080

Current Type : [ AC min. 50 V / DC (+) ] Diameter [ mm ]

Length [ mm ]

2.50 3.25 4.00

300 300 350

Current [A]

1670 2730 4750

84

GGG 40 GGG 50 GGG 60 GGG 70 GGG 80

Welding Positions

Weight (100 pcs) [g]

45 - 80 60 - 120 90 - 140

-


AS

Pik - 65

AS Pik-65 is a Ni-Cu alloyed monel cored electrode. It is used for the welding of all types of cast irons. It gives a minimum amount of spatter and a very stable arc. The slag is easy to remove. Heat effected zone is very narrow. Porosity free weld metal can be easily machined. Filler metal has the same color with that of the work piece.

Classification and Typical Weld Metal Composition (%) EN ISO 1071 : E C NiCu-B 3 AWS A5.15 : E NiCu-B

C

Si

Mn

Fe

Cu

Ni

0.5

0.4

1

3

30

65

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength [%] Elongation (L=5d) [ HB ] Hardness

: : : :

260 - 280 400 - 420 15 140 - 160

Applications AS Pik-65 is particularly used for the joining and build up welding of parts made from gray cast iron, nodular cast iron, malleable cast iron and of parts whose analysis is not known. Monel alloy core has 65 % Ni / 30 % Cu. It is an ideal electrode for the joining of cast iron pieces to monel alloys, stainless and ordinary steels. It can also be used for filling up cavities in castings, or cavities that might form after machining. When welding cast iron without preheat, the smallest possible electrode diameter and the lowest possible welding current should be selected to limit the width of the heat effected zone that might occur due to excess heating. When welding thick pieces, a preheating to 100-200°C and slow cooling is recommended. 0.6010 0.6015 0.6020 0.6025 0.6035

- GG 10 - GG 15 - GG 20 - GG 25 - GG 35

0.8135 0.8145 0.8155 0.8165 0.8170

- GTS 35-10 - GTS 45-06 - GTS 55-04 - GTS 65-02 - GTS 70-02

- GGG 40 - GGG 50 - GGG 60 - GGG 70 - GGG 80

Welding Positions

Current Type : [ AC min. 50 V / DC (+) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

300 300 400

65 - 90 85 - 130 110 - 160

1580 2650 5470

85

0.7040 0.7050 0.7060 0.7070 0.7080

8


AS

Pik - 98 Super

AS Pik-98 Süper is a nickel cored electrode. It enables welding with drop arc metal transfer. It is used for the welding of all types of cast irons. It gives a very stable arc and a negligible amount of slag that can easily be removed. Heat effected zone is very narrow. Porosity free weld metal can be easily machined. It has excellent resistant to cracking.

Classification and Typical Weld Metal Composition (%) EN ISO 1071 : E Ni-C1 2 AWS A5.15 : E Ni-CI

C

Ni

1

balance

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical [ N/mm² ] Yield Strength [ N/mm² ] Tensile Strength Elongation (L=5d) [ % ] [ HB ] Hardness

: : : :

300 380 8 - 10 120 - 140

Applications AS Pik-98 Süper is particularly used for the joining and build up welding of gray cast iron, nodular cast iron and malleable cast iron parts. It is an ideal electrode for the joining of cast iron pieces to monel alloys, stainless and ordinary steels. It can also be used for filling up cavities in castings, or cavities that might form after machining. When welding cast iron without preheat, the smallest possible electrode diameter should be selected to limit the width of the heat effected zone that might occur due to excess heating. When welding thick pieces, a preheating to 150-300°C and slow cooling is recommended.

8

0.6010 0.6015 0.6020 0.6025 0.6035

- GG 10 - GG 15 - GG 20 - GG 25 - GG 35

0.8135 - GTS 35-10 0.8145 - GTS 45-06 0.8155 - GTS 55-04

0.8035 - GTW 35-04 0.8040 - GTW 40-05 0.8045 - GTW 45-07

Welding Positions

Current Type : [ AC min. 40 V / DC (-) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25

300 300

65 - 100 90 - 130

1810 2830

86


AS

Oluk Açma

AS Oluk Açma is an ideal electrode for gouging in and joint preparation of all types of steel, cast iron and non-ferrous metal. It is a general purpose electrode especially used before repair and maintenance welding applications.

Approvals GOST , SEPRO

15 °

Working direction

Functions of the Coating / The Usage and Application of the Electrode The special coating performs several functions: 1 - To form a concentrated powerful arc, 2 - To form a stable arc and to reduce the fast melting of the electrode, 3 - To produce a strong gas jet to blow away the melted material. The angle between the electrode and the work piece should be 15°. It is used for beveling, weld preparation of cracks and for gouging of armour steels, air hardenable steels, stainless steels, cast irons, hard metals, work hardenable and difficult to machine materials. The surface is clean and seldom requires further dressing. Metal removal speed depends on the electrode diameter, ampere selected and to the thickness of the piece. It is recommended to work with a quality power source for best results.

Welding Positions

Current Type : [ DC (-) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 350 350

190 - 220 220 - 280 260 - 350

3560 5170 8080

87

8


AS

Kesme

AS Kesme is an ideal electrode for cutting and piercing of all types of steel, cast iron and non-ferrous metal. It is a general purpose electrode especially used before and during repair and maintenance welding applications.

Approvals GOST , SEPRO

Working direction

Working direction

Functions of Coating / The Usage and Application of the Electrode Due to the physical properties of the coating material, core wire has a higher melting rate than the coating material. Therefore, 3 to 5 mm crater formation occurs at the tip of the electrode. Particularly in cutting and piercing applications, this crater formation enables the operation of the electrode penetrating into the melting piece without short circuit. Pieces up to a thickness of 10 mm can be easily cut with this electrode. For thicker pieces (10 mm), electrode should be moved up and down in the direction of material being cut to move away the melted material. In piercing applications, electrode should be perpendicular to the work piece.

8

It is used for beveling, weld preparation of cracks and for gouging of armour steels, air hardenable steels, stainless steels, cast irons, hard metals, work hardenable and difficult to machine materials. The surface is clean and seldom requires further dressing. Metal removal speed depends on the electrode diameter, ampere selected and to the thickness of the piece. It is recommended to work with a quality power source for best results.

Welding Positions

Current Type : [ DC (-) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

450 450 450

180 - 210 210 - 275 250 - 300

4750 6810 9860

88


STARWELD

Karbon

This process uses carbon, pressurized air and electric current to cut or gouge the metals and has many advantages over the conventionel cutting processes like oxy-fuel or saw blade cutting. Enables high speed gouging and metal removals. Easy usage, Enables cleaner and more comfortables working environment than other ones. Enables to work with different materials like mild and stainless steels, cast irons, copper and light alloys. No risk of explosion. Arc carbon cutting process is based on the integral function of electric arc and pressurized air 체sing in cutting process. The metal that is molten by electric arc, is removed by the air jet. The tip of the Arc Cutting Torch, is suitables for every cutting / gouging positions and supported by special nozzle that directs to air-jet.

How to Use the Arc Gouging / Cutting Carbon Electrodes and Application Areas Connect the electrode with the DC(+) current to the work piece , Connect the air-jet apparatus to the electrode holder, Keep the distance between electrode and work pieces about 150 mm Consider the type of current (DC or AC), diameter of the electrode, amount of current and other parameters like material type, Turn the air-jet valve on, Establish the arc between electrode and work piecei Arc distance must be kept around 1 to 5 mm (very short), To remove the metal, that is cut or gouge, bend the electrode about 30째 (maximum current limit must not be exceeded). APPLICATION AREAS : Foundries : To remove and gouge of the risers and runners of the mild / alloyed steel and iron castings. Steel Industries : The removing of the slag inclusions on the alloyed non-alloyed steel billet and slabs, blums, surface cleaning of the faulty weld beads. Manufacturing of the Pressure-Vessel, Ship and Steel Constructions : The surface cleaning of the rear side of the double sided welding applications before the process removing of the miswelded parts, weld beads from the process region and cutting the alloyed steel work pieces. Repair and Maintenance Factories : Pipe, metal sheets cutting and maintenance of the cast pieces.

Current Type : [ DC (+) or AC (DC recommended) ] and Other Parameters Diameter [ mm ]

Length [ mm ]

Current [A]

Voltage [V]

Weight (100 pcs) [g]

6.40 8.00 10.00

305 305 305

250 - 450 300 - 550 450 - 750

41 - 43 44 - 48 46 - 50

2000 2600 4600

89

Pieces of Electrode per box 50 50 50

8


AS SD Electrodes for Overlay Welding and Hardfacing

Product Name

EN 14700

DIN 8555

AS AS AS AS AS AS AS AS AS AS AS

E Fe8 E Fe7 E Fe4 E Fe4 E Fe1 E Fe1 E Fe4 E Fe9 E Fe9 E Fe15 E Fe15

E6 - UM - 55 R E5 - UM - 45 R E6 - UM - 60 E2 - UM - 60 Z E1 - UM - 300 E1 - UM - 350 E4 - UM - 60 (65) S E7 - UM - 200 K E7 - UM - 200 K (E10 - UM - 60 GR) E10 - UM - 60 G

SD - CR 10 SD - CR 13 SD - 60 SD - 65 SD - 300 SD - 350 SD - HSS SD - MANGAN SD - MANGAN 165 SD - ABRA Nb SD - ABRA Cr

91

Page 93 94 95 96 97 98 99 100 101 102 103

9


0.70

0.10

0.40

0.70

0.07

0.10

0.90

0.70

0.70

3.40

4.50

AS SD - CR 13

AS SD - 60

AS SD - 65

AS SD - 300

AS SD - 350

AS SD - HSS

AS SD - MANGAN

AS SD - MANGAN 165

AS SD - ABRA Nb

AS SD - ABRA Cr

C

AS SD - CR 10

Product Name

92

-

-

0.10

0.10

1.20

0.50

0.20

4.00

0.40

0.50

0.60

Si

-

-

14.00

14.00

1.30

0.70

0.60

0.30

0.50

0.30

0.70

Mn

33.00

22.00

-

-

4.50

3.50

3.40

2.00

6.00

13.00

10.00

Cr

-

-

3.50

3.00

-

-

-

-

-

-

-

Ni

Electrodes for Overlay Welding and Hardfacing

9 -

-

-

-

7.50

-

-

-

0.60

-

-

Mo

-

-

-

-

1.80

-

-

-

-

-

-

W

-

-

-

-

1.50

-

-

-

-

-

-

V

-

10.00

-

-

-

-

-

-

-

-

-

Nb

E Fe15

E Fe15

E Fe9

E Fe9

E Fe4

E Fe1

E Fe1

E Fe4

E Fe4

E Fe7

E Fe8

EN 14700

E10-UM-60 G

(E10-UM-60 GR)

E7-UM-200 K

E7-UM-200 K

E4-UM-60 (65) S

E1-UM-350

E1-UM-300

E2-UM-60 Z

E6-UM-60

E5-UM-45 R

E6-UM-55 R

DIN 8555


AS

SD - CR 10

AS SD-CR 10 is a basic coated electrode. Wear resistant weld metal has a high toughness value and exhibits a high resistance to cracking at operating conditions with high impact. The highest wear resistance is obtained after three passes. 10 % Cr content increases the wear resistance of the weld metal to the simpler forms of corrosive attack. The weld metal is resistant to softening up to 500°C. It can be machined by grinding.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe8 DIN 8555 : E6-UM-55 R

C

Si

Mn

Cr

0.7

0.6

0.7

10

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 52 - 56 HRC

Applications It is used for hardfacing of alloyed and unalloyed steels. Worn surfaces of crushing tools in the mining industry, conveyor screws, excavator bucket and teeth, excavator and bulldozer blades, mixer parts, screws of cement pumps, and cutting edges of cold worked tool steels can be hardfaced with AS SD-CR 10. While there is no need to have a buffer layer for unalloyed steels up to St 70; for high alloyed steels, it is recommended to have a buffer layer with AS B-248 or AS B-255, and in special cases with AS P-308 Mn or AS P-312. HRC 70 60 50 40 30 20 10

100

300

500

700 °C

Welding Positions

Current Type : [ DC (+) / AC min. 65 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

110 - 140 150 - 190 180 - 240

4340 8410 13460

93

9

Tempering at 700 °C for 1-2 hour

Hardening in oil or air at 950 - 1000°C Softening in furnace at 850°C


AS

SD - CR 13

AS SD-CR 13 is a rutile coated electrode. It gives a corrosion and wear resistant ferritic-martensitic stainless steel weld metal. It is used in hardfacing applications where a hardness of 42-46 HRC is required. The weld metal is resistant to softening up to 500°C.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe7 DIN 8555 : E5-UM-45 R

C

Si

Mn

Cr

0.1

0.5

0.3

13

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 42 - 45 HRC

Applications It is used for hardfacing of alloyed and unalloyed steels. Worn surfaces of rails and rail surfaces, crane and conveyor wheels, cast steel valve seats, pinions, track rollers and links of earthmoving equipment can be hardfaced with AS SD-CR 13. It can also be used for joining of low carbon steels having 13 % Cr. It is recommended to use AS SD-CR 10 in multipass applications as it is a basic coated electrode. It is also recommended to have a preheating and interpass temperature of minimum 200°C.

HRC 70 60 50 40 30 20 10

9

Tempering at 700 °C for 1-2 hour

Hardening in oil or air at 980 - 1000°C Softening in furnace at 780 - 800°C

100

Current Type : [ AC min. 70 V / DC (+) ]

500

700 °C

Welding Positions

Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 350 350

85 - 120 120 - 160 160 - 210

4640 6880 10600

94

300


AS

SD - 60

AS SD-60 is a general purpose, rutile coated hardfacing electrode especially designed to use with small transformers having a relatively low open circuit voltage. It is resistant to softening up to 500째C. It gives a high abrasion resistant martensitic type weld metal with a medium toughness. Weld metal can not be machined.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe4 DIN 8555 : E6-UM-60

C

Si

Mn

Cr

Mo

0.4

0.4

0.5

6

0.6

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 57 - 62 HRC

Applications It is used for hardfacing of alloyed and unalloyed steels. Protective lining of worn surfaces of machines used in mines, bulldozer blades, excavator teeth, crushing jaws, conveyors, agricultural and forestry machines that are exposed to wear can be hardfaced with this electrode.

9 Welding Positions

Current Type : [ AC min. 65 V / DC (+) ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

60 - 120 100 - 160 130 - 190 170 - 240

2450 4190 8040 12760

95


AS

SD - 65

AS SD-65 is a basic coated electrode. It gives a high oxidation resistant (up to 850°C) weld metal that also have a high wear resistance. It is resistant to wears of medium abrasions at high temperatures.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe4 DIN 8555 : E2-UM-60 Z

C

Si

Mn

Cr

0.7

4.0

0.3

2

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 58 - 62 HRC 50 - 60 HRC

(3 passes, no preheating) (3 passes, 300°C preheating)

Applications It is particularly used for repair applications of machine parts that are particularly exposed to wear by stone, coal, sand and soil. Loading machines, band plates, wear plates and parts of grinders can be hardfaced with this electrode. It is recommended to use AS SD-65 in high temperature applications where oxidation resistance is more important than hardness and resistance to tempering like feed screws in furnaces. HRC 70 60 50 40 30 20 10

Hardening in oil or air at 920 - 980°C Softening in furnace at 680 - 700°C

Tempering at 700 °C for 1-2 hour

100

300

500

700 °C

9 Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

100 - 140 150 - 190 190 - 240

3370 6660 9790

96


AS

SD - 300

AS SD-300 is a heavily coated basic electrode particularly used for wear conditions where impact stresses are considered. It gives a weld metal that is resistant to deformations of high rolling forces including metal-to-metal friction. Weld metal is air hardenable and can be machined with carbide cutting tools. Hardness varies with respect to the number of passes and cooling rate. It has about 115 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe1 DIN 8555 : E1-UM-300

C

Si

Mn

Cr

0.07

0.2

0.6

3.4

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 290 - 330 HB

Applications It is used for hardfacing of rollers, gears, rail crossings, switch points, brake shoes and crane wheels. Joining of heat treatable steels having a tensile strength of 80 - 90 kg/mm² is another application area.

HRC 70 60

Tempering for 1 hour. Tempering for 24 hour.

50 40 30 20 10 100

300

500

700 °C

9 Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

110 - 140 150 - 190 190 - 230

3340 6730 9740

97


AS

SD - 350

AS SD-350 is a heavily coated basic electrode particularly used for wear conditions where impact stresses are considered. It gives a weld metal that is resistant to deformations of high rolling forces including metal-to-metal friction. Weld metal is air hardenable and can be machined with carbide cutting tools. Hardness varies with respect to the number of passes and cooling rate. It has about 115 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe1 DIN 8555 : E1-UM-350

C

Si

Mn

Cr

0.1

0.5

0.7

3.5

Approvals GL GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 325 - 350 HB

Applications It is used for hardfacing of rollers, gears, rail crossings, switch points, brake shoes and crane wheels. Joining of heat treatable steels having a tensile strength of 80-90 kg/mm² is another application area.

HRC 70 Tempering for 1 hour. Tempering for 24 hour.

60 50 40 30 20 10 100

300

500

700 °C

9 Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

110 - 140 150 - 190 190 - 240

3440 6770 10080

98


AS

SD - HSS

AS SD-HSS is a basic coated electrode. It gives a Mo alloyed, high speed steel type weld metal. Deposited metal retains its toughness properties at high temperatures enabling the formation of high strength welds, particularly during the hardfacing of cutting and punching tools.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe4 DIN 8555 : E4-UM-60 (65) S

C

Si

Mn

Cr

Mo

W

V

0.9

1.2

1.3

4.5

7.5

1.8

1.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 57 - 60 HRC (as welded) 65 HRC (after double tempering)

Applications It is particularly used for hardfacing of cutting and punching tools made of alloyed and unalloyed steels with a hot tool steel structured weld metal. Part that is going to be welded should be preheated to 400-500째C and small beads should be preferred to inhibit overheating. Machine tools, drilling parts, and tools made of high speed steels are among other application areas.

HRC 70 60 50 40 30 20

Tempering for 1 hour. Tempering for 24 hour.

10 100

500

700 째C

Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00

350 350 350

70 - 100 100 - 140 150 - 185

2580 4370 6680

99

300

9


AS

SD - MANGAN

AS SD-MANGAN is a basic coated electrode. It gives an austenitic Hadfield Manganese steel type weld metal with 13 % Mn content. 3 % Ni content increases the ductility and impact properties. Soft weld metal has a low resistance to abrasion after the application; but it hardens rapidly when cold worked or subject to gritty abrasion.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe9 DIN 8555 : E7-UM-200 K AWS A5.13 : E FeMn-A

C

Si

Mn

Ni

0.7

0.1

14

3

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 175 - 200 HB (as welded) 450 HB (after cold working)

Applications It is used for the surfacing and reclamation of austenitic 12-14 % Mn steels and joining of these to mild or medium carbon steels. Teeth used for mineral handling, cone, roll and jaw crushers, crushing and grinding hammers, screens and grid bars and parts exposing to impact can be hardsurfaced with AS SD-MANGAN. Especially on 12-14 % Mn steels, it is important to use this electrode before using chromium carbide structured hardfacing electrodes to form a buffer layer as it enables a healthy joining of the subsequent hardsurface to the base metal. Attention ! As % 12-14 Mn containing weld metal has poor corrosion resistance, its properties are similar to carbon steels.

9 Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00 5.00

350 450 450

80 - 140 140 - 180 180 - 230

3810 7440 11610

100


AS

SD - MANGAN 165

AS SD-MANGAN 165 is a zircon-basic coated electrode. It gives an austenitic Hadfield Manganese steel type weld metal with 13 % Mn content. 3.5 % Ni content increases the ductility and impact properties. Soft weld metal has a low resistance to abrasion after the application; but it hardens rapidly when cold worked or subject to gritty abrasion. It has about 165 % metal recovery.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe9 DIN 8555 : E7-UM-200 K AWS A5.13 : E FeMn-A

C

Si

Mn

Ni

0.7

0.1

14

3.5

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 175 - 200 HB (as welded) 450 HB (after cold working)

Applications It is used for the surfacing and reclamation of austenitic 12-14 % Mn steels and joining of these to mild or medium carbon steels. Teeth used for mineral handling, cone, roll and jaw crushers, crushing and grinding hammers, screens and grid bars and parts exposing to impact can be hardsurfaced with AS SD-MANGAN 165. Especially on 12-14 % Mn steels, it is important to use this electrode before using chromium carbide structured hardfacing electrodes to form a buffer layer as it enables a healthy joining of the subsequent hardsurface to the base metal. Attention ! As % 12-14 Mn containing weld metal has poor corrosion resistance, its properties are similar to carbon steels.

9 Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

2.50 3.25 4.00 5.00

350 350 450 450

70 - 100 100 - 150 150 - 185 200 - 240

3050 5350 10500 15720

101


AS

SD - ABRA Nb

AS SD-ABRA Nb is a basic coated electrode that is highly resistant to abrasion wear caused by fine or coarse hard minerals. Concentrated Cr and Nb carbides have been finely dispersed in its structure. In corrosive environments, it gives a better resistance to wear caused by fine minerals than hardfaced structures having an ordinary chromium carbide structure.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe15 DIN 8555 : (E10-UM-60 GR)

C

Cr

Nb

3.4

22

10

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 55 - 57 HRC Carbide hardness : > 1500 HV

Applications Wear plates, dredgers, rock crushers, grinding hammers and rollers can be hardfaced with AS SD-ABRA Nb. It should not be used for more than three passes. In applications requiring a thick deposit metal, AS P-308 Mn or AS P-312 should be used for buffering. It is crucial to have a buffer layer with AS P-308 Mn for 12-14 % Mn containing steels before hardfacing applications.

9 Welding Positions

Current Type : [ DC (+) / AC min. 65 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00

350 350

100 - 150 140 - 200

5750 8930

102


AS

SD - ABRA Cr

AS SD-ABRA Cr is a basic coated electrode that is highly resistant to abrasion wear caused by coarse hard minerals. It has a highly concentrated chromium carbide in its structure.

Classification and Typical Weld Metal Composition (%) EN 14700 : E Fe15 DIN 8555 : E10-UM-60 G AWS A5.13 : E FeCr-A1

C

Cr

4.5

33

Approvals GOST , SEPRO

Mechanical Properties of the Weld Metal, Typical Hardness : 58 - 62 HRC Carbide hardness : 1400 - 1500 HV

Applications Bucket conveyors, extruder screws, dragline buckets, dredgers, scrappers, screw conveyors, press screws, heads in ceramic industry, mixer blades and grinding rollers can be hardfaced with AS SD-ABRA Cr. It should not be used for more than three passes. Interpass temperature should be 300-500°C. In applications requiring a thick deposit metal, AS P-308 Mn or AS P-312 should be used for buffering. It is crucial to have a buffer layer with AS P-308 Mn for 12-14 % Mn containing steels before hardfacing applications.

9 Welding Positions

Current Type : [ DC (+) / AC min. 65 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00

350 350

115 - 170 120 - 190

5760 9140

103


AS Gas Metal Arc (GMA) Welding Wires

Product Name

EN 440

AWS A5.18

Page

AS SG2 / ASFİL 250 AS SG3

G42 3 CM G3Si 1 G42 3 CM G4Si 1

ER 70 S - 6 ER 70 S - 6

108 109

10

105


D

106

D

100±2

d1

16.5

+1 0

d1 (mm)

0

45 -2

W

0.1

AS SG3

W

0.1

AS SG2 / ASFİL 250

S100 Plastic Spool (1 kg)

C

Product Name

1.0

0.9

Si

Gas Metal Arc (GMA) Welding Wires

10

D

d1

200±3

D

50.5

+2.5 0

d1

S200 Plastic Spool (5 kg)

1.7

1.5

Mn

10

+1 0

d2 (mm)

d2

44.5±0.5

A

A

W

W 0

55 -3

ER 70 S-6

ER 70 S-6

AWS A5.18

D

H

H ~ 800±20

(mm) ~ 500±20

D

ASFIL DRUM (250 kg)

®

G42 3CM G4Si 1

G42 3CM G3Si 1

EN 440


107

D

300±5

D

d1

50.5

+2.5 0

d1

S300 Plastic Spool (15 kg)

10

10

+1 0

d2 (mm)

d2

A

W

0

44.5±0.5 103 -3

A

W

D

300±5

D 50.5

+2.5 0

d1

d1

(mm) 180±2

d

BS300 Basket Spool Without Needing Adapter (15 kg)

W 100±3

W

d D

0

300 -5

D

B300 Basket Spool (15 kg)

180±2

d (mm)

100±3

W

W

d


AS SG2 / ASFİL 250 AS SG2 is a copper coated gas metal arc welding wire in 15 kg spools or 250 kg drums. It is particularly designed for semi-automatic and full-automatic GMAW applications. Working temperature can range between -50 to +450°C. CO2 or 80 % Ar- 20 % CO2 are used for gas shielding.

Classification and Typical Wire Composition (%) EN 440 : G42 3CM G3Si 1 AWS A5.18 : ER 70 S-6

Approvals

CO2

CO2+Ar

ABS : 3SA, 3YSA 3YSA BV : 3YM C Si Mn DNV : III YMS III YMS GL 3YS : 3YS 0.08 0.85 1.5 LRS : 3S 3YS H15 *) 0.06 0.55 1.1 RINA : 3Y42 : 3Y *) Typical Weld Metal Composition (CO2 gas shielding) RMRS CE , DB , GOST , NAKS , SEPRO , TÜV

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: 440 : 540 : 30 : 60 @ - 30°C

Applications It is used for the gas metal arc welding of unalloyed structural steels with a tensile strength up to 530 N/mm²; ship's plate and fine grained carbon-manganese steels.

10

Structural Steels :

Pipe Materials :

Ship Plates :

1.0035 1.0037 1.0570 1.0301 1.0501

0.8135 1.0457 1.0484 1.0430 1.0582

Grade

- St 33 - St 37-2 - St 52-3 - C10 - Ck10 - C35 - Ck35

- St E 210-7 - St E 240-7 - St E 290-7 - St E 320-7 - St E 360-7

Pressure Vessel Steels :

Fine Grained Steels :

1.0345 1.0425 1.0481 1.0473

1.0461 - St E 255 1.8902 - St E 420

- HI - HII - 17 Mn 4 - 19 Mn 6

Current Type : [ DC (+) ]

-A -B -C -D -E - AH - DH - EH

Welding Positions

Diameter [ mm ]

Current [A]

Voltage [V]

Spool Weight [ kg ]

Short Arc

0.8 1.0 1.2

60 - 140 80 - 175 120 - 200

18 - 22 18 - 24 18 - 27

15 15 15

Spray Arc

1.2 1.6

150 - 280 225 - 480

25 - 40 28 - 40

15 15

108


AS SG3 AS SG3 is a copper coated gas metal arc welding wire in 15 kg coils. It is particularly designed for semiautomatic and full-automatic GMAW applications. Working temperature can range between -50 to +450°C. CO2 or 80 % Ar- 20 % CO2 are used for gas shielding.

Classification and Typical Wire Composition (%) EN 440 : G42 3CM G4Si 1 AWS A5.18 : ER 70 S-6

*)

C

Si

Mn

Approvals

0.08 0.06

1.0 0.6

1.7 1.2

CE , TÜV GOST , SEPRO

*) Typical Weld Metal Composition (CO2 gas shielding)

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [%] [ Joule ] Impact (ISO-V)

: 470 : 570 : 25 : 60 @ - 30°C

Applications It is used for the gas metal arc welding of unalloyed structural steels with a tensile strength up to 570 N/mm²; ship's plate and fine grained carbon-manganese steels. Structural Steels :

Pipe Materials :

Ship Plates :

1.0035 1.0037 1.0570 1.0301 1.0501

0.8135 1.0457 1.0484 1.0430 1.0582

Grade - A -B -C -D -E - AH - DH - EH

- St 33 - St 37-2 - St 52-3 - C10 - Ck10 - C35 - Ck35

- St E 210-7 - St E 240-7 - St E 290-7 - St E 320-7 - St E 360-7

Pressure Vessel Steels :

Fine Grained Steels :

1.0345 1.0425 1.0481 1.0473

1.0461 - St E 255 1.8902 - St E 420

- HI - HII - 17 Mn 4 - 19 Mn 6

Current Type : [ DC (+) ]

Welding Positions

Diameter [ mm ]

Current [A]

Voltage [V]

Spool Weight [ kg ]

1.0 1.2 1.6

80 - 175 120 - 200 225 - 480

18 - 28 18 - 30 28 - 40

15 15 15

109

10


AS Submerged Arc (SA) Welding Wires

Product Name

EN 756

AWS A5.17 AWS A5.23 *

AS AS AS AS AS

S1 S2 S2 S2 Si S2 Mo

EL 12 EM 12 EM 12 K EM 12 K EA 2 *

S1 / ASFİL S1 S2 / ASFİL S2 EM12K S2 Si S2 Mo

Page

113 114 115 116 117

11 111


112

D

0.10

0.10

0.07

0.10

AS S2

AS EM12K

AS S2 Si

AS S2 Mo

B435 Basket Spool (30 kg)

0.10

AS S1

C

W

d

0.10

0.15

0.13

0.07

0.07

Si

Submerged Arc (SA) Welding Wires

11

d (mm)

300±5

435 max

0.030

0.025

0.025

0.025

0.025

S

D

1.00

1.00

0.90

0.90

0.50

Mn

100±3

W

0.30

0.30

0.30

0.30

0.30

Cu

0.50

-

-

-

-

Mo

D

EA 2 *

EM 12 K

EM 12 K

EM 12

EL 12

H

AWS A5.17 AWS A5.23 *

(mm)

H ~ 600±20 ~ 1000±20

D

ASFİL® DRUM (320-350 kg)

S2Mo

S2Si

S2Si

S2

S1

EN 756


AS S1 / ASFİL S1 AS S1 (30 kg spool) and ASFİL S1 (320-350 kg drum) are copper coated submerged arc welding wires designed particularly for the welding of mild steels.

Classification and Typical Wire Composition (%) EN 756 : S1 ( S 38 2 AB S1 with flux LincolnWeld 860 ) AWS A5.17 : EL 12

*)

C

Si

Mn

S

Cu

0.10 0.05

0.07 0.25

0.50 1.00

max. 0.025 max. 0.020

max. 0.30 max. 0.25

Approvals ABS BV DNV GL LRS

*) Typical Weld Metal Composition with flux LincolnWeld 860

: : : : :

3M A3M III M 3M 3M

CE , GOST , SEPRO , TÜV

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] : 370 - 400 Tensile Strength [ N/mm² ] : 440 - 490 Note : Tensile and Yield Strength values are given in a wide range, as the submerged arc welding flux compositions might vary considerably. with flux LincolnWeld 860 Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] Impact (ISO-V) [ Joule ]

: : : :

400 490 34 50 @ - 20°C

General Applications It is used for the submerged arc welding of unalloyed structural steels with a tensile strength up to 490 N/mm²; ship's plate and fine grained carbon-manganese steels.

Diameters and Packaging AS S1 (30 kg spool)

2.0

2.4

3.2

4.0

ASFİL S1 (320-350 kg drum)

2.0

2.4

3.2

4.0

113

11


AS S2 / ASFİL S2 AS S2 (30 kg spool) and ASFİL S2 (320-350 kg drum) are copper coated submerged arc welding wires designed particularly for the welding of middle and high strength steels.

Classification and Typical Wire Composition (%) EN 756 : S2 ( S 35 2 AB S2 with flux LincolnWeld 860 ) AWS A5.17 : EM 12

*)

C

Si

Mn

S

Cu

0.10 0.05

0.07 0.25

0.90 1.20

max. 0.025 max. 0.020

max. 0.30 max. 0.15

Approvals ABS BV DNV GL LRS RINA

*) Typical Weld Metal Composition with flux LW 860

: : : : : :

3M, 3YM A3YM III YM 3YM 3M, 3YM 3Y42

CE , GOST , SEPRO , TÜV

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] : 370 - 440 Tensile Strength [ N/mm² ] : 450 - 530 Elongation (L=5d) [ % ] : 25 - 30 Note : Tensile and Yield Strength values are given in a wide range, as the submerged arc welding flux compositions might vary considerably. with flux LincolnWeld 860 Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] [ Joule ] Impact (ISO-V)

: : : :

430 490 25 50 @ - 20°C

General Applications It is used for the submerged arc welding of unalloyed structural steels with a tensile strength up to 520 N/mm²; ship's plate and fine grained carbon-manganese steels.

Diameters and Packaging

11

AS S2 (30 kg spool)

2.0

2.4

3.2

4.0

ASFİL S2 (320-350 kg drum)

2.0

2.4

3.2

4.0

114


AS EM12K AS EM12K is copper coated submerged arc welding wires designed particularly for the welding of middle and high strength steels.

Classification and Typical Wire Composition (%) EN 756 : S2 ( S 35 2 AB S2 with flux LincolnWeld 860 ) AWS A5.17 : EM 12 K

*)

C

Si

Mn

S

Cu

0.10 0.05

0.13 0.30

0.90 1.20

max. 0.025 max. 0.020

max. 0.30 max. 0.15

*) Typical Weld Metal Composition with flux LW 860

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] : 370 - 450 Tensile Strength [ N/mm² ] : 450 - 540 Elongation (L=5d) [ % ] : 25 - 30 Note : Tensile and Yield Strength values are given in a wide range, as the submerged arc welding flux compositions might vary considerably. with flux LincolnWeld 860 Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] Impact (ISO-V) [ Joule ]

: : : :

440 510 25 50 @ - 20°C

General Applications It is used for the submerged arc welding of unalloyed structural steels with a tensile strength up to 530 N/mm²; ship's plate and fine grained carbon-manganese steels.

Diameters and Packaging AS EM12K (30 kg spool)

2.0

2.4

3.2

4.0

ASFİL EM12K (320-350 kg drum)

2.0

2.4

3.2

4.0

115

11


AS S2 Si AS S2 Si is copper coated submerged arc welding wire designed particularly for the welding of middle and high strength steels.

Classification and Typical Wire Composition (%) EN 756 : S2 Si ( S 46 2 MS S2Si with flux LincolnWeld 761 ) AWS A5.17 : EM 12 K

*)

C

Si

Mn

S

Approvals

0.07 0.07

0.15 0.65

1.00 1.70

max. 0.025 max. 0.025

GOST , SEPRO

*) Typical Weld Metal Composition with flux LW 761

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] : 370 - 440 Tensile Strength [ N/mm² ] : 450 - 530 Impact (ISO-V) [ Joule ] : 47 @ - 20°C Note : Tensile and Yield Strength values are given in a wide range, as the submerged arc welding flux compositions might vary considerably. with flux LincolnWeld 761 Yield Strength [ N/mm² ] : 430 Tensile Strength [ N/mm² ] : 560 Impact (ISO-V) [ Joule ] : 47 @ - 20°C

General Applications It is used for the submerged arc welding of unalloyed structural steels with a tensile strength up to 530 N/mm²; ship's plate and fine grained carbon-manganese steels.

Diameters and Packaging

11

AS S2 Si (30 kg spool)

3.2

4.0

ASFİL S2 Si (320-350 kg drum)

3.2

4.0

116


AS S2 Mo AS S2 Mo is copper coated submerged arc welding wire designed particularly for the welding of high impact resistant steels.

Classification and Typical Wire Composition (%) EN 756 : S2 Mo ( S 46 4 AB S2Mo with flux LincolnWeld 223 ) AWS A5.23 : EA 2

*)

C

Si

Mn

Mo

Approvals

0.10 0.06

0.10 0.25

1.00 1.30

0.50 0.50

GOST , SEPRO , TÜV

*) Typical Weld Metal Composition with flux LW 223

Mechanical Properties of the Weld Metal, Typical Yield Strength [ N/mm² ] : 460 - 600 Tensile Strength [ N/mm² ] : 550 - 670 Impact (ISO-V) [ Joule ] : 50 @ - 20°C Note : Tensile and Yield Strength values are given in a wide range, as the submerged arc welding flux compositions might vary considerably. with flux LincolnWeld 223 Yield Strength [ N/mm² ] Tensile Strength [ N/mm² ] Elongation (L=5d) [ % ] [ Joule ] Impact (ISO-V)

: : : :

470 550 29 55 @ - 20°C

Diameters and Packaging AS S2 Mo (30 kg spool)

3.2

4.0

ASFİL S2 Mo (320-350 kg drum)

3.2

4.0

117

11


PALLET INFORMATIONS

119


120

Length

300

350

450

Product

SMAW Electrodes

SMAW Electrodes

SMAW Electrodes

for carton boxes

for carton boxes

for carton boxes

Packing

6

5

2 - 2.5

18

15

12

Plastic Box Foil Pack. Weight Weight (kg) (kg)

107 x 95

107 x 95

107 x 95

Pallet Size (cm)

Table 1 - SMAW Electrodes STANDARD PALLET

1080

1365

1092

18 x 1080

15 x 1365

18 x 1092

19 x 1080

15 x 1365

19 x 1092

Pallet Pallet Unit Pallet Unit Weight for Container for Truck (kg) unit x (kg) unit x (kg)


121

Length

300

350

450

Product

SMAW Electrodes

SMAW Electrodes

SMAW Electrodes

for carton boxes

for carton boxes

for carton boxes

Packing

6

5

2 - 2.5

18

15

12

Plastic Box Foil Pack. Weight Weight (kg) (kg)

120 x 80

120 x 80

120 x 80

Pallet Size (cm)

Table 2 - SMAW Electrodes EURO PALLET

1080

1080

1008

18 x 1080

18 x 1080

19 x 1008

18 x 1080

18 x 1080

19 x 1008

Pallet Pallet Unit Pallet Unit Weight for Container for Truck (kg) unit x (kg) unit x (kg)


122

all

all

SAW Wires

SAW Wires

for drums

for basket rims

355 *

30

250

15

for plastic spools, basket spools and basket rims

for drums

Unit Weight (kg)

Packing

* approx. weight

all

all

GMAW Wires

GMAW Wires

Dia

Product

130 x 130

95 x 95

95 x 95

95 x 95

Pallet Size (cm)

1420

960

1000

1080

Pallet Weight (kg)

Table 3 - GMAW and SAW Wires STANDARD PALLET

8 x 1420

12 x (960 x 720)

20 x 1000

12 x (1080 x 540)

Pallet Unit for Container unit x (kg)

10 x 1420

28 x 720

20 x 1000

19 x 1080

Pallet Unit for Truck unit x (kg)


MAINTENANCE and REPAIR WELDING CONSUMABLES


"KOBATEK" helps you to cut spares and repair costs Because wear exists wherever there is motion, nearly every industry encounters wear problems. Excessive wear causes billions of dollars to be lost annually through: unplanned downtime, repetitive replacement of costly parts, inordinate maintenance costs, lowered production efficiency and losses of sales due to poor product reliability. Kobatek repair and maintenance welding electrodes have been instrumental in reducing losses and increasing cost savings for companies in a number of diverse industries and applications. Companies use Kobatek products to : Reduce cost : Fewer man-hours for repair and maintenance jobs; minimized downtime and rejects; reduction in purchases of spare parts, energy and resources. Prolong equipment time : Surfacing extends life 30-300 %, depending upon application, as compared to that of a non-surfaced part. Reduce down-time : Save dismantling time and downtime due to replacement delays; minimizes re-fitting time, etc... Reduce inventory of spare parts : There is no need to keep numerous spare parts when worn parts can be rebuilt. There are basically two main areas where Kobatek electrodes are used : 1. The rebuilding of worn metal parts to their original dimensions. This is accomplished with buildup or with build-up and overlay welding. 2. The protection of new metal parts against the loss of metal. Hardsurfacing overlay is used on both new and/or original parts where the parts are most susceptible to wear. The higher alloy overlay offers much better resistance than that of the original base material. This usually increases the work life of the component up to two or more times that of a part which is not surfaced. With over 20 years experience in the field of repair and maintenance welding, Kobatek can recommend and supply the most cost-effective solution to any repair-maintenance and welding problems. Kobatek offers you a complete range of welding electrodes for every repair and preventative maintenance need. Kobatek research teams are constantly seeking better methods of combating wear and welding problems; creating new products for new preventative maintenance and welding problems, and improving existing products for old problems. New products to match operating requirements in your plants can also be developed. This part briefly outlines the Kobatek product line which includes electrodes for: surface preparation, cast irons, steels, stainless steels, hardfacing, copper and aluminium alloys.

125


Wear Factors Wear is a general term used to describe a progressive deterioration of a surface with loss of shape, often accompanied by loss of weight due to the creation of debris. We have to understand the wear factors involved before making a hard surfacing product selection. There are seven major types of wear which are caused by mechanical and chemical actions: Mechanical causes of wear : Abrasion, impact, erosion, cavitation, friction Chemical causes of wear : Corrosion and heat. Abrasion : Abrasion is the most common form of wear. It is caused by foreign materials (non-metallic materials such as sand, oxides or grit) moving over a metal part. The worn surface can be recognized by its polished appearance or by very fine scratches in the direction of particle movement. It can be broken down into three main categories : 1. Low-stress scratching abrasion : typical components subjected to this kind of abrasion include: agricultural implements, classifiers, screens, slurry pump nozzles, sand slingers and chutes, etc. 2. High-stress grinding abrasion : typical components subjected to this kind of abrasion include: augers, scraper blades, pulverizers, ball and rod mills, muller tires, brake drums, roll crushers, rollers sprockets and mixing paddles etc. 3. Gouging abrasion : typical components subjected to gouging abrasion include: dragline buckets, power shovel buckets, clam shell buckets, gyratory rock crushers, roll crushers and jaw crushers, etc.

abrasive particle

metal sliver

conventional metal

Abrasion

Impact : Wear by impact is the result of a succession of local shock loads on the material surface. When the stress exceeds the elastic limits of the metal, the metal deforms both beneath the point and laterally across the surface away from the impact point. Some of the effects of impact are: fatigue, cracking, flaking, compression and deformation. Typical components subjected to impact include: coupling boxes, crusher rolls, impact hammers, impactor bars, railroad frogs and crossings.

126


Impacting Mineral Particles

Ductile metal work hardening. Cracks following deformation. Small metal particles break away.

Metal Particle Breaks Away

Impacting Mineral Particles

Brittle metal cracks, without deformation. Large metal particles break away.

Impacting Mineral Particles

Wear by smaller mineral particleshigh impact. Brittle metal cracks and fractures readily.

Impact

Erosion : It occurs in liquid or gaseous media, when extraneous, fine and hard particles strike a surface at an angle of incidence. Erosion can be considered a combined form of impact and abrasion. Grit-blasting is a technological application of this phenomenon. Erosion wear involves two typical mechanisms: 1. In cases of vertical impact we are dealing with local phenomena, which can lead to both elastic and plastic deformation, with grooves on the worn surface. 2. In cases of oblique or glancing impact by solid particles, the mechanism of surface damage involves the formation of chips.

fine particles

conventional metal

Erosion

Cavitation : This wear results from the rapid formation and collapse of tiny gas bubbles in a liquid. This causes high speed localized pressure changes or explosions creating shock waves that impact on the base metal surface resulting in local deformation. The damage to the surface arises from a similar mechanism to that of erosion by impact deformation, except that in the case of cavitation the solid abrasive particles are replaced by microwaves that produce pitting fatigue, subsequent micro crevices (fissures) and the removal of metal.

127


Cavitation Corrosion : It is deterioration of a metal by a chemical or electrochemical reaction between the metal and the environment such as scaling and pitting caused by oxidation when a metal is heated, or by acids eroding the base metal. The most common type of corrosion is rust. Rust transforms the surface of a metal into oxide which eventually flakes off, thus reducing the original thickness of the metal. In most cases, several different types of wear work together, with a combined destructive effect which is often greater than the sum of their individual effects. To propose an effective solution to complex combined wear problems, one approach is to analyze the exact manner in which the mechanisms are interacting. This brief description of the main types of wear shows that a detailed theoretical evaluation of any given wear problem is highly complex. But you can easily find a solution with the appropriate special KOBATEK alloys.

acidified water (electrolyte)

Corrosion

rust carbone impurity (anode) plain steel (cathode)

High Temperature : Heat affects the metal's microstructure and generally reduces its durability. A major cause of metal failure from high temperature service is the thermal fatigue (fire cracking) that results from repetitive intense heating followed by cooling. The repeated expansion and contraction caused by this thermal cycling eventually exceeds the ability of the metal to recover and causes deep cracking. The most common form of wear caused by heat is probably oxidation. This takes place during the build-up of an oxide layer. Wear occurs when the layer is broken away by a cycle of expansion and contraction, and the whole oxidation operation is repeated. Typical components subjected to high temperature wear include: continuous caster rolls, steel mill work rolls, hot forging dies, tongs and sinter crushing equipment.

128


HEAT

HEAT

CONTRACTION

Oxide Scale breaks away Oxide Scale

EXPANSION

Fatigue Cracks

Adhesion and Friction

OXIDATION OF THE METAL GRAIN BOUNDARIES

OXIDATION OF THE METAL SURFACE HEAT & OXIDIZING ATMOSPHERE

Adhesion and Friction (metal-to-metal) : This wear results from the sliding or rolling contact of one metal surface against another. To the naked eye, metal surfaces may appear smooth and even highly polished, but under a microscope they show definite hills and valleys. As metal surfaces slide against each other, the high areas (hills) are broken and tiny fragments of metal are torn away. Typical components subjected to friction include: steel mill rolls, undercarriage components, shear blades, shafts, trunnions and non-lubricated bearing surfaces.

sliding metal component

sliding metal component

sliding metal component broked asperity

sliding metal component

sliding metal component

sliding metal component

Sliding metal components have tiny Contact under heat and pressure When machine force fractures cold raised or roughened areas, called causes the metal to flow and bond welded asperities, jagged metal from asperities, which collide. momentarily in "cold welding". one surface remains bonded to the opposite surface, accelerating wear.

Adhesion and Friction

How can you select the most appropriate "KOBATEK" product ? The graphic system is a simple method which helps to eliminate guesswork and chance in the selection of the proper welding alloy for repair or wear protection applications. Each product data page contains a table designation. These tables summarize the principal characteristics and properties of the deposited alloys. You can analyze their environmental factors encountered causing wear or repair, and make a similar table and compare your application's factors with the product's factors.

129


0 - 20 21 - 40 41 - 60 61 - 80 81 - 100 0

: : : : :

Inferior Fair Good Very good Excellent

20

40

60

80

100

PRESSURE IMPACT ABRA SION HEAT CORROSION CAVITATION

Welding Methods In addition to the properties of its chemical elements, the properties of the weld filler metal is based on the following factors : - electrode diameter, - arc length, - preheating temperature, - current and type of polarity. The last factor leads to two welding methods : METHOD - A High Current Operation It is suitable for large and thick sectioned components. It enables high speed welding. This method is particulary used for assembly and machine parts where pieces are removed from the surface and for multipass filler welding applications. METHOD - B Low Current Operation It is used to eliminate the overheating of small and thin sectioned components. It also provides a protective layer in the weld metal due to the limited melting of the base metal. Minimum fluidity and liquidification is obtained on the base metal.

130


Table of Contents Surface Preparation Electrode Electrodes for Cast Irons Page Kobatek Kobatek Kobatek Kobatek

111 46 418 458

137 138 139 140

Electrodes for Steels Page Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek

326 326 N 345 350 352 381 382

143 144 145 146 147 148 149

Electrodes for Non-Ferrous Metals ( Electrodes for Aluminium and Copper Alloys ) Page Kobatek 213 Kobatek 250 Kobatek 725

153 154 155

Electrodes for Hardfacing Applications Page Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek

512 520 543 550 562 578 S-643

159 160 161 162 163 164 165

131


CONTENTS Surface Preparation Electrode Electrodes for Cast Irons

1

Electrodes for Steels

2

Electrode for Non-Ferrous Metals Aluminium and Copper Alloys

3

Electrodes for Hardfacing Applications

4

12 133


Kobatek - 1xx 4xx Surface Preparation Electrode Electrodes for Cast Irons

Product Name

Page

Kobatek 111

137

Kobatek 46 Kobatek 418 Kobatek 458

138 139 140

135

1


Kobatek 111 Kobatek 111 is used for ferrous or non-ferrous metals where grooving is necessary without supplementary gases and special electrode holder. For preparing sections prior to welding, gouging out old or defective weld metal, removing flash and risers. All these operations can be carried out in all positions; except vertical upwards. A thick, specially developed exothermic coating produces a forceful gas jet which blows the molten metal away, to give a smooth, clean groove. A finishing operation is unnecessary. RECOMMENDED PROCEDURE : Strike the arc with the electrode normal to the workpiece and then immediately incline the electrode at an angle of 15-20° to the workpiece. Point the arc in the direction of travel, move the electrode forward to melt the metal and then pull it back to allow the gas jet to blow the molten metal away.

Approvals GOST , SEPRO

Principal Applications -

Gouging, bevelling cast iron and other metals Removal of old welds and rivets Removal of weld defects Piercing holes Back-gouging root runs

Current Type : [ DC (-) / AC ]

Diameter 3.25 mm 4.00 mm 5.00 mm

Welding Current (A) 180 - 220 200 - 275 250 - 300

137

1


Kobatek 46

1

An AC/DC nickel electrode for welding of old, contaminated, oil-soaked gray and alloyed castings with a minimum preheat. The welding should proceed step by step so that the workpiece is not heated more than necessary. It has excellent application properties on welding in position. The deposit is always soft and machinable.

CRACK RESISTANCE BONDING MACHINABILITY

Approvals

Mechanical Properties, Typical

GOST , SEPRO

Tensile Strength [ kg/mm² ] : 26 - 30 Elongation (L=5d) [ % ] : 8 - 10 Hardness [ HB ] : 100 - 140

Principal Applications -

Engine blocks Pump housings Cylinder heads and blocks Valves Gear and gear boxes Eccentric wheels Work-bench sledges Drums Reclamation of faulty castings Joining of castings in all-cast and composite fabrications

Current Type : [ DC (-) / AC ]

Diameter 2.50 mm 3.25 mm

Welding Current (A) A B 70 - 90 50 - 60 100 - 120 80 - 90

138


Kobatek 418 A pure nickel, non-conductive flux coating electrode for repair and maintenance welding of cast iron components. Kobatek 418 exhibits excellent arc characteristics by producing a drop arc transfer which assists in combating surface contamination such as when joining badly oiled cast iron parts. For all types of machinable repairs on old, contaminated, oil-soaked gray and alloyed castings. Sound, dense deposits are fully machinable. It can be used for thin, as well as thick sections.

CRACK RESISTANCE BONDING

Approvals

Mechanical Properties, Typical

GOST , SEPRO

Tensile Strength [ kg/mm² ] : 26 - 30 : 8 - 10 Elongation (L=5d) [ % ] [ HB ] : 120 - 160 Hardness

Principal Applications -

Pump housings Pump rotors Compressors Valves Gear boxes Engine blocks Cylinder heads and blocks Pulleys Eccentric wheels

Current Type : [ DC (-) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm

1

MACHINABILITY

Welding Current (A) A B 70 - 90 50 - 60 100 - 120 80 - 90 130 - 150 100 - 120

139


Kobatek 458

1

Kobatek 458 has nickel-iron-copper alloyed deposit and it has been specially designed for welding of malleable cast iron and nodular or ductile spheroidal graphite iron where ease of welding, low heat input and high crack resistance are important. Therefore, it is very suitable for making thick joints and for filling up deep cavities.

CRACK RESISTANCE BONDING MACHINABILITY

It has high crack resistant deposits which are fully machinable. It can be used on both heavy and thin sections, especially for welding in position. The special arc characteristics also allow welding even on contaminated surfaces. It is also suitable for joining cast iron to steel. The deposit is the optimum colour match with the cast iron parts.

Approvals

Mechanical Properties, Typical

GOST , SEPRO

Tensile Strength [ kg/mm² ] : 38 - 44 Elongation (L=5d) [ % ] : 15 - 20 Hardness [ HB ] : 140 - 180

Principal Applications - Repair of nodular and ductile iron castings and foundry defects - Machine housings - Pipes and flanges - Pump impellers - Pulleys - Gears and gear boxes - Turbine blades - Engine blocks - Transmission housings - Joining of gray cast iron to steels and stainless steels - Joining of steels to copper alloys

Current Type : [ DC (-) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) A B 80 - 90 60 - 70 110 - 120 90 - 100 140 - 150 120 - 130

140


Kobatek - 3xx Electrodes for Steels

Product Name Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek

Page

326 326 N 345 350 352 381 382

143 144 145 146 147 148 149

141

2


Kobatek 326 Kobatek 326 has a very crack proof weld metal. It is suitable for the joining and welding of special steels used at both sub-zero and elevated temperatures, also recommended for 5-9 % nickel steels and nickel alloys such as Inconel 600, Incoloy 800, Nimonic 75, NiCr 80/20, NiCr 60/15, NiCr15Fe and dissimilar ferrous metal combinations, including stainless steel to steel.

MECHANICAL STRENGTH CRACK RESISTANCE HEAT RESISTANCE

2

Kobatek 326 provides the ultimate fatigue resistance for highly stressed constuctions using thick sections. The weld metal has a good impact strength down to -196°C and a good tensile strength up to 1000°C. Also the corrosion and oxidation resistance are good.

Approvals

Mechanical Properties, Typical

GOST

Tensile Strength [ kg/mm² ] : 66 - 71 Elongation (L=5d) [ % ] : 40 - 44 Hardness [ HB ] : 160 - 200

Principal Applications - Joining or repairing of heavily constrained massive sections - Bearing rings of rotary kilns - Walls of ball mills - Ball mill driving gears, journals and collars - Blast furnaces - Flame hardening equipments - Heat treating trays - Pipe flanges - Machine parts subject to thermal cycling and sub-zero temperatures such as cryogenic equipments - Joining dissimilar combinations of steels

Current Type : [ DC (+) ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) A B 80 - 90 60 - 80 100 - 110 70 - 100 120 - 140 100 - 110

143


Kobatek 326 N

2

Kobatek 326 N has a very crack proof weld metal. It is suitable for the joining and welding of special steels used at both sub-zero and elevated temperatures, also recommended for 5-9 % nickel steels and nickel alloys such as Inconel 600, Incoloy 800, Nimonic 75, NiCr 80/20, NiCr 60/15, NiCr15Fe and dissimilar ferrous metal combinations, including stainless steel to steel.

MECHANICAL STRENGTH CRACK RESISTANCE WELDABILITY

Kobatek 326 N provides the ultimate fatigue resistance for highly stressed constuctions using thick sections. The weld metal has a good impact strength down to -196°C and a good tensile strength up to 1000°C. Also the corrosion and oxidation resistance are good.

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] Yield Strength [ kg/mm² ] Elongation (L=5d) [ % ] Hardness [ HB ]

: : : :

GOST

60 - 65 38 - 42 38 - 40 140 - 180

Principal Applications - Joining or repairing of heavily constrained massive sections - Walls of ball mills - Bearing rings of rotary kilns - Boom welding of earth moving equipments - Machine parts subject to thermal cycling and sub-zero temperatures such as cryogenic equipments - Heat treating trays - Ball mill driving gears, journals and collars - Blast furnaces - Flame hardening equipments - Pipe flanges - Joining dissimilar combination of steels

Current Type : [ DC (+) ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 140 - 160 90 - 110 160 - 200 120 - 150

144


Kobatek 345 A special electrode for welding steels having limited weldability, such as manganese steels, hardenable steels and others. It is an AC/DC electrode giving a non-magnetic and work hardenable stainless steel deposit containing Cr/Ni/Mn/Mo. The tough weld metal is able to absorb high welding stresses which is very important for achieving crack-free welds.

PRESSURE IMPACT ABRASION HEAT

2

CORROSION CAVITATION

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] : 58 - 64 Elongation (L=5d) [ % ] : 38 - 42 [ HB ] : 160 - 180 (as welded) Hardness 400 - 420 (cold worked)

Principal Applications -

Site machinery Drilling tools Rails, points Valve seats Earth moving equipments Stone working machines Coal machines Armoured cars Joining between X5 CrNiMo 18 10, X10 CrNiMoNb 18 10, HI-HIII, 17 Mn 4

Current Type : [ DC (+) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm 5.00 mm

Welding Current (A) A B 85 - 110 65 - 90 120 - 150 90 - 120 150 - 180 110 - 140 180 - 220 160 - 190

145

GOST


Kobatek 350 Kobatek 350 is a basic coated electrode used for welding martensitic and martensitic-ferritic type steels.

2

MECHANICAL STRENGTH IMPACT

It exhibits high corrosion resistance to water, vapor and salt water. A preheating of 100-200°C should be applied for thick sectioned parts. Interpass temperature should be constant. Weld beads are smooth and the slag is easy to remove.

PRESSURE HEAT CORROSION CAVITATION

Approvals

Mechanical Properties, Typical Tensile Strength Yield Strength Elongation (L=5d) Hardness Impact (ISO-V)

[ kg/mm² ] [ kg/mm² ] [%] [ HRC ] [ Joule ]

: : : : :

GOST

90 - 110 70 - 80 10 - 15 38 - 40 24 @ 20°C

Annealing temperature for stress relief is 550-600°C.

Principal Applications It is particulary used for the protection of % 12-15 Cr, % 4 Ni containing steels against corrosion. -

Water turbines and compressors Pelton, Francis turbine rotors Kaplan turbine blades Valves used in gas, vapor and water pipelines operating under service temperatures up to 450°C - Erosive and corrosive attacks caused by sea water - Welding of X4 CrNi 13 4 and G-X5 CrNi 13 4 (1.4343) steels.

Current Type : [ DC (+) ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) 90 - 120 120 - 170

146


Kobatek 352 Kobatek 352 has a manganese alloyed stainless steel deposit containing Cr/Ni/Mn/Mo which is a work hardening alloy. It is used for build-up applications and cushion layers prior to harder overlays, and for a wide range of steel, low alloy steel and 12-14 % austenitic manganese steel components subjected to severe impact combined with high pressure. Steel deposit will also resist a wide range of corrosive conditions and cavitation.

PRESSURE IMPACT ABRASION HEAT

2

CORROSION CAVITATION

Deposits exhibit a smooth even shaped bead, high metal recovery rates and ease of slag removal. The electrode can be deposited in contact with the workpiece.

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] : 64 - 66 : 40 - 44 Elongation (L=5d) [ % ] [ HB ] : 160 - 200 (as welded) Hardness 400 - 440 (cold worked)

Principal Applications -

Welding and repairing 12-14 % manganese steels Crusher jaws Tractor sprocket tooth Guides and rollers on tracked vehicles Armour plates Perforated plating on ore-sorters Gyratory crusher cones Conveyor rollers Crusher cylinder hooks Dozer cutting edges Bucket lips and sides Impactors, hammers Joining austenitic manganese steels to carbon steels - Stainless cladding carbon steels and low alloy steels

Current Type : [ DC (+) / AC ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 140 - 160 100 - 160 210 - 240 140 - 190

147

GOST


Kobatek 381

2

Kobatek 381 deposits a Cr/Ni/Mo based stainless steel weld metal. It is designed for welding large, high strength steel components requiring fast multi-layer deposits with crack resistance. It is ideal for repairing difficult-to-weld steels and for putting down buffer layers before filling up with hardenable deposits. It can be used as a buffer layer on high manganese Hadfield steel and for surfacing where some resistance to impact and battering is required under corrosive conditions.

MECHANICAL STRENGTH CRACK RESISTANCE HEAT INPUT

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] [ kg/mm² ] Yield Strength Elongation (L=5d) [ % ] [ HB ] Hardness

: : : :

GOST

76 - 82 58 - 62 20 - 25 220 - 260

Principal Applications - Press cylinders in plastic and food industries - Earth moving equipments - Hydraulic cylinders - Injection moulds - Extrusion screws - Turbine blades - Valve seats for superheated steam - Heat exchangers - Coal washing screens - Wear plates - Bucket tooth - Dies, gears, shafts, tools

Current Type : [ DC (+) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) A B 90 - 120 70 - 80 130 - 150 110 - 120 180 - 210 120 - 160

148


Kobatek 382 It is extremely high strength and crack-resistant when joining steels of difficult weldability, such as hard manganese steels, tool steels, spring steels as well as dissimilar metal joints. A highly alloyed manual metal arc electrode with good deposition qualifies for the welding of air hardening steels, cementation steels, high carbon steels, vanadium-moly spring steels, stainless steels and any dissimilar combinations of these alloys.

MECHANICAL STRENGTH CRACK RESISTANCE HEAT INPUT

2

Also ideal for the buffering of higher carbon and alloy steels prior to final hard overlays including 12-14 % austenitic manganese steels. It gives work-hardenable weld metal. The arc is stable and spatter-free.

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] [ kg/mm² ] Yield Strength Elongation (L=5d) [ % ] [ HB ] Hardness

: : : :

GOST

80 - 86 64 - 66 20 - 25 220 - 260

Principal Applications -

Cutting tools Gears, shafts and cams Forging dies Extrusion and hydraulic cylinders Vibration sieves Forming tools Earth moving parts Chassis frames Cushion pass for tool steels Joining stainless steels to carbon steels and low alloy steels - Joining austenitic manganese steels to carbon steels and low alloy steels

Current Type : [ DC (+) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) A B 60 - 80 40 - 50 90 - 100 60 - 80 125 - 150 90 - 120

149


Kobatek - 2xx 7xx Electrodes for Non-Ferrous Metals

Product Name

Page

Kobatek 213 Kobatek 250

153 154

Kobatek 725

155

151

3


Kobatek 213 A metal arc electrode designed for the repair and fabrication of a wide range of wrought and cast aluminium alloys. Ideal for the build up of lost sections and casting defects, also for the repair of cracked parts. Kobatek 213 is intended for the welding of aluminium alloys containing up to 6 % silicon and for low magnesium containing alloys.

MECHANICAL STRENGTH INTENSITY OF HUMIDITY WELD METAL QUALITY

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] Yield Strength [ kg/mm² ] Elongation (L=5d) [ % ] Hardness [ HB ]

: : : :

GOST , SEPRO

14 - 16 8 - 10 15 - 18 50 - 60

Principal Applications -

Truck bodies and conveyers Rails Floor plates Engine blocks Machine casing Foundry defects Frames Rectification and fabrication of conveyers

Current Type : [ DC (+) ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) 60 - 90 80 - 110 100 - 140

153

3


Kobatek 250

3

An aluminium alloyed, basic electrode recommended for production and maintenance applications including the repair of cracks, casting defects and building up sections and broken parts, also suitable for overlaying applications. It is specially designed for welding of wrought and cast aluminium alloys, mainly of the half silumin and silumin type, containing up to 12 % silicon, like ; G-AlSi8Cu3, G-AlSi10Mg, G-AlSi12. It should not be used with aluminium magnesium alloys like : AlMg2, AlMg3, AlMg5. In case of necessity, it can be applied with oxyacetylene flame.

MECHANICAL STRENGTH INTENSITY OF HUMIDITY WELD METAL QUALITY

Approvals

Mechanical Properties, Typical Tensile Strength [ kg/mm² ] Yield Strength [ kg/mm² ] Elongation (L=5d) [ % ] [ HB ] Hardness

: : : :

GOST , SEPRO

16 - 20 6-8 6 - 10 50 - 70

Principal Applications -

Engine blocks Truck bodies Housings, pumps, tanks Molds, pistons, fans, frames Casting defects Manufacture of petrol engines Window frames and stairs Gear boxes Engine pistons

Current Type : [ DC (+) ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) 60 - 90 80 - 110 100 - 140

154


Kobatek 725 Kobatek 725 is a tin-bronze electrode for coating and repairing parts made of copper, bronze, red brass and for joining of these to steels, cast iron, nickel and nickel alloys. Possible to work on very large bronze parts without preheating. Excellent resistance to metal-metal friction and good resistance to corrosion, particularly attack by acetone and dry ammoniac, industrial atmospheres and salty air, sea water and acids. It gives dense, porosity and spatter free, fully machinable deposits.

COMPATIBILITY MACHINABILITY CORROSION RESISTANCE

Approvals

Mechanical Properties, Typical

GOST

Tensile Strength [ kg/mm² ] : 30 - 36 Elongation (L=5d) [ % ] : 15 - 25 [ HB ] : 100 - 140 Hardness

Principal Applications -

Electrode holders Bearings Rotors Screws Valve seats Pump rotors Spindles Gears Spirals Pistons Repairing defective castings Turbine balades

Current Type : [ DC (+) ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 110 - 130 80 - 100 145 - 160 110 - 140

155

3


Kobatek - 5xx Electrodes for Hardfacing Applications

4

Product Name Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek Kobatek

Page

512 520 543 550 562 578 S-643

159 160 161 162 163 164 165

157


Kobatek 512 An AC/DC electrode which has high alloyed Cr/Mo/V weld metal. Deposits produce high resistance to pressure and abrasion and moderate impact resistance. It is used on steels, alloy steels and carbon manganese steel components. The weld metal is heat resistant up to about 550째C. The alloy combines with a special flux coating formulation to provide a high metal transfer across the arc.

PRESSURE IMPACT ABRASION HEAT CORROSION CAVITATION

Approvals

Mechanical Properties, Typical

GOST

Hardness [ HRC ] : 50 - 55

4 Principal Applications -

Excavator buckets Dredge pump impellers Drill bits Crushers Breaker bars Gyratory crusher cones Bulldozer buckets Chipper rotors Screw conveyers Cold pressing tools Shear blades Slideways and guide rails

Current Type : [ DC (-) / AC ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 140 - 160 120 - 150 220 - 230 170 - 190

159


Kobatek 520 A DC electrode specially designed for low-alloy steels with a tensile strength up to 900 N/mm² and the reclamation of the parts subjected to metal-to-metal friction under high pressure. The readily machinable deposit gives an alloy steel providing high mechanical properties and can be heat treated. It is also suitable for applications where resistance to deformation during service is required for maximum operational life.

PRESSURE IMPACT MECHANICAL STRENGTH CRACK RESISTANCE MACHINABILITY

Approvals

Mechanical Properties, Typical

4

Tensile Strength [ kg/mm² ] Yield Strength [ kg/mm² ] Elongation (L=5d) [ % ] Hardness [ HB ]

: : : :

GOST

92 - 96 76 - 80 12 - 16 300 - 360

Principal Applications -

Rollers Forging dies Forming dies Anvil dies Anvil guides of power hammer Hammers Table rollers Turbine blades Cushion layers before hardfacing

Current Type : [ DC (+) ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) 90 - 120 110 - 150

160


Kobatek 543 A cobalt alloyed electrode for producing excellent wear resistance overlays on carbon and alloy steels. Excellent results can be obtained even when high temperature service conditions exist. It has been designed to withstand corrosion, oxidation and heat, and also has moderate resistance to pressure and abrasion.

PRESSURE IMPACT ABRASION HEAT CORROSION CAVITATION

Approvals

Mechanical Properties, Typical

Hardness [ HRC ] :

20 째C

600 째C

40 - 44 HRC

30 - 32 HRC

Principal Applications -

Hot shear blades Hot pressing tools Forging dies Steam and chemical valve seats Pump and bearing sleeves Handling equipments for hot steel Trimming dies and punches Stripper crane points Hot pressing dies Screw conveyors (for rubber) Valve steam tips Wear pads Drill collars Bearing sleeves Wire mill rolls Beaters for coke comminution

Current Type : [ DC (+) / AC min. 70 V ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 100 - 120 80 - 110 130 - 150 100 - 120

161

GOST

4


Kobatek 550 Kobatek 550 deposits a Cr/Mo alloyed, medium carbon, low-alloyed steel hard-surfacing weld metal, that is wear resistant under conditions of high pressure and impact combined with mild abrasion. It is particularly suited for surfacing cold cutting tools and for re-building manganese hard steel. The deposit is airhardening, non-mechinable and can resist plastic deformation without cracking. It is suitable for protective overlays on steels including plain carbon steels, carbon manganese steels, low alloy steels and also for welding of cementation steels. Deposits are usually very smooth and may require little or no finishing operation.

4

PRESSURE IMPACT ABRASION HEAT EROSION

Approvals GOST

Mechanical Properties, Typical Hardness [ HRC ] : 54 - 60

Heat Treatment : Annealing at 800째C : 30 HRC (except austenitic Hardening at 1030째C : 60 HRC manganese steels) Tempering at 500째C : 57 HRC

Principal Applications -

Earth moving equipments Dragline bucket tooth Farming machinery Forestry tools Bulldozer blades, scraper blades Bucket lips Excavator tooth, crusher jaws and hammers Concrete mixers Plough shaves, pulping knives Stamping dies Gravel pump housing Conveyors Tractor pads, links and rollers

Current Type : [ DC (+) / AC ]

Diameter 2.50 mm 3.25 mm 4.00 mm

Welding Current (A) A B 80 - 90 70 - 80 110 - 130 80 - 120 135 - 160 100 - 125

162


Kobatek 562 Kobatek 562 is a W, Co and Cr enriched electrode. It gives a speed steel type weld metal that has very good resistance to softening up to 500°C. It gives high hardness and high resistance to impact and pressure. Low preheating temperatures enable the welding of hard metals. A controlled increase of hardness of the deposit can be obtained by heat treatment after welding.

PRESSURE FRICTION MACHINABILITY

Approvals

Mechanical Properties, Typical Hardness

[ HRC ] : 46 - 52 (as welded) 52 - 54 (after heat-treatment) Working Temperature [ °C ] : max. 500 Deposit can be heat treated by tempering for 1 hour at 550°C to obtain a deposit hardness of 52-54 RC.

Principal Applications -

Cold shear cutting edges and blades Profile and slab cutting edges used within the steel industry Hardfacing applications of injection molds Manufacturing of machining tools

Current Type : [ DC (+) / AC ]

Diameter 3.25 mm

Welding Current (A) A B 110 - 140 80 - 120

163

GOST

4


Kobatek 578 An AC/DC high chromium-carbide electrode. It has been designed to withstand high abrasive wear under pressure, combined with medium impacts which are specially caused by coarse sand and hard minerals. Also resistant to corrosion and oxidizing. For overlaying carbon steels, low alloy steels and 12-14Â % austenitic manganese steels, it produces very thick deposits and so only one pass is usually required for most applications.

PRESSURE IMPACT ABRASION HEAT EROSION

Deposits are smooth, of good shape and with little or no slag residues as the electrode is almost totally consumed in producing the weld bead. Deposits may check crack to relieve stresses but this will not adversely affect weld adhesion or wear characteristics.

4

Approvals

Mechanical Properties, Typical

GOST

Hardness [ HRC ] : 60 - 63 (single pass)

Principal Applications - Dragline buckets (lips, points, cutting edges, teeths) - Scraper blades and mixers - Conveyor chains - Mixer blades - Sludge pumps - Hammers and crushers - Crusher jaws - Guide plates - Dozer and bits - Clinker chains - Screw conveyors - Crushing mills - Edge runners and chutes - Moulding screen segments - Wearing strips

Current Type : [ DC (-) / AC min. 60 V ]

Diameter 3.25 mm 4.00 mm

Welding Current (A) A B 150 - 170 100 - 120 190 - 220 140 - 160

164


Kobatek S-643 Kobatek S-643 is a basic coated electrode that is highly resistant to abrasion wear caused by fine or coarse hard minerals in environments of low pressure and weak impact. It gives an austenitic weld metal with "Cr" and "Nb" carbides in its structure. It enables welding in vertical upwards position with a small diameter electrode.

PRESSURE IMPACT ABRASION HEAT CORROSION

Approvals

Mechanical Properties, Typical

---

Hardness [ HRC ] : 54 HRC (single pass) : 63 HRC (at 3 passes) Weld bead is free of slag.

4

Principal Applications Equipment used in mining and cement industry, press screws, extruder plates and heads in the ceramic industry, wear plates and dredger blades can be hardfaced with Kobatek S-643. It should not be used for more than three passes. In applications requiring a thick deposit metal, Kobatek 352 or Kobatek 382 should be used for buffering of alloyed steels, whereas, AS B-248 should be preferred for buffering of unalloyed steels. It is crucial to have a buffer layer with Kobatek 352 for 12-14 % Mn containing steels before hardfacing applications.

Welding Positions

Current Type : [ DC (+) / AC min. 70 V ] Diameter [ mm ]

Length [ mm ]

Current [A]

Weight (100 pcs) [g]

3.25 4.00

350 350

110 - 140 140 - 180

5750 8370

165


Main Applications Guide (by Industry) - 1 IRON and STEEL WORKS Applications

Recommended Alloys

Anvil guides of power hammers Blast furnace pressure release valves Casting drills Chutes of ingot heating furnaces Cold adjusting rollers (Montbard) Cold cutting blades Connection sleeves of rolling mills Cooling water pump bodies Drive sprockets Driving gear wheels of polishing machines Electric furnace electrode holders Electrode holder slides Forging dies Forming dies Foundry defects Handling equipments for hot steels Heat treating trays Hot shear blades Housing of high pressure pumps Mill roll couplings Neck rings of the forming rolls Pinions of bearer reduction gears Roller bed rolls Rotary piercer wobblers Shafts of winding coil on STRECKEL rolling Shovel tooth Sinter chutes Stamping dies Stripper crane points Suction covers of water pumps Wagon wheels

520 543 543 543 512 512 382 418 512 418 725 725 382 / 520 / 543 382 / 520 458 543 326 352, 543 111, 382 352 543 326 352 752 382 512 578 550 543 111, 418, 458 345 / 352

MECHANICAL WORK SHOPS Applications

Recommended Alloys

Bearing blocks of diesel engines Cast iron engine blocks Cylinder blocks Diesel cylinder liners Extrusion screws Gear pinions Brick press screws Marine engine pistons Pistons Pump housings Reduction shaft bearings Valve seats

418 46, 418 250 418 381, 512 / 578 382 345 / 578 250 / 458 418 111, 46, 418 382 543

167


Main Applications Guide (by Industry) - 2 SUGAR MILL Applications

Recommended Alloys

"Rota" pump rotors 8 valve seat with two clappers Bearings of pulp press shafts Beet pump housings Cane pusher arms Centrifuge drums Clamshell buckets Cleaning wheels for sugar beets Geared pump rotors Mill cylinder bearing shells Mixer vats Pellet press rollers Pump blades Rollnecks of cane-mill cylinders Shock bars of shredder (GRĂ&#x153;NDLER) Steam cotters Steam engine pistons (CORLIS) Sugar cane mill cog-wheels Wear plates of sugar beet pumps Pump impellers

725 418 418, 458 458 550 111, 382 512 418, 382 418, 458 725 250 578 725 382 382, 578 382 458 382 550 458

EARTH MOVING and MINING Applications

Recommended Alloys 382 382 111, 418 381 381 382, 550, 512 381 578 578 512 326 352 352, 578 512 345 578 382 512 352 352, 512 382 578 418 111, 382 382 352 326 352 345 352 111,382,512

Arms of bulldozer blades Articulation arms Babbitless crusher housing Balance beam Blades of loader buckets Bulldozer buckets Coal washing screens Conveyor shutes Crusher cones Crusher jaws Dampers exhaust pipe lines cracks Dozer cutting edges Dragline bucket tooth Drill bits Drilling tools Elevator and excavator buckets Gears of an excavator Grabs of a dredge Guides and rollers on tracked vehicles Gyratory crusher cones (Babbitless) Hydraulic pistons Loader buckets Motor blocks Neck parts of caterpillar scrapers Oil pressure cylinders Perforated plating on ore-sorters Ripper tooth Sprockets Tension rollers Track pads of dragline cranes Trench excavator buckets

168


Main Applications Guide (by Industry) - 3 CEMENT WORKS Applications

Recommended Alloys

Ball-crusher gears Breaker hammers Buckets of clinker elevators Clinker crusher hammers Crane wheels Exhaust fan blades F端ller cooler plates Feed cake screws Furnace drive roll bearings Hazemag crusher buffers Rings of rotary ovens Roller press chutes Roller press cylinders Rotor disks of crushers Rotors Rotary oven cog wheels Segment of helical screws of fuller pumps Tracks pads Vibratory tables for filling cement into sacks

326 352, 578 578 578 345 578 543 352, 578 111, 418, 458 352,512 326 578 326, 352, 512 578 352, 578 111, 326 578 352 381

PAPER MILL Applications

Recommended Alloys

Chip mill chutes Chipper bed knives Chipper log feeding spouts Chipper rotors Conical refiner rotors and stators Conveyor chain sprocket wheels Defiberiser screws Disk refiner shafts Endless screw pinions Hydrapulper rotors Kneaders tooth Paste refiners Pulping knives Pump housings

578 382, 578 578 382, 512 543 382, 550 512 512 418 352 550 382, 543 550 458

169


TABLES


TABLE OF CONTENTS

Pages

Conversion Tables

173

Classification of Gas Metal Arc Welding Wires According to EN 440

178

Classification of Wire and Wire/Flux Combinations for Submerged Arc Welding Wires According to EN 756

180

Classification of Covered Electrodes According to EN 499

182

Classification of Covered Electrodes According to DIN 8555

183

Welding Positions

184

Determination of the Preheating Temperatures

185

Preheating Temperatures

186

Handling and Storage of the Covered Electrodes

187

172


Conversion Tables (for welding electrodes and wires) 1. Electrode and Wire Diameter

2. Electrode Length

inch

mm

inch

mm

0.024 0.030 0.035 0.039 3/64 1/16 5/64 3/32 7/64 1/8 5/32 3/16 1/4

0.6 0.8 0.9 1.0 1.2 1.6 2.0 2.4 2.8 3.2 4.0 5.0 6.0

10 12 13 14 18

250 300 330 350 450

4. Wire Feeding Rates

3. Deposition Rates lb/hour

kg/hour

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

0.45 0.90 1.36 1.81 2.26 2.72 3.17 3.68 4.08 4.53 4.98 5.44 5.89 6.35 6.80 7.25 7.71 8.16 8.61 9.07 9.52 9.97 10.43 10.88 11.33

173

inch/min

m/min

25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600 625 650 675 700

0.6 1.3 1.9 2.5 3.1 3.8 4.4 5.1 5.7 6.3 6.9 7.6 8.2 8.9 9.5 10.2 10.8 11.4 12.0 12.7 13.3 14.0 14.6 15.2 15.8 16.5 17.1 17.8


5. Hardness Values - 1 Brinell HB P = 30 D²

80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 310 320 330

HRC

Vickers HV

Tensile Strength

Tensile Strength

P = 30 kgf

N/mm²

kgf/mm²

19.2 20.2 21.2 22.1 23.0 23.8 24.6 25.4 26.2 26.9 27.6 28.3 29.0 29.6 30.3 31.5 32.7 33.8

80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 310 320 330

270 290 310 320 340 360 380 390 410 420 440 460 470 490 500 520 540 550 570 590 610 620 640 660 670 690 710 720 740 760 760 780 800 820 830 850 870 880 900 920 940 950 970 990 1010 1040 1080 1110

28 30 32 33 35 37 39 40 42 43 45 47 48 50 51 53 55 56 58 60 62 63 65 67 68 70 72 73 75 77 78 80 82 84 85 87 89 90 92 94 96 97 99 101 103 106 110 113

Rockwell HRB 36.4 42.4 47.4 52.0 56.4 60.0 63.4 66.4 69.4 72.0 74.4 76.4 78.4 80.4 82.2 83.8 85.4 86.8 88.2 89.6 90.8 91.8 93.0 94.0 95.0 95.8 96.6 97.6 98.2 99.0

174


5. Hardness Values - 2 Brinell HB P = 30 D²

340 350 359 368 376 385 392 400 408 415 423 430

HRC

Vickers HV

Tensile Strength

Tensile Strength

P = 30 kgf

N/mm²

kgf/mm²

34.9 36.0 37.0 38.0 38.9 39.8 40.7 41.5 42.4 43.2 44.0 44.8 45.5 46.3 47.0 47.7 48.3 49.0 49.7 50.3 50.9 51.5 52.1 52.8 53.3 53.8 54.4 54.9 55.4 55.9 56.4 56.9 57.4 57.9 58.5 58.9 59.3 60.2 61.1 61.9 62.8 63.5 64.3 65.0 65.7 66.3 66.9 67.5

340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 720 740 760 780 800 820 840 860 880 900 920

1150 1180 1210 1240 1270 1290 1320 1350 1380 1410 1430 1460

117 120 123 126 129 132 135 138 141 144 146 149

Rockwell HRB

175


6. Stress Conversion Table - 1 N/mm²

kgf/mm²

psi

N/mm²

kgf/mm²

psi

15.4 30.9 46.3 61.8 77.2 92.7 108.1 123.6 139.0 154.4 169.9 185.3 200.8 216.2 231.7 247.1 262.6 278.0 293.4 308.9 324.3 339.8 355.2 370.7 386.1 401.6 417.0 432.4 447.9 463.3 478.8 494.2 509.7 525.1 540.5 556.0 571.4 586.9 602.3 617.8 633.2 648.7 664.1 679.5 695.0 710.4 725.9 741.3

1.6 3.2 4.7 6.3 7.9 9.5 11.0 12.6 14.2 15.7 17.3 18.9 20.5 22.0 23.6 25.2 26.8 28.3 29.9 31.5 33.1 34.6 36.2 37.8 39.4 40.9 42.5 44.1 45.7 47.2 48.8 50.4 52.0 53.5 55.1 56.7 58.3 59.8 61.4 63.0 64.6 66.1 67.7 69.3 70.9 72.4 74.0 75.6

2240 4480 6720 8960 11200 13440 15680 17920 20160 22400 24640 26880 29120 31360 33600 35840 38080 40320 42560 44800 47040 49280 51520 53760 56000 58240 60480 62720 64960 67200 69440 71680 73920 76160 78400 80640 82880 85120 87360 89600 91840 94080 96320 98560 100800 103040 105280 107520

756.8 772.2 787.7 803.1 818.5 834.0 849.4 864.9 880.3 895.7 911.2 926.7 942.1 957.5 973.0 988.4 1004 1019 1034 1050 1066 1081 1097 1112 1127 1143 1158 1174 1189 1205 1220 1236 1251 1266 1282 1297 1313 1328 1344 1359 1375 1390 1405 1421 1436 1452 1467 1483

77.2 78.7 80.3 81.9 83.5 85.0 86.6 88.2 89.8 91.3 92.9 94.5 96.1 97.6 99.2 100.8 102.4 103.9 105.5 107.1 108.7 110.2 111.8 113.4 115.0 116.5 118.1 119.7 121.3 122.8 124.4 126.0 127.6 129.1 130.7 132.3 133.9 135.4 137.0 138.6 140.2 141.7 143.3 144.9 146.5 148.0 149.6 151.2

109760 112000 114240 116480 118720 120960 123200 125440 127680 129920 132160 134400 136640 138880 141120 143360 145600 147840 150080 152320 154560 156800 159040 161280 163520 165760 168000 170240 172480 174720 176960 179200 181440 183680 185920 188160 190400 192640 194880 197120 199360 201600 203840 206080 208320 210560 212800 215040

176


6. Stress Conversion Table - 2 N/mm²

kgf/mm²

psi

N/mm²

kgf/mm²

psi

1498 1514 1529 1544 1560 1575 1591 1606 1622 1637 1653 1668 1683 1699 1714 1730 1745 1761 1776 1792 1807 1822 1838 1853 1869 1884 1900 1915 1931 1946 1961 1977 1992 2008 2023 2039 2054 2070 2085 2100 2116 2131 2147 2162 2178 2193 2209 2224

152.8 154.3 155.9 157.5 159.1 160.6 162.2 163.8 165.4 166.9 168.5 170.1 171.7 173.2 174.8 176.4 178.0 179.5 181.1 182.7 184.3 185.8 187.4 189.0 191 192 194 195 197 198 200 202 203 205 206 208 209 211 213 214 216 217 219 221 222 224 225 227

217280 219520 221760 224000 226240 228480 230720 232960 235200 237440 239680 241920 244160 246400 248640 250880 253120 255360 257600 259840 262080 264320 266560 268800 271040 273280 275520 277760 280000 282240 284480 276720 289960 291200 293440 295680 297920 300160 302400 304640 306880 309120 311360 313600 315840 318080 320320 322560

2239 2255 2270 2286 2301 2317 2332 2348 2363 2378 2394 2409 2425 2440 2456 2471

228 230 232 233 235 236 238 239 241 243 244 246 247 249 250 252

324800 327040 329280 331520 333760 336000 338240 340480 342720 344960 347200 349440 351680 353920 356160 358400

Conversion Factors 1 kgf/mm² = 9.80571 N/mm² 1 kgf/mm² = 1422.22 psi

177


Classification of Gas Metal Arc Welding Wires According to EN 440

PRODUCT TYPE Gas Shielded Metal Arc Welding Wire

EN 440

G 46 3 M G3Si1

IMPACT PROPERTIES Code

Temperature Required for 47 J Impact Resistance (°C)

Z A 0 2 3 4 5 6

+20 0 - 20 - 30 - 40 - 50 - 60

SHIELDING GASES M

gas mixtures according to EN 439 EN 439-M2 (except Helium)

C

carbondioxide EN 439 - C1

MECHANICAL PROPERTIES Wire Description

Yield Strength (N/mm²)

Tensile Strength (N/mm²)

Elongation (%)

35 38 42 46 50

355 380 420 460 500

440 - 570 470 - 600 500 - 640 530 - 680 560 - 720

22 20 20 20 18

178


179

0.06 - 0.14

0.06 - 0.14

0.08 - 0.12

0.06 - 0.14

0.08 - 0.14

G3Ni1

G2Ni2

G2Mo

G4Mo

G2Al

0.30 - 0.50

0.50 - 0.80

0.30 - 0.70

0.40 - 0.80

0.50 - 0.90

0.40 - 0.80

1.00 - 1.30

0.80 - 1.20

0.90 - 1.30

1.70 - 2.10

0.90 - 1.30

0.80 - 1.40

1.00 - 1.60

0.90 - 1.40

1.30 - 1.60

1.60 - 1.90

0.025

0.025

0.020

0.020

0.020

0.025

0.025

0.025

0.025

0.025

0.020

0.020

0.020

0.025

0.025

0.025

0.025

0.15

0.15

0.15

2.10 - 2.70

0.80 - 1.50

0.15

0.15

0.15

0.15

* ) Cr < 0.15, Cu < 0.35 and V < 0.03, unless otherwise stated. Sum of other impurity elements should not exceed % 0.35. **) Single values are maximum numbers.

0.04 - 0.14

0.06 - 0.14

G2Ti

0.06 - 0.14

0.025

G3Si2

1.30 - 1.60

0.15

G4Si1

0.70 - 1.00

0.025

0.06 - 0.14

Ni

G3Si1

S

0.025

0.90 - 1.30

P

No specifications are stated for this standard.

0.50 - 0.80

Mn

0.06 - 0.14

Si

G2Si

C

G0

Symbols

CHEMICAL ANALYSIS AND CHEMICAL SYMBOLS OF THE WELDING WIRE (%)

0.15

0.40 - 0.60

0.40 - 0.60

0.15

0.15

0.15

0.15

0.15

0.15

0.15

Mo

0.35 - 0.75

0.02

0.02

0.02

0.02

0.05 - 0.20

0.02

0.02

0.02

0.02

Al

0.15

0.15

0.15

0.15

0.15

0.05 - 0.25

0.15

0.15

0.15

0.15

Ti + Zr


Classification of Wire and Wire/Flux Combinations for Submerged Arc Welding Wires According to EN 756 PRODUCT TYPE Submerged Arc Welding Wire MECHANICAL PROPERTIES Symbol

Tensile Strength (N/mm²)

Yield Strength (N/mm²)

Elongation (L=5d) (%)

35 38 42 46 50

440 - 570 470 - 600 500 - 640 530 - 680 560 - 720

min. 355 min. 380 min. 420 min. 460 min. 500

22 20 20 20 18

IMPACT PROPERTIES two run technique Symbol

Re (N/mm²)

Rm (N/mm²)

3T 4T 5T

min. 355 min. 420 min. 500

min. 470 min. 520 min. 600

EN 756

Temperature Required for 47 J Symbol Impact Resistance (°C) Z A 0 2 3 4 5 6 7 8

S 46 3 AB S2 TYPE OF FLUX MS CS ZS RS AR AB AS AF ZB Z

Manganese + Silicate Calcium + Silicate Zirconium + Silicate Rutile + Silicate Aluminate + Rutile Aluminate + Basic Aluminate + Silicate Aluminate + Fluorid basic Fluorid + Basic any other type

180

+20 0 - 20 - 30 - 40 - 50 - 60 - 70 - 80


CHEMICAL ANALYSIS AND CHEMICAL SYMBOLS OF THE WELDING WIRE (%) Symbol S0 S1 S2 S3 S4 S1Si S2Si S2Si2 S3Si S4Si S1Mo S2Mo S3Mo S4Mo S2Ni1 S2Ni1.5 S2Ni2 S2Ni3 S2Ni1Mo S3Ni1.5 S3Ni1Mo S3Ni1.5Mo

Si 0.15 0.15 0.15 0.15 0.15 - 0.40 0.15 - 0.40 0.40 - 0.60 0.15 - 0.40 0.15 - 0.40 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25 0.05 - 0.25

Mn

Ni

any other agreed composition 0.35 - 0.60 0.80 - 1.30 1.31 - 1.75 1.76 - 2.25 0.35 - 0.60 0.80 - 1.30 0.80 - 1.30 1.31 - 1.85 1.86 - 2.25 0.35 - 0.60 0.80 - 1.30 1.31 - 1.75 1.76 - 2.25 0.80 - 1.30 0.80 - 1.20 0.80 - 1.30 1.21 - 1.80 0.80 - 1.30 1.81 - 2.40 0.80 - 1.30 2.81 - 3.70 0.80 - 1.30 0.80 - 1.20 1.31 - 1.70 1.21 - 1.80 1.31 - 1.80 0.80 - 1.20 1.20 - 1.80 1.20 - 1.80

181

Mo

0.45 - 0.65 0.45 - 0.65 0.45 - 0.65 0.45 - 0.65

0.45 - 0.65 0.45 - 0.65 0.30 - 0.50


Classification of Covered Electrodes According to EN ISO 2560-A PRODUCT TYPE

COVERING TYPE

Covered Electrode Manual Arc Welding

A C R RR RC RA RB B

MECHANICAL PROPERTIES Symbol

Yield Strength (N/mm²)

Tensile Strength (N/mm²)

Elongation (%) (L=5d)

35 38 42 46 50

355 380 420 460 500

440 - 570 470 - 600 500 - 640 530 - 680 560 - 720

22 20 20 20 18

IMPACT PROPERTIES

acid cellulosic rutile rutile (thick) rutile + cell. rutile + acid rutile + basic basic

EFFICIENCY / CURRENT TYPE

Symbol

Temperature Required for 47 J Impact Resistance (°C)

Symbol

Electrode Efficiency (%)

Current Type

Z A 0 2 3 4 5 6

no requirement +20 0 - 20 - 30 - 40 - 50 - 60

1 2 3 4 5 6 7 8

< 105 < 105 > 105 < 125 > 105 < 125 > 125 < 160 > 125 < 160 > 160 > 160

DC / AC DC DC / AC DC DC / AC DC DC / AC DC

E 46 3 1Ni B 5 4 H5

EN ISO 2560-A

HYDROGEN CONTENT CHEMICAL COMPOSITION

(ml/100 g max.)

Alloy

Mn

Mo

Ni

Mo MnMo 1Ni 2Ni 3Ni Mn1Ni 1NiMo

2 1.4 1.4 - 2 1.4 1.4 1.4 1.4 - 2 1.4

0.3 - 0.6 0.3 - 0.6 0.3 - 0.6

0.6 - 1.2 1.8 - 2.6 2.6 - 3.8 0.6 - 1.2 0.6 - 1.2

Z

other compositions

182

H5 H10 H15

5 10 15

WELDING POSITIONS 1 2 3 4 5

All positions All positions except vertical-down Flat butt and fillet; horizontal vertical fillet Flat butt and fillet Vertical-down and positions according to symbol 3


Classification of Covered Electrodes According to DIN 8555

E 9 UM 200 CZ WELDING METHOD G E MF TIG MIG UP

WELD METAL PROPERTIES

gas welding manual-arc welding metal-arc welding using cored wire electrodes tungsten inert gas welding metal shielding gas welding submerged-arc welding

C G K N P R S T

ALLOY GROUP 1 Unalloyed up to 0.4 % C or low alloy up to 0.4 % C and up to a maximum of 5 % of the alloying elements Cr, Mn, Mo, Ni in total. 2 Unalloyed with up to more than 0.4 % C or low alloy with more than 0.4 % C and up to a maximum of 5 % of the alloying elements Cr, Mn, Mo, Ni in total. 3 Alloyed, with the properties of hot working steels. 4 Alloyed, with the properties of high speed steels. 5 Alloyed with more than 5 % Cr, with a low C content (up to about 0.2 %). 6 Alloyed with more than 5 % Cr, with a higher C content (about 0.2 to 2.0 %). 7 Mn austenites with 11-18 % Mn, more than 0.5 % C and up to 3 % Ni. 8 Cr-Ni-Mn type austenitic alloys. 9 Cr-Ni steels (resistant to rusting, acid and heat). 10 With a high C content and high Cr alloying content and without additional carbide forming agents. 20 Co based, Cr-W alloyed, with or without Ni and Mo. 21 Carbide based (sintered, cast or cored) alloys. 22 Ni based, Cr or Cr-B alloyed. 23 Ni based, Mo alloyed, with or without Cr. 30 Cu based, Sn alloyed. 31 Cu based, Al alloyed. 32 Cu based, Ni alloyed.

183

Z

Corrosion resistant Resistant to abrasive wear Capable of work hardening Non-magnetizable Impact resistant Rust resistant Cutting ability (high speed steels etc.) High temperature strength as for high-temperature tool steels Heat resistant (non-scaling) i.e. for temp. over about 600째C

WELD METAL HARDNESS 150 200 250 300 350 400

125 - 175 HB 176 - 225 HB 226 - 275 HB 276 - 325 HB 326 - 375 HB 376 - 450 HB

40 45 50 55 60 65 70

37 - 42 HRC 42 - 47 HRC 47 - 52 HRC 52 - 57 HRC 57 - 62 HRC 62 - 67 HRC over 67 HRC

PRODUCTION METHOD GW GO GZ GS GF UM

rolled cast drawn sintered cored covered


Welding Positions

: Butt and fillet welding in the flat/downwards position. : Fillet welding in the horizontal/vertical position. : Butt welding in the horizontal position. : Butt and fillet welding in the overhead position. : Butt and fillet welding in the vertical upwards position. : Butt and fillet welding in the vertical downwards position.

s

端 q h w

f

w : Butt welding in the horizontal position. h : Fillet welding in the horizontal vertical position. s : Vertical upwards position. f : Vertical downwards positions. q : Butt welding in the horizontal position. 端 : Overhead position.

184


Determination of the Preheating Temperature

Tpreheating (°C) = 350

[ Ceq ] - 0.25

[ Ceq ] = [ Cc ] ( 1 + 0.005.e ) [ Cc ] = C +

Mn Cr + Mo + V Ni + Cu + + 6 5 15

[ Ceq ]

= Carbon equivalent (%)

[ Cc ]

= Chemical carbon equivalent (%)

e

= Part thickness (mm)

Tpreheating = Preheating temperature (°C)

Example : Preheating temperature required for 25 CrMo 4 steel of 12 mm thickness :

[ Cc ] = C +

Mn Cr + Mo + V Ni + Cu + + 6 5 15

[ Cc ] = 0.25 +

0.8 1 + 0.25 + 0 + 6 5

+

= 0.63

[ Ceq ] = [ Cc ] ( 1 + 0.005.e ) [ Ceq ] = [ 0.63 ] ( 1 + 0.005.12 ) = 0.67

Tpreheating (°C) = 350

[ Ceq ] - 0.25

Tpreheating (°C) = 350

[ 0.67 ] - 0.25

= 220 - 230 °C

185

0+0 15


Preheating Temperatures

Material Group

Material (Wr.) Number

Ceq

Preheating Temperature (째C)

Carbon Steels

1.1141 1.0402 1.1172 1.1186 1.1248

Ck 15 C 22 Cq 35 Ck 40 Ck 75

0.28 0.33 0.48 0.58 0.95

----150 - 200 200 - 250 300 - 350

Carbon Steels

1.1165 1.1167 1.0912 1.3401

30 Mn 5 36 Mn 5 46 Mn 7 X 120 Mn 12

0.63 0.69 0.78 ---

200 - 250 200 - 250 250 - 300 ---

Molybdenum Steels

1.5415 1.5419

15 Mo 3 22 Mo 4

0.50 0.50

200 - 250 200 - 250

1.7218 1.7220 1.7225 1.7360 1.7362

25 CrMo 4 34 CrMo 4 42 CrMo 4 31 CrMo 12 5 12 CrMo 19 5

0.70 0.80 0.90 1.25 1.45

250 - 300 300 - 350 325 - 350 400 - 450 400 - 450

Nickel-ChromiumMolybdenum Steels

1.6523 1.6565 1.6577 1.6747

21 NiCrMo 2 40 NiCrMo 6 22 NiMoCr 47 30 NiCrMo 16 6

0.60 1.00 0.75

200 - 250 300 - 350 250 - 300 350 - 400

Chromium Steels

1.7015 1.7006 1.7035 1.7176 1.3505

15 Cr 3 46 Cr 2 41 Cr 4 55 Cr3 100 Cr 6

0.42 0.62 0.84 0.92 1.47

100 - 150 250 - 300 300 - 350 350 - 400 500

Nickel-Chromium Steels

1.5713 1.5736

13 NiCr 6 36 NiCr 10

0.52 0.90

200 - 250 300 - 350

Stainless Steels

1.4301 1.4571 1.4845

X6 CrNi 19 10 X6 CrNiMoTi 17 12 2 X6 CrNi 25 20

-

no preheating

ChromiumMolybdenum Steels

Attention ! The preheating temperatures for the steel types mentioned in this table are determined mathematically and are listed to give the user a basic idea. These values might change with respect to the welding process and the dimensions of the welded component.

186


Handling and Storage of the Covered Electrodes Manufacturing : Covered electrodes are manufactured by extruding different materials on a core wire. As binder for the coating materials silicates are used which contain 60 % water. The electrodes are dried at different temperatures depending on kind of the electrode. Acid, rutile and cellulosic type of electrodes are dried up to a moisture content of 0.3-2.0 %. Basic and alloyed types of electrodes are dried; actually baked at higher temperatures up to 500째C and the final moisture content is very low. Humidity of the Coating : Covered electrodes must be handled carefully. Electrodes and their coverings can be damaged through absorption of moisture. Too high a moisture content in the electrode covering can be dangerous and therefore must be avoided. All the electrodes have a certain moisture content, which varies according to the type. Moisture content of the covering of Askaynak electrodes is controlled strictly before they leave the factory. A limited moisture content is normal and has no effect on weld quality. The moisture limits actually have a large safety margin in moisture content when they leave the factory. All electrode coverings are hygroscopic and absorb moisture from the air depending on the relative humidity of the air. At higher relative humidity levels ; e.g. 90 % the covering of basic electrodes absorbs moisture so quickly that after exposure for one day the electrode cannot be used anymore. Acid, rutile and cellulosic type of electrodes are not as sensitive as basic electrodes but they will all pick up moisture if left unprotected. It is not only direct moisture in the air, which can damage the electrodes but also condensation. Specially on high relative humidity levels and at large temperature differences between day and night condensation can occur. The dew wets the packages and this moisture is gradually absorbed by the electrode covering. Humidity in the coverings of the electrodes can cause severe damage to the weld. It can cause porosity in the welds. Unfortunately porosity is not always visible to the naked eye but radiography reveals at once. As a source of hydrogen it is the main cause for hydrogen cracking in the welds, which is very dangerous. There is the danger of underbead cracking in the heat affected zone of the parent material. Packing : Because of the danger of moisture pick-up the packages of the electrodes should be suitable to avoid this danger. Unless stored in appropriate conditions coated electrodes will remain unaffected and provide satisfactory welds. All of Askaynak covered electrode boxes are tightly wrapped in polyethylen. For sensitive welds tin-can boxes are available. Plastic boxes are used for stainless steel type of electrodes.

187


Handling and Storage of the Covered Electrodes Storage Conditions (*) : The electrodes must be kept in their original packages. The electrodes should be protected against rain, damp and dew. The relative humidity level at the storage place should be 40 % and less. The temperature of the storage should be constant and above 15°C. The boxes should be kept on shelves or pallets avoiding to contact directly the floor and the walls. When welding outside loose packets of electrodes should not lie about unprotected on the site. Electrodes should not be taken out of the store in quantities greater than necessary for daily or two days consumption. Redrying : Rutile Types : Redrying is not necessary. In case of high moisture redrying at 100-150°C for 1-2 hours is recommended. At lower drying temperatures electrodes should be kept longer. Cellulosic Types : Cellulosic type of electrodes are not very sensitive to moisture pick-up. Redrying must be made very carefully otherwise the coating can get cracks. In general redrying is not recommended for cellulosic electrodes. In case of a necessity the drying temperature should not exceed 70°C. Basic and Alloyed Electrodes : If the electrodes are stored in recommended storage conditions (15°C / 40 % relative humidity) and in original packages there is generally no need for redrying. When the plastic wrappings of basic type of electrodes are opened the electrodes ought to be put into a heating cabinet at about 50°C. If the boxes are opened and exposed to open air for more than 2 hours redrying is recommended. Basic and alloyed electrodes are dried for 2-3 hours at 250-400°C. It is not recommended to redry the same electrodes more than 3 times.

(*) These storing conditions are necessary for basic type of coverings. In case of rutile and cellulosic type of electrodes the conditions are not as tough as for basic type of coatings.

188


Askaynak product catalogue 2009