Unitor™ Welding Handbook 16th edition by Wilhelmsen Ships Services

2022

The Welding Handbook 16th Edition

Maritime Welding Handbook Welding and Related Processes Onboard 16th edition Product no. 807003 Scan now

for a closer look

Notice: welder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are based on general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not to

by anybody using the information and guidelines in this Welding Handbook.

INTRODUCTION

required is a good command of modern welding techniques.

and would like to thank the many who have taken the effort to contribute with

Unitor’s business activity

maritime deliveries from Acetylene as fuel gas for the guiding light beams from numerous lighthouses beaten coast of Norway. The focus changed towards gas and arc welding techniques when these were

that is suitable for onboard welding, backed by a worldwide service network, training and documentation.

UNITOR WELDING HANDBOOK 1 SAFETY IN WELDING

1.01

1.01 Introduction 1.02 How to use the handbook

1.02

1.03 Welding instructions and training

1.03

1.04

1.05

1.06

1.06 Welding fumes

1.07

1.07 Safety check list

2.01

2 SOLUTIONS

2.02 2.03 2.04 61

2.06

2.06 Stainless steels 2.07 Cast iron

2.10 Evaluation of welds

3 CONSUMABLES

2.05

2.07

103

2.08

111

2.09

113

2.10 3.01

3.01 Coated Electrodes

3.02 3.03

3.03 Wires for Wire Welding

3.04 3.05 3.06

4 ARC WELDING AND CUTTING PROCESS & EQUIPMENT

316

4.01

366

4.02

386

4.03 4.04

5 GAS WELDING AND CUTTING PROCESS & EQUIPMENT

5.01

6 MISCELLANEOUS INFORMATION

6.00

7 CHECKLISTS

7.00

5.02

UNITOR WELDING HANDBOOK 1 SAFETY IN WELDING 1.01 Introduction 1.02 How to use the handbook 1.03 Welding instructions and training 1.04 Personal protection

8 9 10 11 12 13

2.06.06 Clad Steel 2.06.08 Storing and handling of Stainless Steel onboard

70 71 73

for Stainless Steel 17 1.05 Work site protection

1.06 Welding fumes 1.06.01 Welding fumes 1.06.02 Fume extraction 1.07 Safety check list

21 21 21 22 23 23 26 29 30 31 31

2 SOLUTIONS 2.01 Introduction 2.01.01 Quick reference for cutting 2.01.02 Quick reference for joining 2.01.03 Quick reference for rebuilding, hardfacing and coating 2.02 Filler material consumption 2.03 Metal identification 2.04 Unalloyed / low alloyed steel

34 35 36 37

2.07 Cast iron 2.07.01 Introduction 2.07.03 White cast iron

2.07.06 High alloy cast iron

2.08 Copper and copper alloys 2.08.01 Introduction

2.10.03 Crack detection 3 CONSUMABLES 3.01 Coated Electrodes 3.01.01 Introduction

2.05 Problem steels 2.06 Stainless steels 2.06.01 Introduction 2.06.02 Austenitic Stainless Steel 2.06.03 Ferritic Stainless Steel

61 64

67 68

80 81 82 83 86

103 103 103

2.08.03 Aluminium brass (Yorcalbro)

2.09 Aluminium 2.10 Evaluation of welds 44 47 52

76 77 77 78

High Recovery Electrode

106 111 113 113 117 122 124 125 126 127 133

UNITOR WELDING HANDBOOK 187

Electrode for Aluminum Electrode for Chamfering Electrode for Air Carbon 3.02 TIG welding rods and fluxes 3.02.01 Introduction

196

Hydrogen Electrode for 161

201 203

163

207

Electrode for High

3.03 Wires for Wire Welding 3.03.01 Introduction

Electrode for Weathering Steel 167 Electrode for

3.03.03 Storage and handling for Flux Cored wires

Electrode for Heat Resistant Overlays

211 214 216 218

221 223 3.03.07 Coreshield 8 Selfshield

171 Electrode for Joining & Wear Resistant Overlays

227 173

231 233

Electrode for Stainless Steel Electrode for Stainless Steel 177

3.04 Gas Welding Rods & Fluxes

237 240

181 3.05

Nickel Iron Electrode for Cast Iron

Brazing Rods & Fluxes

248

183 Nickel Electrode for Cast Iron

UNITOR WELDING HANDBOOK

261 263

Cable Connection Assembly connectors & return

267 268

3.06 Cold Repair Compounds 3.06.01 Introduction

270 271 272 273 274

welding & gouging 4.02 TIG Welding

277 278

3.06.07 Product overview

371 373 376 378

280 281 283 287

380 383 4.03 Wire Welding

386 387 388

4.04 Plasma Cutting

424

3.06.13 Aquagrade Rebuild 302 3.06.17 Rubbergrade 6 Rebuild 3.06.18 Rubbergrade 6 Remould

308 311

4 ARC WELDING AND CUTTING PROCESS & EQUIPMENT 4.01 Electrode welding & gouging

315 316 317 320 321 323 328 331 333

362 366 367 368

UNITOR WELDING HANDBOOK 5.02 Gas supplies and gas distribution system shooting 5 GAS WELDING AND CUTTING PROCESS & EQUIPMENT 5.01 Ac/Ox cutting, welding, brazing

499

445 447

for handling and use

for Acetylene and Oxygen 6 MISCELLANEOUS INFORMATION 6.01 International system of units

524

for Acetylene and Oxygen of fractions of an inch 2

6.07 Common gauge series for sheet thickness and wire

in sea water 6.12 Pressure variations related to & heating torch

6.13 Abbreviations and welding terminology 7 CHECKLISTS

of steel

546

Welding & Heating 7.02 Unitor Welding Inverter 7.03 Unitor Plasma Cutter

for gas welding techniques

SAFETY IN WELDING Introduction How to use the handbook

Welding instructions and training

1.01

13 21 Welding fumes

Safety check list

SAFETY IN WELDING 1.01

Introduction Welding and related thermal concentrated heat source which melts or burns away steel and other metals. observed when welding and related to avoid accidents related to the gas heat, fumes, and visible and invisible rays from the heat source. Authorities in most countries have laid down regulations and guidelines related to welding and other hot work

materials, and some guidelines as to identifying metals. This handbook, however, cannot be for each of these areas, dealing in

These regulations must be available onboard, and be known and adhered to when hot work is to be done.

societies and other authorities have consequently issued regulations and be known and followed wherever

various items.

Additional information

from authorities and others and by Unitor welding courses will deal in detail not only with the technique required for a successful weld, but welding onboard.

SAFETY DEPENDS ON YOU

– Rules and regulations relating to the handling and installation – Rules and regulations relating to hot work onboard.

SAFETY IN WELDING How to use the Handbook Read this first

1.02

advice given here whenever you weld. If you know little about welding and your

the other hand, you have a basic understanding of welding, read the book from the

When facing a problem joining, rebuilding and coating, as well as information on how to identify metals,

Use the consumables correctly

The process

going to use.

Power and gas supply

The remaining questions Reading through the handbook you will come across terminology and

SAFETY IN WELDING Welding instruction and training around the world. These academies offer tailor made solutions for maintenance and

1.03

numerous kinds of metals onboard, can be very challenging. These are all elements the crew must take into consideration in order to work effectively. The Wilhelmsen

• Stick electrode welding • Steel • Stainless Steel • Plasma cutting

• Cast iron • Cast steel • Aluminium

Unitor Welding Centre – Piraeus, Greece

International Maritime Training Centre – Mumbai, India

Maritime Academy of Asia and the Pacific – Mariveles, Bataan, Philippines

People Soft Inc. – Antipolo, the Philippines

SAFETY IN WELDING Welding Safety Inspection (WSI) Product No. 190-770077

1.03

Safety Standards and Best Practices Reference

Questionnaires for Oil Tankers, Combination Carriers, Shuttle Tankers, Chemical

This is how our WSI service works:

1. One of our trained Port Service Engineers (PSE) goes on board to conduct

2. PSE will create a

with your Account

to you, along with key

Welding Safety Inspection Global Port List Middle East AMB & India

Europe

Fujairah

Rotterdam

Americas Portsmouth

Jakarta Hong Kong

Wilhelmshaven Hamburg

Asia & Oceania

Piraeus

Shanghai Port Canaveral New York

Algeciras

Kobe Yokohama Kaohsiung

Rio de Janeiro check for availability.

SAFETY IN WELDING Personal protection Protection against electric shocks

1.04

burns to heart failure.

Protection against burns electrodes etc.

Protection against ultraviolet and infrared light

Protection against chemicals considered harmless. Nevertheless we always recommend that one does the

Protection against flying chips

damage to the eyes.

General body protection A welder at work is isolated from his surroundings. He must concentrate on the He must therefore always wear a safety helmet, safety shoes etc. which will offer him

welder in all situations.

Work site protection

SAFETY IN WELDING Arc welding face shields and glasses welding slag in the eye.

which is unaffected by heat, cold or moisture, and both glasses and shields conform to relevant EN standards.

1.04

The Autodark 820 FreshAir Complete

to the user’s facial. The fan battery recharges in 3 hours and will The Autodark 820

The Autodark 300 Welding Shield The basis is a lightweight well designed shield

The Autodark 300 Welding Shield

• Angle in relation to face • Height on head • Head diameter

The Flip-Vision Welding face shield

SAFETY IN WELDING

as standard with the shield. The glasses have dimension 60 x 110 mm.

1.04

Safety helmet with face shield with safety helmet instead of headband.

Face Shield with handle

Face shield

Face shields Description

Product no. 196 779034 196 779032 196 709485 196 619114 196 619098

Spares and accessories for Autodark 300

Sweatband H1 Spares and accessories for Autodark 820 196 779040 196 779041 196 779043 196 779044 196 779056 196 779045

196 779057 196 779061 196 779059 196 779060

196 779046 196 779047 196 779048 196 779049 196 779055

SAFETY IN WELDING Glasses for Arc Welding The glasses have dimension 60 x 110 mm and are

Items to be mounted into Unitor face shield in the following manner:

glass of correct shade should be ordered in addition

1.04 shade glasses.

A. Safety glass (Polycarbonate)

B. Filter shade glass rays from the welding arc, and reduces

should be selected after consulting the The glasses are marked Protane Shade SO

C. Protection glass

Guide to arc welding glasses Amperage

Filter Shade

< 20 A 10 11 12 13

Quantity in Unit

Product number unit 196-633230 196-633248 196-633255 196-633263 196-633271 196-633289 196-633222 196-633214

SAFETY IN WELDING Safety spectacles clear for eye protection with integrated side guards. The

1.04

length and angle is adjustable. For use during daily maintenance work in Product

Pcs.

Product no.

176-632943

– Clear

Safety spectacles Shade 5 for brazing and welding Same modern lightweight design and features as the Clear version. Fitted welding and cutting work. Not for use when doing arc welding. Product

Pcs.

Product no.

176-632950

Welding and grinding goggles comfortable surfaces against the face. The ventilation slots are designed to

fogging of the glasses.

Product

Pcs.

Product no.

176-175273

Safety grinding goggles Half mask goggle of clear soft Product

Safety grinding goggles non mist

Pcs.

Product no.

176-653410

grinding only.

SAFETY IN WELDING Glasses for gas welding and cutting Items to be mounted into Unitor face shield in the following manner:

1.04

A. Protection glass

B. Filter shade glass

A. Protection glass

Guide to gas welding glasses Application

Filter Shade Glass

Pcs/ set

Product number

176-633305

176-633313

176-633321

176-633354

176-633297

& Cutting –

& Cutting – Thick material Protection

SAFETY IN WELDING E

1.04

A F

Welder’s protective clothing are heat and wear resistant. They

Protective clothing Pos.

Product

Welders gloves for electric arc welding Working gloves

where movement is restricted. It is

Pcs/set

Product no. 196-632786 197-632794 196-633057 196-510438

jacket is worn when welding 196-510446

C Extra large for welding

196-633016

shock. When dry the leather acts as an electric insulator. Therefore

196-184184

196-510420 Heat resistant mitten

when doing arc welding.

196-510453 176-233148 196-175935

SAFETY IN WELDING Electric arc welding gloves

gloves with long gauntlets are necessary. These must be of leather. recommended for welding with coated electrodes.

1.04

TIG and Gas welding gloves

softskin gloves are available for

than the thicker welding gloves when touching hot metal.

EN 388 3232

Heat resistant mitten

outer layer, and further insulation against heat in the inner layers. It is an acetylene cylinder valve even

is also suitable for handling hot work

Working gloves

SAFETY IN WELDING Work site protection Welding Curtain

1.05

ultraviolet and infrared light from the welding arc, but still enables one to see extinguishing material, but is not heat

has 7 holes and the curtain comes

to join two or more curtains together

Product

Welding curtain

Pcs.

Product no.

196-633065

Welding spatter blanket

combustible materials and delicate welding and cutting. Available in a roll 1m x 10m. Nom. Thickness 0,82mm.

Standard A2 Product

Pcs.

1 blanket

Product no.

196-646067

SAFETY IN WELDING Fire extinguisher

Technical Properties This device was designed using highly

1.05

be ideally suited to the requirements of the maritime environment.

its category.

Efficiency

extinguisher ensures that it is effective

sometimes not recommended for use with

Instructions for use

Extinction Mechanism

embers, by cooling and forming a layer of

from heat radiation.

Easy to use

incorrect use are greatly reduced.

SAFETY IN WELDING Welding fumes Welding fumes consist of a mixture including risk assessment and risk controls should be taken to mitigate or welding. 2. The base material.

1.06

different metals, means that the fumes given off may contain numerous use of a fume extraction unit. When

or materials surface treated with Inhalation of these fumes can result effects. It should be avoided by the use of a good extraction unit, or the use of a face shield with fresh air connection.

contaminating the area for others. inhalation of this substance. extraction unit, the welder can

When welding or cutting old steel

rises some distance from his nose and mouth or by using a welding face

coating may contain lead or mercury. Fumes from these substances can result in serious health damage if inhaled.

board use a self contained unit with Electric arc welding with coated

taken against dangerous fumes before welding commences.

divided into fume classes 1 to 7, which See the Coated Electrodes section on fume classes.

Risks

items. Inhaling these substances can

The International Agency for Research substances containing chrome, cadmium, nickel lead or mercury, it is

SAFETY IN WELDING essential that a smoke extractor unit is face shield with fresh air connection.

may contain several toxic substances.

1.06

the nitrous gases (NO2 on several conditions. The use of concentrations. No warning is given

Avoid direct inhalation of welding fumes.

the form of irritation of the muceous membrane in eyes, nose or throat. the welder must not leave the torch alight when he is not actually using it. Carbon monoxide may be given off due or if the material being welded or cut or oily. High concentrations, which constitute a health risk, can be formed

Use fume extraction.

Inhalation of large quantities of carbon monoxide can lead to suffocation. more usual risks connected with books on the subject, and welding smoke is also undergoing continuous research. The result of this research factors to light and all those involved

may, as yet, be unknown.

SAFETY IN WELDING Welding fumes All Unitor Electrodes are issued a fume Class number. These are the

1.06

For outdoor welding see Fume Class 3.

that is a theoretical value to describe the amount of fresh air needed to dilute

Fresh air needed to dilute the fumes Fume Class 1

3000

– – –

<3000

– –

60000

>100000

–

< 60000

–

< 100000

SAFETY IN WELDING FumeClean 230 welding fume extractor inhaling welding fumes that might have harmful used anywhere a welder can work.

Four-stage filtration system

1.06 2

which has a total area of 12m . The large area of the

Active carbon filter

required.

Two powerful motors The two motors guarantee an adequate extraction

reduced maintenance.

Automatic start

used and the unit will automatically switch on when

SAFETY IN WELDING Technical Data Number of motors

2 2x1kW

Dimensions

Noise level High vacuum suction

22 000 Pa

1.06 12 m2

IP class Net weight

16 kg

Ordering information Description

Optionals Hose Connection Outlet Side Active Carbon Filter Spare parts

Product no.

WELDING HANDBOOK NOTES

1.06

SAFETY IN WELDING Safety check list for welding and related processes should include, without being limited to Equipment functions correctly, is correctly connected to mains, and that you are

1.07

Ensure that gas cylinders are

well maintained.

functioning regulators for the gas. Acetylene and oxygen regulators arrestors. Protect cylinders against heat and mechanical damage.

and a heat resistant mitten shall be available. Hoses shall be in good condition, without leaks or damage, and with correct colour coding for the gas. (Red for acetylene, blue for oxygen, air). Use correct hose connectors twisted wire must never be used. Never use oil or grease in connection with welding gases and never use Never use defective welding cables.

with undamaged insulation and Use safety cable connectors disconnected.

SAFETY IN WELDING Check that torches and electrode holders are in good working order. Check all gas connectors for leaks, including torch valves. Even Argon

original gaskets only.

1.07 damage e.g. in doorways, hatches, etc. cables should be stretched to the should be fastened with good electrical contact directly on the

Work place

for hot work.

fumes when heated.

SAFETY IN WELDING

1.07

Hot work procedure Ensure that all relevant check lists, have been issued.

the same manner as the welder should If work has been done inside a

safety cable connector may act as Operator / assistant protection not wear clothes of highly combustible materials or wet clothes, and do not carry combustible material, e.g. matches, lighters, oily rags. Welding gloves should always be used, and when necessary also use additional

are unbroken and have the correct shade.

SAFETY IN WELDING

1.07

retardant material). Preferably without

• Working overall • Safety boots with steel toes.

Avoid synthetic materials, including

• Welders gloves

• Safety boots with steel toes. head band • Welders gloves

Where necessary use a fresh air unit or breathing

Never use acetylene or oxygen to blow away dust

When work is paused or completed Always remove coated electrodes from the electrode source (welding machine, cylinder valve, gas outlet) also during short breaks for meals etc.

remains. Only when this has been assured should • Working overall • Safety boots with steel toes

Available wall chart: Safety checklist for welding and related

ADDITIONAL WELDING LITERATURE AVAILABLE:

1.07

Cylinder safety

Protect your crew & vessel from flashbacks

Welding consumables selector

Safety checklist for welding and related thermal processes

Gas distribution system

Quick coupling system

Gas welding and cutting solution

The solutions guide Unitor maintenance and repair welding

The solutions guide Unitor cold polymer repair

SOLUTIONS Introduction • Quick reference for cutting

• Quick reference for joining

• Quick reference for rebuilding, hardfacing and coating

Problem steels

2.01

Stainless Steel • Austenitic Stainless Steel • Ferritic Stainless Steel

67 68

• Clad Steel

70 71

• Storing and handling of Stainless Steel onboard Cast iron

73 77 103

• Aluminium brass (Yorc albro) 106 Aluminium

111

Evaluation of welds

113 113 117

• Crack detection

122

SOLUTIONS Introduction material, but also on the electric material which should be used. All solutions are linked to one of the symbols below which relates the

2.01

right one for the job. The overview

SYMBOL FILLER MATERIAL

PROCESS

Solid Wire Flux Cored Wire

Flux Cored Arc Welding

Coated Electrodes (Stick Electrodes)

Plasma Cutting

SOLUTIONS Quick reference for cutting PROCESS

AC/OX

MMA

ACA

Plasma

ALLOY

Mild steel

Low alloy/ cast steels

High alloy/ stainless steels

Cast iron

Copper with alloys

Aluminium with alloys

Consumable parts

Cutting gouging

ACA electrode

2.01

Torch electrode

Comments

SOLUTIONS Quick reference for joining outside corners in sheet metal constructions.

suggest some solutions for joining advantages and limitations, and further information will be found in this

How to use the table:

one metal to another are found on the

You should also note that with the

metal through the diagram, as shown for stainless steel below. The corner

2.01

material thickness is small and the joint is suited for it, e.g. welding

METAL

Cunifer Nickel Alloys

Bronze

Yorcalbro

will always show the alternatives for joining the metal to itself. Brass

Copper

Cast Iron

Unalloyed/ Stainless “Problem” Lowalloyed/ Steels Steels Cast Steels

Unalloyed/ Lowalloyed/ Cast Steels

Icuni (W) Tinbro (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) *) **)

Nife (E) Nickel 23/14 (E) (E) Tinbro (E) Tensile (E) Albronze (E) Impact (E) *) *) **)

Tensile (E) Impact (E) *) **)

“Problem” Steels

Icuni (W) Tinbro (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) *) **)

Tensile (E) Nickel (E) *) **)

Tensile (E) Impact (E) *)

Stainless Steels

Icuni (W) Tinbro (E) 23/14 (E) *)

AG-60 AG-45

Tensile (E) 23/14 (E) 18/8 (E) *)

18/8Mo (W) 23/14 (E) 18/8 (E) Duplex (E) Iduplex (W) *)

Cast Iron

Nickel (E) Tinbro (E) Albronze (E) *) **)

Tinbro (E) Albronze (E) *) **)

Nife (E) Nickel (E) Tinbro (E) Albronze (E) *) **) ****)

Copper

Icuni (W) *)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Icuni (W) Tinbro (E) *) **)

Icuni (W) Tinbro (E) Albronze (E) *) **)

Brass

Icuni (W) Tinbro (E) *)

Ialbro (W) Tinbro (W) Albronze (E) *) **)

Icuni (W) Tinbro (E) *) **)

Ialbro (W) Tinbro (E) Albronze (E) *) **)

Icuni (W) Tinbro (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Ialbro (W) *)

Icuni (W) Tinbro (E) *) **)

Ialbro (W) Tinbro (E) Albronze (E) *) **)

Yorcalbro

Bronze

Cunifer Nickel Icuni (W) *) Alloys

Example, joining stainless steel to:

Yorcalbro

box 1 box 2 box 3

Cast iron Stainless steel “Problem” steels

box 6 box 7 box 8

Full scale table overleaf

LH (E) LHV (E) LHT (E) LHL (E) *) **) ***)

Icuni (W) Tinbro (E) *) **)

Icuni (W) Tinbro (E) 23/14 (E) *)

Nickel (E) Tinbro (E) Albronze (E) *) **)

Icuni (W) *)

Icuni (W) Tinbro (E) *)

Icuni (W) Tinbro (E) *) **)

Icuni (W) *)

“Problem” Steels

Stainless Steels

Cast Iron

Copper

Brass

Yorcalbro

Bronze

Cunifer Nickel Alloys

Unalloyed/ Lowalloyed/ Cast Steels

METAL

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Tinbro (E) Albronze (E) *) **)

AG-60 AG-45

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Yorcalbro

Ialbro (W) Tinbro (E) Albronze (E) *) **)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Ialbro (W) *)

Ialbro (W) Tinbro Icuni (W) Tinbro (W) Albronze (E) (E) *) **) *) **)

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Tinbro (E) Albronze (E) *) **)

AG-60 AG-45

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Bronze

Quick reference for joining

Ialbro (W) Tinbro (E) Albronze (E) *) **)

Icuni (W) Tinbro (E) *) **)

Tinbro (E) Albronze (E) *) **)

AG-60 AG-45

Ialbro (W) Icuni (W) Tinbro (E) Albronze (E) *) **)

Brass

Icuni (W) Tinbro (E) Albronze (E) *) **)

Tinbro (E) Albronze (E) *) **)

AG-60 AG-45

Ialbro (W) Icuni (W) Tinbro (E) *) **)

Copper

Tensile (E) 23/14 18/8Mo (W) (E) 18/8 (E) 23/14 (E) 18/8 *) (E) Duplex (E) Iduplex (W) *)

Aluminium welding:

Nife (E) Nickel (E) Tinbro (E) Albronze (E) *) **) ****)

“Problem” Steels

Unalloyed/ Lowalloyed/ Cast Steels

Tensile (E) Impact (E) *)

23/14 (E) Tensile Tensile (E) LH (E) LHV (E) (E) Impact (E) *) Impact (E) *) **) LHT (E) LHL (E) *) **) ***)

Stainless Steels

Tensile (E) Nickel Tensile (E) (E) *) **) Impact (E) *)

Nife (E) Nickel (E) Tinbro (E) Albronze (E) *) **)

Cast Iron

SOLUTIONS

2.01

WELDING HANDBOOK NOTES

2.01

SOLUTIONS Quick reference for rebuilding, hardfacing and coating further information will be found under

Examples of applications Wearmax (E) Tensile (E)

Wearmax (E) Tensile (E)

2.01

Cargo grab teeth

Tensile (E)

Rebuilding valve seats on exhaust valves

overlay on tools

Tensile (E)

Rebuilding edges

Rebuilding gear teeth

Rebuilding valve closing surfaces

SOLUTIONS Quick reference for rebuilding, hardfacing and coating Property Base material

Rebuilding with approx. base material

Unalloyed/ low alloyed cast steels

2.01

Wearmax (E)

Rebuilding with improved corrosion resistance Wearmax (E) Tensile (E)

Tensile (E)

“Problem” steels

Tensile (E)

Cast iron

Nife (E) Nickel (E)

Wearmax (E) (E)

Stainless steels

Rebuilding with improved wear resistance properties

Nife (E) Tinbro (E)

Nickel (E)

Tensile (E)

W E

Copper

Icuni (W) Tinbro (E)

Brass

Ialbro (W) Tinbro (E)

Yorcalbro

Ialbro (W)

Icuni (W)

Bronze

Ialbro (W) Tinbro (E)

Cunifer

Icuni (W)

Nickel (E)

Aluminium

Alumag (W) Alumin (E)

SOLUTIONS Quick reference for Cold repairs 1. Where there is a need for emergency repairs.

2. Where hot work like welding is not permitted due to fire / explosion hazard.

2.01

3. Where the base material is not weldable. Certain casted metal alloys are not weldable due to their chemistry. Sometimes

4. Where distortion of base material is unacceptable.

5. Where there is restricted space.

6. Where specific properties are required.

7. Where you need non-metal repairs.

WELDING HANDBOOK NOTES

2.01

SOLUTIONS Filler material consumption

Fillet Weld

also given. – For steel welding wires and rods a measure

Section size

a mm

s mm2

Deposit volume per m. a cm3/m 6

3 16

– For coated electrodes the required number of electrodes (for steel) is by the value “(number of electrodes

6 7 8 10 11 12 13

Deposit weight per m. W kg/m

36 81 100 121

0.07 0.10 0.16

2.02

0.33

138 162

1.08 1.27 1.76

material section. and work routines, e.g. throwing away

Outside Corner

Square Butt Joint

Plate thickness

Root opening

Deposit volume per m.

Deposit weight per m.

cm3/m

kg/m

2 3

0.02 0.02 0.03

2 6 7

3 3

7 22

0.17 0.20

32 0.33

Plate thickness

Section size

t mm

mm2

2 3

Deposit volume per m. V cm3/m

Deposit weight per m. W kg/m

16 22

0.03 0.06 0.08 0.13 0.17

2 8

6 7 8 10 12 18 20 22

18 32

0.32

72 113 162 200

0.73 1.11 1.60

323

3.18

SOLUTIONS Single V-joint

Single V-joint

50° Flat

2.02

Plate thickness

Root opening

t mm

s mm

6 7 8 10 11 12 16 18 20

70° Vertical

Deposit volume per m.

V cm3/m

1 1 1

Deposit weight per m.

W kg/m 0.13 0.17 0.26 0.31 0.38

Plate thickness

Root opening

t mm

s mm

6 7 8

120

227

0.86 1.33 1.63

Single V-joint

16 18 20

60° Flat Root opening

t mm

s mm

6 7 8 10 11 12 16 18 20

2 2 2 2 2 2 2 2 2

W kg/m 0.13

31 0.38

2 2 2 2 2 2 2 2 2

0.76 107 188 211 263 320

2.17 2.62

Single V-joint

Plate thickness

1 1 1

V cm3/m

Deposit weight per m.

70 10 11 12

2 2 2 2 2 2 2 2 2

1 1 1

Deposit volume per m.

80° Vertical

Deposit volume per m.

Deposit weight per m.

13 20 27

0.10

V cm3/m

W kg/m

0.20 0.30 0.37

61 78 107

0.66 0.77 1.02

160 180 223 271

1.23 1.60

Plate thickness

Root opening

t mm

s mm

6 7 8 10 11 12 16 18 20

1 1 1

Deposit volume per m.

Deposit weight per m.

18 26 36

0.22 0.30

V cm3/m

W kg/m

66 82 2 2 2 2 2 2 2 2 2

0.86 1.02 1.23 1.60 1.81 2.02 308 376

3.11

WELDING HANDBOOK NOTES

2.02

SOLUTIONS Metal identification

Test

Appearance of untreated metal surface

Appearance of surface after filling

Appearance of fracture surface and relative toughness

rather smooth. rusty. Rough granular surface.

uneven granular surface. Rather brittle.

Metal Grey cast iron

2.03

White cast iron

As above

Normally too Shiny white

Unalloyed steel. wrought iron, low-alloy steel, carbon steel

rusty, can be smooth or rough,

Stainless steels

Shiny

Copper to green (verdigris). Brass and bronze

Aluminium and aluminium alloys

Other tests for identification, see following pages for description

Heavy

Chiselling test.

Heavy

None

grained, silvery crystalline surface. Heavy test. Chisel test

tough to very brittle,

Heavy grey. Smooth surface. Some

grey surface. From tough to brittle.

Shiny

Not necessary

Heavy

None

Not necessary

Heavy

None

surface. From

brown or

Lead and white metal

Shiny grey, very smooth surface. Some alloys are

Comparative weight of metal

Yellow, smooth surface. Not necessary

Acid test

Not necessary

None

and smooth surface. White to grey, smooth velvety surface.

White, very smooth shiny surface.

SOLUTIONS Filing test Restance to file

Type of steel

Brinell hardness 100

the metal.

alloyed steel 200

be increased. 300 not bite into the metal and the High resistance. The metal can be

2.03

Tool steel marks, but the metal is almost as

Spark test

Chisel test

Unalloyed steel

the end into several small

Manganese steel

in stars.

High speed steel

forked ends.

Unalloyed steel (Cast steel). when chiselled.

Stainless steel Cast iron

Monel

Cast iron.

extinguished.

material chiselled away is in the form of brittle fragments.

SOLUTIONS Magnet test

Aluminium/magnesium test 1. Clean a small area of the metal. caustic soda (NaOH) solution. water.

2.03

Non-magnetic

Flame test

This indicates an Austenitic stainless steel.

with magnesium (seawater resistant must not be welded.

Magnetic Indicates a Ferritic normal steel.

good weldability.

checks.

bright red colour dulls to brown oxide. Usage

Red to yellow

alloys

fume. Colour variation assists with usage check. common usage.

Heavy

Aust. stainless steel

Aust. manganese steel

boiling lead under oxy

Won’t oxy cut

and Stainless Steel

Oxy cuts

SPARK TEST

burns brightly

SPARK TEST

iron

smoothly & brittle

Fractured surface

Aluminium drosses

Won’t cut Work hardened Aust. stainless or hard ferrite stainless

Hard

rough

Nickel

Soft silvery Stainless (Ferritic)

Stainless Nickel

& fracture.

stainless steel, High alloy tool & die steels

White cast iron,

Files hard

carbon steels

Files soft

Won’t oxy cut Cst irons, Chromium steels, High alloy tool and die steels, Nickel

Oxy cuts

High carb. steel stee. high tensile Ability to harden, common usage, will

Work hardened

Oxy cuts

Aluminium & alloys

White

Cuts easily

METAL IDENTIFICATION

SOLUTIONS

2.03

WELDING HANDBOOK NOTES

2.03

SOLUTIONS: Unalloyed/low alloyed steel Introduction steel, weather steel, and tool steel. alloy of Ferrum (Fe), better known as iron, and carbon (C). Iron is the main deck beams and bulkheads. A common C also termed mild steel, carbon steel and carbon manganese steel. elements).

0.18

1.30

0.02

0.03

– High alloy steel (containing more then Alloy elements are metals such as Carbon is not an alloy element.

be used for welding low alloy steel.

2.04

If there is doubt as to whether steel to be welded is unalloyed or low alloy,

Unalloyed steel Often referred to as carbon steel, mild unalloyed steel will usually be found in

always be used. They should always be used for welding the following

usually in unalloyed steel. A common subject to sudden loads. – Parts which are subject to heavy Fe

Rest

0.18

0.60

0.30

0.03

etc.) (winches, cranes, etc.). differentiate between cast steel and cast iron, see the section on

Heat resistant steel Low alloy steel

Heat resistant steel is a low alloy steel, chromium (Cr). The addition of these

referred to as high tensile steel), heat

characteristics and the steel retains its

SOLUTIONS: Unalloyed/low alloyed steel Low temperature steel nickel is today used more and more in Fe

0.10

0.30

1.00

0.03

Weathering steel

For welding of heat resistant steel, the correct electrode for the job will

2.04

electrode for welding. Unitor range.

Standard construction steel A.S.T.M. S.A.E. A.I.S.I.

Wekstoff W.-Nr

1018 1018 1018 1018

DIN

BS 970

C16 C16.8

1.0726 1.0727

8620 8620

UNI

1.0736 1.0718 1.0737

En1A

1.7218

708A30

JIS

SOLUTIONS: Unalloyed/low alloyed steel Corresponding steel classifications Norske Veritas A

Lloyds

Germanischer Lloyd

Bureau Veritas

American Bureau of Shipping

USSR Register

Nippon Kaigi Kyoka

AH32

A32

AH32

A32

EH32

E32

EH32

E32

A36

AH36

A36

E36

EH36

E36

EH36

2.04

Grade

Tensile strength Rm (MPa)

Elognation A5 minimum (%)

Temperature (°C)

– 27 27 27

Impact energy L (J) t 50 (mm)

– – –

–

Fe360C

ISO 630-80 4950/2/3 1981

2.04

Yield stress R cH minimum (MPa)

Mechanical properties typical values

– – –

EN 10025-93 EN 10113-93

G 3106 A 131

EH36

AH36

EH32

– –

–

– – – – – –

AH32

– E

JIS

ASTM

SOLUTIONS: Unalloyed/low alloyed steel

Description

Solution

Examples

Joining of smaller (diameter less than 30 mm) where a used.

Small diameter steel 160 mm) with a wall

2.04

with a wall thickness more than 3 mm

edges on the joint.

steel constructions like air ducts and air channels.

SOLUTIONS: Unalloyed/low alloyed steel

Description

Welding of thin constructions as for

2.04

Fabrication of like shelves, ladders and gangways in unalloyed steel.

and brackets, and tack welding constructions before full welding.

jobs like welding of unalloyed steel bulkheads and deck

Solution

Examples

SOLUTIONS: Unalloyed/low alloyed steel

Description

Solution

Examples

in the downhand steel constructions.

building steel used in the hull, beams, deck, bulkheads, stiffeners, tanks, holds, hatch covers, frames etc.

2.04

Steel that takes vibration, strain and sudden loads. Seawater, steam and low alloyed steel.

auxiliaries welded to

Welding on cranes

SOLUTIONS: Unalloyed/low alloyed steel

Description

tubes of heat resistant chromium molybdeniujm alloyed steel.

Welding subject to

2.04

lugs, etc.).

Weathering steel

Solution

Examples

WELDING HANDBOOK NOTES

2.04

SOLUTIONS: Problem Steels Problem Steels (difficult to weld steels) Among the low alloy steels, there

steel, tool steel, etc. All these steel

Unitor Tensile-328N

cases the steel has been hardened by annealing, and welding can destroy the hardening. be welded with matching ferritic consumables with the aid of treatment to avoid hydrogen cracking

Cracks in bearing housings.

2.05 heat treatment. So, in this case, welding with consumables is considered to be one of the best methods. The risk of cracking is reduced by the higher solubility of hydrogen and the greater ductility of the weld metal. alloy steel on the market today that

Unitor Tensile having a tensile strength 2 . This electrode may be

considered.

restoring worn edges.

SOLUTIONS: Problem Steels

steel subject to vibration and loads (engine foundations etc.).

2.05

Shafts, rebuilding damaged and keyways.

maintenance.

Frame fractures.

may also be a solution.

WELDING HANDBOOK NOTES

2.05

SOLUTIONS: Stainless Steel Introduction Stainless steel belongs to the high alloy

Carbon increases strength, but in connection with stainless steel and

Chromium (Cr) is the element that makes stainless steel stainless or corrosion resistant. The chromium combines with oxygen and creates an invisible

chromium carbide formation (chrome

on the surface. It must contain at least which an effective layer is formed that seals the surface against any further

combine with oxygen to create chrome oxide. This reduces the corrosion resistance in local areas leading to intergranular corrosion. The carbon content in stainless steel materials and very low level.

amounts of chromium for further increase resistance to oxidation at high

increases corrosion resistance slightly

resistance to certain corrosive media. Stainless steel alloy with molybdenum is therefore referred to as acid resistant.

treatment, or a combination, the stainless steel receives one of the following micro structures when

The American Iron and Steel Institute (AISI) established a numbering system to classify the stainless steel alloys. The

2.06

metallurgical structures. This system is useful because the structures (Austenitic, ferritic or martensitic) indicates the

The following are some characteristic differences between stainless steel and normal steel:

or crack formation along or through the crystals (stress corrosion).

SOLUTIONS: Stainless Steel Austenitic Stainless Steel The highest tonnage of weldable austenitic grades. These are the chromium nickel steel of the AISI 200 and 300 series in which chromium

Austenitic stainless steel has the highest corrosion resistance of all chemical carriers are selected from is the most commonly used.

AISI Type

Composition % * Carbon Chromium C Cr 16,0 – 18,0

301 302

8,0 – 10,0 8,0 – 10,0

303

8,0 – 10,0

303 Se

8,0 – 10,0 0,08 0,03

2.06

Nickel Ni

308

18,0 – 20,0 18,0 – 20,0

0,12 0,08 0,20

8,0 – 12,0 10,0 – 13,0 10,0 – 12,0

0,08

Other

May be welded with (E) Electrode (W) Wire Welding (T) Tig

2,0–3,0Si – 2,0–3,0Si

– –

(W)

– – – –

(W) 310 310 S

0,08

316

0,08

23,0 – 26,0 16,0 – 18,0

0,03

16,0 – 18,0

(W) 316 N

0,08

16,0 – 18,0

317

0,08 0,03 0,08 0,10 0,08 0,08 0,03 0,08

18,0 – 20,0 18,0 – 20,0

321 330

3,0 – 6,0 17,0 – 20,0

(W)

10,0 max 0,20 Co)

SOLUTIONS: Stainless Steel Austenitic stainless steel has the following characteristics: • Cannot be hardened by heat treatment, but can be hardened by working. • Can easily be welded

resistance), 317 (for best corrosion resistance).

Avoid welding mild steel to stainless steel.

S 31000, S 31600, S 31700.

Some limitations: Austenitic stainless steel has some

2.06 • They are suitable only for low concentrations of reducing acid.

Crossed weld joints are undesirable. In general welds must not be located too close to one another.

• In crevices and shielded areas, there might not be enough oxygen to are available in these situations).

Flange ring made by hammering back must be avoided. Flange ring welded on gives less

SOLUTIONS: Stainless Steel Ferritic Stainless Steel

They are magnetic in all conditions. requiring resistance to corrosion and

hardening by heat treatment.

AISI Type

2.06

rather than high strength.

May be welded with: (E) Electrode (W) Wire Welding

Composition % * Carbon C 0.08 0.08 0.12 0.12 0.12 0.12 0.12 0.12 0.07 0.20 0.20 0.06 0.01 0.01

Chromium Cr

16.0 – 18.0 16.0 – 18.0 18.0 – 23.0

Manganese Ni 1.0

Other 0.1–0.3AI

1.0 1.0

1.0 Si –

1.0 1.0 1.0 1.0 1.0

23.0 – 27.0 28.0 – 30.0 28 – 30.0

0.3 0.3

Ferritic stainless steel has the following characteristics: • Cannot be hardened by heat treatment. • Poor weldability.

(W)

SOLUTIONS: Stainless Steel Martensitic Stainless Steel conditions. They are not as corrosion resistant as the austenitic and ferritic of being heat treated to a wide range of hardness and strength levels. Chromium content is lower and carbon

to resist abrasion in stream and gas

These grades are magnetic in all

AISI Type

May be welded with: (E) Electrode (W) Wire Welding

Composition % * Carbon C

Chromium Cr

Other –

2.06 – 11,0 – 13,0

(W)

0,20 16,0 – 18,0 16,0 – 18,0 16,0 – 18,0

Martensitic stainless steel, has the following characteristics: • Can be hardened by heat treatment. • Poor welding characteristics.

SOLUTIONS: Stainless Steel Duplex Stainless Steel (Austenitic – Ferritic)

can be reduced considerably in corrosion resistant alternative to the 300 series austenitic stainless steel. the high ferrite levels by increasing

ladder material.

2.06

May be welded with

Composition (%) Cr

Avesta Creusot Ind. Sandvik

23 23 23

– – –

Other

0,1 0,12 0,1

– – –

PREN

Product forms

Electrode Avesta

0,16

–

Ind. Fabr. de

0,17

–

Falc 223 Sandvik NK Cr22 Sumitomo TEW

manufacturer

Duplex Stainless steel has the following characteristics: • High resistance to stress corrosion cracking. • Increased resistance to chloride ion attack. • Have higher tensile and yield strength than austenitic or ferritic stainless steel.

SOLUTIONS: Stainless Steel Clad steel steel or sandwich steel. Clad steel 2. When the steel backing is one layer short of the stainless steel cladding, an alloy steel. The cladding metal may be a stainless steel alloy, nickel or nickel

must be used. Stainless steel

of the backing steel and with corrosion resistance, abrasion resistance of the clad face.

Alloy cladding • Nickel

• Inconel

Alloy Cladding (AISI)

Cladding

steel

Clad steel with a stainless cladding is found on board some chemical tankers. It

Welding (E) Electrode (W) Wire Welding

2.06

316 317

is followed.

SOLUTIONS: Stainless Steel Stainless steel corrosion types A very thin layer of chromium oxide which is formed on the surface of the

then have a decreased corrosion resistance.

damaged by mechanical or chemical action. elements like Nb or Ti. in an aggressive environment, the material will corrode.

Pitting corrosion

and the choice of stainless steel is based on the requirements from the actual environment.

General corrosion

2.06

is highly destructive, resulting in holes in the metal. This kind of attack is most commonly found in stainless steel in chloride containing environments.

This is a corrosion attack that entire surface. It occurs almost exclusively in acidic or strongly alkaline solutions. The resistance against general corrosion is mainly

contents. Also N has a favourable The Pitting Resistance Equivalent, PRE, is a way of describing the relative

Intergranular corrosion

(CPT). to the grain boundaries is called intergranular corrosion. Some stainless steels can be made sensitive to intergranular corrosion by elevated grain boundaries resulting in

SOLUTIONS: Stainless Steel Crevice corrosion The resistance of the austenitic increased Ni content. The ferritic Cr steels totally without Ni are under normal conditions unsensitive for SCC Crevice corrosion is a kind of corrosion

austenitic.

with a liquid and where the oxygen level joints and under bolt and rivet heads.

corrosion have also good resistance to crevice corrosion.

2.06

Stress corrosion cracking, SCC

Corrosion attacks on a metal subjected a corrosive environment are called stress corrosion cracking (SCC). metal or alloy can remain virtually unattacked on most of its surface, For austenitic stainless steels the risk containing chlorides or other halogens. The risk increases with increasing salt concentration, tensile stress and also

SOLUTIONS: Stainless Steel Storing and handling of stainless steel onboard • Stainless steel must be stored that can trigger corrosion.

away from grit blasting and grinding. Stainless steel wire brush

surfaces.

2.06

• Cover tank bottom so that not get in direct contact with the stainless surface. • Slag, electrode ends and coating to be removed after welding.

Stainless steel martensitic

• Using ordinary unalloyed steel and iron oxides triggering rusting. Use only tools made out of stainless steel.

Special tools for welding of stainless steel • Stainless steel wire brush. 2 rows.

stainless steel.

discoloration after welding. 2 litre. Pickling gel for stainless steel

SOLUTIONS: Stainless Steel Grinding/cutting consumables for stainless steel Generally: When working on stainless steels, one

the metal structure and damage the

with iron.

tools enable better control of heat

Iron on the steel surface, will act as Never switch a grinding disc between Stainless steels are normally softer than with iron. (e.g. grinding consumables). The corrosion resistance in stainless steels is created by oxide layers from one chrome) This oxide layer can be drastically corrosion

2.06

resistance at its best, the aim must be to

grinding on steels. This may change

Smooth surface. Provides better corrosion resistance

SOLUTIONS: Stainless Steel INOX, disc with soft grit bonding for cutting and grinding on soft metals. Contains no iron and the aluminium oxide grit used contains very small amounts of bonded iron.

INOX depressed wheels SS Aluminium oxide Resin, soft stainless steels, aluminium,

Size

Cutting wheels Packs of 25 pcs

Grinding wheels Packs of 10 pcs 633603

2.06

633611

Mop discs

Contains no iron.

Mop discs for SS Resin

Size

Mop discs packs of 10 pcs #60

#80

633723

633731

SOLUTIONS: Stainless Steel Unitor Safety Grinder area inside a metal tank, there is a high risk of electric shock, so low voltage hand tools should be used. SafetyGrinder

Conversion cable

Side handle standard

Unit

2.06

Product no.

633523 Cutting disc

633515 633699

SOLUTIONS: Cast Iron Introduction vibrations and ready machinability. be understood, and the techniques for joining it together followed.

cast iron is brittle and has very little elongation when subjected to strain. subjected to local heating and cooling, as is the case when welding. Thus the

why.

However, many grades of cast iron can indeed be welded successfully. Cast iron is essentially an alloy of ferrum (iron), carbon and silicon. The

2.07

in excess of the amount that can be contained in solid solution. Although in iron when molten, actually less than

throughout the cast iron in the form of

from those of steel.

making it easier to melt and allowing it to run freely into a mold to assume wide uses as for instant engine blocks, heads, liners, water jackets, cargo lines, etc.

White

High alloy length of time it takes to solidify and Silicon tends to drive out any carbon

function of the cooling rate. This excess carbon is the reason for

These different cast irons cannot be It is the form of the excess carbon that determines the kind of iron that the melt becomes. With regard to the is obtained by adding quantities of alloying elements to gray, white or ductile irons. In the following we shall take a look at the characteristics of the

SOLUTIONS: Cast Iron Grey cast iron most commonly used of all cast metals.

in the form of gray iron. When using casting molds of sand the molten metal gets a slow rate of cooling. This gives most of the carbon

which gives the alloy its name. The wide range of strengths in gray

between the iron crystal borders. In where high resistance to dynamic stress is not a governing factor. material near the surface will contain

will cool slower and contain fewer, but

2.07

Carbon Silicon

Ferrum

Rest.

Soft. High machinability.

SOLUTIONS: Cast Iron White cast iron White cast iron has a similar chemistry to gray iron, but is different in that

Malleable cast iron ordinary white cast iron, very hard and brittle. It is then annealed (heat

iron carbide (Fe3C) instead of as free can break down the iron carbides from 1 to 6 days, the carbon actually moves through the solid iron to collect inside the crystals. This results in a martensitic structure, which is very brittle and hard. In a fracture the iron carbide will give the surface a silvery white cast iron. White cast irons are useful for wear resistant service but due to their

Iron with this microstructure is called which it is derived. Instead of being hard and brittle, it is easily machinable, manufacturing it, malleable cast iron is

to weld and may be considered unweldable.

2.07 Hard

Will absorb mild to medium torsion forces. Fair to good weldability.

Iron Carbides

Etched white iron

Ferrite aggregates

SOLUTIONS: Cast Iron Ductile cast iron Carbon Silicon gray iron and steel. It meets the demands for increased having high strength, toughness, and a resistance to shock loading. Ferrite

or cerium to the molten metal, the surface tension mechanism is altered and when

malleable iron. the casting contributes remarkable ductility to the casting, and creates strengths equaling many good grade steels, yet retains the advantages of

In addition magnesium not in excess

2.07

SOLUTIONS: Cast Iron High alloy cast irons

Ni-Resist irons

High alloy cast iron is a general

In this series of cast iron alloys the corrosion resistance of gray cast iron is enhanced by the addition of

white irons, and ductile irons. They are considered high alloy when the alloy

and silicon. alloys to that extent radically changes of the castings to which they are added. The most common alloying elements are nickel, chromium and molybdenum. In general high alloy cast iron is weldable.

Carbon Silicon Nickel Chromium

Meehanite of cast ferrous materials manufactured under rigid metallurgical control so

High resistance to corrosive acids and Excellent weldability.

2.07 exceed that of many cast steels.

High density Fair weldability

SOLUTIONS: Cast Iron How to identify cast iron be in the form of casting. Castings have

distinguish cast iron from cast steel is to

welded joints, and most often they will have a visible casting line where the two halves of the mold they were cast in met.

the casting where a little chiseling will do no harm. Cast steel when chiseled will

an aluminum alloy casting by their color. However, to distinguish between cast ferrous metals. metal a casting is made from we have a

Shaving Mild steel Some streaks are shorter.

Unalloyed steel (Cast steel).

2.07

Cast iron

in colour.

at Wheel Colour at end

GREY CAST IRON

MALLEABLE CAST IRON

Small 0.6 m Red Straw

Straw than grey iron,

Cast iron.

SOLUTIONS: Cast Iron Preparation of the work piece First clean off all oil, grease, rust and crack is absolutely recommended (see or by chemical means. Then remove casting skin to a width of 20 mm on both sides of the edges to be welded. A grinding machine may be used for

When this has been established, drill a 3 mm hole at a distance of 3 mm in

weld area, such as blowholes, cracks, sound metal. If the damage is in the form of a crack

out, using either a grinding machine or by gouging electrodes. Suitable

determine where the crack actually ends. The use of a crack detector

2.07

Groove preparation by grinding

bevel.

melting of the base material in these

SOLUTIONS: Cast Iron

removed from the metal and smeared over the surface to be welded by the be done this carbon must be removed, in cast iron

smear

the weld.

File after grinding

2.07

To avoid this, always remove a thin layer grinding. Use a steel brush to remove loos material.

Searing The more carbon you can remove from the weld area, the less chance there will

along each side of the groove.

remove excess carbon embedded in the

both sides of the welding groove. You will know immediately when the free carbon is removed. As the carbon or “star”. Use a wire brush over the surface from time to time.

This gives a cleaner surface.

Regardless of what we do to remove

Searing must not be confused with remove surface carbon. Take care not

electrodes are so made that they can

when executing it.

formation of iron carbide.

SOLUTIONS: Cast Iron Groove preparation by electrode gouging

for welding is to use gouging and

that used for ordinary arc welding groove that is clean, bright and makes an ideal base for welding. In addition it gives the advantage that if the 2.07

the metal are saturated with oil.

bound to be), the heat generated

2.07 the chill from the metal welding will be welds will be evident.

Consumables”.

Repairs of areas requiring drilling and tapping subsequently require drilling and

The variance in density in the weld

Always remove enough metal initially to. This method, of necessity, requires increase in time and labor will be

SOLUTIONS: Cast Iron Arc welding of cast iron the correct electrode for the work.

heading “Poor Welds”.

for Consumables”. Remember that cold welding of cast iron can only be done by electric arc welding.

Unitor NICKEL-333N and on thin material dimensions. Use this electrode to “butter” the sides of oily cast iron to seal the surface. Then

Unitor NIFE-334N

Hot welding

2.07

To be used on cast iron that takes strain, vibrations and sudden loads. Also to be used for joining cast iron to steel, heavy gauge material. It has greater

Electrode binding test

heating can cause tension cracks.

will normally be limited to the welding each of them without weaving. and which can be dismantled and Use a hammer and chisel to remove the beads. The bead which exhibits the

welded on board. When hot welding cast iron the

indicates the most suitable electrode

SOLUTIONS: Cast Iron indicator crayons or by an electronic

changes in the base material, which may drastically reduce its strength.

welded.

Amperage setting When cold welding cast iron a low cooling rate. The reason why slow of cooling is high, the carbon will have is avoided. It should be remembered

2.07

crystal border areas. We will instead have the carbon bound to the iron in the form of iron carbide. This structural state will be very similar to that of the base material with increased risk of cracking. In order to avoid digging into the base the direction of travel. This will cause

Cold welding

act as a cushion.

required slow cooling rate is not available, the alternative is “cold” arc welding. The method is so called the base material when correctly executed. On board cold arc welding is by far the most commonly used method, and dismantle should be cold welded.

a high bead contour, the setting is too

SOLUTIONS: Cast Iron To ensure good electric conductivity the high.

with conventional cast iron electrodes.

Choice of polarity If the current source for the welding

work. Some electrode manufacturers make cast iron electrodes that can Furthermore, some years ago the general low quality of cast iron electrodes made it necessary to use

2.07

between base material and weld cast iron electrode is very high, and the electrodes can be used with both must be aware of the effects of the is too high the electrode may become red hot.

the melting of the base material varies

In general, the welding current should

selected.

vertical welding.

SOLUTIONS: Cast Iron If the electrode is connected to the

than the following runs. This would be base material makes good bonding

will cause excessive melting and digging into the material. In addition

Correct size electrode

quantities of the gassed nitrogen, oxygen, carbon dioxide and carbon monoxide. Excessive melting will bring unwanted quantities of these material the lower the quality of the cause the formation of iron carbides,

as much weld metal at only two times

heat affected area. If we connect the electrode to the

2.07

The welding carbides.

Remember that cast iron is very brittle, the shrink forces exceed the tensile strength of the cast iron it will crack. Hence, when welding it is crucial to

the cast iron is heavily contaminated at a minimum to avoid cracking. melting to achieve bonding between the base material and the weld

Length of arc To reduce the voltage across the into the base material, the shortest

be done with a somewhat longer arc

The way to achieve this is to avoid (as when welding mild steel), and instead to weld short, straight stringer

SOLUTIONS: Cast Iron beads of maximum length 20–30 mm (1”) at a time. Weaving should be avoided or

Rounded edge

of the groves. electrode diameter to each side of the direction of the weld. When each bead the crater and withdraw the electrode a little backward on the bead before breaking the arc.

must be ductile. Peening the bead Weld contraction may cause cracks.

it to accommodate some dimensional change in the weld area, and will

2.07

Peening offsets contraction forces.

little or no effect in relieving stresses. not be vertical on the bead, as vibrations

Wrong

Correct

you burn yourself, it is too hot to go on with the welding. Take your time, do not

SOLUTIONS: Cast Iron Sometimes more than one short run can be done at a time, but only when the length to be welded is considerable, and the beads can be

Repairing crack with free end Start welding at tied end, then

Repairing crack with tied ends

2.07

each) starting from the hole drilled at each end of the crack. Then weld alternatively from each end of the

Repair of separated parts Starting from one edge, use the

Parts subject to high stresses transverse grooves may be cut in the sides of the welding groove, using Cut transverse grooves in the sides. Fill

and then cover the entire surface

SOLUTIONS: Cast Iron A way to reduce shrinkage stress In order to reduce the shrinkage

down its wall thickness. Remember to

shown in the sketch, advancing each bead (starting always with the root half the thickness of the casting’s wall. and hammer each bead while still hot. A this kind of hammering. Hammering

bulge is formed.

2.07

Stacking

Steel insert technique It is sometimes desirable to insert a large housing or motor block. A gear Casting

have suffered the same damage. Usually

Remove all damage material on the

SOLUTIONS: Cast Iron Build up of missing section Occasionally, it will be necessary to been worn down or broken off. In

there should be a minimum of 6 not use a grinder for cutting stress relieving grooves. The groves will not be geometrically correct for the surface. weld metal by using a long arc and fast

2.07

not quench.

areas, such as bosses, which must be machined after welding, it is unwise

Filling holes that penetrate clear through the casting the required dimension to allow for machining. All machining will then be which is fully machinable.

straight stringer beads side by side until the hole is closed. Weld from one weld around the edges. Such action will create stress cracks. Peen each stresses. Remove slag.

SOLUTIONS: Cast Iron Braze welding of cast iron General be heated to form a bound (surface gas welding.

occurs, is called “tinning” (also called “wetting out” or “bonding”). Actually, it layer in which the alloys of both the cast

and thinner dimensions. For larger is recommended.

necessary heat will be the method

Preparation of the workpiece melted and forms a chemical bonding

has the decided advantages of low heat

of 20 mm on each side of the edges to be welded. If the damage is in the form of a crack in the material, it is recommended

traditionally associated with welding cast iron.

mm holes at each end of the crack, at a distance of about 3 mm from the ends to

I. The tendency for high heat to form unwanted white cast iron, a form of martensitic cast iron that is very

Groove preparation

of iron carbide. The low heat used

due to the lower heat required, and

2.07

and that the lager the surface of a joint

from the groove, and round off edges

accommodate any cooling stresses. quality of the base material.

SOLUTIONS: Cast Iron Searing heat. Touch the rod to the surface and

material, which can inhibit “tinning”.

moving the torch, which should be

over the surfaces off the groove, most,

1 cm above the groove. When the

Preheating

Remember that cast iron is one of the metals. Thus care should be exercised

2.07

even and uniform.

Braze welding

brushing. extremely easy to work with, has high tensile strength and the structure and color of cast iron. Welded connections

Alternatively, where a hardwearing surface is required, the joining can technique as described for Castiron 237.

such as gear and gear wheel teeth. Use Castiron 237 in combination with Castiron Flux 236F. Heat the end of the

strength and machinability is lower than for Castiron 237. Technical details on the rods are found in the section “Consumables”.

SOLUTIONS: Cast Iron Cold repair of cast iron General Where there are limitations to hot work, are organic material that will start to

curing materials consisting of a base and activator that are mixed together. materials form a surface bonding and it is absolutely essential that the base materials surface be cleaned in order to give good addition.

1) Surfaces must be cleaned and ruffed

according to instructions together. Any unmixed material will not solidify.

2.07

securing good bonding. Afterwards to required height. If needed, a reinforcement bandage can be added strength.

SOLUTIONS: Cast Iron Repair case 1.

welding cannot be done. In this kind solution. Clean surface to remove grease and accumulated dirt. Remove as much of Thoroughly abrade the edge and the surrounding surface of the hole. If the hole is large, a metal mesh

hard into the surface to secure good

2.07 hole so that it makes contact with the

With the mesh securely fastened

reinforcement bandage on the mesh to

The wires can be fastened to the edge by a small tack weld or by drilling a hole with slightly bigger diameter.

SOLUTIONS: Cast Iron Repair case 2. After welding has successfully been

oil in the cast iron structure. Instead of risking cracking by further welding, area. The surface must be thoroughly degreased and abraded. In some cases grind or drill out the the surface and require abrading afterwards.

2.07

larger areas are to be covered. It is very into the surface in order to secure good bonding and sealing.

SOLUTIONS: Cast Iron Repair case 3.

conduit and ducting made of cast iron. be tackled from the outside of the

cable ties.

Thoroughly degrease the area to abraded.

2.07

damaged area.

Thoroughly abrade the inside and

smoothed out and blending in with the

SOLUTIONS: Cast Iron Repair case 4. with good results on cast iron that Welding will in most cases crack the

where cavitational wear gouges out the

2.07

100

SOLUTIONS: Cast Iron

Description

and sudden loads, and where several layers of weld metal may be needed, e.g. cargo

often found in motor blocks, gear boxes, cylinder heads,

2.07 cool slowly after welding, e.g. blocks, exhaust manifolds, broken or worn teeth.

to steel.

Rebuilding cast iron, for cylinder heads, or exhaust valve housings.

101

Solution

Examples

WELDING HANDBOOK NOTES

2.07

102

SOLUTIONS: Copper and Copper Alloys Introduction

amount of oxygen. Oxygen combines

to the crystal boundaries where it collects and weakens the strength of the metal, in hot and cold condition. In this way, welding will weaken the metal in a joint. The best method of

The oxide is distributed in the metal in very small quantities and does not affect the mechanical characteristics of the metal. However, during welding

Straight brasses

2.08

brasses Naval brass

Admiralty brass

Aluminium brass (Yorcalbro)

Brass

brasses. Aluminium brass however

103

SOLUTIONS: Copper and Copper Alloys Aluminium brass (Yorcalbro)

brass) is an alloy with the following

Some years ago, numerous welding tests were carried out on Yorcalbro

in these tests, and the conclusions were

Hard (untreated) . . . . . . Heat treated. . . . . . . . . .

2 2

Annealed. . . . . . . . . . . . . . . . . . . . . . . . . .

Hard (untreated) . . . . . . Heat treated . . . . . . . . . . Annealed . . . . . . . . . . . . Hard (untreated) . . . . . . Heat treated . . . . . . . . . . Annealed. . . . . . . . . . . . . 000013.

2.08

use in cooling water installations, sanitary installations, oil coolers, heat exchangers, heat coils etc.

maintenance is inevitable. Common

min. Finished welds, and an area side of the bead should be annealed.

104

SOLUTIONS: Copper and Copper Alloys Bronze and tin, which may also contain small quantities of other alloys. before welding.

Aluminium bronze (Cu + Al)

2.08

also suitable for casting. The main excellent resistance to corrosion in seawater which makes them suitable

Nickel

Cunifer metal

105

Aluminium

NiAl

SOLUTIONS: Copper and Copper Alloys Nickel bronzes (Cunifer)

These alloys are corrosion resistant – the higher the nickel content, the higher the resistance. Strength and hardness also increase in relation to nickel content.

cleaner waters. In such cases the use of “Cunifer 10”

CUNIFER 10 (Copper nickel)

CUNIFER 30 (Cupro nickel)

(Alloy)

– Hard (untreated) – Heat treated – Annealed

630–700

– Hard (untreated) – Heat treated – Annealed

2.08

– Hard (untreated) – Heat treated – Annealed

87–107 0.000016 limited due to high cost. However, the recommendation for the use of these

lakes, or on vessels which regularly They have excellent resistance against wear by erosion, corrosion and abrasion.

water. The same recommendation systems.

with good resistance against water of

106

SOLUTIONS: Copper and Copper Alloys

Description

is used for butt welding or

2.08 have worn down.

housing.

wear.

107

Solution

Examples

SOLUTIONS: Copper and Copper Alloys

Description

Filling holes in small valve housings where wear or corrosion has caused damage.

Solution

Examples

261

2.08 Rebuilding worn sliding bearings.

less than 100 mm, where a

joining.

108

SOLUTIONS: Copper and Copper Alloys

Description

in Yorcalbro, like heating coil boxes.

diameter under 100 mm,

2.08

like heat exchangers.

Conductors and cables of

109

Solution

Examples

WELDING HANDBOOK NOTES

2.08

110

SOLUTIONS: Aluminium Metals and welding solutions: Aluminium Pure aluminium (Al) is a soft, easily

Included oxides will also reduce the strength of the weld. Thorough cleaning and the use of

corrosion resistance and good electrical conductivity. The strength of aluminium can be

welding aluminium. Welding should be done immediately after cleaning, before a new oxide

of small quantities of alloy elements. As an alloy, aluminium retains the good electrical and heat conductivity, and the absence of colour change to mild steel. Only a limited number of aluminium alloys are considered

Filler materials for Aluminium in the

resistant aluminium alloys. When aluminium can be used for the (silumin).

2.09

When aluminium and its alloys come into contact with air, a refractory skin of oxide quickly forms on the surface. than that of aluminium, which melts effectively removed during the welding

111

For gas welding of aluminium it is

SOLUTIONS: Aluminium

Description

aluminium, seawater resistant aluminium and cast aluminium.

Solution

Examples

and

2.09 and Holes or fractures in

Plate and tube constructions in gang way.

112

SOLUTIONS: Evaluation of welds Typical welding faults Unmelted edge

Undercut Crack

Poor fusion Embedded slag Pores

Root fault

Root faults

Bead edge defects

edge faults may also occur at When current is excessive, too long or if electrode movement is

2.10 to the current setting being too low, or the rate of travel too high. The electrode may also be too large for the groove to be welded.

Fusion faults

and avoid edge defects. Edge faults and undercut may act as fracture indicators in the welded connection.

If the current is too low or rate of travel too high, fusion faults may

Pores

metal. Fusion faults may also occur if a small electrode is used on a large area of cold base material. A larger electrode diameter should be used, and the base

113

movement, the electrode should be momentarily held still at each side of

Pores in the weld may be due to moisture content in the electrode basic electrodes. Pores in the weld may also arise if the base material reasons can be because of to long an

SOLUTIONS: Evaluation of welds Heat cracks movement. Shrinkage cracks will usually

have a tendency to segregate and may form a layer in the middle of the crystals. Segregated substances are In cases where heat cracks are caused by these substances, switch to basic welding with basic electrodes, the material is not weldable. Tension across the weld can cause heat cracks even if the base material does not segregate in the weld. At a narrow, range, just after coagulation of the bead, there is very little deformation Heat cracks and if shrinking in the metal is greater than the stretch in the weld, a heat crack will result.

which control shrinkage. A heat crack will occur in the middle of crack on the surface.

Shrinkage cracks Shrinkage cracks occur when the

the weld direction and be caused by considerable lengthwise shrinkage. the best safeguard against shrinkage cracks.

Shrinkage cracks

Hydrogen cracks (Cold cracks) Weld metal cracks are caused by of steel which has been hardened or which may become hardened during amount of hardened structure, normally the higher is the risk of hydrogen cracks. The most common reason for hydrogen cracks is that moist used during welding. The water in the coating will change into hydrogen in the

2.10

dissolved in the weld metal and the heat immediately adjacent Hydrogen cracks (cold cracks) When combined with stress it will form cracks.

weld is less than the actual shrinkage

114

SOLUTIONS: Evaluation of welds The cracks might occur long time after

Tension cannot be avoided when

often referred to as cold cracks. Other hydrogen sources are rust,

heat treatment can reduce tension considerably.

welding groove. Preheating the groove

Slag embedded in weld

reducing the amount of hydrogen.

originating from the coating of the

there is risk of cold cracking.

Note the following: in the weld will seriously affect the strength of the weld. Try to avoid elements, mostly carbon, are forced to dissolve in the weld metal and make it brittle. The following formula describes

remove.

removal. Clean off mill scale and rust from the surfaces to be welded and make sure you choose the correct be used.

2.10

at normal steel thickness. For the more highly alloyed steels and steels with thicker dimensions, an elevated order to reduce the cooling rate. the hydrogen to diffuse. To determine elevated working

are known, these standards will state whether heating is necessary and the

115

WELDING HANDBOOK NOTES

2.10

116

SOLUTIONS: Evaluation of welds Inspection of welded joints Prior to welding been met. This function may be the should be examined to see if they

Visual inspection from start to finish

discontinuities. Foreign matter

during and after welding. In a sense, everyone involved in the job, as well as

A conscientious worker does not recognises discontinuities of his own making. Nevertheless, it is usually desirable that someone is assigned

scale – that should be detrimental to to be joined should be checked for

2.10

magnifying glass, and sometimes a straight edge and square for determining straightness, alignment,

access for the welder, adequate to minimise volume of weld metal. before welding is started, not only to Torch, Ruler and Welders gauge

117

give assurance of weld quality.

SOLUTIONS: Evaluation of welds Remember: 50% of quality is edge preparation Faults to look for:

at the root.

it will melt through

Check at regular intervals that the consumables used match specification

2.10

advantages and limitations, and each

containers unharmed by moisture. To ensure uniform results the welders and followed rigorously during welding. to the job.

118

SOLUTIONS: Evaluation of welds

along the edges, increasing the risk of

by a convex bead

2.10 of consumable etc.

During welding

weld is being done. Examination of a weld bead and the end crater may

slag inclusions.

119

the next. the most critical one with regard to weld soundness.

SOLUTIONS: Evaluation of welds After welding

in submitting an obvious bad weld to Underwelding is a violation of

are detected visually at this stage. The extent and continuity of the weld, in intermittent welds can be readily measured or recorded. Welds must be cleaned from slag to Overwelding is costly and serves no

other faults. Shot blasting should not

construction stiffer and heavier.

make them invisible.

2.10

this stage is not only to detect non clues as to what may be wrong in the welding, he can read much from what he

if the dial readings on the machine tell otherwise. Subsequent tests will acquired through visual examination allows corrections to be made before methods become available.

The designer has specified a weld size and this should be observed. For filled joints it is also important that the leg lengths are equal.

120

SOLUTIONS: Evaluation of welds Summing up inspection of welded joints What to look for PRIOR TO WELDING:

What to do DURING WELDING:

• Joint design • Consumables

What to look for AFTER WELDING:

Faults and causes:

Surface porosity

Cold cracks (Hydrogen cracks)

gas coverage.

2.10 Hot cracks

Slag inclusion Faulty technique.

Underfill

Undercut High current, travel too fast

121

SOLUTIONS: Evaluation of welds Crack Detection

It is a low cost and easy to use,

surface cracks not readily visible to the methods. For detection of internal cleaner to clean the surface for grease must be used, but they require

Step 1)

Step 2) soak for about ten minutes.

2.10

Step 3)

Step 4) area and wait a few minutes until the area dries white. Any surface defects will

Dye Penetrant Inspection product Product description

Unit

Product no.

Set

096-653535

122

WELDING HANDBOOK NOTES

2.10

123

CONSUMABLES Coated Electrodes

Wires for Wire Welding

278

3.01

124

COATED ELECTRODES Introduction

126 127 133

161 163 167 171 3.01

173 177 181 183 187

125

COATED ELECTRODES Introduction The Unitor standard electrode range

LMA Properties ( they absorb moisture from the

• Cast steel • Heat resistant steel

moisture turns into hydrogen in the

• Weathering steel

with other undesirable effects this can turn into hydrogen cracking also known as cold cracking in the weld. In order to extend the electrodes usable lifetime and safeguard against cold cracking, the Unitor electrodes for

• Cast iron • Aluminium and aluminium alloys

manufactured. This greatly reduces the

A Product Range Selected for Maritime Use is a basic factor for the selection of arc welding electrodes in the Unitor

Packed for Maritime Conditions The electrode box is made of high

Each electrode therefore covers a wide board.

With the Best Welding Properties

the box gives all relevant information to how the electrodes are to be used.

3.01

same recycled material and does not electrodes are necessary to achieve good results without too stringent demands on the welder’s skill. Welding on board is often required in awkward

number.

126

COATED ELECTRODES Types of electrodes What happens when the arc is struck?

The arc will immediately melt some of the coating and core wire of the

circuit. To strike an arc the electrode must causes a shortcircuit, and when the electrode is withdrawn slightly, the arc is formed.

Electrode holder

Arc Electrode

Welding cable Welding machine

in the arc. The actual transfer of metal from in the form of molten globules of of electrode used. Some electrodes that they actually shortcircuit the arc for a moment.

Return cable

are avoided.

3.01 effect and the metal is drawn towards

The Arc

force is stronger than the force of gravity, and overhead welding is

Core rod Coating

As soon as the globule leaves the electrode, it is covered by slag material is then carried through the arc to the

Slag

The core rod in the electrode melts faster than the coating, and the resulting crater in the end of the electrode aids directional stability of the weld.

127

COATED ELECTRODES Types of electrodes Electrodes for manual arc welding (sometimes referred to as stick welding) consist of a rod and a coating material. As a rule, the alloy in the rod will be similar to the material to be welded.

base material and the rod core in the electrode. When molten, the coating

The coating elements form a slag when

circuit, and when it is melted together

coating may also contain substances

welded joint.

electrode during welding. Electrode

The object of the electrode coating is

diameter of the rod core.

arc. The coating material also contains

Control of Recovery we can regulate the electrodes recovery

to the alloy formed between the

The coated electrode

3.01 Coating

Rod core

128

COATED ELECTRODES Types of electrodes The function of the core rod is to

Alloying Elements In the arc the

The coating consisting of metals, minerals and organic substances have

Ionisation Air is a non conductor.

the elements might

elements into the coating.

elements that welding we create a

AIR

the current can travel. For AC welding this function is essential welding.

Crater Formation

3.01

Elements in coating that makes the melting boundary of the coating to be behind that of the core rod. The arc is in this way concentrated to one

Gas Shield The shielding ingredients in the

Slag Formation Slag forming of the electrode coating and they are

Metal Transfer The transfer of metal globules from

1) Protect crater and globules against oxygen during the

a combination of elements in the coating

mould. The slag is the mould.

129

COATED ELECTRODES Types of electrodes a weld metal quality equal to or better than that of the base material and, when

Unalloyed rutile electrodes are not normally recommended for welding steel with nominal tensile strength are low because of oxygen level in the weld metal. Rutile electrodes are relatively insensitive to moisture. Acid

the choice of electrode, as different the metallurgical character which is an acid. The coating contains oxides of the joint. a high rate of welding and are equally and slag is easily removable, even if it is

Organic electrodes contain large quantities of organic substances such as cellulose. The metal transfer is electrodes are well suited for vertical down welding. Rutile electrodes contain large

Alloyed acid electrodes are suitable for welding steel with a nominal tensile

Basic electrodes

heat treatment the coating has a very low hydrogen content, hence the name.

3.01 Titanium Oxide. Rutile electrodes can remoisturing is much lower than of normal basic electrodes. Unalloyed basic electrodes give advantage when welding in different reason for this is that basic electrodes hard surfacing because of its shallow

electrode is greater than that of other electrodes, which can be used in slag is easily removed.

130

COATED ELECTRODES number of electrode changes. The normal result is therefore a higher

extruded onto the core rod followed by a thicker basic layer. In this way transfer of rutile electrodes and

quite as easy to remove as the slag from acid or rutile electrodes, but,

basic electrode.

easily detachable. The slag from basic electrodes has a lower melting electrodes. The risk of slag inclusions therefore unusually small when basic electrodes are used, even if the slag

The weld metal from basic electrodes has a low hydrogen content and usually has good toughness even at

3.01 the hardenability of the steel to be welded, the greater the necessity to use basic electrodes and the greater the need for low moisture content in the coating.

Double coated electrodes These electrodes consist of a thin layer of rutile coating

Core rod

Rutile coating

131

COATED ELECTRODES Unitor LMA electrodes

LMA gives you less problem with porosity. electrodes from the very beginning. The during the day is very low. The electrode

LMA will decrease the risk for HAZ cracking. (Cold cracks/Hydrogen cracks) If you weld high tensile steels or very

Unitor LMA electrodes:

The risk for hydrogen cracking in the

All other properties are unchanged.

3.01

You will still get • the same good weldability • the same low fume formation marked

132

COATED ELECTRODES Storing and re-drying used electrodes will form weld

Storage and handling Welding consumables should be

hydrogen cracking (cold cracking) if

guideline we recommend the following

vibration or load.

General background

Temperatures °C

(°F)

low alloyed steels cold cracking (often referred to as hydrogen cracking) can occur. These cracks generally form

Max. Relative humidity in % 60

(77)

to maintain low relative humidity

• Cooling rate • Hydrogen content of the weld metal relative humidity can be maintained by quantities during welding and is a cracking.

3.01

The most common sources of

Redrying Rutile electrodes showing signs of damage by moisture can be redried at a

2 hours, to achieve a hydrogen level and redrying , the moisture level in electrode coatings can be minimised, along with the associated risk of cold cracking. Hydrogen levels are measured as ml H2 levels for different electrode coating

133

Redrying should be restricted to a maximum of 3 cycles. To achieve extreme low hydrogen recommended for 1–2 hours. Redrying should be restricted to 1 cycle.

COATED ELECTRODES box and have become damaged by

Stainless steel electrodes which have been stored outside of their electrode

hours. Redrying should be restricted to a maximum of 3 cycles.

Welding electrodes should be or in a heating cabinet.

Heating Cabinet

All basic electrodes and stainless steel electrodes should

Rutile electrodes normally no need for

use. Always do when

3.01

requirements. Observe recommended and holding times for Unitor electrodes stated on box label Unused electrodes time for electrodes before being returned to the heating cabinet.

hours.

Worksite

134

COATED ELECTRODES Storing and re-drying Minidryer-350

electrodes before welding when this is required. The dryer may be used

accessible.

thermostat for continuous selection of

The dryer is very robust in design mm mineral wool. It can also stand

Ordering Information: unwanted moist air. When the dryer

3.01

Caution: Use gloves when handling warm drying electrodes only.

Heater Primary Current W A

Electrode mm

Net Weight kg

230, 1.8

135

COATED ELECTRODES Re-drying of Electrodes Customers are recommended to redry low hydrogen electrodes before

the electrodes can be returned to a

requirements relating to weld metal soundness. This information is given on the box label for the individual electrodes. Failure to follow these

Unitor Heating Cabinet-85 (094-637850)

and weld failure.

holding time two hours, for Unitor

three times is not recommended.

Normally no need for Normally no need for

3.01

136

COATED ELECTRODES Storing and re-drying The Heating Cabinet-85

maintenance electrodes.

every shelf is removable. The shelves rough seas. enclosed in a unit located in the bottom of the oven. This unit can be easily removed as one unit.

3.01

It is delivered with 1,7 m cable and

are to be used within the heating cabinet.

Caution:

Ordering Information:

Use gloves when handling warm electrodes from inside the heating

Heater Primary Current W A Heating

Net Weight kg

230, 1,3

137

Electrode

COATED ELECTRODES Storing and re-drying Arc Welding Cabinet

electrodes selected to cover all normal

aluminium.

Arc Welding Cabinet

welding handbook.

Ship quality steel and cast steel:

• Sturdy, corrosion resistant

3,2 mm

8,2 kg

Ship quality steel, horizontal, high recovery: Ship quality steel, vertical down welding: 3,2 mm

scratch resistance.

Heat resistant steel:

Product Description

Product no.

Electrode cabinet

094-670000

3,2 mm

1,7 kg 1,7 kg

094-669994

Low temperature steel: 3,2 mm

1,8 kg

Weathering resistant steel:

3,2 mm

1,8 kg

3.01

Stainless steel, stainless to mild steel, compound steel:

Dimensions: 600x600x300 mm free distance above cabinet 310 mm.

3,2 mm 3,2 mm

Weight with electrodes

1,7 kg 1,7 kg 2,0 kg

"Problem" steels: 1,6 kg

Contents and Applications Areas Cast iron: Sheet metal and thin walled pipes: 2,0 mm

1,7 kg

General mild steel repairing, horizontal, high recovery:

10,8 kg

2,0 kg 2,2 kg

3,2 mm

1,1 kg

3,2 mm

1,3 kg

Aluminium:

General mild steel repairs, all positions: 3,2 mm

3,2 mm

Bronze & brass: Hardfacing: 1,6 kg Cutting & gouging: 3,2 mm

138

COATED ELECTRODES Storing and re-drying Arc Welding Cabinet Compact

electrodes selected to cover normal

alloys and aluminium.

welding handbook. • Sturdy, corrosion resistant

corrosion and scratch resistance. Product Description

Product no.

Electrode cabinet

094-670001

Electrode cabinet

094-669999

“Problem” steels: 1,6 kg Cast iron:

3.01

2,0 kg 2,2 kg

3,2 mm

1,1 kg

3,2 mm

1,3 kg

Aluminium:

Width

Bronze & brass:

Height closed 8 kg 33 kg Contents and Applications Areas

General mild steel repairs, all positions: 3,2 mm Ship quality steel and cast steel: Stainless steel 1,7 kg

139

3,2 mm

COATED ELECTRODES Classification and Approvals nomenclature in welding, Euronorm

near future. In America one refers to AWS (American Welding Society) for

have come in force already and more

of this we will mostly refer to EN and AWS in the Nomenclature for Welding Consumables.

Covered electrodes for manual metal arc welding of high strength steel EN 1600

Covered electrodes for manual metal arc welding of stainless and heat resisting steel

Classification and Approvals CLASSIFICATIONS Product Name

APPROVALS

AWS

DNV·GL

E 6013

E 38 0 RC 11

3, 3YH10

3H10, 3Y

E 7016

3YH10

E 7018

ABS

3H10, 3Y

3.01

E 7028 3YH10

3YH10 –

3YH10

3Y 3YH10 3YH10

– –

– – – –

E Cu Sn C

–

E Cu A1 A2

–

140

COATED ELECTRODES Guide to Approvals the electrode has under its relevant The full grading code consists of a digit and one or more letters. The digit indicates the tensil and notch indicate higher tensile steels.

Grade

Tensile properties Yield strength

Tensile strength

Impact properties Elongation

(min)

3.01

1 2 3 2Y 3Y

22 22 22 22 22 22 22 22 20 22 20 22 20

141

COATED ELECTRODES Guide to EN 499-1995 Symbol

Tensile strength MPa

Yield strength MPa

Symbol

Elongation min. %

22 38

380

Welding position

1 3

20 20 20 18

Symbol

according to symbol 3.

Metal recovery %

Type of current

1 2 3 6 7 8

Covered electrode for

Symbol

Impact energy Charpy-V Temp °C for 47J min. No requirements

2Ni

160 160 >160 >160

Symbol

Coating type

Acid

Cellulosic

Symbol

Hydrogen ml/100 g deposited weld metal, max.

H10

3.01

Rutile

Rutile (thick coated)

RC RA

A 0 2 3

Symbol No symbol

1Ni 2Ni 3Ni

Chemical composition* Mn

2.0

– 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

Single values shown in the table mean maximum values.

142

COATED ELECTRODES Guide to EN 757-1997 Symbol

Yield strength min. MPa

Tensile strength MPa

620

Elongation min. %

Symbol

Welding position

17 16 according to symbol 3.

Symbol

Metal recovery %

Type of current

1 2 3 6 7 8

E 62

MnNI

160 160 >160 >160

Indicates mechanical relief treatment.

Only basic electrode covering.

manual metal arc welding

Symbol

Hydrogen content, ml/100 g deposited weld metal, max

H10

3.01 Symbol

Impact Energy Charpy-V Temp °C for 47J min. No requirements

A 0 2 3

Symbol

Chemical composition of all-weld metal, %* Mn

–

– – – – – – –

6 7 8

Single values shown in the table are maximum values.

143

Mo –

COATED ELECTRODES Guide to EN 1600-1977 Symbol manual metal arc welding.

Metal recovery %

Type of current

1 2 3

E 23 12 2L R

Symbol

160 160 >160 >160

6 7 8

Welding position

1 2 3

according to symbol 3. Alloy Symbol 13 17

Chemical composition of all-weld metal, %* C

0.12 0.06 0.12

1.0 1.0 1.0

0.08

1.2 1.2 1.2 1.2 1.2 1.2 1.2

2.0 2.0 2.0 2.0 2.0 2.0

1.2 1.2 1.2 1.2

2.0

Other elements

0.030 0.030 0.030

Austenitic 0.08 0.08 0.08

0.20 0.10

23 12 Nb

0.10

16 8 2

0.08

22 12 18 36

Nb N 0.20

3.01

N 0.20 0.030 0.030 0.030 N 0.20 0.030 0.030 0.030

1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.2 1.2 1.2 1.2 1.2 1.2

0.030

Fully austenitic. High corrosion resistance 1.2 1.2 1.2 1.2 1.2 1.2

20 10 3

0.030 0.030 0.030 0.030 0.030 0.030 0.030

0.030 0.030 0.030 0.030

2.0

N 0.20 N 0.20

0.030 0.030 0.030 0.030 0.030 0.030 0.030

144

COATED ELECTRODES Guide to AWS A5.1-1991 Covered electrode arc welding

toughness, low moisture level and limits for weld metal.

meets the requirements of the

mandatory.

70 70

E E

18 16

M –1

strength in ksi.

AWS Classification

3.01

E 6010 E 6011 E 6012 E 6013 E 6020 E 6022 E 6027 E 7016 E 7018

E 7027 E 7028

For

Tensile Strength min. ksi 60 60 60 60 60 60 60 60 70 70 70 70 70 70 a) 70 70 70 70

MPa

Yield strength min. ksi

MPa

Elongation min %

331 331 331 331 331 331

22 22 17 17 22 22

331

22 17 22 22 22 22 22

b) 17 22 22 22

Impact Energy Charp-V J/°C

Welding Type of coating Position 10 11 12 13

Cellulosic Cellulosic Rutile Rutile

20 22 27

Acid Acid Acid, high reco.

16 16 18 18 18 27 28

Code 1 2

145

Rutile, high reco. Acid, high reco.

Welding position

Type of Current AC – x x x x x x x x – x x x x – x x x x

COATED ELECTRODES Guide to AWS A5.5-1996 Covered electrode for manual

welding

and current

AWS Classification

Welding Position

Exx10 Exx11 Exx12 Exx13

1 1 1 1 1 1 1 2 2

Exx16 Exx18 Exx20 Exx27

E 80 18 C1

Type of coating

Type of current AC DC

Cellulosic Cellulosic Rutile Rutile

Acid Acid, high recovery

– x x x – x x x x

strength in ksi. metal.

AWS classification

Tensile strength min./MPa

Yield strength min./MPa

620 620 600 760 760 830 830 830

Suffix

Alloying system

Code

Welding position

1 2

AWS classification

670 680–760

Nominal values Wt%

–A1

–C1 –C2

Ni Ni Ni Ni

–C3

All other alloy steel electrodes

All other

Impact energy min. J 27 27 27 27 27 27 27 27 27 27 27 27 27 27 68 27 27 27 27 27 27 27 27 27 27 27 27 Not required

°C

3.01

–18 –18 –18 –73 –73 –73 –73 –73 –101 –101 –101

146

COATED ELECTRODES Guide to AWS A5.4-1992 Covered electrode for

Suffix

arc welding

–16 –17

Coating type and usability characteristics

E 312 17 Indicates –26

AWS Classification

Chemical composition of undiluted weld metal C

0.06 0.06 0.06 0.08 0.08

18.0–21.0 18.0–21.0 18.0–21.0 18.0–21.0 18.0–21.0

2.0–3.0 2.0–3.0

0.12 0.12

3.01

2.0–3.0 2.0–3.0

0.08–0.20 20.0–22.0 20.0–22.0

0.12 0.12 0.08 0.08 0.08 0.07 0.03 0.08 0.13 0.03 0.03 0.12 0.06 0.10 0.10 0.10 0.10 0.10 0.06

147

28.0–32.0 17.0–20.0 17.0–20.0 17.0–20.0 18.0–21.0 18.0–21.0 17.0–20.0

2.0–3.0 2.0–3.0 2.0–3.0

32.0–36.0 32.0–36.0 33.0–37.0 33.0–37.0 18.0–21.0 18.0–21.0

2.0–3.0

2.0–3.0 2.0–3.0 2.0–3.0

8.0–10.0 30.0–33.0

– – – – – – – – – – – 0.70–1.00 – – – – 0.70–1.00 – – – – – – – 6xC 1.0 8xC 1.0 8xC – – 8xC 1.0 – – – – – – –

0.7 0.6

1.0–2.0 6.0–8.0

Nb+Ta

– – – –

Mn 8.0–10.0

1.0 1.0

0.03 0.03 0.03 0.03

0.60 0.30 0.02

0.02 0.03 1.0 1.0 1.0 1.0 1.0 0.60 0.03 1.0 1.0

0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

0.10–0.30 0.10–0.30 0.10–0.30 – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –

0.03 0.03 0.03 0.03 0.02 0.02 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03

0.08–0.20

1.2–2.0

COATED ELECTRODES Welding positions Welding positions according to EN 26947

AWS according to ASME section IX EN according to ISO 6947, NEN-EN 287

1F PA

2F PC

3.01

148

GPO-302 N General Purpose Electrode for Mild Steel Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 6013

E 38 O RC 11

Approvals

DNV·GL

ABS

Type of current Welding positions PA

Materials to be welded Cast steel

vessel steel

Fine grained steel

All weld metal composition

3.01

Typical mech. properties of weld metal

Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

27 Typical mech. properties of weld metal

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

60–100 3.2 100–200

Diameter mm.

Length mm.

Electrodes per box

3.2 120

149

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

0.8 1.3 1.6

1 1 1

Net weight, kg per box

Product No. per box

Boxes per carton

3 3 3

GPO-302 N electrode with a medium thick organic

It is a versatile electrode for all mild the higher grade steels that require beams, etc.) and is the electrode least affected by

makes the electrode well suited for tack welding. including vertical down, if necessary without changing the welding current setting. This, and the electrode’s ability to electrode on board.

Suitable for welding in the

3.01 jobs of medium strength. With its good welding characteristics

Suitable for tack welding and welding

150

GPR-300 H High Recovery Electrode for Mild Steel Identification:

Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 7024

E 42 0 RR 73

Approvals

DNV·GL

ABS

Type of current Welding positions PA Materials to be welded Cast steel

vessel steel

Fine grained steel

All weld metal composition

3.01

Typical mech. properties of weld metal

max. 0.12 Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

Recovery %

26 Welding data

Diameter mm.

Current range, A

3.2

130–170 180–230

Diameter mm.

Length mm.

151

Electrodes per kg weld metal**

Fume class

21.0

2 2 3

3.8

Electrodes per box

3.2

6.0

Deposition rate** Kg/h

68 72

6.0 Packaging data

Arc time **/ electrode, sec.

180

6.6 Net weight, kg per box

Product No. per box

Boxes per carton

3 3 3 3

GPR-300 H

the coating to be in contact with the

The electrode can be used at a

heavier material, a large electrode

The electrode is suitable for welding However, observe all necessary safety material thickness.

on welding fumes.

3.01

where large sections of steel are to

heat deformation and stress. Welding with this electrode ensures

This electrode is recommended

152

SPECIAL-303 N Double Coated Electrode for Mild and Ship Quality Steel Identification:

Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 7016

E 38 2B 32 H10

Approvals

DNV·GL

ABS

3YH10

3YH15

3, 3YH10

3H10, 3Y

Type of current Welding positions PA

Materials to be welded Cast steel

vessel steel

Fine grained steel

All weld metal composition

3.01

Typical mech. properties of weld metal

max. 0.10 Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

28 Welding data

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

2.0

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

0.6

3 3 3 3

77 3.2

Packaging data

Diameter mm.

Length mm.

Electrodes per box

2.0 3.2 2.0

153

Net weight, kg per box

1.7 200 120

Product No. per box

Boxes per carton

6 3 3 3

SPECIAL-303 N

excellent running characteristics of a rutile electrode with the very good electrode.

Core rod

Rutile coating

Ideal electrode for high quality jobs

Root edge Controlled burn through

3.01

154

LH-314 N Low Hydrogen Electrode for Ship Quality Steel Identification:

Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 7018 H4

E 42 4 B 42 H5

Approvals

DNV·GL

ABS

3YH5

3, 3YH5

3YH5, 3Y

Type of current Welding positions PA

Materials to be welded Cast steel

vessel steel

Fine grained steel

3.01

All weld metal composition Typical mech. properties of weld metal

Welding data

Tensile strength MPa

Diameter mm.

Current range, A

Yield strength MPa

Arc time **/ electrode, sec.

Elongation %

Deposition rate** Kg/h

Impact value ISO-V (J)

Electrodes per kg weld metal**

Fume class

31.3

2 3 3

1.0 3.2

80 2.1

Packaging data

Diameter mm.

Length mm.

Electrodes per box

161 3.2 78

155

Net weight, kg per box

Product No. per box

Boxes per carton

3 3 3

LH-314 N

you are uncertain as to whether the steel is unalloyed or low alloyed, you cannot go wrong when using a basic A short arc.

All basic electrodes should be used

Hydrogen content is low, less than the risk of cold cracks. Slag is easily

3.01

therefore well suited for heavily loaded

examination. welding ordinary cast steel in high

To determine whether you have cast iron or cast steel, use a hammer and chisel on the material and consult the chisel test under the section on metal Welding cast steel.

156

LHH-314 H High Recovery Low Hydrogen Electrode for Ship Quality Identification:

Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 7028

E 42 4 B 73 H5

Approvals

DNV·GL

ABS

3YH5

Type of current Welding positions PA Materials to be welded Cast steel

vessel steel

Fine grained steel

3.01 All weld metal composition Typical mech. properties of weld metal

Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

Recovery %

26 Welding data

Packaging data

Diameter mm.

Current range, A

Length mm.

Arc time **/ electrode, sec.

Deposition rate** Kg/h

70 72

3.7

Electrodes per box

Net weight, kg per box

Electrodes per kg weld metal**

Product No. per box

Fume class

Boxes per carton

3 3

157

LHH-314 H

the coating to be in contact with the base material. The electrode can be used at a

heavier material, a large electrode

The electrode is suitable for welding However, observe all necessary safety material thickness.

on welding fumes.

3.01

where large sections of steel are to

heat deformation and stress. This electrode is recommended

158

LHV-316 N Vertical Down Welding Low Hydrogen Electrode for Ship Quality Steel Imprint

Classifications

SFA/AWS A 5.1

EN-ISO 2560-A

E 8018-G

E 46 4 B 41 H5

Approvals

DNV·GL

ABS

3YH10

4Y40H10

3YH10

Type of current Welding positions PA

Materials to be welded Cast steel

vessel steel

Fine grained steel

3.01 All weld metal composition Typical mech. properties of weld metal

Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

27 Welding data

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

3.2

Packaging data

Diameter mm.

3.2

159

Length mm.

Electrodes per box

137

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

1.6 2.8

27.0

2 2

Net weight, kg per box

Product No. per box

Boxes per carton

3 3

LHV-316 N basic electrode for welding unalloyed, controlled steel. It can be used in

frames, lifting lugs and electric motor A short arc

electrode should travel in a straight with both sides of the groove. The electrode should be held at an angle The electrode can also be used for overhead welding. with very good mechanical strength and high crack resistance. The slag from this electrode is very easily removed, even from narrow grooves.

used for welding a root bead where

3.01

electrode, maximum welding current can be used also in vertical welding. three times faster than normal. There is little heat transfer to the base 316N and deformation and stress is

drying of basic electrodes.

required, weld a bead on either side of the root bead as shown

160

LHT-318 N Electrode for High Temperature Steel Identification:

Imprint

Classifications

SFA/AWS A 5.5

EN 1599

E 8018-B2

E CrMo 1B 42 H5

Approvals

DNV·GL

ABS

–

1% Cr 0,5% Mo, H5

Type of current Welding positions PA

Materials to be welded Case hardening steel Q & T steel Creep data: Test temperature °C

3.01

400

500

550

300

110 80

600 (80)

170

All weld metal composition

Typical mech. properties * of weld metal

Welding data

Tensile strength MPa

Yield strength MPa

Elongation %

Diameter mm.

3.2

Impact value ISO-V (J)

20 Current range, A

Arc time **/ electrode, sec.

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

0.8 1.1

3 3

3.2

Packaging data

max. 0.020

620

161

450

Length mm.

Electrodes per box

Net weight, kg per box

1.7 1.7

Product No. per box

Boxes per carton

6 6

LHT-318 N basic electrode for welding low alloy

The basic coating is of extra moisture against humidity. See section on after drying of basic electrodes.

Electrode for heat resistant steels,

For best results on Chromium alloyed materials thicker than 8–10 mm,

The electrodes may be used in all

As for all basic electrodes the arc

3.01

In cases where stress relieving is

ensure full effect. For t >12 mm welding from both sides is recommended

162

LHL-319 N Electrode for Low Temperature Steel Identification:

Imprint

Classifications

SFA/AWS A 5.5

EN-ISO 2560-A

E 8018-C1

E 46 6 2 Ni B 32 H5

Approvals

DNV·GL

ABS

5Y46H5

5Y42H5

5Y 40M H5

3Y400H5

Type of current Welding positions PA

Materials to be welded Fine grained steel

High strength steel

All weld metal composition

3.01

Typical mech. properties of weld metal

Tensile strength MPa

max. 0.020

Yield strength MPa

Elongation %

610 Welding data

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

Deposition rate** Kg/h

70–110

Diameter mm.

3.2

163

Impact value ISO-V (J)

3.2

Packaging data

Electrodes per kg weld metal**

Fume class

2 3

Length mm.

Electrodes per box

Net weight, kg per box

1.8 1.8

Product No. per box

Boxes per carton

6 6

LHL-319 N

containing Nickel is used more and

with short arc. High notch values are grained structural steel with thickness

Store dry.

3.01

164

LHR-320 N Electrode for Weathering Steel Identification:

Imprint

Classifications

SFA/AWS A 5.5

EN-ISO 2560-A

E 8018-G

E 46 5 Z B 32

Approvals

DNV·GL

ABS

3YH10

3YH15

3YH10

Type of current Welding positions PA

Materials to be welded Fine grained steel

High strength steel Weathering steel

All weld metal composition

3.01

Typical mech. properties of weld metal

Commercial names

P, S

Elongation %

Impact value ISO-V (J)

max. 0.020 Tensile strength MPa

Yield strength MPa

Welding data

Diameter mm.

Current range, A

3.2

Packaging data

Diameter mm.

3.2

165

Length mm.

Arc time **/ electrode, sec.

Deposition rate** Kg/h

1.3

Electrodes per box

Net weight, kg per box

1.7 1.8

Electrodes per kg weld metal**

Fume class

2 2

Product No. per box

Boxes per carton

6 6

LHR-320 N

with good corrosion resistance to of weathering steel (Patinax steel,

The weld metal has excellent

wears off.

forms naturally on the steel when it is This tight oxide coating reduces continuing corrosion. The corrosion resistance of weathering steels is four to six times that of normal structural carbon steels, and two to three structural steels.

Flue gases corrosion

3.01

The weathering steels are covered by steels have a minimum yield strength

To maintain the weather resistance characteristic of the steel, it is

Sea water corrosion

166

TENSILE-328 N Electrode for Difficult-to-Weld Steel Identification:

Imprint

Classifications

Approvals

SFA/AWS A 5.5

EN-ISO 3581-A

EN 14 700

E 312-17

E 29 9 R 32

E Fe 11

N.A.

Type of current Welding positions PA

Various steel grades such as:

Materials to be welded

– Work hardening austenitic manganese steel

All weld metal composition

3.01 Typical mech. properties of weld metal

Welding data

Tensile strength MPa

Diameter mm.

Current range, A

Yield strength MPa

Elongation %

610

Arc time **/ electrode, sec.

3.2

Packaging data

Diameter mm.

167

Electrodes per kg weld metal**

Fume class

6 7

1.3

Length mm.

300 3.2

Deposition rate** Kg/h

Impact value ISO-V (J)

Electrodes per box

Net weight, kg per box

1.6 2.0

Product No. per box

Boxes per carton

6 6

TENSILE-328 N

are commonly used in main engine shafts, gear wheels, etc. This electrode can be used for joining

surface. area must be grinded and cleaned threaded surfaces adjacent to the

hold the electrode almost at right Preheating is not usually necessary.

3.01

before continuing.

168

IMPACT-329 S Electrode for Heat Resistant Overlays Identification:

Imprint

Classifications

DIN 8555 E 20-UM-250-CRTZ

Approvals

N.A.

Type of current Welding positions PA

Materials to be welded

– High corrosion resistance – High resistance against abrasion by metal to metal friction or caviation

3.01

– Extrusion screws – Stream through valves

All weld metal composition

Typical mech. properties of weld metal

Welding data

Packaging data

Rest

Tensile strength MPa

0.1

2.0

1.0

0.8

Elongation %

Hardness as welded HB

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

Deposition rate** Kg/h

3.2

70–120

1.36

Diameter mm.

Length mm.

Electrodes per box

Net weight, kg per box

3.2

169

Impact value ISO-V (J)

Electrodes per kg weld metal

Fume class

7 Product No. per box

Boxes per carton

IMPACT-329 S 1. Machine preparation

Suggested jig for holding

2. Weld preparation

outer side of the groove Second layer

allowing it to be rotated.

First layer or buffer layer

3. Preheating can consist of several beads

4. Welding

minimise heat effects, the welding should be the outer side of the groove, and do about one third of the circumference.

started. Finally do the third, starting where the

3.01 Small diameters Welding bead sequence

5. Cooling be immersed in insulating material or dry sand in order to ensure slow cooling.

6. Final machining After cooling, machine to correct tolerances, use Ensure slow cooling.

170

WEARMAX-327 Electrode for Joining & Wear Resistant Overlays Identification:

Imprint

Classifications

AWS A5.4 ~ E 307-26

Approvals

N.A.

Type of current Welding positions PA

Materials to be welded

for both joining and making wear resistant overlays.

All weld metal composition

3.01 Typical mech. properties of weld metal

Welding data

Rest

16–20

7–10

1.3–2.3

Tensile strength MPa

Yield strength MPa

Elongation %

Hardness as welded HB

Diameter mm.

Current range, A

80 103

3.2

Packaging data

Diameter mm.

Arc time / electrode, sec.

Length mm.

Electrodes per box

171

Hardness after work hardening HB

Recovery %

Deposition rate Kg/h

Electrodes per kg weld metal

Fume class

1.2 1.8

31 21

6 6 7

Net weight, kg per box

Product No. per box

Boxes per carton

1.6 3.2

6 3 3

WEARMAX-327 Winch wheel

with excellent resistance against elongation. When subjected to grinding, machining or wear, the

Chain

chain wires etc. The electrode is also designed to achieve high tensile it an excellent electrode for joining dissimilar metals.

Areas of application: Anchor winch wheels and guides, windlasses drums and rollers, cranes

grain steel and shear blades.

3.01

172

18/8-321 N Electrode for Stainless Steel Identification:

Imprint

Classifications

SFA/AWS A 5.4

EN-ISO 3581-A

E 316L-17

E 19 12 3 LR 12

Approvals

DNV·GL

ABS

VL316L

316L

E 316L 17

Type of current Welding positions PA Materials to be welded

Steel grades

BS 970 DIN 17440/17445 1554

W.Nr. AFNOR NF A35573/574/576/582

ASTM/ACI SIS A240, A312, A351

Extra low 316S11 carbon 316S13

S31603

316S31 316S33 316S33 316S33 316S33 320S31

carbon

UNS

316 (TP) 316

316Ti 2338 2338

3.01

All weld metal composition Typical mech. properties of weld metal

Welding data

max. 0.030

3–10

Tensile strength MPa

Diameter mm.

Current range, A

1.6

Yield strength MPa

Elongation %

Impact value ISO-V (J)

Arc time **/ electrode, sec.

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

0.6 1.1

230

3.2 Packaging data

Diameter mm.

Length mm.

Electrodes per box

Net weight, kg per box

1.6

300 300

213

1.6 1.7 1.7

3.2

173

Product No. per box

Boxes per carton

6 6 6

18/8-321 N electrode for welding stainless and molybdenum.

When welding tanks containing corrosive elements, it must be

2nd run

1st run

steel. Use a brush with stainless steel wire If an ordinary wire brush is used, iron left by the brush, as this can lead to formed on either side of the bead to remove discolouration and oxides

3.01 Welding: 1. Use a short arc. A long arc will increase arc tension, resulting in

4. against humidity and welding with

2. The electrode should be held almost A stainless steel electrode should 3. When terminating the weld, the electrode should be move in a finally moved quickly backwards in the groove for a distance of

as the base material, but there are of high alloy content may be used for welding material which has a slightly lower alloy content than the electrode.

slag in the middle of the crater is thereby avoided.

174

23/14-322 N Electrode for Stainless Steel Identification:

Imprint

Classifications

SFA/AWS A5.4

EN-ISO 3581-A

E 309MoL-17

E 23 12 2 LR 32

Approvals

DNV·GL

ABS

VL309Mo

SS/CMn

309Mo

SS/CMn

Type of current Welding positions PA Materials to be welded

Steel grades BS 970 DIN 17440 First layer

316S11

claddings

316S13

W.Nr. AFNOR

ASTM/ACI

SIS

UNS S31603

316S31 316S33 320S31

316 (TP) 316 (H) 316Ti 316Ti 316Cb

3.01

All weld metal composition Typical mech. properties of weld metal

12–22

Tensile strength MPa

Yield strength MPa

Elongation %

610 Welding data

max. 0.030

Impact value ISO-V (J)

Diameter mm.

Current range, A

3.2

60–120

Arc time **/ electrode, sec.

Deposition rate** Kg/h

Electrodes per kg weld metal**

1.2 1.7

Fume class

28 Packaging data

Diameter mm.

Length mm.

300

Electrodes per box

Net weight, kg per box

1.7

3.2 2.0

175

Product No. per box

6 Boxes per carton

6 6 6

23/14-322 N alloyed electrode for welding stainless

be seen from the sketch, the unalloyed unalloyed steel electrode, followed by Unalloyed steel

A certain amount of mixing with the unalloyed steel is unavoidable and the to ensure that the weld will remain stainless.

Stainless steel Procedure to be followed when welding

be used for welding unalloyed steel to stainless steel. This combination used the weld will remain stainless.

resistance. It is suitable for all welding

The electrode may also be used for

Stainless

Welding mild steel to stainless steel.

ordinary steel.

3.01

and oxides after welding.

Stainless steel overlay on ordinary steel.

176

DUPLEX-325 N Electrode for Duplex Steel Identification:

Imprint

Classifications

SFA/AWS A5.4

EN-ISO 3581-A

E 2209-17

E 22 9 3 N L R 32

Approvals

DNV·GL

ABS

DUPLEX

–

2209

DUPLEX

Type of current Welding positions PA

Materials to be welded W. Nr.

AFNOR SIS UNS

S 2377 S 31803 S 31200

3.01 All weld metal composition

max. 0.030 Typical mech. properties of weld metal

Tensile strength MPa

Yield strength MPa

Elongation %

Impact value ISO-V (J)

820 Welding data

Packaging data

Diameter mm.

Current range, A

3.2

80–120

Diameter mm.

Length mm.

300 3.2

177

Arc time **/ electrode, sec.

Deposition rate** Kg/h

1.0

Electrodes per box

Net weight, kg per box

1.7 2.0

Electrodes per kg weld metal**

Product No. per box

Fume class

Boxes per carton

6 6

DUPLEX-325 N

stainless steel used in tanks, cargo ladders.

two in one structure, results in a very high yield and tensile strength as well

mild steel. It has high resistance to general

will increase arc tension, resulting in

Name

and oxides after welding.

Material

3.01

1. Hull. 2. Hull (Section weld). 3. Stiffeners to hull. Stainless steel.

(Section weld).

mild steel.

178

PICKLING GEL Pickling Gel for Stainless Steel Identification:

Packaging type

Product consistency and colour

White HD-polyethylene plastic container (approval according to UN- recommendation) Classifications

White gel

ASTM A-380 A1

BS CP-312

Shelf life

Storage

Caution:

Application data

Stir the gel to a smooth consistency. Rinse off the reminding gel using fresh water. The waste water, after rinsing, contains acids and heavy metals, and must hence be treated according to local wastewater requirements before discharge. This can be done with neutralising agent or slaked lime.

3.01 NB.

Chemical composition Vol. %

Hydrofluoric acid (HF)

pH: 0

Welding data

Binder

8–20

Rest

Flamable: No

Container Content

2 litre Protective clothing

SDS available on request.

179

Nitric Acid HNO3

Net Weight per container

Product No. per container

Containers per carton

PICKLING GEL 8. Pickling residuals and rinse water weld and the adjacent area to the Neutralising Agent, and then rinsed oxidation ranging from light tinting to a regulations should be consulted the oxide also occurs. If this is not removed, corrosion will be the result. this oxides and the underlying chromium

must be avoided since this accelerate

contaminates which may cause local the materials corrosion resistance.

surface

Weld

Application

Chromium

substances that must be handled with

Sheet.

welds are still warm and the weld oxides less hard.

Stir the gel before use

3.01 3. Organic contaminants such as grease, the brush

6. The gel should be allowed to remain to work

steels this time should be extended. If necessary the gel may be allowed to as there is no risk for corrosion. reminding gel using fresh water. If necessary brush the weld with a stainless steel wire brush.

Remove with water

180

NIFE-334 N Nickel Iron Electrode for Cast Iron Imprint

Classifications

Approvals

SFA/AWS A5.15

EN-ISO 1071

E NiFe-CL-A

E NiFe-CL-A1

N.A.

Type of current Welding positions PA DIN 1691

Materials to be welded

All weld metal composition

3.01

Typical mech. properties of weld metal

Welding data

PC DIN 1692

PF DIN 1693

Tensile strength MPa

Yield strength MPa

Elongation %

Hardness HB

300

180

Diameter mm.

Current range, A

Arc time **/ electrode, sec.

Deposition rate** Kg/h

Electrodes per kg weld metal**

Fume class

1.8

2 3

3.2

Packaging data

Diameter mm.

3.2

181

Length mm.

Electrodes per box

Net weight, kg per box

2.2

Product No. per box

Boxes per carton

6 6

NIFE-334 N

cast iron and grey cast iron.

involve considerable risk of transverse the heat transfer to the base material very short beads (2–3 cm) at a time, to cool before welding the next bead. cold welded.

continuously welded. The weld metal is easily machineable.

the crack fracture.

fracturing during welding.

3.01 When welding oily cast iron, Unitor electrode for gouging without the use of oxygen. As well as forming a suitable

the metal are saturated with oil.

out the oil contained in the carbon of cast iron. If the oil is not burnt off, it will have a tendency to surface during

182

NICKEL-333 N Nickel Electrode for Cast Iron Identification:

Imprint

Classifications

Approvals

SFA/AWS A5.15

EN-ISO 1071

E Ni-CL

E Ni-CL3

N.A.

Type of current Welding positions PA DIN 1691

Materials to be welded

All weld metal composition

3.01

Typical mech. properties of weld metal

Welding data

PC DIN 1692

Tensile strength MPa

Yield strength MPa

Elongation %

300

100

Diameter mm.

3.2

183

DIN 1693

Current range, A

Arc time **/ electrode, sec.

Deposition rate** Kg/h

Electrodes per kg weld metal**

Hardness HB

Fume class

0.8 1.2

3.2 Packaging data

Length mm.

Electrodes per box

Net weight, kg per box

300

121 68

2.0 2.2

2 2

Product No. per box

Boxes per carton

6 6

NICKEL-333 N electrode for cold welding of oily cast iron.

Use a crack detector to determine the actual length of the crack or fracture. Weld in short beads.

fracturing during welding. may be used. Use a fairly short arc. Hold the electrode almost at a right angle to the work and weld in short beads of 2–3 cm at a time. When a to counteract shrinkage. Start from the crater and work backwards to the Allow the weld to cool before continuing. A general rule is that the welding area should be hand warm before welding the next bead of 2–3 cm (cold welding).

3.01 of the crack and inwards. The thickness of the material is the deciding factor in choosing between 333 N is for use on thinner materials,

After welding, the bead’s tendency to shrink can cause cracking. Peening the bead counteracts the shrinkage forces.

be followed by beads welded with multibead welding on heavy gauge materials.

Start welding at the end of the crack and work inwards.

184

TINBRO-341 Electrode for Copper Alloys Identification:

Imprint

Classifications

Approvals

AWS A5.6

DIN 8555

~ E Cu SnC

E 30-UM-150-C

N.A.

Type of current Welding positions PA Materials to be welded

Copper and copper alloys i.e.:

Steel Castiron

All weld metal composition

3.01

Rest Typical mech. properties of weld metal

Tensile strength MPa

1 Yield strength MPa

Elongation %

Hardness HB

Recovery %

103 Welding data

Diameter mm.

Current range, A

3.2

Packaging data

Diameter mm.

3.2

185

Length mm.

Arc time / electrode, sec.

Deposition rate Kg/h

1.33

Electrodes per box

Net weight, kg per box

Electrodes per kg weld metal

Fume class

Product No. per box

Boxes per carton

TINBRO-341 Cunifer

these to steel and cast iron. Clean the welding area thoroughly to material. When making joints, a 3 mm

and welding current can be reduced. Use a short arc and hold the electrode almost at right angles to the work. weave the electrode from side to side, the electrode diameter. Parts not be overheated, or where minimum fusion with the base material is required, welding should be carried

3.01

The electrodes must be stored in a dry avoid damage of the coating.

For welding these materials, the

Yorcalbro

186

ALBRONZE-344 Electrode for Copper Alloys Identification:

Imprint

Classifications

Approvals

AWS A5.6

DIN 8555

~ E Cu Al A2

E 31-UM-150-C

N.A.

Type of current Welding positions PA Materials to be welded

Copper and copper alloys i.e.:

Steel Cast iron

All weld metal composition

3.01

Typical mech. properties of weld metal

Rest

1.2

2.8

Tensile strength MPa

Yield strength MPa

Elongation %

Hardness HB

Recovery %

10 Welding data

Packaging data

Diameter mm.

Current range, A

Arc time / electrode, sec.

3.2

80–160

Diameter mm.

3.2

187

Length mm.

Electrodes per box

103

Deposition rate Kg/h

Electrodes per kg weld metal

Fume class

Net weight, kg per box

1.3

Product No. per box

Boxes per carton

ALBRONZE-344 recommended for welding Yorcalbro as for joining these metals to steel and cast iron. It is also used for welding gliding surface overlays on steel.

against cavitational wear and weldability.

condensers, valves and turbine blades. Clean the welding area thoroughly and

The groove can be formed by grinding.

during welding. When surfacing steel

3.01 base material. Use a short arc. Hold the electrode The length of each stroke should not exceed three times the electrode diameter. Remove the slag from the brush before starting on the next similar materials must be annealed after welding by heating the welding then be allowed to cool down slowly to

188

ALUMIN-351 N Electrode for Aluminium Identification:

Imprint

Classifications

EN-ISO 18273 EL-AlSi12

Approvals

N.A.

Type of current Welding positions PA

Materials to be welded 10 10 12 12 11

(3.2381) (Cu) (3.2381) (Cu) Cu 3

7 6

3.01

All weld metal composition

max. 0.8 Typical mech. properties of weld metal

Tensile strength MPa

Yield strength MPa

Elongation %

160 Welding data

Packaging data

189

Diameter mm.

Current range, A

Arc time** / electrode, sec.

Deposition rate** Kg/h

3.2

70–120

0.7

Diameter mm.

Length mm.

3.2

Impact value ISO-V (J)

Electrodes per box

Net weight, kg per box

1.0

Electrodes per kg weld metal**

Fume class

Product No. per box

Boxes per carton

ALUMIN-351 N

ventilation or use Fresh Air kit mounted in face shield. castings (covers), gangways, etc. When welding materials more than 3

the electrode almost vertically to the

about 1 cm when restriking. All slag must be cleaned off the Aluminium electrodes absorb moisture very easily and must be stored in a dry,

Aluminium or magnesium?

Hold the electrode almost at right angles

3.01

weld direction Note: Use the shortest possible arc.

Use the following test to determine

File a few shavings onto a small

is magnesium. If there are only a few aluminium alloyed with magnesium, and may be welded.

190

CH-2-382 Electrode for Aluminium Identification:

Imprint

Classifications

N.A.

Approvals

N.A.

Type of current Welding positions PA

Materials to be chamfered Cast iron

All weld metal composition

N.A.

Typical mech. properties of weld metal

N.A.

Welding data

3.01

Packaging data

Diameter mm.

Current range, A

3.2

160–280

Diameter mm.

Length mm.

3.2

191

Arc time / electrode, sec.

Electrodes per box

Deposition rate Kg/h

Electrodes per kg weld metal

Fume class

–

Net weight, kg per box

Product No. per box

Boxes per carton

CH-2-382 Gouging Technique 1. Hold the electrode vertically and The arc will strike after a few seconds. 2. Hold the electrode at an angle of 3. 4. Warning! inadvertently, move the electrode back and lower to correct angle. 5. Work downwards when cutting into a vertical surface, otherwise as 6.

3.01

192

ACA-384 Electrode for Air Carbon Arc Gouging Identification:

Classifications

N.A.

Approvals

N.A.

Type of current Welding positions PA

Materials to be welded All weld metal composition

Metal removal capacity

N.A.

Diameter mm.

Approx. kg/electrode

6.3 8.0

0.27 0.37 0.61

3.01 Welding data

Diameter mm.

Current range, Amps.

Air pressure (bar)

6.3 8.0

Packaging data

Diameter mm.

6.3 8.0

193

Fume class

7 7 7 Length mm.

Electrodes per box

Net weight, kg per box

0.8 1.3 2.1

Product No. per box

Boxes per carton

ACA-384 electrodes and using 100 m cable, the metal, and the molten metal is then This method has several advantages – it can be used for cutting stainless steel and other materials which are

should be able to master the gouging day for about a week.

WARNING!

and must not be inhaled. Arrange for suitable ventilation or use an air mask.

method is the removal of sections which have been welded to the deck Hold the electrode holder so that direction of travel. The air blast is directed along the rear of the electrode towards the arc. The controlled by the electrode angle and A combination of wide electrode angle

The electrode held at a narrow angle to the

3.01 the groove will usually be about 3 mm wider than the electrode diameter.

travel to obtain an even, hissing sound and clean, smooth groove surface. The amount of metal which can be removed increases with increasing current. However, every electrode has an ideal current level which is slightly below its maximum. If the ideal level is exceeded, the welder will notice a considerable increase in electrode

electrode when gouging

194

WELDING HANDBOOK NOTES

3.01

195

TIG WELDING RODS AND FLUXES Introduction

201 203 207 211

3.02

196

TIG WELDING RODS AND FLUXES Introduction an arc is struck between a Tungsten

Power source

surrounding air. The electrodes

Return cable

similar welding technique as gas welding but use electricity as energy source.

Welding cable

torch

Rods for TIG welding

for convenient use. The label on each and also gives rod data and basic shielding

use. Rod

3.02

197

TIG WELDING RODS AND FLUXES Classification

Guide to AWS A5.28-1979

Mechanical properties of weld metal AWS Classifications

Tensile strength min. MPa

Yield strength min. MPa (0.2% proof)

620 620

Elongation min. %

Impact Energy Charpy-V J/°C

17 17

Not required Not required Not required Not required

Condition

17 16 16 760 830 Not required

Not required

then in still air.

3.02

then in still air.

Suffix

Alloying system

Nominal value, wt%

Ni Ni Ni

198

IMS 210 Description:

tensile steels. Identification:

Classifications

AWS A5.28

EN 12070

DIN 8575

Werkstoff No.

Type of current Welding positions

Flux Materials to be welded

Fine grained steel

3.02

Chemical composition as welded (W%) Welding data

0.1

0.6

Tensile strength MPa

Yield strength MPa

Rest Elongation %

Impact value ISO-V (J)

Packaging data

Diameter mm.

2.0

199

Length mm.

Rods per package

Net weight per package kg

180

Product No. per package

IMS 210 welding rod for welding of unalloyed

It is also recommended for welding of high tensile steel.

of small diameters where the wall 6 mm. advantage when making root runs on large thicknesses where the are done by arc welding with coated electrodes. Thoroughly clean the welding area before commencing welding.

the other hand, have a high silicium

3.02

200

ICROMO 216 Description:

recommended for welding of high tensile steels.

Identification:

Classifications

AWS SFA 5.28

EN 12070

BS 2901

DIN 8575

Werkstoff No.

A32

Type of current Welding positions

Flux Materials to be welded

Elevated temperature steel

Case hardening steel

Quenched & Tempered steel

3.02

Chemical composition as welded (W%) Mechanical properties as welded

0.1

0.6

1.2

Temperature

Tensile strength MPa

Yield strength MPa

Packaging data

Diameter mm.

Length mm.

Rods per package

Net weight per package kg

201

Rest Elongation %

Impact value ISO-V (J)

100

130

Product No. per package

ICROMO 216

welding of heat resistant steel, like boiler tubes. It is suitable for working wall thicknesses it can be used for welding with coated electrodes.

electrode.

3.02

202

18/8 Mo 221 Description:

Identification:

Classifications

AWS A5.9

EN 12072

DIN 8556

Werkstoff No.

Type of current Welding positions

Flux Materials to be welded

Steel grades BS 970 DIN 17440/1744.5

W.Nr. AFNOR NF A35-

ASTM/ACI

SIS

UNS

Ext. low carb. 316S11 316S13 316S31 316S33 316S33

3.02

316 (TP) 316

316S33 316S33 320S31

316Ti 2338

Chemical composition as welded (W%)

Mechanical properties as welded

<0.02

1.7

0.8

18.8

Tensile strength MPa

Yield strength MPa

Elongation %

320

Packaging data

Diameter mm.

2.0

203

Length mm.

Rods per package

2.8

Rest

Impact value ISO-V (J)

80 At

Net weight per package kg

Product No. per package

18/8 Mo 221 stainless and acid resistant steel.

offer. When welding thin sheets and rod may also be used as a root bead when welding thicker sheets with

avoid when using coated electrodes on thin sheets. stainless and acid resistant sheet and board chemical tankers. welding current is used, combined alloyed with rare earth metals. The Note: The hot surface of the back of the weld will be attacked by air this can be done by introducing

3.02

ends. When welding sheets, sheet underneath the weld will Remember there is considerably more shrinkage in stainless steel than in mild steel and the tacks should

Argon hose

Small hole to let the

204

IDUPLEX-222 Description:

Identification:

Classifications

AWS A5.9

EN 12072

DIN 8556

Werkstoff No.

Type of current Welding positions

Flux Materials to be welded

Chemical composition as welded (W%)

3.02

Mechanical properties as welded

EN 10088

W. No. DIN 17440/1744.5

1.6

23.0

Tensile strength MPa

Yield strength MPa

> 680 Packaging data

Diameter mm.

2.0

205

3.0 Elongation %

Rest

Impact value ISO-V (J)

>22 Length mm.

Rods per package

Net weight per package kg

Product No. per package

IDUPLEX-222 Included angle

strength and toughness resistance to areas are similar to those for coated

than 2 mm) it is always an advantage used as a root bead when welding bigger than for AISI 316 stainless steel.

avoid when using coated electrodes on thin sheets. The rod can also be

must be used. Shielding gas must be welding, remove discoloration by using Unitor Pickling Paste.

avoided as the material structure may suffer

Note: The back of the weld will

3.02

the hot surface) unless it is and introducing Argon gas. Remember there is considerably more shrinkage in stainless steel than in mild steel and the tacks should therefore be Remember there is considerably more

Remember to only use stainless steel wire brushes and when working with stainless steel

than in mild steel and the tacks should

206

ALUMAG 235 Description: can be used for all cast alloys containing magnesium as the main alloying element. Identification:

Classifications

AWS A5.10

DIN 1732

Werkstoff No.

Type of current Welding positions

Flux Materials to be welded

Aluminium wrought alloys:

Aluminium cast alloys:

(generally all cast alloys containing magnesium as main alloying element).

Chemical composition as welded (W%)

3.02

Mechanical properties as welded

Packaging data

Rest Tensile strength MPa

Diameter mm.

2.0

207

Length mm.

Yield strength MPa

Elongation %

110

Rods per package

Net weight per package kg

Melting range °C

Product No. per package

ALUMAG 235

resistant aluminum and cast aluminium. Clean the joints and adjacent surfaces thoroughly. Use a stainless steel brush, not an ordinary steel brush which will rub iron oxides into the aluminum and contaminate the

so that they do not sag when the to cool slowly after being welded. TIG (GTAW) welding necessary to use an alternating required to break the oxide layer on the aluminium surface.

3.02

208

ICUNI 30 239 Description:

Identification:

Classifications

AWS A5.7

BS 2901

ER Cu Ni

C 18

DIN 1733

Werkstoff No.

2.0837

Type of current Welding positions

Flux Materials to be welded

Copper-nickel wrought alloys

Werkstoff No. 2.0872 Werkstoff No. 2.0883 Chemical composition as welded (W%)

3.02

Mechanical properties as welded

Packaging data

31.0

1.0

Tensile strength MPa

Diameter mm.

Length mm.

Yield strength MPa

Elongation %

200

Rods per package

Net weight per package kg

2.0

209

Rest Hardness HB

Product No. per package

ICUNI 30 239

is used in combination with a thorium as shielding gas. Thoroughly clean the welding and adjacent area with a stainless

adjacent areas must be thoroughly cleaned with a stainless steel brush or

Unitor ICUNI 30.

3.02

210

IALBRO 237 MF Description:

Classifications

AWS A5.7

DIN 1733

Type of current Welding positions

Materials to be welded

Wrought copper aluminium alloys:

Cast copper aluminium alloys:

Trade name types:

3.02

Chemical composition as welded (W%) Mechanical properties as welded

Packaging data

1.0 Tensile strength MPa

Diameter mm.

Yield strength MPa

Length mm.

Rods per package

Elongation %

Net weight per package kg

1.2

211

Rest Hardness HB

Product No. per package

IALBRO 237 MF

either side of the bead should be

– Use a contact thermometer when

combined with Albro Flux 263 PF.

welding.

necessary. For thicknesses recommended. – Thoroughly clean the welding area

3.02 – Welding continuous beads as

Permanently

is extinguished the groove must be cleaned before the bead is continued.

Permanently

212

WELDING HANDBOOK NOTES

3.02

213

WIRES FOR WIRE WELDING Introduction 216 Storage and handling for Flux Cored wires

218 221 223

Coreshield 8 227 231 233 237

3.03

214

WIRES FOR WIRE WELDING Introduction In Wire welding an arc is struck between a continuously fed wire and

Wire feeder Power source

The wire used can be solid or and does not require any additional shielding gas.

Cylinder Argon CO2 2

Return cable Wire welding torch

Wires for wire welding (GMAW and FCAW): Description Unitor standard range of welding wires

shielding

and Flux Cored Arc Welding (FCAW) is Wire

cartons and labelled with information fully identifying the wire with technical

3.03

215

WIRES FOR WIRE WELDING Classification

Guide to AWS A5.18-1993

AWS Classifications

Chemical composition of wire or rod C

<0.07

Mechanical properties of weld metal AWS Classifications

Tensile strength min. MPa

Yield strength min. MPa (0.2% proof)

Elongation min. % 22 22 22 22 22 22 22

Impact Energy Charpy-V J/°C

Not required Not required

Not required

Shielding gas CO2 CO2 CO2 CO2 CO2 CO2 CO2

2 2 2 2 2 2 2

3.03

216

WIRES FOR WIRE WELDING Classification

Guide to AWS A5.20-1995 Indicates a cored wire

an electrode

-1

Indicates min. tensile strength in 10 ksi

AWS Classifications

Tensile strength MPa

No requirements

Indicates usability and

Yield strength min. MPa

Elongation min. %

No requirements

22 22 22 22 22 22 22 22 No requirements

No requirements No requirements

3.03

No requirements No requirements Suffix

22 No requirements No requirements 22 22 22 22 22 No requirements 22 22 No requirements

Impact Energy Charpy-V J/oC No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements No requirements

Shielding gas

Multiple-pass

Single-pass

x x

x x x x x

x x x x x x x x x

x x

217

x x

Flux type Rutile Rutile Rutile Rutile Rutile Rutile

Current type

WIRES FOR WIRE WELDING Storage and handling recommendation for Flux-cored Wires used in Gas-shielded Flux-cored Arc Welding and Self Shielded Flux-cored Arc Welding Scope

Gas shield range

Storage in the original undamaged cartons, requires controlled storing conditions

the wire coils shall be stored under the conditions mentioned above in a

contamination. Recommended storing for a maximum of 30 days.

Deteriorated products have suffered from serious water or moisture contamination, or have

Handling

moisture contamination over long their original condition and shall be discarded.

3.03

maximum 2 weeks.

218

GPS W 200 Description:

Wire Identification:

Classifications

AWSA5.18

EN 440

DIN 8559

Werkstoff No.

Type of current Welding positions PA

Shielding gas

Materials to be welded

vessel steel Part 1 HPS 33 Fine grained steel

3.03

Chemical composition as welded (W%) Mechanical properties as welded

0.08

0.03

Tensile strength MPa

Yield strength MPa

Rest

Elongation %

Impact value ISO-V (J)

22 Welding data

Packaging data

Wire speed

Diameter mm.

0.8

219

Volt

Spool size mm

Stick out

Deposition rate kg/h

10–20 mm

0.67–2.68

Net weight per spool kg

70 Kg wire/kg weldmetal

Fume class* SS-062802

1 Product No. per package

GPS W 200 welding wire for welding of unalloyed and low alloyed structural steel. It can be used for welding sheets in thin as well as larger thicknesses. Stable arc

the area.

3.03

220

MS-W-201 SELFSHIELD Description: vertical down.

Wire Identification:

Classifications

AWS A 5.20

Type of current Welding positions PA

Shielding gas

No shielding gas required. Materials to be welded Cast steel

3.03

Chemical composition as welded (W%)

0.23

0.7

Mechanical properties as welded

Welding data

Packaging data

0.007

0.01

Rest

Tensile strength MPa

Wire speed

Diameter mm.

0.8

221

Volt

Stick out

Spool size mm

Deposition rate kg/h

Net weight per spool kg

Kg wire/kg weldmetal

Fume class* SS-062802

1.3

7 Product No. per spool

MS-W-201 SELFSHIELD shielded electrode wire designed for required.

good with minimal slag sticking. It will make root beads in groove welds without backing bars.

Typical applications

3.03

222

MS-W-203 SELFSHIELD Description: including vertical down.

Wire Identification:

Classifications

SFA/AWS A 5.36 SFA/ AWS A 5.36M

EN ISO 17632-A

Type of current Welding positions PA

Shielding gas

No shielding gas required. Materials to be welded

Structural Steel

EN10216 EN10208

3.03 All Weld Metal Composition (W%)

Elongation A (L0=5d0)%

Impact value ISO-V (J)

Not Required

1.00 Typical mech. properties of weld metal

Tensile Strength Rm,MPa

Yield Strength Re,MPa

600 Welding data

Packaging data

Wire speed

Diameter mm.

1.2

223

Volt

Stick out

Deposition rate kg/h

20 mm

2.68

Spool size mm

Net weight per spool kg

Kg wire/kg weldmetal

Fume class* SS-062802

7 Spool Qty per Product No

Product No.

MS-W-203 SELFSHIELD

alloyed steels.

levels and easy to remove slag. The resistance to rust and the seamless with low content of diffusible hydrogen levels (< H8).

Typical applications Onboard outdoor fabrication welding.

3.03

Suitable for tack welding and

224

CORESHIELD 8 SELFSHIELD Description:

Wire Identification:

Tubular Flux Cored Wire on a coil. Classifications

AWS A 5.20

Approvals

DNV/GL

EN ISO

BS 7084

NFA 81-350

ABS

3S 3YS (H10)

3SA 3YSA (H10)

Type of current Welding positions PA

Shielding gas

No shielding gas required. Materials to be welded Cast steel

Fine grained steel

3.03 Chemical composition as welded (W%)

0.18 Mechanical properties as welded

0.1

Tensile strength MPa

Yield strength MPa

0.1

0.03

Elongation %

Impact value ISO-V (J)

22 Welding data

Packaging data

Wire speed

Diameter mm.

1.6

225

Volt

Stick out

Spool size mm

Deposition rate kg/h

Net weight per spool kg

11.3

Kg wire/kg weldmetal

Fume class* SS-062802

1.33

7 Product No. per spool

CORESHIELD 8 SELFSHIELD Unitor Coreshield 8 is designed for the and thicker steel. It has excellent low

diam. 1.6 mm is recommended for welds

handling of Coreshield 8 make it a high The Coreshield 8 also has excellent slag

Typical applications

ballast tanks.

3.03

226

S 316 M-GF 221 Description:

Wire Identification:

Classifications

AWS A5.22

EN 12073

Werkstoff No.

Type of current Welding positions PA

Shielding gas 2

Materials to be welded

Steel grades BS 970 DIN 17440/1745

W.Nr. AFNOR NF A35-

ASTM/ACI

SIS

UNS

Ext. low carb. 316S11

S31603

316S13 316S31 316S33 316S33

316 (TP) 316

316S33 316S33 320S31

316Ti 2338

3.03 Chemical composition as welded (W%) Mechanical properties as welded

0.03

0.6

Tensile strength MPa

12.0

2.8

Rest

Yield strength MPa

Elongation %

Impact value ISO-V (J)

30 Welding data

Packaging data

227

Wire speed

Diameter mm.

Volt

Spool size mm

Stick out

Deposition rate kg/h

Kg wire/kg weldmetal

Fume class* SS-062802

1.2–3.2

1.10

Net weight per spool kg

Product No. per spool

S 316 M-GF 221

also suitable for related stabilised steel

bright, smooth weld bead surface. The 2

considered.

3.03

228

S 309 M-GF 222 Description: Flux cored wire for welding of stainless steel and welding mild steel to stainless steel. Also welding of clad steel. Wire Identification:

Classifications

AWS A5.22

EN ISO 1763-A

EN ISO 1763-B

Type of current Welding positions PA

Shielding gas 2

Materials to be welded

Steel grades BS 970 DIN 17440/1745 First layer

316S11

claddings

316S13

W.Nr. AFNOR NF A35-

ASTM/ACI

SIS

UNS S31603

316S31 316S33 320S31

316 (TP) 316 (H) 316Ti 316Ti 316Cb 316Cb

3.03

Chemical composition as welded (W%) Mechanical properties as welded

0.03 Tensile strength MPa

0.6

Yield strength MPa

2.7

Rest

Elongation %

Impact value ISO-V (J)

32 Welding data

Packaging data

229

Wire speed

Diameter mm.

Volt

Spool size mm

Stick out

Deposition rate kg/h

Kg wire/kg weldmetal

Fume class* SS-062802

1.2–3.2

1.10

Net weight per spool kg

Product No. per spool

S 309 M-GF 222 wire designed for welding of clad steel steel and corrosion resistant overlays on mild steel. It can also be used for welding of stainless steel with chemical

shielding gas.

3.03

230

ICUNI W 239 Description:

Wire Identification:

Classifications

AWS A5.7

DIN 1733

Werkstoff No.

ER Cu Ni

2,0837

Type of current Welding positions PA

Shielding gas

Materials to be welded

Copper-nickel wrought alloys DIN 17664 CuN20Fe

Copper-nickel cast alloys

3.03

Chemical composition as welded (W%) Mechanical properties as welded

Welding data

Packaging data

UNS

2.0872 2.0878 2.0882 2.0883

C 70600 C 71600

W.No.

0.80

0.6

Rest

Tensile strength MPa

Yield strength MPa

Elongation %

Hardness HB

360

>200

120

Wire speed

Diameter mm.

0.8

231

DIN 17658

W.No.

Volt

Spool size mm

Stick out

Deposition rate kg/h

8–10 mm

1.2–2.80

Net weight per spool kg

Kg wire/kg weldmetal

Fume class* SS-062802

1 Product No. per spool

ICUNI W 239

corrosion resistant overlays on cast shielding gas. Thoroughly clean the welding and adjacent area with a stainless

welding.

considered.

3.03

232

IALBRO W 237 Description: Yorcalbro. High resistance to corrosion and wear.

Wire Identification:

Classifications

AWS A5.7

DIN 1733

Werkstoff No.

Type of current Welding positions PA

Shielding gas

Materials to be welded

Copper-nickel wrought alloys DIN 17665

W.No.

CuA18 Copper-nickel cast alloys

3.03

Chemical composition as welded (W%) Mechanical properties as welded

DIN 1714

W.No.

1.0

Rest

Tensile strength MPa

Yield strength MPa

Elongation %

180 Welding data

Wire speed

Volt

Hardness HB

Melting range °C

± 120

Stick out

Deposition rate kg/h

Kg wire/kg weldmetal

Fume class* SS-062802

8–10 mm Packaging data

Diameter mm.

0.8

233

Spool size mm

Net weight per spool kg

1 Product No. per spool

IALBRO W 237

wrought as well as cast forms. It is also suited for rebuilding or joining materials to steel or cast iron, and for wear or corrosion resistant overlays on shielding gas. Thoroughly clean the welding area with before commencing welding. and thin walls should be welded using considered.

3.03

234

ALUMAG W 235 Description:

Wire Identification:

Classifications

AWS A5.10

DIN 1732

Werkstoff No.

Type of current Welding positions PA

Shielding gas

Materials to be welded

Aluminium wrought alloys:

Aluminium cast alloys:

(generally all cast alloys containing magnesium as main alloying element)

3.03

Chemical composition as welded (W%) Mechanical properties as welded

Welding data

Rest Tensile strength MPa

Wire speed

Volt

Yield strength MPa

Elongation %

110

Stick out

Deposition rate kg/h

Kg wire/kg weldmetal

Fume class* SS-062802

8–10 mm Packaging data

Diameter mm.

235

Spool size mm

Net weight per spool kg

1 Product No. per spool

ALUMAG W 235 alloyed wire for welding all common wrought and cast aluminium alloys, e.g. which must be resistant to seawater and high tension, and also where high shielding gas. As the aluminium wire is quite soft, torch cables of more than 3 m length

Clean the joints and adjacent surfaces thoroughly. Use a stainless steel brush, not an ordinary steel brush which will rub iron oxides into the aluminium

be allowed to cool slowly after being welded.

3.03

236

ABRATECH-W-230 (On Request Basis) Description: Self –Shielded Flux Cored Wire for Hard Surfacing Wire Identification:

Classifications

DIN 8555

Type of current Welding positions PA Shielding gas

No shielding gas required

Materials to be welded Chemical composition as welded (W%)

Mechanical properties as welded

Hardness HRC

3.03

Welding data

Wire speed

Volt

Stick out

Deposition rate kg/h

10 mm Packaging data

237

Diameter mm.

Spool size mm

1.6

300 x 100

Net weight per spool kg

Kg wire/kg weldmetal

Fume class* SS-062802

6.3

Product No. per spool

ABRATECH-W-230 (On Request Basis) General information

with excellent resistance to abrasive carbides in an austenitic matrix. welds should be removed using

Feeder screws

Ce <0.2 Ce Ce

is no need for shielding gas because Weld using a small weaving motion from side to side. The required hardness is obtained in one layer. There is no slag to be removed after welding.

3.03

hardness at regular intervals without material.

Areas of application: Protection of surfaces subject to extreme wear and abrasion caused by dredgers and cement carriers facing heavy abrasion combined with medium

238

WELDING HANDBOOK NOTES

3.03

239

GAS WELDING RODS AND FLUXES Introduction

3.04

240

GAS WELDING RODS AND FLUXES Introduction Regulator

material.

Flashback arrestors Cylinder

Filler rod

Welding attachment

Hoses

Shank

Flashback arrestors

Filler rod

Welding attachment Weld

We distinguish between two different and Rightward welding.

3.04

For material thickness above 3.2 mm

Rightward welding.

Rods for gas welding

for convenient use. The label on each and also gives rod data and basic and use.

241

GAS WELDING RODS AND FLUXES The neutral flame

The oxidising flame

extends only a short distance from the

is used for heating, cutting and for most steel welding work.

and is used for welding cast iron, brass,

The carburizing flame acetylene, and is recognised by a is less bright and more white in colour than the inner cone, but is considerably

only slightly for Oxygen, obtaining a Oxygen (and if necessary reducing the

twice as long as the inner cone. This is used for welding of aluminum and aluminum alloys, and for soft soldering.

3.04

242

MS 200 Description: alloyed structural steel with a carbon content of less

Identification:

Classifications

AWS / A 5.2

EN 12536

BS 1453

DIN 8554

R 60

OII

61121

Flame setting

Neutral

Flux Materials to be welded

Chemical composition approx. (%)

R St 37.2, U St 37.2, St 37.3

0.1 Mechanical properties

3.04

Packaging data

Tensile strength MPa

Diameter mm.

2.0 3.0

243

1.0

0.030

Rest

Yield strength MPa

Elongation %

300

Length mm.

Rods per package

280

Net weight per package kg

Impact value ISO-V (J)

Product No. per package

MS 200 welding of unalloyed and low alloyed structural steel. It can be used for welding thin as well as heavier sheets. Select the diameter of the wire according to the thickness of the

In general, gas welding of unalloyed steel is suitable for thin sheets and thickness does not exceed 6 mm. For larger dimensions it may be advantageous to use electric arc welding with coated electrodes. welding, having a viscosity that makes

mm thick should be welded with the Rightward welding

welding rods have a high silicium

3.04

vice versa.

244

ALUMAG 235 Description: for all cast alloys containing magnesium as the main alloying element. Identification:

Classifications

AWS A5.10

Flame setting

DIN 1732

Werkstoff No.

Slight acetylene

Flux

Materials to be welded

Aluminium wrought alloys:

Aluminium cast alloys:

(generally all cast alloys containing magnesium as main alloying element).

Chemical composition approx. (%)

3.04

Mechanical properties

Packaging data

Rest Tensile strength MPa

Diameter mm.

245

Yield strength MPa

Elongation %

110

Length mm.

Rods per package

Net weight per package kg

Melting range °C

Product No. per package

ALUMAG 235

aluminum and cast aluminium. Clean the joints and adjacent surfaces thoroughly. Use a stainless steel brush, not an ordinary steel brush which will rub iron oxides into the aluminum

to cool slowly after being welded.

Gas welding excess of acetylene is used, together reduces oxides and counteracts

corrosive on aluminum and should be removed immediately after welding, by scrubbing with hot water.

TIG (GTAW) welding

3.04

required to break the oxide layer on the aluminium surface.

contaminated. Therefore, always

246

ALUFLUX 234 F Description: Identification:

Application

HARMFUL

R22

Harmful if swallowed

adverse effects in the aquatic environment S13 S22 S60 Packaging data

3.04

247

Gross weight in grams

Product No.

BRAZING RODS AND FLUXES Introduction

Cast Iron 237 261 263 267 268 270 271 272 Cast Iron Flux 236 F

273

3.05

248

BRAZING RODS AND FLUXES Introduction

alloy

we obtain a surface alloying.

Welding is a chemical bonding which involves structural changes in the base material.

is not melted, but brought to the

surface must be cleaned. and bind to the surface

bonding.

3.05

249

BRAZING RODS AND FLUXES the method is termed Soldering. If the joints.

Brazing Methods Soldering

Parallel surfaces with minimal that used in gas welding.

Typical Capillary/Silver brazing joints. Note that they all utilise capillary action.

3.05

250

BRAZING RODS AND FLUXES have been selected with versatility and ease of use in mind. In the industry

have been selected to ensure the

use with the Unitor alloys, either as

certain advantages with regard to can be reduced without reduction of

lengths, which is a suitable length if unnecessary bending of the rod shall in the coating, excessive bending should be avoided to ensure that the coating remains undamaged. It is

drinking water or food.

rods may therefore safely be used as onboard. Each alloy has been selected This reduces the number of alloys

3.05

251

the contents, and also gives basic

WELDING HANDBOOK NOTES

3.05

252

BRONZE 264 Description: alloys, nickel and nickel alloys. It gives a very smooth

Identification:

Classifications

AWS A5.8

EN 1044

BS 1453/1845

DIIN851133

Werkstoff. No.

Type of joint Classification

Flame setting

Neutral or slight oxygen

Flame setting

Working temperature °C

Melting range °C

Flux Chemical composition approx. (%)

3.05

Mechanical properties

0.6

Tensile strength MPa

Yield strength MPa

Elongation %

Hardness HB

– Packaging data

Diameter mm.

253

Length mm.

0.01

Rest Melting range °C

100 Quantity per package

Net weight per package kg

1.7

Product No. per package

BRONZE 264 welding steel, cast iron, malleable

and Cunifer. Cast iron joint surfaces must be clean and bright (i.e. cleaned off with chemicals. Clean off burr, round off

is easier than ordinary welding and tough, strong joint. cleaning of the joint surfaces, good Remove inside burr.

welding neck, or you may overheat with a slight excess of oxygen (oxidising). to the rod and joint edges. Check the from the rod on the joint surface and move the torch in a circle around the

3.05

technique.

water.

254

FC BRONZE 261 Description:

Identification:

Classifications

NF A 81-362

ISO 3677

Type of joint Classification

Flame setting

Neutral or slight oxygen

Flame setting

Working temperature °C

Solidus-Liquidus °C

Flux Chemical composition approx. (%)

3.05

Mechanical properties

0.3

0.1

Rest

Tensile strength MPa

Hardness HB

Elongation %

30 Packaging data

Diameter mm.

Length mm.

Quantity per package

2 3

255

Net weight per package kg

1 32

Product No. per package

FC BRONZE 261 Description and uses

steel. the base metal, due to the low melting

the edges and clean thoroughly. Paint surfaces.

the rod again.

10mm

3.05

256

FC WEARBRO 262 Description:

cast iron. Identification:

Classifications

ISO 3677

Type of joint Classification

Flame setting

Neutral or slight oxygen

Flame setting

Working temperature °C

Solidus-Liquidus °C

Flux Chemical composition approx. (%)

3.05

Mechanical properties

Packaging data

Tensile strength MPa

Diameter mm.

257

Length mm.

Rest

Elongation %

Hardness HB

Quantity per package

Net weight per package kg

1.1

Product No. per package

FC WEARBRO 262 Description and uses cast iron and malleable iron. The metal and easily machineable. It has a low resistant.

strain, e.g. gear wheels, cams of all

and toughness, it is also suitable for The surface must be cleaned down to bare metal and rough edges rounded area to be surfaced. In the case of

of oxygen (oxidising) and heat the area where work is to commence the rod to the surface and melt off a

3.05 overheating. Powder residue must be surface is easily machined.

258

CAST IRON 237 Description: Rod for joining and surfacing cast iron and gas welding welded with Cast Iron 237.

Identification:

Classifications Type of joint Classification

Flame setting

Slight oxygen

Flame setting

Working temperature °C

Solidus-Liquidus °C

1170 Flux Chemical composition approx. (%)

3.05

3.3

3.0

Mechanical properties

Tensile strength MPa

Rest

Hardness HB

200 Packaging data

Diameter mm.

Length mm.

Quantity per package

Net weight per package kg

1.1

259

0.6

Product No. per package

CAST IRON 237 Description and uses welding cast iron, malleable iron and

work with, has high tensile strength and the structure and colour of cast

method – gas welding or arc welding

As a general rule, gas welding is welding (cold welding) on larger, more gear wheels

and any casting skin removed. Round

is usual to drill a hole at the end of the

3.05

the seam, melt off a new globule and

cool slowly in diatomite or dry sand.

260

AG 45 253 Description:

Identification:

Classifications

ISO 3677

DIN 8513

Type of joint Classification

Flame setting

Neutral.

Flame setting

Working temperature °C

Solidus-Liquidus °C

730 Flux

Chemical composition approx. (%)

Rest

3.05 Mechanical properties

Packaging data

Tensile strength MPa

Diameter mm.

2.0

261

Length mm.

Elongation %

Hardness HB

130

Quantity per package

Net weight per package kg

Product No. per package

AG 45 253 Description and uses

metal.

and good mating of joint faces is essential to obtain the required.

to a lathe tool

The joint faces must be cleaned

is essential to coat the surfaces with

3.05 has melted. Too much heat may give

water and a steel wire brush. surfaces 0.1 mm. Coat joint surfaces

262

AG 60 252 Description:

Identification:

Classifications

ISO 3677

DIN 8513

Type of joint

Flame setting

Neutral.

Flame setting

Working temperature °C

Solidus-Liquidus °C

630–660 Flux

3.05

Chemical composition approx. (%) Mechanical properties

Rest

Tensile strength MPa

Elongation %

Hardness HB

130 Packaging data

Diameter mm.

2.0

263

Length mm.

Quantity per package

Net weight per package kg

Product No. per package

AG 60 252 Description and uses suitable for joints requiring high corrosion resistance and strength.

with the same degree of corrosion

residue should be cleaned off with hot water and a steel wire brush.

of joint on Yorcalbro

of the joint surfaces is essential. surfaces should not exceed 0.1mm. the joint surfaces must also be coated

Brazing a patch on a pitted pipe.

Clean the contact surfaces thoroughly,

3.05

be larger than necessary, otherwise

For Yorcalbro use Albro Flux 263 PF

264

TIN 241 AG Description: Flux cored lead free silver alloyed soft solder wire on electrical connections, electrical instruments,

Identification:

Classifications

DIN EN 61190

Type of joint

Flame setting

Preferably use soldering

Working temperature °C

Melting range °C

230

217

Flux Chemical composition approx. (%)

3.05

Mechanical properties

Packaging data

265

3.8

0.7

Tensile strength MPa

Diameter mm.

Length mm.

Quantity per package

–

Net weight per package kg

Product No. per package

TIN 241 AG Description and uses

of materials having an oxide surface

The surfaces must be clean and free or a soldering iron. A soldering iron is recommended, but if a welding torch

so that it travels through the metal

Heat indirectly when using a welding torch.

3.05

266

BRAZING RODS AND FLUXES Fluxes for Brazing • It must dissolve oxides new oxide skin • It must reduce the surface tension • It must act as a heat indicator • It must remain active for a time at burning.

with distilled water or methylated

contamination.

ventilation is necessary wherever

3.05

indicator and shows when the correct reached.

removed by rinsing in clean water and brushing. Fluxes for welding are dealt with in

267

BRONZE FLUX 261 PF Description:

Identification:

Application

Toxicity HARMFUL

R60 R61

In case of accident or if you feel unwell, seek medical advice Packaging data

Gross weight in grams

Product No.

3.05

268

WEARBRO FLUX 262 PF Description:

Identification:

Application

Toxicity HARMFUL

R60 R61

In case of accident or if you feel unwell, seek medical advice Packaging data

3.05

269

Gross weight in grams

Product No.

AG 60/45 FLUX 252 PF Description:

Identification:

Application

Toxicity

R60 R61 Also toxic if swallowed Causes burns S26 and seek medical advice

In case of accident or if you feel unwell, seek medical advice

Packaging data

Gross weight in grams

Product No.

3.05

270

AG 45/60 BRAZING FLUX BAF Description:

Identification:

Application

Toxicity

R61 S26 advice

In case of accident or if you feel unwell, seek medical advice immediately (show the label

Packaging data

3.05

271

Gross weight in grams

Product No.

ALBRO FLUX 263 PF Description:

Identification:

Application

Contents Toxicity

through inhalation and if swallowed the aquatic environment S2 S23 S26 and seek medical advice

S36 If swallowed, seek medical advice immediately and show this container or label Packaging data

Gross weight in grams

Product No.

3.05

272

CAST IRON FLUX 236 F Description:

Identification:

Application

HARMFUL

R60 R61 Also toxic if swallowed Causes burns

In case of accident or if you feel unwell, seek medical advice

Packaging data

3.05

273

Gross weight in grams

Product No.

COLD REPAIR COMPOUNDS Introduction 277 278 280 Product overview

281 283 287

Aquagrade Rebuild Ceramigrade Rebuild

302

Rubbergrade 6 Rebuild

308

Rubbergrade 6 Remould

311

3.06

274

COLD REPAIR COMPOUNDS Introduction excellent chemical resistance and

technology which is the result of many

in many environments including seawater, hydrocarbons, oils and a very wide range of chemical solutions.

materials for use on rubber as well as and extend the various welding and

Typical application areas: Where there is a need for emergency repairs.

acetylene or electricity. The energy and is released when mixing the base and activator. The curing time is down to a few minutes for several of the

3.06

Where hot work like welding is not permitted due to fire / explosion hazard.

Where the base material is not weldable. Certain casted metal alloys are not weldable due to their chemistry.

275

COLD REPAIR COMPOUNDS knowledge is not available. If the base material is so corroded that there is

Where distortion of base material is unacceptable.

Where there is restricted space. injected through small diameter holes.

Where specific properties are required.

resistance and wear resistant surfaces that are worn are also overlays.

Where you need non-metal repairs.

3.06

276

COLD REPAIR COMPOUNDS How do Cold Repairs work? chemical reactions between resin

The adhesion to the base material

or outside energy. Since it is mostly a mechanical material is thus of no concern.

from the chemical reaction between a large number of much smaller molecules. Provided that these small molecules

chain building fashion to yield long

In the uncombined state ,the reactive on account of their relatively small

3.06

the chemical reaction or “cure” chain increases until ultimately the material becomes a solid.

277

COLD REPAIR COMPOUNDS How to prepare the surface Heavy contamination due to oil or grease must be removed using a cleaner. Remove all loose rust and surface coatings.

or angle grinder may also be used. If grinding, make sure the surface is

abrading tool.

medium should be angular grit. Parts which have been salt or chemically by hot air overnight to sweat out the contamination. Remove contamination surface. Parts which should not with a release agent.

Roughening increases the surface area and gives a better ”key”.

Abrading tool for rubber.

Use release agent on the threads of a bolt.

structure that contaminants

3.06

278

COLD REPAIR COMPOUNDS How to apply the product Application should be carried out as soon as possible after surface preparation is completed, otherwise oxidation can take place. Do not apply product when relative humidity exceeds 85% nor when surface is less than 3 °C above the dew point. NB: The work site temperature must be above 5°C (40°F) in order for the polymer chemical reaction to take place. quantities accurately in line with the instructions on the data sheet. If a streak free. Paste materials should

the heat and slow down the curing reaction. This will also remove any grade materials can be mixed together in the base container.

surface, working it down in cracks and like oil and water. After securing the surface, add more

3.06

height. In order to add further strength required thickness and cover it with

Press on a thin layer

279

POLYMER COLD REPAIR KIT-A Unitor Cold Repair System for High Performance Repairs Product no. 106-659300

weldable materials.

resin technology which is the result of

materials for use on rubber as well as

The complete basic package is available in a handy kit. Each

resistance and are suitable for environments including sea water, hydrocarbons, oils and a very wide range of chemical solutions.

The kits consists of:

3.06

and extend the various welding and 1 set Aquagrade Rebuild 1 set Ceramigrade Rebuild available. 1 set Rubbergrade 6 Rebuild 1 set Rubbergrade 6 Remould

280

PRODUCT OVERVIEW Repair Set

Name

Description

Set weight kg

Product no.

Leak Stop Pipe repair Sets

which is activated by immersion in water. Ideal for

Leak Stop I Set

0.16 kg

100-630384

Leak Stop II Set

0.23 kg

100-606006

Leak Stop III Set

0.33 kg

100-630392

0.86 kg

101-659227

Metalgrade Ready Stick Set

Metalgrade Express Set containers. Used wherever there is an emergency and 101-659235 Metalgrade Rebuild Set 1.10 kg

3.06

101-659243

Metalgrade Hi Temp Set voids in cast iron, steel and stainless steel

101-663427

Aquagrade Rebuild Set water. Preferably mix above water. 104-659250

281

PRODUCT OVERVIEW

Name

Description

Ceramigrade Rebuild Set

excellent resistance to cavitation and erosion found

Set weight kg

Product no.

1.00 kg

102-659268

Ceramigrade Liner Set 102-659276 Rubbergrade 6 Rebuild Set hoses, gaskets, electric cables etc.

103-659284

Rubbergrade 6 Remould Set metallic surfaces.

103-659292

3.06

282

LEAK STOP

Product specification sheet – Leak Stop Product Description

Product name/ Product No./Kit weight

Kit consists of:

Application

Identification Application data

Mixing ratio

Pot life (mins) (working life)

2–3 minutes with water before use Recommended Temperature Limits For Application 5 °C to 30 °C/40 °F–100 °F Curing time

Curing times in minutes at ambient temperature

20 °C (68 °F)

Initial setting Full mechanical strength

Technical data Values are determined after 48 hours at 20 °C (68 °F)

3.06

Phys / Mec properties

Service temperatures

Chemical resistance Health and Safety

283

Tensile Strength

Flexural Strength

Dry heat

Minimum temp.

LEAK STOP Instructions for use Leak Stop Repair Tape which is activated by immersion in

1. Surface preparation Rough score surface

oil, grease, loose rust scale, sealant

Leak Stop works best on a rough by rust, remove the loose scale. If the stainless, you must roughen the area release must be removed. Abrade surfaces with a coarse grit be used to create a cross hatch

3.06

2. Mixing Position over leak site the hands.

Leak Stop Repair Tape, submerge the roll

284

LEAK STOP 3. Application

observe resin foam coming through

second roll if necessary.

Wet gloves, smooth out longer tacky.

4. Cleaning

substance showing throught the resins.

5. Health and safety

used.

3.06

A fully detailed Material Safety Data Sheet is included with the set. instruction for use sheet is intended as a general guide only. Users should their own tests.

285

LEAK STOP

Leak Stop I 100-630384 Nominal Pipe Size

Number of Leak Stop I rolls

Leak Stop II 100-606006 Leak Stop III 100-630392 Nominal Pipe Size

Number of Leak Stop III rolls

1 1

3.06

8” (200 mm) 12” (300 mm)

286

METALGRADE READY-STICK Product specification sheet – Metalgrade Ready-Stick Product Description

PRODUCT NAME

PRODUCT NO

KIT CONSISTS OF

Product No 101-659227 3 x 120 g Putty Activator

one carton box set Identification

Activator Component

Pot life (mins) (working life)

Colour

Putty Application data

Putty

Mixing Ratio Volume Activator 1

Curing time

Mixing Ratio Weight Activator

Curing Times in minutes

Full Chemical Resistance Technical data

Pot Life (mins) (Working Life)

Density g/cm3

180

120

8 days

7 days

6 days

8 days

7 days

Volume Solids

3 days

2 days

1 day 3 days

Volume Capacity

Slump Resistance

Activator 100 Phys/Mec Properties

Excellent

Tensile Shear Adhesion Abrasion Resistance

3.06

Corrosion Resistance 80 2

Service temperatures

Dry heat

Wet heat

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

287

Minimum temp

METALGRADE READY-STICK Instructions for use MetalGrade Ready-Stick is a two

2. Mixing

be mixed. This should be broken off or

1. Surface preparation Heavy contamination due to oil or grease must be removed using a sleeve immediately after use. The thoroughly mixed by hand kneading A) Remove all contamination (oil, grease and dirt) with a cleaner.

uniform black colour.

coatings. with abrasive blasting. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface is roughened, not gunning is used, the surface should be

with a cleaner. Cloths should be

Activator sticks

3.06 cleaner should be worked into the surface by brush and washed off using excess cleaner. bearing surfaces) which must but which should not adhere to coated with a release agent.

Thoroughly mix by hand kneading until streak free

288

METALGRADE READY-STICK 3. Application

the material into any cracks or surface defects. When MetalGrade Ready-Stick is

and the MetalGrade Ready-Stick is

4. Machining Once the MetalGrade Ready-Stick has cured for the minimum time indicated grinding and machining etc. can be carried out using standard engineering

5. Cleaning

a cleaner. Failure to follow this

6. Health and safety

3.06

can be safely used. A fully detailed in this Instruction for use sheet is intended as a general guide only. Users should determined the suitability

289

METALGRADE EXPRESS Product specification sheet – Metalgrade Express Product Description

PRODUCT NAME

PRODUCT NO

KIT CONSISTS OF

Product No 101-659235

1 Roll reinforcement bandage

in one Identification

Activator Component

Base Component

Colour

Paste Application data

Paste

Mixing Ratio Volume Activator 1

Curing time

Mixing Ratio Weight

Pot Life (mins) (Working Life)

Activator 1

Curing Times in minutes 8

2 days

1 day

20 300 Full Chemical Resistance Technical data

120

7 days

Density g/cm3

3 days Volume Solids

Volume Capacity

1 day

Slump Resistance

Activator 1.6 Phys/Mec Properties

1.8

1.7

100

Excellent

Tensile Shear Adhesion Flexural Strength Corrosion Resistance 78 Hardness (Rockwell R)

3.06

100

Surface Resistivity Service temperatures

Dry heat

Wet heat

Minimum temp

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

290

METALGRADE EXPRESS Instructions for use MetalGrade Express is a two

2. Mixing

be mixed.

1. Surface preparation Heavy contamination due to oil or grease must be removed using a

3. Application A) Remove all contamination (oil, grease and dirt) with a cleaner. coatings. with abrasive blasting. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface is roughened, not gunning is used, the surface should be

with a cleaner. Cloths should be

3.06 should be worked into the surface by brush and washed off using excess cleaner. bearing surfaces) which must but which should not adhere to MetalGrade Express must be coated with a release agent.

291

Worn bearing housing

METALGRADE EXPRESS material into any cracks and surface defect.

6. Health and safety observed MetalGrade Express can be

MetalGrade Express, or the bandage should be laid over the surface of the MetalGrade Express the surface. Additional MetalGrade Express the surface.

in this Instruction for use sheet is intended as a general guide only. Users should determined the suitability

Once the MetalGrade Express has reached initial set the material can be release agent. When MetalGrade Express is being flow and the MetalGrade Express is set.

4. Machining Once the MetalGrade Express has cured for the minimum time indicated grinding and machining etc. can be carried out using standard engineering

5. Cleaning

3.06

IMMEDIATELY after each use with a Cleaner. Failure to follow this

292

METALGRADE REBUILD Product specification sheet – Metalgrade Rebuild Product Description

PRODUCT NAME

PRODUCT NO

KIT CONSISTS OF

Product No 101-659243

1 Roll reinforcement bandage

in one Identification

Activator Component

Base Component

Colour

Paste Application data

Paste

Mixing Ratio Volume Activator 1

Curing time

Mixing Ratio Weight

Pot Life (mins) (Working Life)

Activator 2

Curing Times in minutes 30

Full Chemical Resistance Technical data

Density g/cm3

100

8 days

6 days

60 3 days

10 days

3 days

7 days

Volume Solids

Volume Capacity

3 days 2 days Slump Resistance

Activator 1.7 Phys/Mec Properties

100

Excellent

Tensile Shear Adhesion Flexural Strength

3.06

Corrosion Resistance 80 Hardness (Rockwell R)

100 Excellent

Service temperatures

Dry heat

Wet heat

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

293

Minimum temp

METALGRADE REBUILD Instructions for use MetalGrade Rebuild is a dual

but which should not adhere to MetalGrade Rebuild must be coated with a release agent.

2. Mixing keyways, scored hydraulic rams etc.

1. Surface preparation

immediately after use. The two

Heavy contamination due to oil or grease must be removed using a

A) Remove all contamination (oil, grease and dirt) with a cleaner. coatings. with abrasive blasting. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface is roughened, not gunning is used, the surface should be

with a cleaner. Cloths should be

Hole in metal casing

3.06

should be worked into the surface by brush and washed off using excess cleaner. bearing surfaces) which must remain

294

METALGRADE REBUILD 3. Application 6. Health and safety material into any cracks and surface defect.

MetalGrade Rebuild, or the bandage should be laid over the surface of the MetalGrade Rebuild the surface. Additional MetalGrade Rebuild the surface.

observed MetalGrade Rebuild can be

in this Instruction for use sheet is intended as a general guide only. Users should determined the suitability

Once the MetalGrade Rebuild has reached initial set the material can be release agent. When MetalGrade Rebuild is being flow and the MetalGrade Rebuild is set.

4. Machining Once the MetalGrade Rebuild has cured for the minimum time indicated

3.06

grinding and machining etc. can be carried out using standard engineering

5. Cleaning IMMEDIATELY after each use with a cleaner. Failure to follow this

295

Flange rebuilt

METALGRADE HI-TEMP Product specification sheet – Hi-Temp Product Description

PRODUCT NAME

PRODUCT NO

KIT CONSISTS OF

Product No 101-663427

APPLICATION For use on high

working data sheet

Identification Application data

Mixing ratio

Pot life (mins) (working life)

Best applied when the ambient temperature is: 7 °C to 35 °C/45 °F–95 °F Curing time

Option 1)

Option 2)

Technical data

Phys / Mec properties

Shear Strength

3.06 Service temperatures

Chemical resistance Health and Safety

296

METALGRADE HI-TEMP Instructions for use Metal Grade Hi-Temp bearing surfaces) which must remain formulated using the most advanced inorganic resin technology and is

which should not adhere to Hi-Temp must be coated with a release agent.

Hi-Temp is used to seal joints, defects, cracks and voids in cast iron, steel and stainless steel. Hi-Temp should not be used on aluminium or aluminium alloys.

2. Mixing Hi-Temp make sure content is mixed thoroughly

1. Surface preparation

a clean working surface.

Heavy contamination due to oil or grease should be removed using a cleaner. Abrasive blasting is the

3. Application

A) Remove all contamination (oil, grease and dirt) with a cleaner.

working the material into any cracks and surface defects. Hi-Temp can be

coatings. with abrasive blasting. Alternatively, a die grinder, needle scaler or angle grinder may be used. If grinding, make sure the surface is roughened, not gunning is used, the surface should be

3.06 with a cleaner. Cloths should be

cleaner should be worked into the surface with a brush and washed off using excess cleaner. If embedded they should be burned out at high

297

incinerators, manifolds, stacks, heat exchangers and turbines.

METALGRADE HI-TEMP When used on heavy sections and

Hi-Temp an aqueous solution. The water must

and bubble. It is also recommended

Hi-Temp second coating of Hi-Temp to cover the screen.

second layer

4. Machining

6. Health and safety

When the material is fully cured for a

Hi-Temp can be safely used as long as

sanding, grinding and machining etc. can be carried out using standard Hi-Temp exhibit high thermal conductivity as well as excellent resistance to abrasives, fuels, oils and solvents.

Instructions for Use sheet is intended as a general guide only. Users should

5. Cleaning In uncured state Hi-Temp is cleaned

3.06

their own tests.

298

AQUAGRADE REBUILD Product specification sheet – Aquagrade Rebuild Product Description

PRODUCT NAME

PRODUCT NO

Aquagrade Rebuild

KIT CONSISTS OF

Product No 104-659250

in one Identification

Activator Component

Base Component

Colour

Paste Application data

Paste

Mixing Ratio Volume Activator 1

Curing time

Mixing Ratio Weight

Pot Life (mins) (Working Life)

Activator 1

Curing Times in minutes 360

120 360

300

180

7 days

6 days

Full Chemical Resistance 16 days 12 days 10 days 8 days

8 days

7 days

7 days 6 days

Density g/cm3

Volume Solids

Volume Capacity

120

Slump Resistance

Activator 1.7 Phys/Mec Properties

1.6

100

Tensile Shear Adhesion Abrasion Resistance Corrosion Resistance

3.06

Service temperatures

Dry heat

Wet heat

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

299

180

10 days 8 days Technical data

White

Minimum temp

AQUAGRADE REBUILD Instructions for use AquaGrade Rebuild is a two wet surface and underwater repair streak free and a uniform colour is tanks etc.

3. Application

AquaGrade Rebuild is designed to be or underwater in both fresh and salt water.

material into any cracks and surface

1. Surface preparation Heavy contamination due to oil or grease must be removed using a

A) Remove all contamination (oil, grease and dirt) with a cleaner. coatings. with abrasive blasting to SA2. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface grinding or needle gunning is used, the surface should be cross scored to

3.06

2. Mixing and Activator containers from the indicated.

300

AQUAGRADE REBUILD in the same manner as above water.

4. Machining Once the AquaGrade Rebuild has cured for the minimum time indicated and grinding can be carried out using

5. Cleaning IMMEDIATELY after each use with a cleaner. Failure to follow this

6. Health and safety observed AquaGrade Rebuild can be

this Instruction sheet is intended as a general guide only. Users should determined the suitability of the

3.06

301

CERAMIGRADE REBUILD Product specification sheet – Ceramigrade Rebuild Product Description

PRODUCT NAME

PRODUCT NO

Ceramigrade Rebuild

KIT CONSISTS OF

Product No 102-659268

in one Identification

Activator Component

Base Component

Colour Paste Application data

Curing time

Colour

Off White

Mixing Ratio Volume

Paste

Mixing Ratio Weight

Activator

Pot Life (mins) (Working Life) 18

Curing Times in minutes 80

Full Chemical Resistance Technical data

180

120

6 days

3 days

8 days

7 days

Density g/cm3 1.8

7 days

Volume Solids

60 2 days 2 days

6 days Volume Capacity

Activator

Phys/Mec Properties

3 days Slump Resistance 10 mm thickness

1.8

100

Tensile Shear Adhesion Abrasion Resistance

3.06

Corrosion Resistance 80 2

Service temperatures

Dry heat

Wet heat

Minimum temp

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

302

CERAMIGRADE REBUILD Instructions for use CeramiGrade Rebuild is a two

E) To ensure that all contamination is with a cleaner. Cloths should be

valves etc.

1. Surface preparation Heavy contamination due to oil or grease must be removed using a

should be worked into the surface by brush and washed off using excess cleaner. bearing surfaces) which must but which should not adhere to CeramiGrade Rebuild must be coated with a release agent.

CeramiGrade Rebuild, or the bandage should be laid over the surface of the CeramiGrade Rebuild the surface. Additional CeramiGrade Rebuild the surface. A) Remove all contamination (oil, grease and dirt) with a cleaner.

Cavitation in housing coatings.

3.06

with abrasive blasting to SA2. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface grinding or needle gunning is used, the surface should be cross scored to

Rebuilding end covers sweat out the salt contamination, then eliminated.

303

CERAMIGRADE REBUILD 2. Mixing

5. Cleaning

and Activator containers from the

IMMEDIATELY after each use with a cleaner. Failure to follow this

immediately after use. The two a uniform colour is achieved, using the

6. Health and safety are observed CeramiGrade Rebuild can be safely used. A fully detailed

3. Application in this Instruction sheet is intended as a general guide only. Users should determined the suitability of material into any cracks and surface defect. Once the CeramiGrade Rebuild has reached initial set the material can with release agent. When CeramiGrade Rebuild is

and the CeramiGrade Rebuild is

coat is required, this should be done

4. Machining Once the CeramiGrade Rebuild has cured for the minimum time indicated

3.06

grinding and machining etc. can be carried out using standard engineering

304

CERAMIGRADE LINER Product specification sheet – Ceramigrade Liner Product Description

PRODUCT NAME

PRODUCT NO

KIT CONSISTS OF

Product No 102-659276

in one Identification

Activator Component

Base Component

Colour

Application data

Curing time

Mixing Ratio Volume

Colour

Mixing Ratio Weight

Activator

Pot Life (mins) (Working Life) 30

360

210 300

180

7 days

8 days

210

Full Chemical Resistance 20 days Technical data

Density g/cm3

180 3 days 2 days

Volume Solids

Volume Capacity

Slump Resistance 2 mm thickness

1.67

100

Tensile Shear Adhesion Abrasion Resistance Corrosion Resistance 80 2

Service temperatures

Dry heat

Wet heat

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

305

120

10 days 7 days 3 days

Activator 1.0

130

270

10 days

3.06

Curing Times in minutes 300

Phys/Mec Properties

Minimum temp

CERAMIGRADE LINER Instructions for use CeramiGrade Liner is a two bearing surfaces) which must

valves etc.

but which should not adhere to CeramiGrade Liner must be coated with a release agent.

1. Surface preparation

2. Mixing

Heavy contamination due to oil or grease must be removed using a

and Activator containers from the

A) Remove all contamination (oil, grease and dirt) with a Cleaner. coatings. with abrasive blasting to SA2. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface grinding or needle gunning is used, the surface should be cross scored to

sweat out the salt contamination,

3.06

is eliminated. E) To ensure that all contamination is with a cleaner. Cloths should be

should be worked into the surface by brush and washed off using excess cleaner.

306

CERAMIGRADE REBUILD immediately after use. The two a uniform colour is achieved, using it sets.

3. Application

6. Health and safety observed CeramiGrade Liner can be

this Instruction sheet is intended as a general guide only. Users should determined the suitability of the

material into any cracks and surface defect. Once the CeramiGrade Liner has reached initial set the material can with release agent. When CeramiGrade Liner is used to flow through CeramiGrade Liner is set. Any leaking When a second coat is required, this

4. Machining Once the CeramiGrade Liner has cured for the minimum time indicated

3.06

grinding and machining etc. can be carried out using standard engineering

5. Cleaning IMMEDIATELY after each use with a cleaner. Failure to follow this

307

valve surface

RUBBERGRADE 6 REBUILD Product specification sheet – Rubbergrade 6 Rebuild Product Description

PRODUCT NAME

PRODUCT NO

Rubbergrade 6 Rebuild

KIT CONSISTS OF

Product No 103-659284 Rubbergrade 6 Rebuild 1 Pair of gloves

in one Identification

Activator Component

Base Component

Colour

Colour Paste

Application data

Mixing Ratio Volume Activator

Mixing Ratio Weight

Pot Life (mins) (Working Life)

Activator 10

Curing time

Curing Times in minutes 60

20 180 10 days 8 days

Full Chemical Resistance 18 days Technical data

Density g/cm3

180 7 days

120 7 days

7 days

12 days 12 days 8 days Volume Solids

Volume Capacity

6 days 7 days 7 days

Slump Resistance

Activator 1.2 Phys/Mec Properties

100

Excellent

Tensile Strength Tensile Shear Adhesion Elongation

3.06

Hardness (Shore A) Surface Resistivity

Service temperatures

Dry heat

Wet heat

Minimum temp

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

308

RUBBERGRADE 6 REBUILD Instructions for use RubberGrade 6 Rebuild is a two

3. Application 1. Surface preparation Heavy contamination due to oil or grease must be removed using a cleaner. Any areas of frayed or fragmented rubber should be cut away Rubber surfaces are best roughened All surfaces MUST be dry.

a cleaner. and castings where one surface is 6 Rebuild, these surfaces should be treated with a release agent.

2. Mixing aluminium outer foil by cutting along the lines indicated. Take care not to

3.06 now ready to be mixed.

being mixed. Ensure there is no unmixed material there is, ease them out of the corners

309

material into any cracks and surface

RUBBERGRADE 6 REBUILD 4. Machining cured for the minimum time indicated and grinding can be carried out using

5. Cleaning

a cleaner. Failure to follow this

6. Health and safety

can be safely used. A fully detailed in this Instruction sheet is intended as a general guide only. Users should determined the suitability of

3.06

310

RUBBERGRADE 6 REMOULD Product specification sheet – Rubbergrade 6 Remould Product Description

PRODUCT NAME

PRODUCT NO

Rubbergrade 6 Remould

Product No 103-659292 Rubbergrade 6 Remould

KIT CONSISTS OF

1 Pair of gloves in one Identification

Activator Component

Base Component

Colour

Application data

Mixing Ratio Volume Activator

Colour

Mixing Ratio Weight

Pot Life (mins) (Working Life)

Activator 10

Curing time

Curing Times in minutes 60

20 180 10 days 8 days

Full Chemical Resistance 18 days Technical data

Density g/cm3

180 7 days

120 7 days

7 days

12 days 12 days 8 days Volume Solids

Volume Capacity

6 days 7 days 7 days

Slump Resistance

Activator 1.2 Phys/Mec Properties

100

Tensile Strength Tear Strength Elongation

3.06

Hardness (Shore A) Surface Resistivity

Service temperatures

Dry heat

Wet heat

Chemical resistance Manufactured under a quality program certified to ISO 9002 Health and Safety

311

Minimum temp

RUBBERGRADE 6 REMOULD Instructions for use RubberGrade 6 ReMould is a two

Ensure there is no unmixed material there is, ease them out of the corners

1. Surface preparation

RubberGrade 6 ReMould onto the

Heavy contamination due to oil or grease must be removed using a cleaner. Any areas of frayed or fragmented rubber should be cut away Rubber surfaces are best roughened All surfaces MUST be dry.

a cleaner. and castings where one surface is not required to bond to RubberGrade 6 ReMould, these surfaces should be treated with release agent.

2. Mixing

Castings of shock absorbers

aluminium outer foil by cutting along the lines indicated. Take care not to

3.06 now ready to be mixed.

being mixed.

312

RUBBERGRADE 6 REMOULD 3. Application

material into any cracks and surface

4. Machining Once the RubberGrade 6 ReMould has cured for the minimum time indicated

Hatch cover seals and grinding can be carried out using

5. Cleaning IMMEDIATELY after each use with a cleaner. Failure to follow this

6. Health and safety observed RubberGrade 6 ReMould can be safely used. A fully detailed in this Instruction sheet is intended as a general guide only. Users should determined the suitability of

3.06

313

WELDING HANDBOOK NOTES

3.06

314

ARC PROCESSES & EQUIPMENT Electrode welding & gouging

317 366

Wire welding Plasma cutting & gouging

4.01

315

386

ELECTRODE WELDING AND GOUGING Introduction

317 320

Power source characteristics

321 323 328 331 333

Primary extension cables Secondary cables Safe & Secure Welding Cable Connection Assembly Accessories Welding techniques Electrodes for welding & gouging Air Carbon arc gouging

362

4.01

316

ELECTRODE WELDING AND GOUGING Introduction

Initially manual metal arc welding was done with bare metal electrodes without

electrode holder.

4.01

317

ELECTRODE WELDING AND GOUGING To establish an arc for welding and cutting, an electric circuit is required,

required to ensure good welding conditions and avoid accidents by unintended

used for cutting.

Practical setup Welding machine

Return cable Welding cable Electrode holder Electrode Arc

4.01 Welding current

318

ELECTRODE WELDING AND GOUGING AC as welding current

sources are transformers that reduce current), still delivering AC to the welding arc. As the AC actually is for AC will be usable with welding transformers.

welding. To avoid the dangers the electric shock, several countries have issued regulations on how smooth

devices. These requirements should be observed when installing welding

Where burns are the main danger

Authorities in several countries have

welding of aluminium, as the back

welding the Wire Welding Process welding which offers several

4.01 DC as welding current commonly used current for welding

319

AC current cycling from one direction

ELECTRODE WELDING AND GOUGING Basic principles Manual Metal Arc welding and AC.

are restrictions on alternating current and can harm vital organs if the body

thereby bombard the base material

Coating

the heat accumulating in the base material. Connecting the electrode

Core rod Shielding smoke

Travel is to take alternating current from the mains and bring the high voltage down to a suitable working voltage.

4.01

– electrons –

electrons

electrons –

AC Alternating current

320

ELECTRODE WELDING AND GOUGING Power source characteristics characteristic with very little current variation is best. For Air Carbon Arc voltage, it shall also automatically adjust these values as conditions in the welding arc changes. A quick

with more current variation and high Welding with coated electrodes needs characteristics between these two.

When welding with electrodes with circuits will constantly occur in the arc. As the short circuit starts, a machine adjusts to the short circuit condition. When the short circuit is Excessive height or duration of these

have adjustable characteristics to enable the welder to choose exactly the characteristic suited for the job at

Constant voltage characteristic (CV) This characteristic is used only for the used. a constant arc voltage by increasing

faults. characteristic curve will therefore be in the dynamic characteristic of the machine.

characteristic of the machine. The two are constant current (CC) and constant

Constant current characteristic (CC)

4.01 constant, with variations within a narrow range when the arc length, and thereby the arc voltage, increases variation range is different for different

321

This characteristic is required for gas metal arc welding in the short arc range, and will also offer advantages

ELECTRODE WELDING AND GOUGING Constant Current characteristic (ACA)

current (within limits) when the arc length shortens.

Constant Voltage characteristic (CV) For Wire Welding the ideal characteristic is constant voltage. It will reduce the current if arc gets too long, and allowing the welding wire to be fed closer to the gets too short the current will increase, and normal arc length will automatically be established again.

4.01

322

ELECTRODE WELDING AND GOUGING Selecting power source when choosing a welding machine for

voltage that exists for welding machines used on board.

3. As welding is only one of many skills

necessary to achieve good results.

handle all the necessary welding jobs that are needed on board. arc welding) from the Unitor range, the

4.01

323

ELECTRODE WELDING AND GOUGING Selection guide, power sources: Unitor welding machine range

UWI 150TP

UWI 203TP

UWI 320TP

12.2

UWI 500TP

UWW 301TP

UWI 230TP AC/DC

dimensions of coated electrodes

Tungsten electrodes Wire welding. Weight kg.

Properties: Choice of welding characteristic to suit all

adjustment during welding Remote control of welding current by cable during welding

Connection to mains:

4.01

the section dealing with welding cables.

324

ELECTRODE WELDING AND GOUGING UWI-150 TP Stick / TIG Dual Process Welding Inverter

3,2mm, including Aluminum electrodes. torch ensures full control during welding and

reduces weight and risk of corrosion.

Technical Data Description

Unit

Property

A A

4.01

Power factor

Recommended fuses (Slow)

Weight

kg mm mm mm

Width Height

325

30 6,2 0,72 1 230 16 S,CE 23 S 310 120

ELECTRODE WELDING AND GOUGING Ordering Information: 2

• Instruction manual Units

Product no. 191-150150

UWI-150 TP Application set-up for Stick Electrode welding UWI-150 TP as a manual electrode welding unit 3m Welding cable with quick connectors and electrode holder and 3m return cable with quick connector and return

Optional Equipment Units Face shield with handle

Wire brush, steel, 2 rows, Wire brush, stainless steel, 2 rows,

Product no. 196 619098 196 709485 196 633248 196 633255 196 633263 196 632786 196 632976 196 632984 196 633008 196 632992 196 516161

4.01

191-150161

326

ELECTRODE WELDING AND GOUGING Application set-up for TIG welding

TIG welding Accessories for UWI-150 TP Units

Product no. 197 632794

Remote control

Flowcontrol needle valve for gas

4.01

327

197 150000 197 607810 191 150151 197 510010 197 619379 197 597328 197 597310

ELECTRODE WELDING AND GOUGING UWI-230 TP AC/DC Stick / TIG Dual Process Welding Inverter • welding fast and easy access to all locations onboard • • • the welder against electric shock • • of alternating current • ability to weld thick material • • • • • • • • •

Technical Data Description

Unit

Property

A A 10 6,2 Power factor

4.01

1 Recommended fuses (slow) Protection class

Height

mm mm mm kg

Width Weight

230 16 IP 23S CE 230

328

ELECTRODE WELDING AND GOUGING Ordering Information:

Units

Product no. 191-230231

• Instruction manual

UWI-230 TP AC/DC Application set-up for Stick Electrode welding Units

Product no.

set

191-670406 195-594317 196-594325 191-670414

Welding gloves 196-709485 Wire brush steel, two rows. 191-764550 191-230233 191-230234

Application set-up for TIG welding Units

Product no. 197 632794

4.01

197 200000 197 607810 197 510010 197 597328 197 597310 cylinders

329

196 778149

WELDING HANDBOOK NOTES

4.01

330

ELECTRODE WELDING AND GOUGING UWI-203 TP Stick / TIG Dual Process Welding Inverter • • • • Automatic Hot Start for stick arc starts makes arc striking easy •

like CH2 and electrodes for ACA gouging. • • • • • • •

Technical Data Description

Unit

Property

A 13 6.7 Power factor 3

4.01

Recommended fuses (slow) Protection class

Height

mm mm mm kg

Width Weight

10 IP 23S CE 230 12.2

Ordering Information:

Product no. 191-203203 2

• 3 m welding cable with quick connector and electrode holder • Instruction manual

331

ELECTRODE WELDING AND GOUGING UWI-203 TP Application set-up for Stick Electrode welding UWI-203 TP as a manual electrode welding unit 3m Welding cable with quick connectors and electrode holder and 3m return cable with quick

Optional Equipment UWI-203 TP

Units

Product no. 196 619098

11 glass

196 709485 196 633248 196 633255 196 633263 196 632786 196 632976 196 632984 196 633008 196 632992 196 516161

Wire brush, steel, 2 rows, Wire brush, stainless steel, 2 rows,

191 764550 191-203205

Application set-up for TIG welding TIG welding Accessories for UWI-203 TP Units

Product no. 197 632794 197 200000 197 607810

4.01

197 510010 197 597328 adjustment

197 597310 196 778149

332

ELECTRODE WELDING AND GOUGING UWI-320 TP Stick / TIG Dual Process Welding Inverter • • • • Automatic Hot Start for stick arc starts makes arc striking easy and •

like CH2 and electrodes for ACA gouging. • • • • • • •

Technical Data Description

Unit

Property

A 30 0.77 3

Power factor

4.01

Recommended fuses (slow) Protection class

Height

mm mm mm kg

Width Weight

Ordering Information:

10 IP 23S CE 230 18

Unit

Product no. 191-320320

• Instruction manual.

333

ELECTRODE WELDING AND GOUGING UWI-320 TP Application set-up for Stick Electrode welding Basic accessories kit for UWI-320 TP

Consisting of:

Units

Product no.

set

191-670406 195-594317

196-594325 191-670414

Welding gloves 196-709485 Wire brush steel, two rows 191-764550 191-320323

Application set-up for TIG welding TIG welding Accessories for UWI-320 TP Units

Product no. 197 632794 197 200000 197 607810 197 510010 197 597328

adjustment

4.01

197 597310 196 778149

334

ELECTRODE WELDING AND GOUGING UWI-500 TP Multi process welding inverter •

• •

•

• • • •

• • •

Technical Data Description

Unit A

Property

Ordering Information: 2

Instruction manual. Power factor 3

4.01 Recommended fuses (slow) Protection class

Height

mm mm mm kg

Width Weight

335

32 IP 23S CE 670

Unit Product no. 191-500500

ELECTRODE WELDING AND GOUGING UWI-500 TP Application set-up for Stick Electrode welding

welding cables. Stick Electrode accessories

Consisting of: 2 2

Welding gloves

Wire brush steel, two rows Miscellaneous

Units

Product no.

set

191-670406 195-594317 196-594325 191-670414 196 632786 196-709485 196 633008 196 632976

4.01

191-670422 196-500103 191-500505

336

ELECTRODE WELDING AND GOUGING UWI-500 TP Application set-up for TIG welding

TIG welding accessories (Based on having Stick electrode accessories)

Units

4.01 mtr

337

Product no. 197-200000 191-670414 197-607810 197-510010 197-597328 197-597310 176-576157 176-175596 401-768416 197-632794 176-778147

ELECTRODE WELDING AND GOUGING UWI-500 TP Application set-up for Wire welding

and return cable. Wire welding accessories (Based on having Stick electrode accessories)

Units

CO2 mtr

Product no. 193-500102 193-607451 193-750179 197-510010 197-510012 197-597328 197-597310 176-576157 176-175596 401-768416 197-632794 197-778147

4.01

Argon or Argon CO2

338

ELECTRODE WELDING AND GOUGING Application set-up for Air Carbon Arc Gouging or Stick Electrode welding using 2 x UWI-320 TP or 2 x UWI-500 TP in parallel Electrode/return clamp assembly

Pos.

Units

Product no. 195-632893 195-632901

195-634121

Conversion assembly

195-633180 3

Welding cable 70 mm2, with safety connector with safety connector and air

339

195-183665 196-528703

4.01

196-522680

Electrode holder assembly

ELECTRODE WELDING AND GOUGING Remote control assembly Important:

machines must be switched on. If only one machine is switched on damage the other machine.

Pos.

Product no.

1 connection cable 2

191-676973 191-670414

4.01 191-670422 radius. The extension cable can be connected into longer lengths if necessary.

340

WELDING HANDBOOK NOTES

4.01

341

ELECTRODE WELDING AND GOUGING Primary extension cables voltage on the mains.

195-526343

UWI-150 TP, UWW-161 TP, UWI-230 TP AC/DC

2 2

60 m

–

UWI-203 TP

–

300 m 80 m

UWI-320 TP/UWW-301 TP

60 m

100 m

200 m

4.01 UWI-320 TP/UWW-301 TP

6.0 mm

–

10.0 mm2

100 m

–

342

ELECTRODE WELDING AND GOUGING Secondary cables (welding and return cables) the welding current which will be used and the total length of welding and return cable which will be used in the welding circuit.

Cable CrossSection

Maximum welding current at varying duty cycles 100% 60% 30%

Weight kg per m.

70 mm2

0.78

1.03

As guideline, it should be noted that normal hand welding using coated stick

cable of four different cross sections is shown for increasing currents in the

4.01

343

ELECTRODE WELDING AND GOUGING

should be noted that for AC current, the – minus the conventional load voltage cables lie across a steel deck. When characteristics suffer accordingly.

The following table shows the theoretical cable lengths relevant to

Current

Cable crossSection

The maximum length of welding cable (total length from return cable and electrode holder cable) for this voltage

section.

Welding machine type UWI-500 TP

UWI-320 TP

UWI-203 TP

UWI-150

176 m

70 mm2

128 m

200 A

70 mm2

136 m

300 A

77 m 108 m

70 mm2 70 mm

330 m

x) x)

4.01

the distance from machine to welding area thereby doubled.

344

ELECTRODE WELDING AND GOUGING Unitor Welding Cable Welding cables used on board, on deck or in an engine room, are

It may also be ordered in other lengths, without connectors mounted.

and mechanical wear. The welding

Cable drum

intervals with the text “Unitor oil

cable. The crank may be disengaged to avoid accidents when unwinding cable. Note that welding cables should always be stretched out when used, and excessive lengths should not be

and the standard for welding cable

drum or in a coil on deck will act as an electromagnet when welding current resistance in the welding circuit which welding result. The electromagnetic

The cable is available in cross section 2 2 and 70 mm2, and

the coil. Safety cable connectors.

Cable size comparison mm2 26.7 33.6

3 2 1

mm2 107.2

Ordering information

4.01

mm2

Max Amp Weight at 60% Duty kg/m Cycle

10M UoM

20M

50M

included w/safety connector

Very Long Cable Length (MOQ 1 = 100M & in multiples of 100M) without safety connector

Stock

0.78

195-175794

195-175786

195-175778

195-509009

195-175828

195-175810

195-175802

195-509013

195-183665

195-509015

50M without safety connector 1.03

195-709017 195-175729

345

195-719017

ELECTRODE WELDING AND GOUGING Electrode holders, Cable connectors and return clamp assemblies

etc. are not used as a bridge for welding current.

The Cable connectors considerable, equal to many meters of additional cable, and the welding arc will suffer accordingly (see section on

The Electrode holders Unitor’s fully insulated electrode holders arrangement for the electrodes. The electrode holder available, the 200A,

The return connection The return connector must be

Cable connectors must be insulated in such a way that the danger of handling both to connected and unconnected and sockets attached to cables, even if they should come into occasional contact with salt water. There must be good contact and little resistance at the contact areas and at the welding cable connections to the connectors. Unitor Safety cable connectors meet these contact area ensuring good contact carefully assembled, the connectors are The connectors may be used on cable

contact for the welding current load to welding current.

hull. The thickness of material between that is to be used. Think carefully before

fully insulated and are therefore not recommended as cable connectors connectors are available.

4.01

346

ELECTRODE WELDING AND GOUGING Safe & Secure Welding Cable Connection Assembly 1

WELDING INVERTER POWER SOURCE

CONVERSION ASSEM. 2 PCS

ACCESSORIES 3a

4.01

CABLE CONNE. SAFETY COMPL

347

CABLE DRUM W/CRANK

ELECTRODE WELDING AND GOUGING

4 EL.HOLDER 400A W/SAFETY CONNECTOR

WELDING CABLE XXMM2 YY METER LENGTH (2 SETS),

4 RETURN CLAMP ASSY 400 A W/SAFETY Product No. 633180

mm2

Max Amp, A Weight @ 60% Duty kg/m Cycle

10M UoM

20M

50M

included w/safety connector

Very Long Cable Length (MOQ 1 = 100M, & in multiples of 100M) without safety connector

Stock 35 50 70

4.01

0.78 50M without safety connector

1.03 2

348

ELECTRODE WELDING AND GOUGING Electrode holder assemblies Electrode holder assembly 2

Product no. 196-627877 UWW 161 TP

Electrode holder assembly 2

Product no. 196-627885

Electrode holder assembly 2

Product no. 196-594325

4.01

Electrode holder assembly 2

Product no. 196-522680 All electrode holder assemblies

349

ELECTRODE WELDING AND GOUGING Return Clamp Assemblies 2

Product no. 195-633164

Product no. 195-633172

Product no. 195-594317

4.01 2

Product no. 195-633180 For use with extension cables where Safety connectors are used

350

ELECTRODE WELDING AND GOUGING Electrode holders Electrode holder Twisty 200 1.6–3.2 mm. Product no. 196-552497

Product no. 196-513051

For electrode dia. 1.6–8.0 mm. Product no. 196-511006

4.01

351

ELECTRODE WELDING AND GOUGING Return clamps

Product no. 195-653899

Product no. 195-175745

4.01

352

ELECTRODE WELDING AND GOUGING Cable Connectors

Product no. 195-632885

Product no. 195-632893

Product no. 195-736744

Product no. 195-513044

4.01

353

ELECTRODE WELDING AND GOUGING

Conversion assembly mm2 cable 0,3 m long. Product no. 195-634121

Product no. 195-632901 machines. For stick welding or air carbon arc gouging

Product no. 195-633073

This is how the Adapter Plug works: PROBLEM:

SOLUTION:

4.01

Female 70

354

ELECTRODE WELDING AND GOUGING Accessories Chipping hammer for the removal of slag after arc welding. The hammer is of robust construction and well balanced. Available in mild steel and stainless steel.

Wire brush A wire brush is used for cleaning the welding surfaces, removal of slag, rust etc. The brush is available with steel or stainless steel bristles. When working on stainless steel, a brush with stainless steel bristles stainless steel must always be used.

Welding gauge

for a successful welded joint. The

for measuring throat thickness

4.01

Units Wire brush, steel, 2 rows, Wire brush, stainless steel, 2 rows,

355

Product no. 196-632976 196-632984 196-633008 196-632992 196-516161

ELECTRODE WELDING AND GOUGING Welding Techniques Having examined the necessary followed, we shall now look at the actual In order to obtain a good weld we must

• • • •

The current The length of the arc The angle of the electrode Electrode travel

Surface welded at correct current value.

beaded surface.

Current

Settings

factor in arc welding, and this is where most mistakes are made. It is a good rule to use slightly more current than required rather than risk using too little.

electrode diameters, as well as rules of thumb for calculating them. The values given are only valid for

fusing with the base material will be unsatisfactory. Slag may become embedded in the weld, and other faults are likely to occur. When current, electrode travel and angle are correct,

overhead welding the welder should use the lower

2.0

6.0

smoothly and slag will form behind the

Length of arc

4.01

Current value too low, uneven surface.

should be equal to the diameter of the wire core of the electrode.

356

ELECTRODE WELDING AND GOUGING Electrode angle The electrode must be held at the correct angle during the welding angles to be used when welding in

Electrode travel of travel in the welding direction, with or without weaving. Correct a good weld. The illustration shows the faults that can occur if the electrode is moved too quickly or too

to electrode diameter

Edge faults Convex Poor fusion Slag

electrode should be held at an angle to side as the weld advances so that

4.01

Correct

357

Incorrect

ELECTRODE WELDING AND GOUGING Edge preparation

4.01

358

ELECTRODE WELDING AND GOUGING The complete Unitor range of maintenance electrodes for shipboard use Product name

Diameter Product no. Application onboard 3.2

095-699165 095-699173 095-699181

Unalloyed steel. including vertical down.

3.2 6.0 2.0 3.2

095-699231 095-699249 095-699256 095-699260

Unalloyed steel.

095-699199 095-699207 095-699215 095-699223 to weld.

3.2

095-699264 095-699272 095-699280 095-699298 095-699306

3.2

095-699314 095-699322 down welding.

3.2

095-699330 095-699348

3.2

095-683631 095-683649 095-683656 095-699389

Weather resistant steel.

3.2

095-699397 095-699405 095-699413

Stainless steel.

095-699421 095-699439 095-699447

Stainless steel.

4.01

1.6 3.2 3.2

steel overlays.

359

ELECTRODE WELDING AND GOUGING

Product name

Diameter Product no. Application onboard 3.2

095-699454 095-699462

3.2

096-699470 096-699488

stainless and steel.

steel, high carbon steel. 3.2

096-699512 096-699520

Cast iron. cast iron to steel.

3.2

096-699496 096-699504

3.2

096-606458

3.2

096-606457

Oily cast iron. Tolerant to high carbon content.

alloys to steel. 3.2

096-699538

Aluminium rolled, drawn and castings.

3.2

095-606454 095-606455 095-606456

Hard surfacing. Wear resistant overlays.

3.2

096-606460

Hard surfacing. Exhaust valves.

3.2

096-606459

6.3 8.0

096-758474 096-758466 096-758458

Air carbon arc gouging.

4.01

360

WELDING HANDBOOK NOTES

4.01

361

ELECTRODE WELDING AND GOUGING Air-Carbon-Arc Gouging arc effect to melt the metal, which is subsequently blown away by a jet of also useful for cutting stainless steel

The power source

surface, free from slag, and further necessary.

General uses include: • Forming welding grooves. • Removal of defective welds. • Removing defects on cast iron and removing excess metal. • Removing welding beads and burrs

Two welding machines may also be connecting the negative terminal from both machines to ground at the terminals are then lead to the worksite and connected at the electrode holder.

4.01

362

ELECTRODE WELDING AND GOUGING The electrode holder used for air carbon arc gouging. The

• Check the current and remember that the high arc voltage will usually require a higher than usual unsatisfactory. • striking the arc. • the electrode once gouging has commenced.

welding cable, cable connectors and a quick connector 30UPH for

• When gouging in the overhead

General rules for air-carbon-arc gouging • Check that all screw connections any loss of effect.

metal does not fall directly on to the electrode holder. • use, dismantle and clean the valve at least once a month and make

• Clean the electrode jaws occasionally with a steel brush to air line before connecting to the holder to remove any condensation. • • Check connections for correct • Fit the electrode in the holder so from the holder.

4.01

• When the electrode is moved from right to left, the air outlets in the on the right side of the electrode so that the main stream of the the electrode.

363

Electrode holder for air carbon arc gouging

ELECTRODE WELDING AND GOUGING Torch for Air Carbon Arc Gouging with safety cable connector and air connector

Air hose

4.01

Welding cable with Cable connector. 2

Product no. 196 528703

10 mm safety cable connector and air connector

195 634121

Conversion assembly

364

WELDING HANDBOOK NOTES

4.01

365

TIG WELDING Introduction

367 368

Shielding gas Tungsten electrodes

371 373

Regulator & accessories

376 378

Welding techniques

380 383

4.02

366

TIG WELDING Introduction on board. The most frequently and stainless, heat resistant or acid may be used with good results on all weldable materials. Among the unique advantages of using the argon gas

• • A stable, intense and well directed

• Clean, smooth welds of high quality, cylinder is an excellent mobile solution

slag).

The TIG Equipment

and an accessories kit.

4.02

367

TIG WELDING Basic principle Tungsten electrode

Filler rod

Remote control for welding current advantage to adjust current during welding.

used for high quality metals such as stainless steel, Cunifer and York Albro.

is struck between a Tungsten electrode

The arc and the electrode are shielded by an inert gas (usually Argon) that also oxidation.

rod is normally made of a metal similar to the metal being welded. The Tungsten be consumed during ignition and to some extent during actual work. This time, it will be necessary to regrind the Equipment set-up:

4.02

368

TIG WELDING Shielding gas Shielding gas is necessary for the chemically inactive (inert), has several • and suitable heat transfer. • effect of the air. • contamination and oxidation from the air. • metal rod from oxidation. • during cooling after the arc is broken.

colourless and odourless inert gas,

is commonly used.

therefore needed.

4.02

200 bar gas cylinders

min. Note that when welding stainless steel it may also be necessary to use regulator and hoses) should be used the air.

369

TIG WELDING Shielding gas ARGON Ar

For use on:

Argon is a colourless, odourless gas,

Steel Stainless steel Aluminium Yorcalbro Cunifer

Cylinder data

715-905174 Welding

715-905565 Welding Colour

10 3.6 2.2 200 18 22 1000

18 11 200 81

230

Outside diameter mm

3 3

4.02

370

TIG WELDING Tungsten electrodes red) are currently the most widely used electrodes worldwide. Thorium is however a radioactive element and to health and environment. Thorium enclosed in a tungsten matrix, the “a” radiation emitted externally is negligible. The danger to the welder arises when thorium oxide gets into

• radioactive constituents • • Suitable for welding all materials • • Standardised in national and

the near future, more stringent legal

as an environmentally friendly and technically better solution is already available. Unitor tungsten electrodes is alloyed

Unit Tungsten electrodes 1.6 mm.

4.02

371

Product no. 197-674710 197-674736

TIG WELDING Overview of Tungsten electrodes CODE

OXIDE ADDITIVES Wt.%

COLOUR CODE

REMARKS

2 3

WC20

Pure Tungsten AC only 2

WT10 WT20 WT30

2 2

Thorium

Yellow Red

2 2

White

Rare earths

Orange Turquoise

Correct Grinding of Tungsten electrodes for DC welding

heat consentration.

wise, straight towards the result in an unstable arc and that bits of tungsten will brake off and fall into the weld Wrong grinding

4.02

Correct

Correct grinding

Out of centre

Too short

Too long

372

TIG WELDING TIG TORCH General description

electrical insulation, the head of the

carelessly.

silicone coating. welding. and has the combined function of forming a gas tight seal for the alumina the torch head.

long working life. The handle ensures transfer to the welder’s hand. A screw turn, switches the gas on and off.

Accessories for use, but the accessories kit is recommended as it contains cm, ensuring accessibility in narrow

cable and gas hose (8) ensure that extensions may be easily connected.

4.02

373

onto the Unitor argon regulator or to the standard right hand threaded

give better gas shielding.

TIG WELDING Parts list and order numbers

Pos.

Product no

–

197-150000

–

197-160010

–

197-200000

–

197-607810

1 2 3

6 6 6 7 7

Units

Spares 197-551192 197-551200 197-551143 197-551168 197-551150 197-551184 197-551176 197-551135 197-551127 197-778924 197-674710 197-674736

Heat shield Collet 1.6mm Collet body 1.6 mm

Accessories kit consists of:

4.02

ColIet 1.6mm Collet body 1.6 mm

Accessories kit for

374

TIG WELDING Remote control set-up

UWI-230 TP AC/DC, UWI-320 TP, UWW-301 TP WIRE WELDER and UWI-500 TP 197-200000 191-670414 191-670422

4.02

197-150000 191-150151 The remote controls may also be used for stick electrode welding.

375

TIG WELDING Regulator & Accessories adjusted on the regulator. torch may deviate from what is set on the gas outlet station or on the gas hoses are used. The Flowcontrol

needle valve used at the gas inlet of adjustment is available at the work

ensure easy control of the torch and eventual welding rod. In addition welding should be used.

Unit mtr

Spare parts for regulator: Contents gauge for regulator

197-510010 176-576157 176-175596 401-768416 197-320202 197-320201

4.02

171-550210 171-550178 197-597328 197-597310 197-632795

376

4.02

377

Welding

Pr. Pcs.

N.A.

Remote Control Pr. Pcs

Acces. KIT Ar. Regl. Pr. Pcs. Pr.Pcs. Pr. m

Hose Joint Pr.Pcs.

TIG Equipment & Accessories for Unitor Welding Machine Range TIC gloves

Pr. Pcs.

Flow contr. Flow contr. meter at needle

TIG WELDING

TIG WELDING Preparing the torch Always disconnect the torch from the or adjusting the electrode. This is Connector at the end of the torch cable.

the whole gas system is thoroughly

Ensure that correct and unharmed contamination of the welds. Then set and electrode are used. If the welding current is to be 100A or electrode, collet and collet body.

is needed, this should be taken from a

For welding above 100A it is

gas from the same regulator that

collet and collet body.

torch.

Check if the work at hand makes it

Connection to Welding Machine

side of the arc, which is bombarded by therefore always be connected to the

damaged.

the return cable shall be connected to

Connection to Gas Supply Connect the gas hose to the argon regulator, and make sure all

If available, connect the remote control to the welding machine and have the current regulator available at the work site. For current setting see table on

4.02

378

TIG WELDING Welding Parameters The material thicknesses given in the table below for the different current ranges

and Stainless steels <1.0mm Welding current,

Electrode

diameter of electrode

no.7 (11mm) Tungsten

4.02

379

no.7 (11mm)

TIG WELDING Welding Techniques torch is connected to the negative

argon cylinder valve and the torch valve. regulator.

Striking the Arc system. Check electrode and electrode

disconnected. If current remote control is available, adjust to low or minimum current.

The lift arc function

mm between the tungsten electrode

This will trigger the lift arc function. Raise the torch and lift it into the normal

Note: To be absolutely certain that contamination is avoided the arc may beginning of the bead. Adjust welding current to correct setting and hold the arc steady until a molten

4.02

Raise the torch

380

TIG WELDING Welding

is largely similar to the gas welding

3–6mm. Note that a longer arc will arc will reduce it, contrary to what current remote control is used, the

Welding with the forehand technique.

current. Hold the torch at an angle of The arc may be used just to melt the edges of the joint together, or

Use of Filler Material Introduce the rod to the molten not touch the electrode or enter added continuously or in a slightly forehand technique.

oxidation, which will contaminate the weld. Hold the rod at an angle of

Finishing the Bead Adjust welding current to minimum and

4.02

Finishing the bead.

381

TIG WELDING Contaminated Tungsten Electrode The tungsten electrode may be contaminated through contact with the It will also be contaminated (by

• That air does not enter into the gas hose. • That wind or draft does not blow away the shielding gas. contaminated (try changing to fresh cylinder).

the gas is shut off before the electrode has cooled down to below red glowing If there is little contamination the electrode may be cleaned by striking an burn for a few seconds. Remember gas If the electrode is heavily contaminated disconnected, the electrode removed The electrode must be reground to the

Contaminated Weld Pool

Clean the electrode by striking an arc

Check the following: • That the gas hose has been correctly set. • That the electrode is held at the correct angle.

being used.

Strong draft may blow away the argon shield, resulting in

4.02

are clean.

382

TIG WELDING Edge preparation Stainless steel Material thickness mm

Type of joint

Welding current A Horizontal

Vertical

Overhead

Tungsten electrode mm ø

1.6 60

1.6

1.6 1.6

80–110

70–100

1.6

100

1.6

120–200

110–180

110

100

130

120

110

100

100 110

4.02 120–200

110–180 170

180

383

160

1.6

TIG WELDING Edge preparation Copper alloys (Cunifer, Yorcalbro) Material thickness mm

Type of joint

Welding current, Horizontal

Tungsten electrode mm ø

NB: When welding Stainless steel and Cunifer, backing gas must be used inside

1.6 1.6 1.6

2 3

1.6 170–200

4.02

Out trough

384

TIG WELDING Rods and Flux for TIG welding Welding rods Product

Product no.

097-604850 2.0 mm 097-305532

097-602979 2.0 mm

The silisium content of the wire ensures smooth transfer and

is also an advantage for the root bead when welding thicker 097-725309 2.0 mm offers elevated mechanical strength and toughness resistance to

092-514265 3.0 mm 097-335547

4.02 097-519736

with Albro Flux.

385

WIRE WELDING Introduction

387 388

Shielding gas

Regulator & accessories

Welding technique Wires for wire welding

4.03

386

WIRE WELDING Introduction In Wire Welding, a wire from a reel is fed through a welding torch welding current. The wire melts and is that is shielded by a gas. The shielding

time that the welder actually is welding).

The gas has the same function as the smoke shield.

Cylinder with shielding gas

Wire feeder

Welding Torch

Power source

4.03

387

WIRE WELDING Basic principle the wire being fed. FCAW – Flux cored arc welding. GMAW – Gas metal arc welding uses a

Solid wire

) to shield the

shielding when welding low carbon and

like Argon. Pure inert gas shielding is essential for welding alloys of Flux

titanium, stainless steel, nickel alloys and highly alloyed steel. 2

Tubular wire Flux tubular wire.

) are regarded as

Spray Arc or Short Circuiting Arc

Wire drive rolls

Continuous wire

Nitrogen & Oxygen Umbrella

4.03

388

WIRE WELDING Spray-Arc relatively intense arc between the The metal transfer is in the form of the arc to the surface of the melted

material thickness above 3 mm. have welding current above a certain minimum value, the transition current.

and the welding current increases

shielding gas, (consisting of minimum guideline a 0.8 mm solid steel wire

no longer can be maintained, and the excellently suited for sheet metal welding, and also for bridging large

Short Arc is also called short circuit transfer. No metal is transferred through the arc with this technique, but is instead

4.03

Short circuiting (short arc welding)

389

WIRE WELDING Flux Cored Arc Welding (FCAW) Self-Shielded. the brittle coating. The need for a continuous arc welding electrode led to

is obtained from an arc between a the arc and a slag covering of the weld

cored wire where the material needed for shielding is contained inside the core of a hollow wire.

the shielded metal arc welding. The versatility and maneuverability of stick electrodes in manual welding stimulated

Continuous electrical contact can be made with the wires at any distance from the arc and they can be coiled

allowing a continuous wire electrode to be used. A continuous electrode would eliminate the welding time lost in changing electrodes and would eliminate the material lost in electrode stubs. The contain in their cores the ingredients making electrical contact with the core wire and coiling it without cracking

and for generating shielding gases and

The arc: Solid slag

Flux Core Wire Flux

4.03

390

WIRE WELDING In essence, semiautomatic welding with an electrode several feet long Knurled wire feeder rolls to be used

the mechanism that feeds the wire to the arc. He uses a welding gun instead of an electrode holder, but it easy to maneuver. The only difference being the weld metal of the electrode surrounding the shielding and surrounded by them.

outdoors where strong air currents are encountered.

Extensions from 6 mm to 30 mm are

cases also be used for Self Shielded Flux Cored Arc Welding with small metal is transferred across the arc,

means that some oxidation and

some low alloy steel.

4.03

391

WIRE WELDING Flux Cored Arc Welding (FCAW) Gasshielded.

Tubular electrode wire is used as in

gas metal arc welding with only small be knurled). Note that the welding gun

alloying additions, rather than for the Although CO2 is generally used as the 2

also be used.

steels and stainless steel. It gives arc shield. The guns and welding heads for to a wide variety of joints and gives the

The arc:

Flux Core Wire Arc

4.03 from cylinder

392

WIRE WELDING Maintaining the arc that an electric arc melts the surface

current regardless of arc length. Alternative 2 above is therefore not

which is continuously fed into the arc,

therefore required.

and thereby the arc voltage must be

The combination of such a wire feeder

uniform weld. This can be obtained in

use such a combination if welding in it melts. exactly the value needed to melt welding with coated electrodes feed the electrode according to

Constant voltage power source requires the combination of a constant

source will automatically maintain the demanding less from the welder’s skill

Constant current power source constant current characteristic is

4.03

393

according to need, once the arc voltage and thereby the arc length has been selected. The constant voltage characteristic is also suitable for

WIRE WELDING Shielding gas ARGON Ar

Cylinder data

Argon is a colourless, odourless gas, slightly

715-905565 Welding

Argon is an inert gas used

Colour 3

against contaminants in the For use on: Aluminium Yorcalbro Cunifer

715-905174 Welding

10 3.6 2.2 200 18 22 1000

18 11 200 81

Outside diameter mm

230 Forged brass with bursting disc, inlet

3 3

ARGON - CO2 MIXTURES

Cylinder data

mixtures are used as shielding gas 2

715-905573

715-905581

715-905673

715-905681

Welding

(Unimix20) (Unimix10)

(Unimix10) mixture are suitable for welding all Colour

steels and stainless steels. The mixtures give a very

transmission. Each cylinder is labelled with the correct label.

4.03

For use on: Stainless steel Steel

394

WIRE WELDING Equipment

voltage control. 2. Welding current switch (contactor).

The sequence of events and the time delay between them is essential for a successful termination of the weld,

valve.

elements of the Wire Welding 8. Wire feed motor with drive rolls. ways, more or less suited to onboard use. welding current cable, gas hose, control circuit cables and wire feed tube (liner). switch. In a welding sequence these elements function as follows when the welder

unit, often even with the gas cylinder mounted on the assembly. As the

aluminium) these units are limited to Another system is built around very elements 7–11 in the torch, and the other elements either in a control

• Wire feed motor starts, feeding wire through the torch. • The arc starts as the wire touches

selection of wires to mainly aluminium

Wire feeder principle

4.03

welder releases the torch control switch and the following sequence of feeder unit, which has the ability to voltage characteristic. Unitor Wire • After a brief moment the contactor and requires only welding current as

395

WIRE WELDING

4.03

396

WIRE WELDING Unitor UWW-301 TP Wire Welder MIG-MAG/STICK/LIFT-ARC TIG WITH HYBRID ARC CONTROL Features and benefits 1. High Performance Portable Welder i.e. Wire Welding, Stick Electrode for all your welding needs onboard.

2. Hybric Arc Control (HAC) and Synergistic function for Wire Welding

synergistic function allows welding machine for wire welding,

works used anywhere onboard.

Code of Safe Working Practices for fastening for heavy lift bulk carriers etc. where heavy welding and high environment damage to the machine in case

4.03

resistance against moisture and to ensure excellent reliability in the harsh maritime environment.

397

WIRE WELDING

• Set of wire guide tube and wire feeder drive rollers machine • User instruction manual

Dimensions/Weight

Technical Data

Recommended fuses Welding current range

Protection class

IP23S

Cooling system

Forced air

4.03

398

WIRE WELDING UWW-301 TP Consumables, Accessories and Spares: Product

Product no.

301301 Accessories for Selfshield Wire Welding and Stick Welding

Consumables for Selfshield Wire Welding - Carbon Steel 72228 Consumables for Selfshield Wire Welding - Stainless Steel

Accessories for Gas Wire Welding (MIG/MAG)

Accessories for TIG WELDING 200000 607810

Accessories for Gas Shielded Welding (Wire/TIG)

Welding Safety PPE 632786 Welding Accessories 633008 ANTI SPATTER SPRAY, 6PCS

4.03

661778 Spares & Consumables

230237

399

WIRE WELDING Application set-up for Wire Welding

Wire Spool Positioning ensuring it is located correctly. Adjust such a way that the wire feed force released.

4.03

400

WIRE WELDING Positioning the Wire In The Wire Feeder feeder rolls and insert it into the

correctly in the roll grooves.

2. Raise the wire feeder

7. Close the wire feeder

that does not deform it while also ensuring constant feed rate without

4.03

suitable for the wire gauge.

401

in the side of the unit.

402

0 7

1,0 1,0 1,2

Aluminium Solid Wir e

1,2 0

3 0

0,8 1,0

Stainless Steel Solid Wir e

1,2

Wire

Flux Cored Self Shield Wire d d

Carbon Steel Solid 0

Unitor Wire e

WEAR EYE PROTECTION

V groove for solid wires except aluminium

6 2

0 3

)

U groove for aluminium wires

1 2

Wire Polarity

Shielding s

s Flow

Knurled V groove for flux cored wires

WIRE WELDING Preparing for MIG/MAG

1. Connect the gas hose from the welding gas cylinder to the relative on the user interface. the EURO TORCH welding socket.

selector cable to the welding socket

10. Close the gas solenoid valve by

6. Feed the wire through the torch until

values on the user interface. The system is ready to start welding.

Application set-up for Stick Electrode welding 1. Connect the electrode holder cable to

4.03

the welding socket on the basis of the

3. This button

serves to select the

on the user interface. The system is ready to start welding.

403

WIRE WELDING Application set-up for TIG (Tungsten Inert Gas) welding

OFF switch to “I” (unit switched on). socket.

interface. The system is ready to start welding.

Lift-Arc TIG Welding

Slowly lift the torch to strike the arc.

extinguish the welding arc.

4.03

404

WIRE WELDING Unitor Wire Feeder UWF-102

it is, in addition to wire welding, also and Air Carbon Arc gouging from the wire feeder without reconnecting back For wire range 0,6 to 2 mm. Adjustable extensions may be used between wires, and gas shielded solid wires. connection cables to welding machine and a drive roll kit for 0.8–1.0 mm solid wire.

0.6 to 2 mm Welding Circuit Rating IP Rating

Height With Weight

torches not included, order number 191-500102

4.03

405

WIRE WELDING Connecting UWF-102 to UWI-500 TP and shielding gas The wire feeder is delivered with the required hoses

connection to a shielding gas regulator on a gas cylinder.

If cable extensions are used the return cable should also

4.03

406

WIRE WELDING Drive rolls The groove walls are smooth and these drive rolls are used for all solid wires

that will deform these tubular wires.

UWF-102 Wire Feeder Drive Rolls Part No. Knurled groove

4.03

Order no

0.8–1.0 mm

1.0–1.2 mm

1.2–1.6 mm

407

Order no

WIRE WELDING Accessories for Unitor Wire Feeder UWF-102 Torches with tools Torch for gas shielded wire welding Torch for gasless wire welding

Shielding gasses

when using the needle valve

2 2 2 2

Cable and gas hose extensions 2

Welding cable 70mm2 2

4.03

408

WIRE WELDING

contact to the wire.

Pos. Order number Unit 1 2 2 2

n.a.

End of swan neck on torch Torch liner, Steel for 0.6–1.0 mm wire (blue) 3.0 m long

4.03

409

set set set

WIRE WELDING

Torch T-400 MP

including aluminium. Pos. Order number Unit 1 2 3 3 3 3 3 6 7 7 7 7

set set set set set set set set

4.03 Torch liner, Steel for 0.6–1.0 mm wire (blue) 3.0 m long

410

WIRE WELDING Regulator & Accessories is adjusted on the regulator. torch may deviate from what is set on the gas outlet station or on the gas hoses are used. The Flowcontrol

Flowcontrol needle valve used at the gas inlet of the machine or the wire

ensure easy control of the torch and eventual welding rod. In addition welding should be used.

Units CO2 mtr

4.03 Spare parts for regulator: Contents gauge for regulator Flowcontrol needle valve

411

Product no. 197-510010 197-510012 176-576157 176-175596 401-768416 197-320202 197-320201 171-550210 171-550178 197-597328 197-597310 197-632795

WIRE WELDING Accessories

and installation, and for cutting and

sticking to the metal surface being on each side of where the welding burning on to the surface. with a brush after welding. Time

canisters.

Units

Product no.

set

193-591990 193-633149

4.03

412

WIRE WELDING Application areas Unalloyed/Iow alloyed and stainless steels Numerous gas mixtures based on the most distinct advantages of the • Welding technique is easy to learn. • High quality welds. • No slag, or for FCAW very little slag. • Unique advantages for sheet metal and aluminium welding.

Helium, Hydrogen, and even traces of other gases, have been introduced to the market for ferrous materials, all

maintenance a stock of several gas

welding with gas or coated electrode

on materials of limited thickness. electrodes. and the need for using several for different metals and alloys. These are to a large degree being eliminated

Non-ferrous metals

4.03

material of Alumag, lcuni and lalbro the material thickness range 3–6 mm, even though thicker materials may be

413

will further add to the usefulness of the

WIRE WELDING Preparation for Welding that the welder and welder’s assistant glass. The guidelines given in the followed.

Preparing the equipment

quantity is available, if shielding gas is

to torch if solid wires are used, and cored wires.

with good electrical contact. Poor correct arc.

Mounting the wire spool • Check, and if necessary clean the wire feed rolls and the wire liner in the torch cable. Ensure that the and quality for the wire to be used. for aluminium and stainless steel wires.

4.03 slightly larger inner diameter than with other alloys, to allow for the

414

WIRE WELDING

damaging the liner or getting the wire stuck when feeding it through the liner, it maybe an advantage to Then insert the wire in the torch cable liner, fasten the feeder rolls and feed the wire through until it

Checking the wire feed function

wire in liner.

• Check and if necessary adjust the

without uncoiling excessive wire

they slide on the wire if the wire

wire when testing this unless the

and using an electrically insulating material to hold the wire back. start the wire should be cut off at

larger wire diameters.

4.03

Shielding the workplace Strong draft may disturb the shielding When necessary, the weld bead should therefore be shielded. Welding with care to ensure they do not affect the shielding gas.

415

Strong draft may disturb the gas shield.

WIRE WELDING Welding technique Too long stickout may result in too cold base material, wire and shielding gas be avoided. Too short stickout may overheat the

Cored Arc Welding Self Shielded is to be used, a too short stick out may result in at a certain setting on the machine, this welder may use the stick out to adjust

wire away from contact with deck or • decrease bead width. wire will be electrically live and an arc will occur if contact is made.

weaving (7).

Wire stickout

including the arc length. This distance decides how long the current carrying in the wire increases with increasing voltage, and the welding current will decrease with increasing stickout and vice versa.

4.03

416

WIRE WELDING Travel speed and direction

to the base material. Welding may

When Flux Cored Arc Welding Self Shielded wire are used.

Shielded” wires are used. forehand technique is always used for all welding of aluminium and aluminium alloys.

Forehand technique

For steel and stainless steels both techniques are used, often with cored wire.

Torch angles

sideways from the weld. The longitudinal angle will affect

4.03

small angle should be avoided as contaminating the weld. Torch angles

417

WIRE WELDING This may be done by increasing travel the transverse angle is increased or

the weld, and releasing the torch switch

in the joint.

Weaving obtainable with a straight welding the groove in a side to side movement (weaving). When this technique is used the side to side movement must of the weld. Weaving in a continuous movement may easily result in will weaken the joint considerably.

Arc starting and stopping When starting the arc on a cold for a short moment before the weld a weakness in the joint the arc may joint, or the welder may increase the beginning of the weld, moving the arc and continue welding over the slightly

Torch angles in vertical welding, backhand technique

4.03

418

WIRE WELDING Edge preparation Steel, Position welding, 90% Ar-10% CO2 or 80% Ar-20% CO2 Shielding gas thickness mm

Wire diameter mm

Welding joint

Number of layers

1.2 1.6

0.8 down.

1.6

2.0

Steel, Position welding, 90% Ar-10% CO2 or 80% Ar-20% CO2 Shielding gas Joint thickness mm 2

joint

Wire diameter mm

Number of layers

0.8

Welding

0.8

4.03

419

1 22

0.8

130

0.8

120

0.8

120

1.2

110

330

1100

1.2

320

1.2

330

1.2

330

300

WIRE WELDING Edge preparation Stainless steel, Position welding, 80% Ar, 20% CO2 Shielding gas thickness mm

joint

Wire diameter mm

Welding

Number of layers

1.6

2 17 3.2

720

1 1

Stainless steel, Horizontal welding, 80% Ar, 20% CO2 Shielding gas Wire diameter mm

Number of layers

1.6

thickness mm

20 20

4.03

420

WIRE WELDING Edge preparation Aluminium, Horizontal welding, Argon Shielding gas thickness mm

Wire diameter mm

1.0

600 700

810

1.3

1.0

1.6

1.0

Welding

Aluminium, Horizontal welding, Argon Shielding gas Wire diameter mm

thickness mm

4.03

421

Welding

180

Welding

Number of layers

With

1.2

With

1.2

With out

1.2

220

With

1.6

280

With out

1.6

260

With out

1.6

270

With

1.6

310

With out

1.6

300

1 1

WIRE WELDING Edge preparation Aluminium, Position welding, Argon Shielding gas thickness mm

Wire diameter mm

Welding

1.2 or 1.6

180

1.2 or 1.6

200

1.2 or 1.6

210

1.6

220

1.6

Welding

Number of layers 2 2

3 3 30

1.6 1.6

1.6

Copper alloys, Horizontal, Argon Shielding gas thickness mm

Wire diameter mm 1.6

310

4.03 26 27

380

422

WIRE WELDING Wires for Wire Welding Unitor Wire

Order no.

Shielding gas

0.8

Coreshield 8

4.03

423

Wire 22

1.0

None

1.6

None

0.8

1.0

1.6

None

Note: Approx. values only

ArgonlCO2

Current

PLASMA CUTTING AND GOUGING Introduction

Cutting technique

4.04

424

WELDING HANDBOOK NOTES

4.04

425

PLASMA CUTTING AND GOUGING Introduction also assists in removing the material

oxidation of the steel (the steel catches Cutting direction Heating to kindling

oxidation and removal of slag.

stainless steel and those other metals Some metals have refractory oxides (sluggish heavy kind of oxides with

above requirements and are readily 2) The oxides (rust) of the metal should metal itself. ignited. It also has a refractory silicate of the metal with oxygen must be

4.04 enough so that the material can be

426

PLASMA CUTTING AND GOUGING of matter as solid, liquid, and gas. For most commonly known element, water these three states are ice, water also have high thermal conductivity.

and technique because of the refractory chromium oxide formed on the surface.

between these states relate to the energy level. If we add energy in the form of heat to ice, the ice melts and the result is water, a liquid. If we add to the gas we normally call steam.

So how can we overcome these become electrically conductive. This (Flame cutting) to an electric (Plasma cutting). In Plasma cutting only one condition 1) The metal must be electrically conductive.

atomic ions and free electrons. When

What is Plasma? is that it is the fourth state of matter. We normally think of the three states

4.04

Plasma, the fourth state of matter

427

conductive because free electrons are available to carry current).

PLASMA CUTTING AND GOUGING Basic principles conductive gas to transfer energy from being cut. struck between the cathode (electrode

the high inherent energy of the jet, and dissociation energy is released,

smooth cut.

Pilot arc

Transferred arc

4.04

428

PLASMA CUTTING AND GOUGING Plasma cutting equipment The torch serves as the holder for the and electrode constrict and maintain for cutting materials under 16 mm gas (usually air or nitrogen) Air is the available at most location and that it The arc starting circuit uses (usually between 100 to 200 starts). charges the air stream, creating a

largely on air quality that must be oil and water free.

as “blowback“ technology. The Unitor

4.04

429

UP-310 ML

UP-85 ML

UPC-NEO NG

Primary side input:

Power source output:

min. 16A slow fuse Power source output:

PLASMA CUTTING AND GOUGING Unitor Plasma Cutter UPC-310 ML Lightweight Single-Phase 110-230V Plasma Cutter inverter build that comes with excellent • Technology “consumable check consumables are ready for frequency blowback ignition system, it also does not interfere with radio communication or other electronic machine for onboard usage.

Features and benefits

damage to torch

Safety features • Plasma torch with trigger release to • Fixed torch connection to the

to withstand rough onboard environments

should be made so that there is no risk for electrical shock and no

12mm (severance), 10mm (quality) and 8mm (recommended)

a tool

device

accidental discharge • Air test button for incoming

whereby regulator drains itself when

4.04

430

PLASMA CUTTING AND GOUGING • • Torch with 6m cable (connected directly to the machine) • • • • User instruction manual

Unitor Plasma Cutter UPC-310 ML Technical Data:

(Slow blow) 160

Process Power

Power Factor Protection Class Environmental Conditions

IP 23

Cooling

Forced H

Weight Severance Cut Quality Cut Recommended Cut

4.04

431

PLASMA CUTTING AND GOUGING Torch consumables and spares

Product no. 310333 310334 310335 310336 310337 310332 310338

Torch parts replacement consumables

4.04

432

WELDING HANDBOOK NOTES

4.04

433

PLASMA CUTTING AND GOUGING Unitor Plasma Cutter UPC-85ML Plasma Cutter with PFC Multi-Link technology Features and benefits • Tested in accordance with and moisture • Perform quality cuts of 16mm

various metals such as mild and stainless steels, castings, aluminium as well as

4.04

434

PLASMA CUTTING AND GOUGING

• Torch with 6m cable (connected directly to the machine)

the machine • User instruction manual

Unitor Plasma Cutter UPC-85ML Technical Data

(Slow blow)

720

280 Process Power

Power Factor Protection Class Environmental Conditions Cooling Severance Cut Quality Cut Recommended Cut

4.04

435

Forced H

PLASMA CUTTING AND GOUGING Torch consumables and spares

Product no. 310336 404181 404165 310334 404173 310337 404169 404161 404177 310335 310333 404153

Electrode

Start Cartridge Torch Head

4.04

New tip

Worn tip

New electrode

Worn electrode

436

PLASMA CUTTING AND GOUGING Unitor UPC-NEO NG

Portable Plasma Cutter with Ecodesign Technology

gouging machine that is designed in line with the latest EU Ecodesign

range of electrically conductive steels such as mild and stainless steels, castings, aluminium, titanium as well

Ingress Protection rating of IP23 and

the maritime environment, with safety features that are in accordance with the

job that is carried out in the outdoor

aluminium casing body makes it lightweight from corrosion.

cutting quality and versatility when

Wider Material Cutting Range

Higher Cutting Speed and Productivity

Portable and Compact

Features and benefits • Tested in accordance with IP23, making it suitable for outdoor use • Has high resistance to dust and moisture

4.04 not correctly mounted on the torch

437

PLASMA CUTTING AND GOUGING

• Torch with 6m cable (connected directly to the machine)

• User instruction manual

Unitor Plasma Cutter UPC-NEO NG Technical Data

(Slow blow) Process Power

Power Factor Idle State

Protection Class

0,80

21W

IP 23

Environmental Conditions Cooling

Forced H

Severance Cut Quality Cut Recommended Cut

4.04

438

PLASMA CUTTING AND GOUGING Torch consumables and spares

TORCH PARTS FOR INPUT VOLTAGE 380-440V 3F. 310337 310336 (30A)

DRAG CUTTING

CUP TORCH

START

STAND OFF CUTTING

TIP

310333

STAND OFF CUTTING

310337

TIP GOUGING

DESCRIPTION

PRODUCT NUMBER

COMMENTS

310336

Electrode 310337

Start Cartridge Torch Head

310333

1 PC 1 PC 1 PC 1 PC 1 PC 1 PC 1 PC

4.04 TORCH AND ACCESSORIES:

310326

439

1 PCS 1 PCS 1 PCS 1 PCS 1 PCS 1 PCS 1 PCS

WELDING HANDBOOK NOTES

4.04

440

PLASMA CUTTING AND GOUGING Cutting technique

Hold the torch away from your body. Slide the trigger release toward the back of the

the trigger.

4.04

441

PLASMA CUTTING AND GOUGING For piercing holes

Press trigger on the torch handle. Air will

and one smooth movement straighten the

Start moving the torch across the work

Gouging (UPC-85ML and UPC-NEO NG only)

Varying the gouge profile Follow these recommendations to change the Increasing the speed of the torch will decrease width and decrease depth. Decreasing the speed of the torch will increase width and increase depth. Increasing the standoff of the torch will increase width and decrease depth.

molten metal to avoid reducing consumable life or damaging the torch.

Decreasing the standoff of the torch will decrease width and increase depth. Increasing the angle of the torch (more vertical) will decrease width and increase depth.

4.04

Decreasing the angle of the torch (less vertical) will increase width and decrease depth.

442

PLASMA CUTTING AND GOUGING Maintenance and trouble shooting Disconnect power before maintenance

Never use a damaged torch.

air and electricity. Remove the cover. Torch Head

Electrode

Start Catridge

Tip

Shield Cup Body

Clean the machine with dry, clean and connections and gas system.

regular intervals, as a general guideline after 3 hours continuous use, or after 200 starts.

Check gas/Air Pressure

the face of the electrode for excessive wear

New tip

Worn tip

New electrode

Worn electrode

in time will dramatically reduce the cutting

Air Supply Precaution

on board will have the best quality.

4.04

443

body with regard to any leak or damage.

PLASMA CUTTING AND GOUGING

Air line unit

Air with oil mist

Rubber air hose

Oil free air can be taken from the centre block

4.04

444

AC/OX CUTTING/WELDING/BRAZING

5.01

445

AC/OX CUTTING/WELDING/BRAZING PROCESS & EQUIPMENT Introduction

Welding and grinding goggles Accessories

Hose connectors Flashback Flashback arrestors

Common cutting faults

Heating techniques Flame straightening techniques Welding techniques

5.01

446

AC/OX CUTTING/WELDING/BRAZING Introduction used for welding and related thermal Acetylene is the fuel gas burning with

degree of dissociation of hydrogen atoms, thereby storing energy. This stored energy is transferred through and recombine to molecules. The total

• S) from the core

at various mixing rates with oxygen.

5.01

447

Hydrogen molecules dissociate on the

AC/OX CUTTING/WELDING/BRAZING

velocity of the mixture. This ensures a The concentrated heat reduces total

sheet metal welding and welding of

will be described.

Safety: lighter than air. heavier than air.

Combustion velocity of acetylene

5.01

448

AC/OX CUTTING/WELDING/BRAZING The Combination Torch UCT-500 It includes a range of seven welding attachments also function as

balanced and easy to handle.

The circular motion bar with centering

The connection between torch

even if the connection nut should loosen. Attachments are easily changed without the use of tools, and may be turned in any desired angle to The gas valves are symmetrically

on the use and maintenance of the

UCT-500 compact kit in heavy-duty PVC case shank, the three most commonly used welding attachments (80 ltr, 230 ltr and

Acetylene and Oxygen inlets are instructions for use and maintenance are also included.

to mix in the hoses, with the danger of

UCT-500 Master kit in heavy-duty PVC case

5.01

assembled to cover all ordinary may occur on board.

449

AC/OX CUTTING/WELDING/BRAZING

170-500000

170-500001

5.01

450

AC/OX CUTTING/WELDING/BRAZING UCT-500 components and spares one each of all items marked 1) below. of all items marked 2) below.

Shank Product No. 1)2)

170-174656 return valves

Welding attachments Product No. 1) 1)2) 1)2) 1) 1)2) 1) 1)

170-174565 170-174573 170-174581 170-174599 170-174607 170-174615 170-174623

Flexible welding attachment Product No. 170-183780

Singleflame heating attachments Product No. 170-183756

Multiflame heating attachments Product No. 170-603399

mild steel.

5.01

451

AC/OX CUTTING/WELDING/BRAZING Cutting attachments Product No.

170-174664 170-234807 170-234815

1)2) Cutting nozzles- general use

Product No.

thickness mm

1)2) 1)2) 1) 1)

302 No. 2 302 No. 3

1300 7800

810

170-174698 170-174706 170-174714 170-174722

Cutting nozzles for difficult access, 165 mm length Product No.

thickness mm

7000

800

170-183855

Gouging nozzle with stellite tip Furrow dimensions Width mm

Product No.

170-174730 Cutting guides Product No.

1) 1) holde diam. for use with roller guide

170-174672 170-174680

Tools Product No.

1)2) 1)2)

170-174649 176-175356

Spares for UCT-500 Product No.

170-597336 170-597344 170-651265 170-651257 170-619270 1) SPARE PART KIT COMPLETE

170-500100

Oxygen valve assembly (blue) Acetylene valve assembly (red)

170-174789 170-613762 170-535005 170-174771 170-174813 n.a n.a

Sleeve for circular motion in roller guide

5.01

452

AC/OX CUTTING/WELDING/BRAZING UCT-500 components and spares 500000

UCT-500 COMBINATION TORCH MASTER consist of the following items in a case with instruction manual:

Torch components

UCT-500 shank, 6 mm and 9 mm hose sockets with non-return valves

Welding attachments: for welding up to 14 mm thick steel plates

Cutting attachment 90 degr. with spare nozzle screw Cutting nozzles for 3-10 mm, 10-25 mm, 25-50 mm and 50-100 mm steel thickness

Roller guide for 45-90 degr. cutting angles, with spare clamp sleeve Circular motion bar complete with center and sleeve for 84-960 mm diameter circles

Torch maintenance equipment

Spanner 15-, 17-, 18-, 19-, 23- and 24 mm for UCT-500 SPANNER Cleaning needles set for UCT-500 welding attachments and cutting nozzles

5.01 Spare valve and complete O-ring set for UCT-500, including spare coupling nut for welding attachments

453

AC/OX CUTTING/WELDING/BRAZING

500001

UCT-500 COMBINATION TORCH COMPACT consist of the following items in a case with instruction manual:

Torch components

UCT-500 shank, 6 mm and 9 mm hose sockets with non-return valves

Welding attachments: for welding up to 7 mm thick steel plates

Cutting attachment 90 degr. with spare nozzle screw Cutting nozzles for 3-10 mm and 10-25 mm steel thickness

Torch maintenance equipment

Spanner 15-, 17-, 18-, 19-, 23- and 24 mm for UCT-500 SPANNER Cleaning needles set for UCT-500 welding attachments and cutting nozzles

5.01

454

AC/OX CUTTING/WELDING/BRAZING The Unitor workshop cabinet for Gas Cutting, Welding, Heating and Brazing. Product No.

094-589861 094-589846

normally occurring onboard.

• Sturdy, corrosion resistant

a stable work surface for torch mounting the cabinet in corners or

Contents: Torch components:

Free distance above cabinet 310 mm.

Torch maintenance equipment

welding attachments. thickness.

Welder’s accessories: Soft skin welding gloves for gas and

5.01

455

AC/OX CUTTING/WELDING/BRAZING Silver brazing:

Aluminium joining:

on Yorcalbro.

Tin soldering:

Bronze brazing: Mild steel/heat resistant steels: 1.0 kg.

Cast iron joining and rebuilding:

Instructions and information:

1,1kg.

instruction manual.

5.01

456

AC/OX CUTTING/WELDING/BRAZING Welding and Grinding Goggles comfortable surfaces against the face. The ventilation slots are designed to

fogging of the glasses.

Product No.

Welding and grinding goggles 176-175273

Glasses for Gas Welding and Cutting The Unitor gas welding glasses have a diameter

Filter Shade Glass Filter Shade

and cutting

Product No. 10

176-633305

10 10

176-633313 176-633321

176-633354

176-633297

cutting thick material Protection glass Safety Spectacles

5.01

457

Safety grinding goggles non mist

176-632943 176-632950 176-653410

AC/OX CUTTING/WELDING/BRAZING Accessories Heat-Resistant Mitten

by acetylene cylinders and outlets to make

Product No.

Heat resistant mitten

176-233148

Gas Welding Glows without hindering feeling or move ability for handling torch valves or rod while Product No.

176-632794

EN 388 3232

Triplex Gas Igniter mounted on head. Product No.

176-633198 176-633206

Miscellaneous Welders chalk is used to mark out

mark on the surface to be heated. When the stick mark goes from solid to liquid, the

5.01 Product No.

196-632968 196-633156

458

AC/OX CUTTING/WELDING/BRAZING Portable Gas Equipment Product No.

mobility is necessary for other reasons, the gas cabinet and gas

176-526509

Portable Welding Table This sturdy work table is made of steel

jobs by allowing cylinders and the worksite as a unit. The necessary standard gas accessories, one of

stable work surface, all four legs are adjustable in length. The legs have and a good hull contact when used for arc welding. The table is excellent for use as a and in cases when it is needed outside

Standard Accessories Kit for Acetylene and Oxygen Cylinders

Acetylene and Oxygen cylinders. • Acetylene and Oxygen cylinder regulators. • Flashback arrestors. • Welding goggles. • Unitor Welding handbook.

5.01

459

as the legs may be detached and fastened under the table surface.

Weight Product No.

Welding table

176-176024

AC/OX CUTTING/WELDING/BRAZING Gas Welding Transportable Equipment A-40/O-40 Cylinder Trolleys Trolley for Two 40 L or 50 L Cylinders for Mobile Gas Welding.

for the test and examination of lifting gear used in the loading

accessories kit for gas welding.

Product No.

Standard gas welding accessories

176-778145 176-526509 170-500000

For One Cylinder

200 kg 10 kg

5.01

Product No.

Trolley for one cylinder

176-778147

460

AC/OX CUTTING/WELDING/BRAZING Gas Welding Transportable Equipment A-5/0-5 Cylinder - Trolley and Back-Frame according to the international labour of lifting gear used in loading and board use, and has a low center of 100 kg The strong lightweight steel

easy carrying and lifting. Two double brackets for Unitor rod containers give

trolley and the accessories box at the back will take all other necessary A double bracket with wing nut Oxygen cylinders.

gas cylinders and the consumables

Product No.

Standard gas welding accessories

5.01

461

176-778143 176-526509 170-500001

AC/OX CUTTING/WELDING/BRAZING Gas Hoses UNITOR’s hoses for Acetylene and

clean internally before connecting to Requirements

Acetylene and Oxygen hoses. Never use 20 bar 60 bar

extreme cold, oil and grease, chemicals, welding, gas welding or Oxygen cutting. Avoid undue stretching and kinking of hoses. Hanging hoses must be When gas hoses are not in use they

internal diameter. Product no Twin gas hoses,

176-526472

Twin gas hoses,

176-526478

Faulty hoses Hoses of doubtful quality or condition Twin gas hoses,

176-526482

176-576157

without cracks (do this by bending the hose). them in water while they are under immediately by cutting off the damaged

hoses are recommended. For medium Product no 195-175729

5.01

diameters are used.

462

AC/OX CUTTING/WELDING/BRAZING Self-retracting Hose Reel for Acetylene and Oxygen For safety, tidiness and reduced wear and tear The handling of hoses cluttering the

length of hose and store the rest out of harms way. This saves time, makes the job easier and contributes to

access for carts and trolleys and allows for easier cleaning. are of robust construction, it is easy design that vouches for safe and maintenance free usage.

service. All steel construction.

Technical data Medium

Acetylene

5.01

463

Max working pressure Mpa (psi)

Hose dimensions Hose size mm

Length m

Net weight Including hose Kg

Product no.

176-725260

AC/OX CUTTING/WELDING/BRAZING Hose connectors Hose connectors have loose hose

the connecting nut has an indentation in the corners of the hexagon for easy

of interchanging hoses. Hose connectors are used where long lengths of hose are needed. Screw

connection.

quick connection of hoses and regulators, or outlet stations, or to for use with Oxygen and Acetylene, and so designed that the interchange of Acetylene and Oxygen hose is

to connect the welding hoses – never use metal tubing.

Screw-couplings for Gas Hoses

Product no

sets. Each set consists of two hose sockets with nuts for connection to gas regulator and torch. Included is also a connection stub for using the set as a hose joint. Nuts and connection stub for Acetylene are left hand threaded and marked with a groove.

176-175588 176-175596 176-175604 176-175612 401-768416 401-768432 401-768507 401-729442 401-729443

5.01

464

AC/OX CUTTING/WELDING/BRAZING Quick Couplings for Oxygen, Acetylene and Shielding gases Acetylene

Hose size

6.3mm

Oxygen

Gas

Colour marking

Letter marking

Red

Shielding Ac Ox

Available wall chart:

N Red

Nut marking

Threads

n.a. Plain Plain

A O

Shielding gas

n.a. n.a. n.a.

Plain

n.a.

Application

Part Number

Regulator to Hose

176-734007

Hose to Hose

176-734004

Regulator to Hose

176-734001

Hose to Hose

176-734010

Regulator to Hose

197-320202

Hose to Hose

197-320201

Regulator to Hose

176-734016

Hose to Hose

176-734013

Regulator to Hose

176-734019

Hose to Hose

176-734022

Lubricants for gas fittings Oil, grease or other organic lubricants

If these lubricants thicken after long storage they must be thinned only with the thinners

5.01

465

AC/OX CUTTING/WELDING/BRAZING Gas Regulators for Cylinders Regulators should

Unitor gas regulators are designed for reliability and safety of use, and

The large adjustment knobs are colour coded red for Acetylene, blue for Oxygen and black for Argon, for easy

washers, hose connection for 6 mm instructions for use. standard Unitor gas cylinder valves. All the cylinder regulators have safety

Cylinder Regulator for

Acetylene bar bar bar m3

Cylinder connection Colour coding

Oxygen

Argon/CO2 w/flow meter

200

2 2000 Red 171-510001

171-510000

197-510010

171-619379 171-550186 171-550202 171-550152

171-550178 171-550194 171-550160

171-550178 171-550210 171-550160

5.01

466

AC/OX CUTTING/WELDING/BRAZING Connection

Operation

1. Never use a regulator for gases make sure that the outlet union on the cylinder valve and the connector

closed by turning the regulating screw so far out that it runs freely on its threads.

the gas cylinder, blow the cylinder the outlet or hold your hand in front gases must never be blown clean if there is any risk of ignition of the gas. 3. Check the inlet union gasket and

regulator until both gauges show

damaging the connection nut.

regulating screw outwards until it runs freely on its threads.

installed.

NOTE:

467

instructions for the torch you are using.

sure to use original gaskets and not homemade ones, which may be a source of danger.

regulator and the hoses in use, a

5.01

by turning the regulating screw inwards until the correct working

AC/OX CUTTING/WELDING/BRAZING Flashback back through the torch and into the in the worst cases even the regulators. cylinder, which lacks the necessary its design.

Various types of flashback:

can occur. Flashback is mostly caused

which occurs when the torch is lit. The

into the torch with continued burning in the

sound from the continued combustion. If the

circumstances should welding or cutting and the handling routines have been checked thoroughly. faulty handling, bad maintenance of

the dangers this entails, the welding

5.01

valves.

468

AC/OX CUTTING/WELDING/BRAZING Flashback Arrestors

Flashback Arrestors Type W-66S and S-55 • Indicator ring showing that the been activated. The ring is also arrestors for acetylene and oxygen, as incorrect maintenance or use of

torch, and are only noticed as a

As a general arrestors should

with the units.

faulty handling, maintenance or

At inlet Product no

through the hose(s). In some cases

110

110 000

10 10

ultimately reach the cylinder. The are designed for use both with gas cylinders and gas outlet stations and

or cylinders.

• Pressure relief valve to vent off

5.01

• Indicator lever showing that the activated. The lever is also used

469

Models

85-10

Product No.

FR-20

Product No.

W-66S

Product No.

S-55

Product No.

Features

FA PV

Features

Non-resettable

Inlet Filter

Resettable

Inlet Filter

Resettable

Non-resettable

Attach to Cutting Torch (UCT-500)

Application

Mobile AC-OX

GDS Outlet Station

Fixed system i.e. Gas Distribution System Cylinder Central

Application

FA = Flame arrestor, NV = Non-return valve, TV = Temperature sensitive cut-off (105°C), PV = Pressure sensitive cut-off; RV = Relief valve

UNITOR Flashback Arrestor Product Range and Application

AC/OX CUTTING/WELDING/BRAZING

5.01

470

AC/OX CUTTING/WELDING/BRAZING The Acetylene/Oxygen Flame

torch. Inaccurate regulators or long

occur. NOTE!

to the torch. In such cases, the actual should be checked. Too low gas the inner cone.

This reaction needs as much Oxygen required Oxygen is taken from the surrounding air. Therefore, always

The neutral flame

5.01

471

steel welding work.

AC/OX CUTTING/WELDING/BRAZING

The carburizing flame

in colour than the inner cone, but is

only slightly for Oxygen, obtaining a

of Aluminium and Aluminium alloys, and for soft soldering.

Oxygen (and if necessary reducing the

The oxidizing flame

5.01

472

AC/OX CUTTING/WELDING/BRAZING Operating instructions for Cutting Torch a. All valves are shut at the

i. Press down the cutting Oxygen lever

valves (1 and 2) are shut, the Oxygen (7). The torch is now ready are screwed so far out that they run freely on their threads, and all torch

long are given in the cutting table. Other materials and hoses may table.

torch Oxygen needle valve must be

cutting Oxygen valve lever (8) at the same time. Then shut the torch Acetylene needle valve (6). k. The torch is normally extinguished needle valve (6) and then the valve

Oxygen (1) and Acetylene (2). and close all valves. the cutting Oxygen valve lever (8), by means of the Oxygen regulator adjusting screw (3). e. Release the cutting Oxygen valve lever (8) and shut the valve for

Important

the cylinder valves (1 and 2) and the torch needle valve for the other gas shut. Finally, make sure that all torch valves are shut, and unscrew the regulator adjusting screws (3

needle valve (6), and adjust the their threads. Acetylene regulator setting screw

2. Check the sealing rings at regular intervals for damage, deformation defective. To facilitate changes of

sooting when the torch is lit.

5.01

473

Oxygen (7).

and sealing surfaces in the torch connection head should be lightly Oil or grease must never be used.

AC/OX CUTTING/WELDING/BRAZING

Cutting table – UCT-500

Product No.

0.2

170-174698

170-174706

170-174714

1600

3600

6800

300

170-174722

700

Table for groove-cutter (Unitor Product No. 174730) Working mm Width

Oxygen

Acetylene

Oxygen

Acetylene

5.01

474

AC/OX CUTTING/WELDING/BRAZING Cutting Procedure

which burns (cuts) mild steel.

most easily done, by starting the cut as bring the cutting torch towards you. Starting the cut from an edge

within the limits given in the cutting table and ensure that the slag blows from the bottom of the cut. Methods for improving cuts

5.01

475

angle iron can be used to guide the torch for both square and bevel cuts.

AC/OX CUTTING/WELDING/BRAZING Starting a cut by piercing

inclining the torch slightly so that the

3. With the cutting oxygen lever fully

Cutting guide

cutting torch

5.01

Circular motion bar

476

AC/OX CUTTING/WELDING/BRAZING Common cutting faults A. A correct cut shall give square corners and a smooth cut surface

surface with gouges in the lower

lines in the surface and a rounded lower edge.

contaminated cutting oxygen hole in

surface.

5.01

477

through the surface, contaminated with slag and melted steel.

WELDING HANDBOOK NOTES

5.01

478

AC/OX CUTTING/WELDING/BRAZING Operating Instructions For UCT-500 Brazing, Welding and Heating Torch a. All valves are shut at the valves (1 and 2) are shut, the regulator adjusting screws (3 and run freely on their threads and both closed.

Acetylene needle valve (6). j. The torch is normally extinguished needle valve (6) and then the torch and close all valves.

given in the welding table.

Important

Oxygen (1) and Acetylene (2).

the cylinder valves (1 and 2) and

regulator adjusting screw (3).

the torch needle valve for the other gas shut. Finally, make sure that all torch valves are shut, and unscrew the regulator adjusting screws (3 their threads.

valve (6), and adjust the working

2. Check the sealing rings at regular intervals for damage, deformation defective. To facilitate changes of and sealing surfaces in the torch connection head should be lightly

troublesome sooting when the torch lightening lit.

5.01

479

torch is now ready for use.

Oil or grease must never be used.

AC/OX CUTTING/WELDING/BRAZING

freely during adjustment. for one gas at a time. To adjust the

Table for welding, brazing, heating

1 Product No.

2 3

3 7

174565 174573 174581 174599 174607 80

230

jobs (heating torch) 174615

174623

1000

174631 1800

0.3

80 73

230

1136

1800 1636

1000

5.01

480

AC/OX CUTTING/WELDING/BRAZING Maintenance of Blowpipes holes with Unitor cleaning drills. These twist them, just stick them straight in

drills for cleaning. These can ruin the smooth surfaces of the hole.

should not be enlarged in any way. carefully cleaned externally by means steel brush.

Grinding blowpipes and cutting nozzles If the end of a welding or cutting

hole with an uneven edge or widened

becoming smaller than that of a new always be left having a length at least equal to the diameter of the hole. It ought not to be shorter than this, to

5.01

481

material may be removed.

WELDING HANDBOOK NOTES

5.01

482

AC/OX CUTTING/WELDING/BRAZING Heating Techniques is frequently used for heating method, normally demanding no other steel for bending or forming. knowledge of how the work reacts to heating and cooling, and how the in straightening. need to be careful not to overheat and

constructions.

high tensile steel.

The steadily growing use of welding calls for an economical method of dealing with the deformations, which often arise in welded steel constructions.

as this can cause deterioration.

On cooling, the heated metal contracts, with the result that the end of the section

5.01 these heating wedges.

483

AC/OX CUTTING/WELDING/BRAZING Flame straightening techniques

direction start at the arrow head 1.

Angle bars, straightening in web direction the arrow head, and then no. 2.

direction. start at arrow head 1.

5.01

484

AC/OX CUTTING/WELDING/BRAZING

the arrow head, and then no. 2.

sideways the arrow head, and then no. 2.

direction starting from the arrow heads 1.

sideways First heat the web no. 1, starting at the

5.01

485

AC/OX CUTTING/WELDING/BRAZING Welding Techniques After lighting the torch, adjust the undertaken.

In gas welding, the joined edges of

Welding can be either leftward or rightward technique. The direction of weld is selected according to the thickness of the material. Rightward

Acetylene is used for welding Aluminium.

are therefore recommended to use

is used for welding cast iron, brass,

method. In either case, make sure and evenly on the reverse side of the

materials.

Rightward welding

5.01

486

AC/OX CUTTING/WELDING/BRAZING Leftward welding the torch in the welding direction, this is called leftward welding. The welding

such as aluminium and brass, always

Horizontal leftward welding

rotational movement to melt both hold the torch too far away from the When the material begins to melt, feed small movements, and welding is in

Vertical leftward welding welded by vertical leftward welding. Weld in the same manner as for

Vertical leftward welding, filler rod angles:

5.01

487

AC/OX CUTTING/WELDING/BRAZING Rightward welding

Rightward welding Rightward welding is used for material

follows the torch in the direction of the weld. Rightward welding is recommended for the joining of sheet

welding direction.

rightward welding, the risk of tensions case of leftward welding.

Horizontal rightward welding

Vertical rightward welding This is used for material thicknesses

must not be moved sideways. It is easier to handle the rod if it is bent as shown in the drawing. See also

Vertical rightward welding and rightward overhead welding.

5.01

488

AC/OX CUTTING/WELDING/BRAZING Butt Joints for Gas Welding of Steel

Flange butt joint

Close square butt joint

5.01

489

AC/OX CUTTING/WELDING/BRAZING Consumables and parameters for Gas Welding MS-200 Description

Packaging data:

Product no. mm 2.0

280

092-539551 092-539569

3.0

Neutral

ALUMAG-235 Description

magnesium as the main alloying element. Packaging data:

Product no. mm 3

092-514265

Product no. 092-603043 Slight acetylene

5.01

the section Consumables.

490

AC/OX CUTTING/WELDING/BRAZING Soldering and Brazing Techniques

wetting of the base material. limited, and they cannot be heated

material to be joined. When heated, it will reach melting removed by rinsing in clean water and brushing.

material.

Fluxes

avoid contact with eyes, mucous

Advantages of brazing and soldering materials which does not involve

material. Fluxes serve three basic functions that are required to obtain a successful result. 1. Flux eliminates the oxide layer on the surface of the base material

soldering.

corrosion resistance. material in such a way that it melts slightly before correct working little deformation and change of

5.01

491

AC/OX CUTTING/WELDING/BRAZING A good brazed or soldered joint depends on: 1. Correct mating of the surfaces to be joined. Whether the joint is to be

2. It is essential that the surfaces to be bonds.

metal.

Soft soldering

Heat indirectly when using a welding torch for soldering.

Brazing tin (Sn). Soft soldering is commonly used in electrical connections, and in joints required.

obtain joints with high mechanical

a weaker joint. The solders alloyed with silver will normally have the best mechanical strength.

that the entire soldering area reaches

the solder.

5.01

492

AC/OX CUTTING/WELDING/BRAZING Edge preparation Capillary brazing

material, which melts to a thin

on the surface tension of the liquid between the surfaces.

Heating should be done with a neutral removing oxides from the surface. Heat the entire area of the joint uniformly. Starting with the thicker

Surface 0.1 mm.

When the joint has reached correct should be touched to the joint, and the

released, and if the material allows, cooled off in water.

5.01

493

Flux residues should be removed to avoid corrosion.

Heat evenly

AC/OX CUTTING/WELDING/BRAZING Edge preparation Braze welding

technique is, however, similar to gas welding with the leftward method, and must be rounded off. wide range of metals, and is also used for rebuilding wear surfaces. As with

Use the leftward technique for

described under gas welding.

5.01

494

AC/OX CUTTING/WELDING/BRAZING Consumables and parameters for Brazing TIN 241 AG Description conductors, electrical connections, electrical instruments, radios, batteries, Packaging data:

Product no. mm 093-777973 Preferably use soldering

AG-45-253 Description

Packaging data:

Product no. mm 2.0

093-519744

28 093-778461

Neutral 093-233604

AG-60-252 Description

Packaging data:

Product no. mm 093-233601

2.0 093-778461

5.01

Neutral

093-233604 093-604371 the section Consumables.

495

AC/OX CUTTING/WELDING/BRAZING Consumables and parameters for Brazing BRONZE-264 Description

Packaging data:

Product no. mm 3

1.7

093-174326 093-603076 Neutral or slight oxygen

FC-BRONZE-261 Description

Packaging data:

Product no. mm 2 3

093-233551

093-233569 093-603076 Neutral or slight oxygen

5.01

the section Consumables.

496

AC/OX CUTTING/WELDING/BRAZING Consumables and parameters for Gas Welding FC-WEARBRO-262 Description

Packaging data:

Product no. mm 3

093-233577

1.1

093-233585

603068 Neutral or slight oxygen

CAST IRON-237 Description

Packaging data:

Product no. mm 12

0.7

096-682310

764487 Slight oxygen

5.01

the section Consumables.

497

WELDING HANDBOOK NOTES

5.01

498

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Introduction Argon

Oxygen Acetylene

5.02

499

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

Introduction

be serviced in a reasonable time.

always having enough full cylinders in stock, ready to meet each customer’s immediate needs.

5.02

500

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM ARGON Product name

Formula

Argon

Hazard class

Appearance and colour

IMDG code

Colourless, odourless

2.2

Specific gravity (Air=1)

Substance Identification

1.38 (heavier than air)

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents Filled Pressure (cu. Metres) (bar) at 15°C (See note 1.) (max)

Nominal Wt. Of Gas (kg) (See note 1.)

Approx. Dimensions (mm) (See note 2.)

Approx. Cylinder Wt. (kg) (See note 3.)

2.2

200

3.6

1.1

200

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

ARGON

known as the “rare”, “inert” or “noble” gases. The terms inert and noble mean that the gases have

the harmful effect of the air.

5.02

501

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM ARGON- CARBON DIOXIDE MIXTURE Product name

Formula

Unimix10

Hazard class 2

Appearance and colour

IMDG code

Colourless, odourless

2.2

Specific gravity (Air=1)

Substance Identification

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents Filled Pressure (cu. Metres) (bar) at 15°C (See note 1.) (max)

2.2

Nominal Wt. Of Gas (kg) (See note 1.)

200 200

Approx. Dimensions (mm) (See note 2.)

Approx. Cylinder Wt. (kg) (See note 3.)

18 17.1

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

ARGON-CARBON DIOXIDE MIXTURES

5.02

502

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM ARGON- CARBON DIOXIDE MIXTURE Product name

Formula

Unimix20

Hazard class 2

Appearance and colour

IMDG code

Colourless, odourless

2.2

Specific gravity (Air=1)

Substance Identification

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents Filled Pressure (cu. Metres) (bar) at 15°C (See note 1.) (max)

2.2

Nominal Wt. Of Gas (kg) (See note 1.)

200 200

Approx. Dimensions (mm) (See note 2.)

Approx. Cylinder Wt. (kg) (See note 3.)

18 17.1

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

ARGON-CARBON DIOXIDE MIXTURES

5.02

503

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM CARBON DIOXIDE Product name

Formula

Carbon dioxide

Hazard class

CO2

Appearance and colour

IMDG code

Colourless, odourless

2.2

Specific gravity (Air=1)

Substance Identification

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents (cu. Metres) (See note 1.)

Nominal Wt. Of Gas (kg) (See note 1.)

Approx. Dimensions (mm) (See note 2.)

230 x 1210

Approx. Cylinder Wt. (kg) (See note 3.)

CgA320 CgA320

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

CARBON DIOXIDE combustible. It is considered a inert gases. The terms inert mean that the gases have an extremely weak

by burning fossil fuels or chemical reactions.

5.02

504

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM OXYGEN Product name

Formula

Hazard class

Oxygen

Appearance and colour

IMDG code

Colourless, odourless, tasteless gas Specific gravity (Air=1)

Substance Identification

1.11 (Slightly heavier than air)

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents Filled Pressure (cu. Metres) (bar) at 15°C (See note 1.) (max)

200

Nominal Wt. Of Gas (kg) (See note 1.)

Approx. Dimensions (mm) (See note 2.)

1.3 7.8

Approx. Cylinder Wt. (kg) (See note 3.)

12 230 x 1360

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

OXYGEN Oxygen (02

5.02

505

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Rules relating to Oxygen – Oxygen that leaks out into the air increases the danger of combustible materials igniting, i.e. body hair, occur even with a small increase in the Oxygen content of the air, and can cause serious burns and other injuries. – Never use Oxygen instead of air to start a diesel engine. Never use Oxygen to blow dust from working clothes. lf clothing has been in Oxygen content it may take a long time to get rid of the excess Oxygen, often several hours.

combustion.

Oxygen-deficient atmospheres The normal Oxygen content of air of Oxygen content in air, either by

given in the table below.

– Never use Oxygen to freshen the air

Oxygen Content (% by Volume)

Effects and Symptoms (At Atmospheric Pressure)

recovery with treatment.

Note: Exposure to atmospheres containing 12% or less Oxygen will bring about unconsciousness without warning and so quickly that the individual cannot help or protect himself.

5.02

506

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM ACETYLENE Product name

Formula

Acetylene

Hazard class

C2 H2

Flammable gas

Appearance and colour

IMDG code

Pure acetylene is a colourless gas with an ethereal odour Commercial (carbide)acetylene has a distinctive

2.1

Specific gravity (Air=1)

Substance Identification

Flammable limits % by volume

Extinguishing media

CO2

Unusual fire and explosion hazard

Cylinder characteristics Cylinder Size

Outlet Connection

Nominal Contents (cu. Metres) (See note 1.)

0.7

Nominal Wt. Of Gas (kg) (See note 1.)

Approx. Dimensions (mm) (See note 2.)

Approx. Cylinder Wt. (kg) (See note 3.)

230 x 1360

0.8 6.2

1. Actual contents and weight of gas in individual cylinders will vary about the nominal contents and weight of gas indicated.

found among cylinders manufactured to older standards.

5.02

507

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM ACETYLENE

gas. It is can be manufactured by reacting Calcium Carbide with water in Acetylene generators. Ordinary commercial grades of Acetylene

odour. The gas is slightly lighter than air.

extinguisher.

Acetylene is that the gas can

Acetylene alone burns in air with is subjected to shock during storage mixed with Oxygen the combustion is more intense than in air, and because of the Acetylene’s high carbon content

for welding and for cutting. Explosion and decomposition hazards

gaseous Acetylene the cylinders for This eliminates the risk that any which Acetylene in gaseous form may

of Acetylene and air or Oxygen is

with Acetone, in which the Acetylene actually dissolves. The combination solvent allows the Acetylene to be contained in cylinders at moderate

good ventilation must be assured in used.

during normal handling and use. However, there still exists the chance by careless handling of the cylinder,

5.02

508

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

longer be touched by the bare hand

shell rises, starting at the area commenced. (only evident when the cylinder is in use and a regulator with gauges is

contains soot, and has an unusual smell. have started in the cylinder, shut the it. The cylinder must be checked for feeling the cylinder shell all over by hand.

cylinder must not be moved. Start cooling the cylinder immediately with large amounts of cold water from a evacuated from the area. When the cylinder has been cooled until the water no longer steams from the shell, it can be moved to the railing and thrown over board. Remember that cooling must be continued without

WARNING: The top valve of a cylinder containing decomposing Acetylene must be kept shut at all times! Fatal mistakes have been made in valve fully, in the mistaken belief that

railing immediately and thrown over board. The cylinder must be cooled much faster than it can be released, with the result that the cylinder may

Inhalation hazards

5.02

509

and cooling the cylinder with large quantities of cold water, but if this is to succeed it must be commenced

Acetylene was combined with Oxygen

continue until the cylinder remains cold. However, out of consideration

air reduces the Oxygen content

to save the cylinder but throw it over

that Acetylene is handled only in well ventilated areas.

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Important safety reminders Under certain conditions Acetylene

quantity of Acetylene normally takes 8 hours.

For this reason contact between Acetylene and these metals,

cylinder falls and the gas is released

concentration alloys must be avoided. occurs in the cylinder, rather similar alloys, and certain nickel alloys, are suitable for use in Acetylene service under normal conditions. Never use makeshift hose connectors made out

sodawater, and some of the Acetone will emerge with the gas. This is harmful both to the cylinder and to the weld. Admittedly, Acetone burns, but with very different characteristics from Acetylene. The rule is therefore that the cylinder should not be

hose connector. Acetylene cylinders must be stored cylinders are used when lying on their will run out and into the reduction valve and hose.

(maximum 30 minutes) extraction from

Drawing gas from Acetylene cylinders

After that, the cylinder must be set

Acetone. An Acetylene cylinder with

a single Acetylene cylinder can

16 litres of Acetone. The Acetylene gas dissolves in (is absorbed by) the

central installation is normally used. The following gives the extraction rates for various combinations of

Acetylene Cylinders A-40

1 2 3

Maximum extraction, nl/hr

Continuous

Intermittent

700 2100 2800

10000

5.02

510

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Rules and safety precautions for handling and use of Gas Cylinders – Always make sure that the cylinder moving the cylinder. Cylinders, when not in active use, should from falling. – Never use slings, chains or magnets to lift gas cylinders. Use racks, designed for hoisting gas cylinders, lugs. – Cargo nets are not recommended for lifting gas cylinders. If a cargo net has to be used, it must be covered internally with a good from sliding out through the mesh. – If a crane or winch is used to lift gas cylinders, and the crane driver is signalman must be stationed where he can see both the load and the crane driver.

to fall, or knock against one another. always be handled as if they were full. Never be indifferent or careless

5.02

511

treat all cylinders as if they were full.

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM – If the cylinder valve cannot be can lead to serious accidents. cylinder aside and inform the

– Never use gas cylinders as rollers

On valves intended for valve keys, – Take care to avoid using or storing

or shut. cylinder valve outlet union and the

circuit. Never touch a cylinder with a live electrode. water.

sure that seals are in good condition

should not be subjected to

arrestors, hoses, etc., designed for use with the gas in question.

of gas cylinders to moisture or salt corrosive chemicals or gases. – The information that is cast or be altered or removed. feature of a gas cylinder or valve. WARNING It is extremely dangerous, and transfer oxygen or acetylene from one cylinder to another on one’s own. Filling of gas cylinders shall be carried

Failure to observe this rule has unfortunately led to the loss of several lives.

5.02

512

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Gas Distribution System for Acetylene and Oxygen

bushing

Stainless steel Closing valve Connecting nut Closing valve

Connecting nut

Plug AC Non return valve

) return valve

Hose

AC HP hose

Rack for 1 cylinder Rack for 2 cylinder Oxygen

Acetylene

1763131

Complete Standard Centrals The standard centrals for Acetylene and Oxygen include all items necessary for the gas central room, including signs,

Product

Product Number

Note

Spares For Regulators Working gauge, Acetylene Contents gauge, Acetylene Working gauge, Oxygen

5.02

513

Contents gauge, Oxygen

Product Number

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

The UnitorTM Gas Distribution System (GDS) Safety may cause serious accidents if handled carelessly. Unitor gas distribution system is based on safe and correct storing of the gas cylinders on board, in a well ventilated room with direct

• Cylinders and accessories are less subject to • • Efficiency gas distribution system on is available simultaneously from several cylinders when needed.

Twin valve unit AC Regulator

Economy

AC Flashback

is used, the total number of cylinders on board is normally Hose stem

Hose stem

5.02

almost 100 kilos. Stretch relief bracket

514

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Signs For Gas Distribution System

attached to the bulkhead by means of screws or glue. A. Signs for entrance doors (size in mm HxW)

Product Number

611 1832021

B. Instruction signs for gas central

Product Number

611 1832361 C. Signs for outlet station

Product Number

Gas Outlet Station Model 700 Unitor outlet station model 700 for bulkhead mounting is designed to obtain the highest degree

Product

Product Number

Steel cabinet for outlet station 700 Fibreglass cabinet for outlet station 700 Spares

5.02

515

Product Number

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM 1

5.02

516

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Gas Distribution Outlet Station Workshop Setup

Outlet Station

Accessories for Single Hose without Fittings

works at 10 m distance with use of twin

Hoses

5.02

517

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

AC-OX Welding, Brazing and Cutting Kit

Product Number

twin hose and secure the hose

System Poster for quick

Product Number

the source hence limiting the gas hoses onwards

ARRESTOR body and connect it directly to

Product Number

(one after another) and with the cutting oxygen lever

5.02

slightly after the needle valves close.

518

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Gas Distribution System for acetylene and oxygen Unitor’s gas distribution system for the storage and distribution of Acetylene and Oxygen was introduced in order

gas cylinders in the engine room and with the risk this entailed, has now

collaboration with the Norwegian maritime authorities, and is now included in the rules and regulations location of the cylinder central with welding gases on board Norwegian countries have shown interest in the system, and have introduced it for

it easy to get rid of the cylinders in

nations. The installation of Unitor’s

everybody on board knows exactly where the cylinders are located.

the risk of accidents to a far greater extent than before, because the gas cylinders remain stored in the cylinder store with the welding gases being fed

gas is assured, even for jobs needing large amounts of gas, e.g. for heating from two or more cylinders at the same time, which means less gas

Naturally, this does not entirely eliminate the need to take cylinders out of the store from time to time in order to carry out certain welding or

5.02

519

cylinders.

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Extracts from regulations relating to central system A central system for Acetylene and Oxygen consists of a cylinder store or more outlet stations. The various

be made by butt welds, of good – Connections such as unions,

are subject to rules laid down by the – Normally, only two outlet stations from the cylinder store or cabinet. – The gas cylinder store shall be a shall have bulkheads, deck and deckhead of steel and have a rooms.

stations must be obtained in each individual case. the gas cylinder valves and other valves shall be shut. from some of the rules relating to

– The gas cylinder store shall be insulated, ventilated and so

rules are to be found in “Regulations for the welding gases Acetylene and

– The ventilation system shall not be connected to any other ventilation system on board. – The room shall not be used for any gas cylinders.

obtained from Unitor.

Approval and certification of central plants

– Electrical installations in a gas cylinder system shall be of degreased, blown through and – Acetylene and Oxygen cylinders

equivalent, and of wall thickness not The original of the installation

5.02

520

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

The layout of the central system

has been set on the regulator (8 bar for oxygen and 0.8 bar for acetylene), the setting is locked by tightening the locknut. This makes it unnecessary

The layout of the central system and

continuous deck, and it must have

set by means of a regulating valve at the outlet station, as required for

to the central store must be marked with a notice warning of gas under

the central regulator (8) must be

Fastening arrangements (1) for the number of Acetylene and Oxygen be welded to the bulkhead. The design

not less than 3 metres above deck, and the outlet must be marked with

easy to release the cylinders in case

threaded for Acetylene, to eliminate

red for Acetylene. bulkheads or decks it must be led

cylinders.

are to be fastened to bulkheads with

connect in series any desired number

to be installed at suitable locations which are well ventilated and where mechanical damage. The standard cabinet (12) which is delivered with the

located. The regulator has an adjusting

5.02

521

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM

from time to time. in work. regulators to set the desired working

5.02

522

GAS SUPPLIES AND GAS DISTRIBUTION SYSTEM Pos. No 1 1 1 2 2 3 3 3 3

6 6 7 7 7 7

Prod. no Rack for 2 cylinders. Rack for 1 cylinder. 1763131

Non return valve Ox. Non return valve Ac. High Pressure connector Ox. High Pressure connector Ac.

Closing valve Ox W bracket. Closing valve Ac.

10 12 12 13

Stretch relief bracket.

Signs for entrance doors

Instructions signs for gas central

1832021

1832361 Signs for outlet station

5.02

523

central regulators.

MISCELLANEOUS INFORMATION International system of units

Roman numerals 2

Common gauge series for sheet thickness and wire

Abbreviations and welding terminology

6.00

524

MISCELLANEOUS INFORMATION International System of Units (SI)

Quantity

mass time electric current amount of substance luminous intensity

solid angle acceleration activity (of a radioactive source) angular acceleration angular velocity area density

Unit

Formula

Base Units metre (m) kilogram (kg) second (s) kelvin (K) mole (mol) candela (cd) Supplementary Units radian (rad) steradian (sr) Derived Units 2

square metre

m2 3

electric conductance

farad (F) stemens (S)

electric inductance

henry (H)

electric resistance electromotive force energy

ohm ( )

force frequency illuminance luminance

newton (N)

joule (J)

N•m 2

lux (lx)

lumen (lm)

cd•sr

weber (Wb) tesla (T)

mangetomotive force watt (W) 2

6.00

525

quantity of electricity quantity of heat

coulomb (C) joule (J)

A•s N•m

MISCELLANEOUS INFORMATION Quantity

Unit

Formula

radiant intensity stress thermal conductivity velocity viscosity, dynamic viscosity, kinematic voltage volume wavenumber work

Pa•s

cubic metre

joule (J)

N•m

Multiplication Factors 12

1 000 000 000 000 1 000 000 000 1 000 000 1 000 100 10 0,1 0,01 0,001 0,000 001 0,000 000 001 0,000 000 000 001 0,000 000 000 000 001 0,000 000 000 000 000 001

6 3

Prefix

SI Symbol

tera giga mega kilo

milli micro nano

k h da d c m μ n

femto atto

f a

2 1

THE PHONETIC ALPHABET A

Charlie

Juliet

Kilo

Sierra

Tango

Uniform

M V

Echo

Foxtrot

November

Oscar

Whiskey

G P Y

Hotel

India

Quebec

Romeo

Yankee

THE GREEK ALPHABET

6.00

526

MISCELLANEOUS INFORMATION General conversion factors Unit

Conversion to

Linear Measure mil (0,001 inch) inch foot yard mile nautical mile

Multiply by

millimetre millimetre metre metre kilometre kilometre

Square Measure square inch square inch square foot square yard acre acre square mile square mile

0 0000 0 0 0 0

square millimeter square centimeter square metre square metre square metre square foot acre square kilometer

Volume cubic inch cubic foot cubic foot cubic foot cubic yard ounce (U.S., liq.) quart (U.S., liq.) gallon (U.S.) gallon (U.S.) barrel (U.S.Petroleum) barrel (U.S.Petroleum) Mass grain

0000 00 0 0,83610 00000 000 00 00000 00

cubic centimeter cubic metre gallon (U.S.) litre cubic metre cubic centimeter litre litre gallon (U.S.) litre milligram gram kilogram metric ton metric ton

short ton long ton

16,38700 0,02832 000 28,32000 0 000 0 0,83270 00 00000 000 0000 000 0 0 1,01610

Reciprocal

3,281

0,3863 0,06102 0,1337

0,03382

0,0238

1,1023

Pressure or Stress 2 2

00000 00

(ksi) 2

bar 2

mm Hg

6.00

527

0,70310 760,00000 00

0,001316

MISCELLANEOUS INFORMATION

Unit

Conversion to

Multiply by

Reciprocal

Pressure or Stress (Cont.) 1,0130 0,1013 133,3200 000

bar torr (mm Hg) inch of water foot of water

0,1000

2,307 10,00

Work, Heat and Energy joule joule joule

calorie

0000 0 0 778,0000 0 00

kilocalorie kilogram metre watt joule kilowatt

watthour

3600,0000

00 00 00 00 00 00 00 000,0002778 00

Miscellaneous 000 0000 000 000 10,7600 0 0 00

cubic foot (STP) litre (STP) cubic metre

gram mole (gas) board foot

metre3 newton newton (N)

00 00 00 000,00236 00 00 00 000,102

Roman Numerals Basic numerals:

I 1

C 100

1000

Combination rules: – A smaller numeral in front of a larger is subtracted from the larger – A smaller numeral after a larger is added to the larger – Equal numerals after each other are added together

with 100.000.

6.00

528

MISCELLANEOUS INFORMATION Metric and Decimal Equivalents of Fractions of an Inch Inches

Inches

0.031 0.063 0.078 2.3812 2.7780

0.172 0.188 0.203

0.672 0.688 0.703

0.266 0.281

0.766 0.781

0.313 0.328

0.813 0.828

20.6371

8.7310 21.8277

23.0183 11.1122

23.8120

1.000 Wire cross sections AWG 20 18 16 12

6.00

529

mm2 0,823 1,31 2,08 3,31

AWG

mm2

AWG

mm2

10 8 6

0 08,367 13,30

33,62

0 0 0 0 107,2

MISCELLANEOUS INFORMATION Common Gauge series used for Sheet thickness and Wire Name

Abbreviation

Name

Abbreviation

Thickness in mm AI(U.S.) Copper Brass B&S Gauge No. AWG

Galv. Iron GSG

Al(U.K.) SWG

Stainless Steel Steel MSG Sheet USG Strip BWG

Zinc AZG

12,7 11,8 11,0 10,2 8,8 8,2 7,62 7,01

1 2 3

6,07 0,20

6 7 8

0,30 0,36

3,66 3,66

10 11 12 13

2,31 2,06 1,83 1,63

16 17 18

1,30

20 21 22 23

0,81 0,71

1,02

3,78

3,18 2,67 2,03 1,80 1,63 1,32 1,17 1,02 0,86 0,71

1,70 1,63 1,22 1,02 0,81 0,71 0,61

3,76 3,18 2,78 2,38

2,11 1,83

1,70 1,37 1,22 1,07

2,77

0,61 0,71 0,81 1,02 1,27

1,27 1,11 0,87

0,76

1,07 0,81 0,71

1,78 2,03

0,71 0,61

3,18

6.00

530

MISCELLANEOUS INFORMATION Physical properties of some elements Symbol Aluminum Antimony Argon Arsenic

Al Sb A As

Density g/cm3 20°C 2,70 6,68

2,3 3,12 Cadmium

Calcium Carbon Chlorine Chromium Colbalt

Ca C Cl Cr Co

Fluorine Hafnium Helium Hydrogen Iodine Iron

1280 271 2300 –7,2 321

7,2

1063 3300

6.00

531

Density g/cm3 20°C

Density Point °C

7,2

1260

10,2

2620

1,82 21,37 0,87

1773 62,3

Hg Nickel Niobium

Ni Nb

Nitrogen Oxygen Platinum Potassium

N O P Pt K

Rhodium Selenium Silicon Silver Sodium

Rh Se Si Ag Na

Tantalum Tin

S Ta Sn

Titanium Tungsten

Ti W

1083

220

2,07 16,6 7,31 1800 3370 1710

7,87 186

Symbol

660 630

–103

Cu F Au Hf He H I Fe Pb

Density Point °C

MISCELLANEOUS INFORMATION Hardness comparison table Brinell HB

Vickers HV (>5 kpl)

100

110

120

130

160

170

180

200

210

220

230

Rockwell Tensile (*HRB) strength HRC N/mm2

260

270

280

Vickers HV (>5 kpl)

300 310 320 330

368 376

360 370 380

280

Rockwell Tensile (*HRB) strength HRC N/mm2 30,3

1010

32,7 33,8

1070 1100

36,0 37,0 38,0

1170

610 620

1600 1660

660 670 600 620

602 20,2 21,2 22,1 23,0 23,8

260

Brinell

627

661 672 682

26,2 27,6 28,3

660 680 700 720

701 711

760 780 800 820 860 880

60,2 61,1

2030 2080 2130 2170

62,7

66,3

68,0

6.00

532

MISCELLANEOUS INFORMATION Corrosion of Galvanic couples in Sea water at 4–27 °c No marking

Unfavorable

Uncertain

increased moderately or severely.

O tolerable limits.

S E L

in the left column.

6.00

533

MISCELLANEOUS INFORMATION

6.00

534

MISCELLANEOUS INFORMATION Temperature Scales

Celsius T (K) Kelvin tre Rèaumur tf Fahrenheit

t t t t

f re

tf tf tf T T T TR TR TR

6.00

535

f R

–32)

MISCELLANEOUS INFORMATION Pressure variations related to Temperature

6.00

536

MISCELLANEOUS INFORMATION Abbreviations and Welding Terminologi

ACETONE Colourless gas with high carbon content, lighter than air, C 2H 2. AC

Alternating current Removal of material from electrically conductive metals by means of an electric arc between carbon electrode and electrode.

AlSl

Abbreviation for American Iron and Steel Institute. Steel which, in addition to carbon, contains certain alloy

Instrument for measuring electrical current measured in

Removal of internal stresses in metal by heating and slow cooling. ANSI

Abbreviation for American National Standard Institute.

welding.

construction of welded installations.

AUSTENITE

Nonmagnetic stainless steel that cannot be hardened by heat amounts of nickel.

6.00

537

MISCELLANEOUS INFORMATION

AWS

Abbreviation for American Welding Society.

to be used. ferromanganese and ferrosilicium. endurance.

and corrosion resistant steel with satisfactory resistance of steel may be unalloyed, low alloyed or stainless. Inside diameter of hole, tube or hollow object. The method where surface bonding between the base

machined to a bright surface to remove scale or oxides.

Weld which has melted through, resulting in a hole and

institute).

mm.

6.00

538

MISCELLANEOUS INFORMATION

CAST IRON of cast iron. The electrode has a core of nickel or nickel alloy CE

Area of weld that has not fused with the base metal. CROWN

Weld crown that is curved inward.

CONSTRUCTION

metal. CONTOUR CROWN

Weld crown that is curved outward.

COPPER CORROSION

Eating away of material by a corrosive medium.

CRATER section. CRATER CRACKS

Cracking that occurs in the crater.

CSA in the relevant standards for Canada and the USA. CUNIFER

Electrodes with acid or rutile organic coatings which

6.00

539

MISCELLANEOUS INFORMATION

of a weld.

Flow of current (electrons) in only one direction, either to the

while electrodes are changed, slag removed etc.

Permanent elastic extension which metal undergoes during tensile testing. Amount of extension is usually indicated the test rod. EN a nomenclature in welding, Euronorm E.N.

6.00

540

MISCELLANEOUS INFORMATION

FCAW

Flux Cored Arc Welding

joint or corner joint.

other contaminating substances from the surface of the base material. Fluxes may be corrosive.

together with Hydrogen or Oxygen.

iron). Cast iron in which most of the carbon is in the form of

welding.

RESISTANCE

6.00

541

MISCELLANEOUS INFORMATION

See duty cycle. INTERPASS started. a very high value thereby reducing the need for a heavy iron core in order to reduce the voltage. ISO Steel which contains fairly large quantities of ferrosilicium connections.

Structure obtained when steel is heated and cooled to achieve its maximum hardness.

welding torch from returning to the gas cylinder.

6.00

542

MISCELLANEOUS INFORMATION

Abbreviation for the Norwegian Standards Association.

NSFI vertical or overhead.

Colourless gas without odour or taste. Chemical symbol 02. together with Acetylene for welding and cutting.

network. POROSITY POSTHEAT

PROPANE formula 3 RECTIFIER

Control of welding current from the welding area. Adjustment is by means of additional cable or through the welding cable.

6.00

543

MISCELLANEOUS INFORMATION

ROOT PASS Coated electrodes containing ilmenite, TiO2, in the coating. The cable which carries current from the secondary side of a S

SPATTER

weld is made.

determines how much tension a weld can withstand before the weld gives.

Tungsten inert gas welding. CRAYONS

levels.

as Wolfram.

6.00

544

MISCELLANEOUS INFORMATION

technique to widen the weld bead.

WHISKERS the root side of the weld.

The stress level at which a steel material starts to become 2

Seawater resistant alloy of aluminium and brass.

6.00

545

CHECKLISTS

Unitor Welding Inverter Unitor Plasma Cutter

7.00 546

CHECKLISTS Safe Work Procedures

UCT-500 Kit for Oxy-Acetylene Cutting, Brazing, Welding & Heating DO NOT

COMPULSORY PPE

PRE-OPERATIONAL SAFETY CHECKS

6. Ensure the area is well ventilated (with fume extraction if required).

OPERATIONAL SAFETY CHECKS

For Cutting:

7.00 547

CHECKLISTS

Cutting table - UCT-500 0.2

0.2

2 1600 300

3 3600

6800

Product No.

700

those given in the table.

regulator adjusting screw (3).

lever (8) at the same time. Then shut the torch Acetylene needle valve (6).

7.00 548

CHECKLISTS For Brazing, Welding & Heating:

2 3

3 7

(heating torch)

Product no. Ox Ac

80 80 73

length are given in the welding table.

Oxygen regulator adjusting screw (3).

7.00 549

230 230

1000 1000 1136

1800 1800 1636

CHECKLISTS HOUSEKEEPING

POTENTIAL HAZARDS

3. Eye Injury

REFERENCE British Compressed Gases Association – Australian Standards –

SPECIAL NOTE

This SOP should be used in conjunction with relevant machinery manuals and manufacturer recommendations. Procedure Reference

Effective

Review

1.0

7.00 550

CHECKLISTS Safe Work Procedures

WELDING INVERTER DO NOT use this machine unless you have been instructed in its safe

PERSONAL PROTECTIVE EQUIPMENT A welding mask with shade must be worn. Safety shoes with rubber soles must be worn.

may be required.

(leather jacket) to cover arms and legs must be worn. Oil free leather welding gloves

required.

PRE-OPERATIONAL SAFETY CHECKS

Procedures such as Hot Work Permit i.e. Risk Assessment and Control to ensure safe before, during and after welding. materials.

welding bay or erecting screens.

OPERATIONAL SAFETY CHECKS

electrical connection.

7.00 551

CHECKLISTS

ENDING OPERATIONS AND CLEANING UP

POTENTIAL HAZARDS AND INJURIES Electric shock. Noise. Radiation burns. Fumes. Welding in high risk area.

DON’T

Never leave the machine running unattended.

and should be used in conjunction with other references.

This SOP should be used in conjunction with relevant machinery manuals and manufacturer recommendations

7.00 552

CHECKLISTS Safe Work Procedures

PLASMA CUTTER DO NOT use this machine unless you have been instructed in its safe

PERSONAL PROTECTIVE EQUIPMENT Safety glasses must be worn at all times in addition to welding mask. Sturdy footwear with rubber soles must be worn.

clothing to cover arms and legs must be worn. required when cutting thick material. Oil free leather gloves and

may be required. A welding mask with shade contained.

PRE-OPERATIONAL SAFETY CHECKS

materials.

welding bay or erecting screens.

OPERATIONAL SAFETY CHECKS

7.00 553

electrical connection.

must be worn.

CHECKLISTS

ENDING OPERATIONS AND CLEANING UP

POTENTIAL HAZARDS AND INJURIES Electric shock. Noise.

Radiation burns. Fumes. Noxious gas.

DON’T

fumes, unless coating is removed from the work surface. Never leave the machine running unattended.

and should be used in conjunction with other references.

This SOP should be used in conjunction with relevant machinery manuals and manufacturer recommendations

7.00 554

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