Cored Wires - ESAB - OK Tubrod

OK TUBROD CORED WIRES PRODUCT BRIEF
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Index
Click to page The cored wire process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OK Tubrod cored wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OK Tubrod metal cored range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OK Tubrod self-shielded range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OK Tubrod flux cored range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OK Tubrod stainless cored wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Robotic welding and cored wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Shielding gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Modes of weld metal transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Welding techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electrode extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Deposition Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OK Tubrod estimating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mechanical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Welding procedure data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Welding of stainless steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Welding of clad steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Welding of dissimilar steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Schaeffler diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 One sided welding and non fusible backing . . . . . . . . . . . . . . . . . . . 52 AWS classifications for cored wire . . . . . . . . . . . . . . . . . . . . . . . . . . 53 European Standard EN 758: 1997 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Cored wire alternatives to manual arc . . . . . . . . . . . . . . . . . . . . . . . . 57 Cored wire fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Cored wire selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 OK Tubrod submerged arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Submerged arc metal cored range . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Submerged arc flux cored range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Welding techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 HV fillet joint data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Selected welding procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrogas welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Calculating electrode consumption . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Stress and energy units conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Welding data tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Conversions and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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The cored wire process

Main Features
Fundamentally the process is MIG/MAG welding and utilises the same equipment as that for solid wire albeit of larger capacity in some cases. The important difference between MIG/MAG welding with solid wire and cored wire is performance in productivity, welding characteristics and weld metal integrity. Variations to suit a particular application or physical requirement are more easily achieved than with solid wire. This involves changes in the filling formulation and to percentage of fill in a similar way to that of manual arc electrodes. The coating formulation and thickness can have a significant effect, whereas little can be done with the electrode core wire alone to improve aspects of performance.
Deposition
The higher deposition rate from cored wires relies upon the I2R heating effect which is greater than with solid wires, at a given current.
Cored Wire Cross-sections

Closed Butt - this type predominates in the Tubrod range lending itself to a wide variety of sizes and fill percentages between 18-33% depending on size required.
SOLID
METAL CORED Overlap - frequently the need arises to fill with the normal slag formers and a high percentage of additional allying elements. Stainless steel and hardsurfacing types are typical examples where this section is employed with fill percentages between 30-50%. The thinner wall section has the advantage of even higher current density and hence deposition rate.
Economics
Whilst there are higher productivity processes available, such as submerged arc and robotics, cored wire semiautomatic MIG offers the fabricator a more flexible process with genuine increases in productivity for the least capital expenditure. Where solid wire is already in use this may only involve a change of accessories such as feed rolls and torch consumables. A move to cored wire MIG/MAG from the use of manual arc will obviously involve the purchase of new equipment but the undisputed increase in productivity will usually guarantee a return on capital invested in less than one year. FLUX CORED
With the solid wire the total cross section carries all of the current but with metal cored wires a partial amount is carried by the core and in the case of flux cored wire all of the current is conducted by the tube. Therefore the current density and hence heating effect ensures a higher burn-off rate from cored wires.
OK Tubrod cored wires

The ESAB range consists of rutile and fully basic flux cored wires, some of which are self-shielded, and a range of metal cored wires. For general fabrication work the metal cored type could satisfy the majority of applications, so the need for three principal types may be questioned. There are a number of factors to be considered and can be summarised as follows:Positional Rutile Flux Cored Wires when used with Argon rich gas offer spray transfer welding with a high level of operator appeal. Metal Cored Wires when used on good quality clean plate will produce very little slag-similar to that of solid wires.
Basic Flux Cored Wires produce a higher and more consistent level of mechanical properties. They also produce radiographic standard deposits with ease when compared to both rutile and metal cored wires.
Self-Shielded Wires produce their own gas shield via decomposition in the arc of various elements within the core.
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Downhand Rutile Flux Cored Wires are easy to use with a smooth arc action giving excellent weld appearance with easy slag detachment.
Product characteristics
Rutile
The rutile OK Tubrod wires may be subdivided into two types. They can be of the EXOT-1 type for high deposition downhand and HV operation, or the EX1T-1 for all positional welding. Ability to operate at one current setting in any position if required. Ideal for open butt joints in conjunction with ceramic backing. May be used with either flat or drooping characteristic power sources. For use with most structural steels with a nominal tensile strength of 510 N/mm2.
Basic
OK Tubrod basic low hydrogen wires are in the EX1T-5 category for all position welding of mild, medium and high tensile steels, together with various low alloy versions. The high purity weld metal also ensures that they possess excellent sub-zero notch toughness. They are designed for either CO2, or Argon + 20% CO2 shielding gases. Outstanding deposit efficiency up to 90% at optimum currents, giving higher deposition rates than other flux cored wires. Thin slag cover which is very easily removed hence reducing the incidence of slag traps. Operate with DC electrode negative. The 1.2mm sizes are excellent for all positional welding using dip transfer. Hydrogen levels are lower than 5mls/100gms of weld metal generally less than 3mls/100gms. Recommended for single or multi-pass welding of heavy sections under conditions of restraint.
EX0T-1 Downhand and HV

OK Tubrod 15.12 and OK Tubrod 15.10 come within this group for use with CO2 shielding, whilst the OK Tubrod 15.18 is designed for Ar + 20% CO2, or CO2 shielding gases. Sizes range from 1.2mm up to 2.4mm. Exceptionally smooth high current operating characteristics, giving low spatter and a regular weld appearance. Very high deposition rates. Slag removal is effortless and self releasing on HV fillets. Ideally suited to the mass production of heavy equipment in a wide variety of mild and medium tensile steels. DC electrode positive. Universally approved to Grade 2 by all major certification authorities.
Metal Cored
A wide range of OK Tubrod metal cored wires is available to suit a variety of applications from high speed general purpose welding to low temperature and high strength requirements. The metal core produces an exceptionally high recovery, enabling approximately 95% of the wire weight to be deposited as weld metal. Used in conjunction with argon rich gases containing 15/25% CO2 weld deposits of smooth consistent finish with minimal spatter and slag are easily produced. Fume levels are significantly lower than those of conventional flux cored wires and approximately 50% less than high recovery iron powder manual arc electrodes. Weld metal savings of up to 30% can be achieved on single pass fillets through deep penetration which increases the effective throat thickness with a corresponding reduction in leg length of up to 20%. Further economies can be realised by a reduction in deposited weld metal through the use of smaller preparation angles. All OK Tubrod metal cored wires produce low hydrogen quality weld metal. Metal cored wires have the advantage in catering for the majority of downhand applications at one current setting.The only variable necessary is the travel speed which will determine the size of deposit.
EX1T-1 All Positional

OK Tubrod 15.14 and OK Tubrod 15.15 are included under this heading, together with a number of low alloy OK Tubrod wires which have a similar slag system. The majority may be used with either Ar + 20% CO2, or CO2, although the low alloy types benefit from the Ar rich gas in terms of improved operability. Sizes range from 1.2mm to 1.6mm. Low hydrogen quality weld metal.
Self Shielded
Designed for on-site operation OK Tubrod 14.17 (E71T-7) is for welding mild steel in all positions and OK Tubrod 14.18 (E70T-4) for heavy deposition and/or high travel speeds in the flat and HV positions where impact properties are not required. Higher deposition than manual metallic arc electrodes. No requirement for special purpose welding equipment. Good clean weld appearance and easy slag removal.
Universally approved to Grade 3. Smooth regular weld appearance with minimum spatter. Excellent slag release qualities. Consistent spray type transfer in any position for higher deposition.
Note: All classifications referred to are AWS see page 53 and 54
Product characteristics
Rutile
The rutile OK Tubrod wires may be subdivided into two types. They can be of the EXOT-1 type for high deposition downhand and HV operation, or the EX1T-1 for all positional welding. Ability to operate at one current setting in any position if required. Ideal for open butt joints in conjunction with ceramic backing. May be used with either flat or drooping characteristic power sources. For use with most structural steels with a nominal tensile strength of 510 N/mm2.
Basic
OK Tubrod basic low hydrogen wires are in the EX1T-5 category for all position welding of mild, medium and high tensile steels, together with various low alloy versions. The high purity weld metal also ensures that they possess excellent sub-zero notch toughness. They are designed for either CO2, or Argon + 20% CO2 shielding gases. Outstanding deposit efficiency up to 90% at optimum currents, giving higher deposition rates than other flux cored wires. Thin slag cover which is very easily removed hence reducing the incidence of slag traps. Operate with DC electrode negative. The 1.2mm sizes are excellent for all positional welding using dip transfer. Hydrogen levels are lower than 5mls/100gms of weld metal generally less than 3mls/100gms. Recommended for single or multi-pass welding of heavy sections under conditions of restraint.
EX0T-1 Downhand and HV

OK Tubrod 15.12 and OK Tubrod 15.10 come within this group for use with CO2 shielding, whilst the OK Tubrod 15.18 is designed for Ar + 20% CO2, or CO2 shielding gases. Sizes range from 1.2mm up to 2.4mm. Exceptionally smooth high current operating characteristics, giving low spatter and a regular weld appearance. Very high deposition rates. Slag removal is effortless and self releasing on HV fillets. Ideally suited to the mass production of heavy equipment in a wide variety of mild and medium tensile steels. DC electrode positive. Universally approved to Grade 2 by all major certification authorities.
Metal Cored
A wide range of OK Tubrod metal cored wires is available to suit a variety of applications from high speed general purpose welding to low temperature and high strength requirements. The metal core produces an exceptionally high recovery, enabling approximately 95% of the wire weight to be deposited as weld metal. Used in conjunction with argon rich gases containing 15/25% CO2 weld deposits of smooth consistent finish with minimal spatter and slag are easily produced. Fume levels are significantly lower than those of conventional flux cored wires and approximately 50% less than high recovery iron powder manual arc electrodes. Weld metal savings of up to 30% can be achieved on single pass fillets through deep penetration which increases the effective throat thickness with a corresponding reduction in leg length of up to 20%. Further economies can be realised by a reduction in deposited weld metal through the use of smaller preparation angles. All OK Tubrod metal cored wires produce low hydrogen quality weld metal. Metal cored wires have the advantage in catering for the majority of downhand applications at one current setting.The only variable necessary is the travel speed which will determine the size of deposit.
EX1T-1 All Positional

OK Tubrod 15.14 and OK Tubrod 15.15 are included under this heading, together with a number of low alloy OK Tubrod wires which have a similar slag system. The majority may be used with either Ar + 20% CO2, or CO2, although the low alloy types benefit from the Ar rich gas in terms of improved operability. Sizes range from 1.2mm to 1.6mm. Low hydrogen quality weld metal.
Self Shielded
Designed for on-site operation OK Tubrod 14.17 (E71T-7) is for welding mild steel in all positions and OK Tubrod 14.18 (E70T-4) for heavy deposition and/or high travel speeds in the flat and HV positions where impact properties are not required. Higher deposition than manual metallic arc electrodes. No requirement for special purpose welding equipment. Good clean weld appearance and easy slag removal.
Universally approved to Grade 3. Smooth regular weld appearance with minimum spatter. Excellent slag release qualities. Consistent spray type transfer in any position for higher deposition.
Note: All classifications referred to are AWS see page 53 and 54
OK Tubrod 14.01
A metal cored tubular wire containing Cu especially for the welding of Corten A & B and similar weathering steels or other high tensile structural steels with a tensile strength up to 510 N/mm2. Shielding gas Ar + 20% CO2 Metal Recovery 95% Classification AWS A/SFA 5.18-93 E70C-GM EN 758:1997 T 42 0 Z M M 2 H10 Applications Bridge and general structural steelwork, ships and chimneys. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 100-320 16-32 1.4 F.H.V.O. 120-380 16-34 1.6 F.H. 140-450 18-36 Typical weld metal composition C Si Mn Cu 0.07 0.6 1.4 0.5 Mechanical properties All weld metal specimens Typical Minimum Yield stress 470 N/mm2 420 N/mm2 Tensile Strength 550 N/mm2 510 N/mm2 Elongation 28% 22% Charpy V impact values Test temp Typical 0OC 130J Approvals DS E51 3M (H)
OK Tubrod 14.02
A metal cored tubular wire similar to 14.00 with an addition of Mo for use on high tensile and quenched and tempered steels with tensile strengths up to 550 N/mm2. Shielding gas Ar + 20% CO2 Metal recovery 95% Classification AWS A/SFA 5.28-96 E80C-G EN 758:1997 T 50 2 Z M M 2 H10 Applications Marine structures, heavy machinery and high strength applications requiring good notch ductility. RQT 500, 600 Hyplus 29 DUCOL W30 OX602 Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 100-320 16-32 1.6 F.H. 140-450 18-36 Typical weld metal properties C Si Mn 0.07 0.6 1.4 Mechanical properties All weld metal specimens Typical Yield stress 580 N/mm2 Tensile Strength 650 N/mm2 Elongation 26% Charpy V impact values Test temp Typical -20OC 65J
OK Tubrod 14.03
A metal cored tubular wire alloyed with nickel and molybdenum to provide extra high strength with good notch ductility down to -40OC. A 1.2 and 1.4mm size is available to cater for out of position welding. Shielding gas Ar + 20% CO2 Metal recovery 95% Classification AWS A/SFA 5.29-80 E111T-G Applications Offshore jack-up structures and general structural fabrication of high tensile steels for low temperature service. RQT 700 T1 HY80 Q1N. Welding Dia mm 1.2 1.4 1.6 data DC electrode negative Welding Current Volts positions amps F.H.V.O. 100-320 16-32 F.H.V.O. 120-380 16-34 F.H. 140-450 18-36
Typical weld metal composition C Si Mn Ni Mo 0.07 0.5 1.6 2.2 0.6 Mechanical properties All weld metal specimens Typical Yield stress 750 N/mm2 Tensile Strength 830 N/mm2 Elongation 23% Charpy V impact values Test temp Typical -40OC 70J Approvals DB 42.039.23 TUV 4143 MRS 5YMS HH
Mo 0.5
Minimum 690 N/mm2 760 N/mm2 15%
Minimum 54J
Minimum 47J
Minimum 47J
OK Tubrod 14.04
A metal cored tubular wire containing nickel for applications involving service down to -60OC. Available in a range of sizes to maximise versatility including a positional capability with a high resistance to cracking on heavy plate. Shielding gas Ar + 20% CO2 Metal Recovery 95% Classification AWS A/SFA 5.28-96 E70C-G EN 758:1997 T 42 6 2Ni M M 2 H10 Applications All general fabrication and structural steelwork including offshore equipment where sub-zero impact properties are of prime importance. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 100-320 16-32 1.4 F.H.V.O. 120-380 16-34 1.6 F.H. 140-450 18-36 Typical weld metal composition C Si Mn Ni 0.05 0.4 1.0 2.2 Mechanical properties All weld metal specimens Typical Yield stress 480 N/mm2 Tensile Strength 580 N/mm2 Elongation 28% Charpy V impact values Test temp Typical -60OC 90J
OK Tubrod 14.05
A metal cored tubular wire offering similar characteristics to Tubrod 14.04 but containing 1%Ni for the attainment of good notch toughness down to -40OC. It is produced in a wide range of sizes including a 1.0mm which is ideal for root passes when used for one sided welding. All sizes are capable of positional welding using the dip transfer mode. Shielding gas Ar + 20% CO2 Metal Recovery 95% Classification AWS A/SFA 5.28-96 E70C-G EN 758:1997 T 42 4 1Ni M M 2 H10 Applications All structural and general fabrication work requiring good charpy V notch properties down to -40OC. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.0 F.H.V.O. 80-250 14-30 1.2 F.H.V.O. 100-320 16-32 1.4 F.H.V.O. 120-380 16-34 1.6 F.H. 140-450 18-36 Typical weld metal composition C Si Mn Ni 0.05 0.5 1.3 0.9 Mechanical properties All weld metal specimens Typical Yield stress 460 N/mm2 Tensile Strength 550 N/mm2 Elongation 26% Charpy V impact values Test temp Typical -40OC 100J Approvals ABS 3SA,3YSA BV SA3YM HH KV-40 DNV IIIYMS HH LR 3S 4Y40S H15 DS E51 5M (H)
OK Tubrod 14.06
A metal cored tubular wire containing Ni and Mo for use on high tensile as well as quenched and tempered steels with a minimum yield strength of 550 N/mm2. The composition also ensures that this wire can be used on applications requiring good notch toughness down to -40OC. Shielding gas Ar + 20% CO2 Metal Recovery 95% Classification AWS A/SFA 5.29-80 E91T-G Applications Off-road contractors plant, rail rolling stock, marine and bridge structures and similar items where high strength and good notch toughness is required. RQT 500, 600 DUCOL W30 OX 602 Welding data DC electrode negative Dia Welding Current Volts mm positions amps 1.2 F.H.V.O. 100-320 16-32 Typical weld metal composition C Si Mn Mo Ni 0.06 0.4 1.4 0.3 1.5 Mechanical properties All weld metal specimens Typical Yield stress 620 N/mm2 Tensile Strength 700 N/mm2 Elongation 24% Charpy V impact values Test temp Typical -40OC 70J
Minimum 47J
Minimum 47J
Approvals ABS 3SA,3YSA BV UPHH KV-60 DNV lll YMS HH NV 2-4, NV 4-4 LR 3S 5Y40S H15 GL 6YH10S DS E51 5M (H) MRS 5YMSHH -60 TUV 4298
Minimum 47J
OK Tubrod self-shielded range

OK Tubrod 14.17
A self-shielded flux cored tubular wire designed for all-positional welding of mild and medium tensile steels. It can be used for single or multi-pass welding and is equally suitable for flat and drooping characteristic power sources. Classification AWS A/SFA 5.20-95 E71T-7 EN 758:1997 T 38 Z W N 2 Applications On-site general fabrication and structural work, with steels having a nominal tensile strength not exceeding 510 N/mm2 and no impact requirements. Welding data DC electrode negative Dia Welding Current Volts mm positions amps 1.2 F.H.V.O. 100-280 24-26 1.6 F.H.V.O. 110-350 22-28 Typical weld metal composition C Si Mn 0.13 0.1 1.1 Mechanical properties All weld metal specimens Typical Yield stress 450 N/mm2 Tensile Strength 555 N/mm2 Elongation 26%
OK Tubrod 14.18
A self-shielded flux cored tubular wire designed for the single and multi-pass welding of mild and medium tensile steels in the flat and HV positions. Capable of high deposition rates, it is ideal for general fabrication work where atmospheric conditions have to be tolerated. Classification AWS A/SFA 5.20-95 E70T-4 Applications Site welding of general and structural steelwork with steels not exceeding 510 N/mm2 tensile strength. Welding data DC electrode positive Dia Welding Current Volts mm positions amps 1.6 F.H. 150-400 24-26 2.4 F.H. 350-450 27-30 Typical weld metal composition C Si Mn 0.2 0.4 0.6 Mechanical properties All weld metal specimens Typical Yield stress 440 N/mm2 Tensile Strength 600 N/mm2 Elongation 26%
OK Tubrod flux cored range

OK Tubrod 15.10
A rutile flux cored tubular wire principally designed for rapid fillet welding in the HV position. It is characterised by a very thin slag cover which, together with special formulation, affords a high tolerance to shop primer and is seen as a particular benefit to shipbuilders. The rutile base provides for a flat, extremely attractive weld appearance. Shielding gas CO2 Classification AWS A/SFA 5.20-95 E70T-1 EN 758:1997 T 42 0 R C 3 H10 Applications All general fabrication of mild and medium tensile steels. It is especially suited to shipbuilding, structural steel work, bridges, dumper bodies, etc where fillet welding predominates Welding data DC electrode positive Dia Welding Current Volts mm positions amps 1.2 F.H. 180-320 24-32 1.4 F.H. 200-350 26-34 1.6 F.H. 250-400 26-36 Typical weld metal composition C Si Mn 0.05 0.6 1.4 Mechanical properties All weld metal specimens Typical Yield stress 510 N/mm2 Tensile Strength 570 N/mm2 Elongation 28% Charpy V impact values Test temp Typical 0OC 80J Approvals ABS 2SA 2YSA BV SA2YM HH DNV IIYMS H10 LR 2S 2YS H10 GL 2YH10S
OK Tubrod 15.12
A rutile flux cored tubular wire designed especially for heavy deposition in the flat and horizontal positions on mild and medium tensile steels up to 510 N/mm2 tensile strength. Slag removal is easy and generally self-releasing. The weld appearance is exceptional and spatter level minimal. Shielding gas CO2 Classification AWS A/SFA 5.20-95 E70T-1 EN 758:1997 T 42 0 R C 3 H10 Applications Mass production situations demanding heavy deposition such as contractors plant, bed plates and pit-props in steel thicknesses of 9mm upwards. Welding data DC electrode positive Dia Welding Current Volts mm positions amps 1.2 F.H.V.O 180-320 24-34 1.4 F.H. 200-350 26-36 1.6 F.H. 250-400 26-38 2.0 F.H. 300-450 27-38 2.4 F.H. 350-550 28-40 Typical weld metal composition C Si Mn 0.06 0.6 1.5 Mechanical properties All weld metal specimens Typical Yield stress 520 N/mm2 Tensile Strength 580 N/mm2 Elongation 26% Charpy V impact values Test temp Typical 90J 0OC Approvals ABS 2SA BV SA2,2YM DNV llYMS LR 2S,2YS GL 2YS Co CDS 0880 DS E51 2R (H) DB 42.039.13 TUV 4211
OK Tubrod 15.16
A flux cored tubular wire intended for applications requiring the highest possible deposition rates and also suitability for fully mechanised welding. It has a high efficiency at 87% and can deposit in excess of 8kgs/hr at 450A. It is designed for welding mild and medium tensile steels having a nominal tensile strength of 500 N/mm2 in both the flat and HV positions. Used with CO2 shielding the arc action is extremely stable producing an attractive weld finish with self releasing slag and low spatter. Shielding gas CO2 Classification AWS A5.20-95 E70T-1 EN 758:1997 T 42 0 R C 3 H10 Applications Repetition welding of >12mm plate where heavy deposition is important, using either single or multi-pass welding techniques. Welding data DC electrode positive Dia Welding Current Volts mm positions amps 2.4 F.H. 450-650 32-38 Typical weld metal composition C Si Mn Ni 0.06 0.5 1.2 0.4 Mechanical properties All weld metal specimens Typical Yield stress 510 N/mm2 Tensile Strength 580 N/mm2 Elongation 28% Charpy V impact values Test temp Typical -20OC 50J
Minimum 54J
Minimum 47J
Minimum 27J
OK Tubrod 15.18
A rutile flux cored tubular wire designed for high deposition welding in the flat and HV positions. It is characterised by an exceptional weld finish with minimal spatter and self releasing slag using either Argon rich or CO2 shielding gases. Approved to grade 2 and manufactured in four sizes for maximum versatility, this wire is capable of single and multi-pass welding of fillet and butt joints in mild and medium tensile steels with a nominal tensile strength of 510 N/mm2. Shielding gas Ar + 20% CO2 or CO2 Classification AWS A/SFA 5.20-95 E70T-1M, E70T-1 EN 758:1997 T 42 0 R C 3 H10 T 42 0 R M 3 H10 Applications All general fabrication of medium to heavy sections where weld appearance and high weld metal integrity is important. This will include bogie frames for railway rolling stock, contractors plant, bedplates, structural steelwork, bridge construction and shipbuilding. Welding data DC electrode positive Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O 180-320 24-32 1.4 F.H. 200-350 26-34 1.6 F.H. 250-400 26-36 Typical weld metal composition C Si Mn 0.06 0.6 1.1 Mechanical properties All weld metal specimens Typical Yield stress 500 N/mm2 Tensile Strength 560 N/mm2 Elongation 28% Charpy V impact values Test temp Typical 70J 0OC Approvals ABS BV DNV LR DS DB TUV Ar + 20% CO2 2SA,2YSA SA2YM IIYMS 2S, 2YSH15 E51 3R(H) 5197 CO2 2SA,2YSA SA2YM IIYMS 2S, 2YSH15 E51 3R(H) 42.039.02 5197
OK Tubrod 15.14
A rutile flux cored tubular wire for all positional welding using either Ar/CO2 or CO2 shielding gases. This wire is suitable for all mild and medium tensile structural steels with tensile strengths up to 510 N/mm2. Running characteristics are exceptional, using the spray mode of transfer, and applies equally to both shielding gases. OK Tubrod 15.14 is also universally approved to grade 3 by all major authorities. Shielding gas Ar + 20% CO2 or CO2 Classification AWS: A5.20-95 E71T-1M, E71T-1 EN 758:1997 T 46 2 P M 2 H10 T 46 2 P C 2 H10 Applications All general fabrication including multipositional welding of fillet and butt joints. This will include shipbuilding, selected offshore segments, automated pipe welding and heavy fabrication where rotation of the work to the downhand position is impractical. It is also excellent for one sided welding in conjunction with non-fusible backing. Welding data DC electrode positive Dia Welding Current Volts mm positions amps 1.2 F.H.V.O. 110-300 21-32 1.4 F.H.V.O. 130-320 22-32 1.6 F.H.V.O. 150-360 24-34 Typical weld metal composition C Si Mn 0.05 0.5 1.3 Mechanical properties All weld metal specimens Typical Yield stress 530 N/mm2 Tensile strength 580 N/mm2 Elongation 26% Charpy V impact values Test temp Typical 120J -20OC Approvals ABS BV DNV LR GL Co DS RINa DB MRS Ar/CO2 3SA,3YSA SA3YM lllYMS 3S,3YS 3YS CDS 1185 E51 3R(H) SG 52.3 42.039.05 3S 3YS CO2 3SA,3YSA SA3YM lllYMS 3S,3YS 3YS
OK Tubrod 15.15
A rutile flux cored tubular wire designed as a truly all-positional general purpose wire for welding mild and medium tensile steels up to 510 N/mm2 tensile strength. Using either type of shielding gas the 1.2 and 1.4mm sizes can be used in the vertical position on spray transfer providing for maximum deposition and time savings. Weld pool control is easy both vertically up and downwards and slag removal is rapid. In addition all sizes are approved to Grade 3. Shielding gas Ar + 20% CO2 or CO2 Classification AWS A/SFA 5.20-95 E71T-1M, E71T-1 EN 758:1997 T 46 2 P C 2 H10 T 46 2 P M 2 H10 Applications General purpose welding of large fabrications in situ. Ideal in situations where manipulation of the work is not practical. Welding data DC electrode positive Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 22-32 1.4 F.H.V.O. 140-320 23-32 1.6 F.H.V.O. 150-360 24-34 Typical weld metal composition C Si Mn 0.05 0.3 1.3 Mechanical properties All weld metal specimens Typical Minimum Ar + 20%CO2 Yield stress 520 N/mm2 460 N/mm2 Tensile Strength 580 N/mm2 530 N/mm2 Elongation 28% 22% Charpy V impact values Test temp Typical 140J -20OC Approvals CO2 ABS 3SA,3YSA BV SA3,3YM DNV lllYMS LR 3S,3YS H15 GL 3YHHS Co CDS 0390 DS E51 3R(H) MRS 3YMSHH DB 42.039.14 TUV 4314
Minimum 54J
Minimum 54J
Minimum 54J
SG 52.2 42.039.05 3S 3YS
Ar + 20% CO2 3SA,3YSA SA 3YM lllYMS 3S,3YS H15 3YHHS CDS 0390 E51 3R(H) 3YMSHH 42.039.14 4314
10
OK Tubrod 15.17
A rutile tubular wire for welding of structural steels with a nominal tensile strength of 550 N/mm2 and in all positions. Particularly for use where good sub-zero toughness is required down to -40OC. Shielding gas Argon + 20% CO2 Classification AWS A/SFA 5.29-80 E81T1-Ni1 EN 758:1997 T 46 3 1Ni P C 2 H5 (H10 1.6mm) T 46 3 1Ni P M 2 H5 (H10 1.6mm) Applications Areas of application are primarily in the offshore, structural steel and shipbuilding industries. Eminently suitable for open butt joints using non-fusible backing materials. Welding data DC electrode positive Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O 110-300 21-32 1.4 F.H.V.O 130-320 22-32 1.6 F.H.V.O 150-360 24-34 Typical weld metal composition C Si Mn Ni 0.05 0.3 1.1 1.0 Mechanical properties All weld metal specimens Typical Yield stress 560 N/mm2 Tensile Strength 600 N/mm2 Elongation 25% Charpy V impact values Test temp Typical 130J -40OC Approvals Ar + 20% CO2 ABS 3SA,3YSA BV SA 3YM DNV lllYMS HH LR 3S, 4Y40S H15 DS E51 5R(H) MRS 4YMSH(-40) TUV 5198 DB 42.039.26
OK Tubrod 15.11
A rutile all positional flux cored tubular wire containing 2.5% Ni for the welding of mild and medium tensile steels where good notch toughness down to -50OC is required. Extra productivity is available via the use of the spray transfer mode when compared to the traditional basic types using short arc for vertical and overhead welding. Shielding gas Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E81T1-Ni2 EN 758:1997 T 50 6 2Ni P M 2 H5 Applications All types of fabrication involving mild and medium steels having a minimum yield strength of 490 N/mm2 and toughness requirements down to -60OC. This will include shipbuilding and offshore fabrication. Welding data DC electrode positive Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 22-32 Typical weld metal composition C Si Mn Ni 0.05 0.4 0.9 2.3 Mechanical properties All weld metal specimens Typical Yield stress 580 N/mm2 Tensile Strength 620 N/mm2 Elongation 24% Charpy V impact values Test Temp Typical -50OC 95J Approvals DNV
OK Tubrod 15.19
A rutile type flux cored tubular wire especially formulated to produce high yield strength and good sub-zero fracture toughness with an all-positional welding capability using spray transfer. The weld metal composition is controlled to ensure a minimum yield strength of 550 N/mm2 and good toughness down to -50OC. Shielding gas Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E81T1-Ni1 Applications General fabrication of high strength C-Mn and low alloy steels in all positions. Ideally suitable for quenched and tempered steels such as HY80 and Q1N. Welding data DC electrode positive Dia Welding Current Volts mm positions amps 1.2 F.H.V.O. 110-300 21-32 Typical weld metal composition C Si Mn Ni 0.05 0.4 1.3 1.0 Mechanical properties All weld metal specimens Typical Yield stress 620 N/mm2 Tensile Strength 650 N/mm2 Elongation 24% Charpy V impact values Test temp Typical 95J -50OC
Minimum 550 N/mm2
Minimum 70J
Minimum 75J
Minimum 50J
CO2 3SA,3YSA SA 3YM HH 3S, 3YS, H15 E51 5R(H)
H NV E460
42.039.26
11
OK Tubrod 15.00
A fully basic flux cored tubular wire producing low hydrogen quality weld metal with a high resistance to cracking under conditions of restraint. A 1.2mm size is available for positional welding using the dip transfer mode, while the 1.6mm and 2.4mm sizes permit heavy deposition in the downhand position. The slag cover is thin and easily re-melted eliminating inter-run deslagging in some cases. Shielding gas Ar + 20% CO2 or CO2 Metal Recovery 90% Classification AWS A/SFA 5.20-95 E71T-5M, E71T-5 EN 758:1997 T 42 3 B M 2 H5 T 42 3 B C 2 H5 Applications All general fabrication work involving the multi pass welding of heavy sections in tensile strength up to 510 N/mm2. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.0 F.H.V.O 100-230 14-30 1.2 F.H.V.O 120-300 16-32 1.4 F.H.V.O. 130-350 16-32 1.6 F.H. 140-400 18-34 2.0 F.H. 200-450 24-34 2.4 F.H. 300-500 26-36 Typical weld metal composition C Si Mn 0.07 0.7 1.4 Mechanical properties All weld metal specimens Typical Yield stress 470 N/mm2 Tensile Strength 550 N/mm2 Elongation 30% Charpy V impact values Test temp Typical 135J -20OC 120J -30OC Approvals CO2 ABS 3SA,3YSA BV SA3MH DNV lllYMS LR 3S,3YS H15 GL 3YHHS Co CDS 0485 DS E15 3B(H) MRS 3YMSHH DB 42.039.12 TUV 2181 RINa SG52-3
OK Tubrod 15.02
A fully basic flux cored tubular wire for the all position welding of mild and medium tensile steels including vertical down. It has particularly stable running characteristics at low current levels which enhances operability and minimises spatter. The arc action is such that penetration is good and together with the basic slag system ensures that this wire has a high tolerance to plate condition and shop primer. Shielding gas Ar + 20% CO2 Classification AWS A/SFA 5.20-95 E71T-5M EN 758:1997 T 42 3 B M 2 H5 Applications All general fabrication using either single or multi - pass techniques for fillet and butt joints where the combined effect of restraint and hydrogen must be minimised. Industries would include ship and bridge building, heavy pipe fabrication and marine structures. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H.V/D 140-400 18-34 Typical weld metal composition C Si Mn 0.07 0.6 1.4 Mechanical properties All weld metal specimens Typical Yield stress 450 N/mm2 Tensile Strength 550 N/mm2 Elongation 30% Charpy V impact values Test temp Typical -30OC 130J Approvals DNV III YMS H5 LR 3S 3YS H5 GL 3Y H5S
OK Tubrod 15.24
A fully basic flux cored tubular wire producing 1% Ni weld metal. It combines high strength with low temperature toughness for service down to -50OC and has good CTOD performance. This applies to both the as-welded and stress relieved condition. Used with either mixed gas or CO2 it has a high tolerance to plate condition with good operability and slag release. Shielding gas Ar + 20% CO2 or CO2 Classification AWS A/SFA 5.29-80 E80T5-G EN 758:1997 T 46 5 Z B M 2 H5 Applications All structural and general fabrication where a minimum yield strength of 470 N/mm2 is required and for service down to -50OC. Applications will involve such steels as 450 EMZ which find popular use in the offshore industry. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.0 F.H.V.O 100-230 14-30 1.2 F.H.O 120-300 16-32 1.6 F.H.V 140-400 18-34 Typical weld metal composition C Si Mn Ni 0.06 0.5 1.5 0.8 Mechanical properties All weld metal specimens Typical Minimum Yield stress 540 N/mm2 470 N/mm2 Tensile strength 600 N/mm2 550 N/mm2 Elongation 28% 22% Charpy V impact values Test temp Typical -50OC 120J
Minimum 47J
Minimum 54J 47J
Minimum 47J
Ar + 20% CO2 lllYMS 3S,3YS H15 3YHHS CDS 0485 E15 3B(H) 42.039.12 2181 SG52-3
12
OK Tubrod 15.25
A fully basic flux cored tubular wire containing approximately 2.5% nickel for welding a wide variety of structural work in all positions for service down to -60OC. The scope for applications is increased further by the excellent CTOD performance at -10OC. While the 1.6mm size will give most acceptable deposition rates in the flat and H.V. positions. The 1.2mm can be used in the vertical and overhead positions using dip transfer. Shielding gas CO2 or Ar + 20% CO2 Classification AWS A5.29-80 E70T5-G EN 758:1997 T 42 6 2Ni B M 2 H5 Applications All fabrication work involving thick sections under restraint and required for service at low temperatures. Offshore platforms, pressure vessels and bridges. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H. 140-400 18-34 Typical weld metal composition C Si Mn Ni 0.05 0.5 0.8 2.2 Mechanical properties All weld metal specimens Typical Yield stress 480 N/mm2 Tensile Strength 570 N/mm2 Elongation 30% Charpy V impact values Test temp Typical -60OC 100J
OK Tubrod 15.26
A fully basic flux cored tubular wire for welding high strength steels for service at both ambient and sub-zero temperatures down to -50OC. The weld metal has a minimum yield strength of 570 N/mm2 and is ideal for situations involving high levels of restraint and where the deleterious effects of hydrogen must be avoided. Shielding gas Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E90T5-K2 Applications A wide range of structures using high tensile steels such as HY80, OX540E, OX542, OX602, and DOMEX 480. Cranes, earth moving plant, and offshore marine jack-up type platforms are typical examples. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H. 140-400 18-34 Typical weld metal composition C Si Mn Ni 0.06 0.5 1.5 1.5 Mechanical properties All weld metal specimens Typical Yield stress 620 N/mm2 Tensile strength 690 N/mm2 Elongation 24% Charpy V impact values Test temp Typical -50OC 100J
OK Tubrod 15.27
A fully basic flux cored tubular wire for the welding of high strength steels such as HY100. The weld metal contains 2.5% Ni giving the additional benefit of low temperature toughness down to -50OC. This wire is capable of welding in all positions and uses the dip transfer mode for the vertical-up technique, which can be further enhanced by the synergic pulsed process. Shielding gas Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E110T5-G Applications The fabrication of high tensile steels with a yield strength in the region of 700 N/mm2. Such steels will include HY100, RQT701 and Weldex 812EM, all of which find applications in submarines, cranes, jack-up marine structures etc. Welding data DC electrode negative Dia Welding Current Volts mm priorities Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H. 140-400 18-34 Typical weld metal composition C Si Mn Ni 0.06 0.5 1.6 2.5 Mechanical properties All weld metal specimens Typical Yield stress 750 N/mm2 Tensile strength 820 N/mm2 Elongation 21% Charpy V impact values Test temp Typical -50OC 80J
Minimum 70J
Minimum 50J
Minimum 47J
Approvals DNV lllYMS HH NV2-4 NV4-4 LR 3S, 5Y40, H15 Co CDS 0551 TUV 4299
13
OK Tubrod 15.20
A fully basic flux cored tubular wire containing 1.25% Cr and 0.5% Mo designed for welding creep resisting steels of similar composition. High deposition rates are enhanced by the addition of metal powder to the core and the weld metal produced is of exceptional metallurgical quality. Shielding gas CO2 or Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E80T5-B2 Applications All creep resisting steels of similar composition and most commonly used in process plant and the power generation industry at service temperatures in the region of 500OC. Recommendations for welding Preheating at 200-250OC is necessary followed by post weld heat treatment of 600-650OC. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H. 140-400 18-34 Typical weld metal composition C Si Mn Cr 0.06 0.5 1.0 1.25 Mechanical properties All weld metal specimens Stress relieved Yield stress Tensile strength Elongation (690OC 1HR) 570 N/mm2 670 N/mm2 22%
OK Tubrod 15.22
A fully basic flux cored tubular wire containing 2.25% Cr and 1.0% Mo for welding creep resisting steels of similar composition and intended for service at temperatures in the region of 600OC. The weld metal produced is of low hydrogen and very high metallurgical and radiographic standard. A pre-heat and interpass temperature of 250OC followed by a post weld heat treatment of 670OC710OC is essential for good results. The 1.2mm size is ideal for positional welding using the dip or controlled dip modes of transfer. Shielding gas CO2 or Ar + 20% CO2 Classification AWS A/SFA 5.29-80 E90T5-B3 Applications Process and power generation plant and welded fabrication involving steels of similar composition for service at elevated temperatures. Boilers, pressure vessels and piping. Welding data DC electrode negative Dia Welding Current Volts mm positions Amps 1.2 F.H.V.O. 120-300 16-32 1.6 F.H. 140-400 18-34 Typical weld metal composition C Si Mn Cr Mo 0.06 0.5 0.9 2.25 1.0 Mechanical properties All weld metal specimens Stress relieved Yield stress Tensile strength Elongation (690OC 1HR) 570 N/mm2 680 N/mm2 26%
Mo 0.5
14
OK Tubrod stainless cored wires

Traditionally the most popular processes for the welding of stainless steels have been manual arc followed by MIG, TIG and submerged arc. Solid wire is faster than manual arc, but can lack appeal due to spatter levels, a heavily oxidised weld deposit or fusion defects related to low current positional welding using dip transfer. Obviously, the use of TIG and submerged arc will continue due to their particular attributes for certain applications. The rapidly developing range of cored wires, however, which include types for Duplex steels offer the fabricator a genuine opportunity for increased quality and productivity over solid wire MAG and manual arc electrodes. The benefits can be summarised as:
G
achieved from the wire. Across the two sizes and within their recommended current ranges, efficiency will vary from a minimum of 81.5% up to 84%. Two sizes, 0.9mm and 1.2mm are available for most wires within the OK Tubrod 14.2X series and together they can handle a very wide field of application. With regard to productivity, the 1.2mm types are in excess of three times faster than 3.2mm manual arc electrodes and almost twice as fast as 0.9mm solid wires in the vertical position. Refer to OK Tubrod deposition rates page 27.
Productivity
OK 14.2X OK 14.2X
Up to 30% increase in weld metal deposition rate over solid wire and four times that of manual arc, hence faster welding speeds which in turn reduce distortion. Two ranges of wires to permit welding of all the popular grades of stainless steels both for the downhand and out of position welding. Moisture regain is minimal ensuring that start porosity is eliminated. The rutile types are designed for use with Ar/CO2 or CO2 shielding gas. The latter serves to reduce gas costs and radiated heat is also significantly lower giving greater operator comfort. Individual batch testing of weld metal composition means that the most stringent of quality standards are met.
6mm
Vertical up Fillet Joint (6mm throat = 0.33kg weld metal/metre) Process Size Amps Hour Kgs/Arc Arc Time mins/m
MMA AWS: E308L-16 3.2
90
1.0
14.2
OK Tubrod 14.2X Series

The range of wires within the OK Tubrod 14.2X series have been especially designed to produce superior operability for all-positional welding applications. Regardless of position, the weld deposit will be flat, which is a quality provided by the faster freezing slag. In having a rutile based slag system they always operate in the spray transfer mode and can be used at high currents and hence give high deposition rates. Slag release problems do not exist even in V butt joints and when not totally self releasing, the slag can be removed with the very minimum of chipping. As can be expected from these types of wire, the spatter levels are almost non-existent allowing additional savings in cleaning time. This is afforded by the extremely stable arc action under spray transfer conditions which ensures that the maximum possible efficiency is being
Solid Wire MIG (Dip Transfer) AWS: ER308L 0.9 95 0.9 Cored Wire MIG/MAG OK 14.20 (AWS E308LT-1) 1.2 160 2.75
9.3
3.4
and composition to produce an exceptional partnership for stainless steel welding. The OK Tubrod 14.3X series can in fact be used for vertical upwards welding, but their more fluid slag, which is for optimum downhand operation, does impose certain limitations. Single pass or narrow deposits are not possible using the vertical-up technique due to excessive heat build up. The weaving technique is excellent on thicker plate when there is greater heat sink and additional dissipation from the weaving. Single passes for fillet welding and the root areas of butt joints should be completed using the vertical downwards technique, but there is the attendant reduction in depth of penetration. This technique is restricted to the 1.2mm sizes, and can also be used to advantage for rapid welding of sheet material. The operability of the OK Tubrod 14.3X wires is exceptional combining extreme ease of use, high performance with regard to metal deposition and a weld appearance comparable to the latest generation of manual arc electrodes. As with rutile based C/Mn types the spray transfer mode is used at all acceptable current levels even down to 100A with the 1.2mm size. Such a facility affords high welding speeds, reduced operator fatigue, better fusion and a low risk of defects when compared to solid wire. Although normally used at higher current levels than the OK Tubrod 14.2X series, spatter is still virtually non-existent and the thin slag is generally self releasing leaving a bright smooth weld finish. This is an obvious advantage on fabrications where subsequent dressing and polishing is required, especially in the case of fillet joints. Moisture regain is not a problem as is sometimes the case with manual arc electrodes when start porosity can occur. In tests at 30OC and a relative humidity of 80% OK Tubrod 14.2X and 14.3X wires gave an increase in moisture of 0.5% after four weeks. This compares with 0.7% after two weeks for moisture resistance manual electrodes and 3% for standard electrodes, Fig 1.
Length of completed joint per hour - Duty Cycle 20% MMA Solid MIG OK 14.20 = 0.8 Metres = 1.3 Metres = 3.5 Metres
Fig 1
Moisture absorption rate (%) 0.10 0.075 0.050 0.025 80%RH 30OC 50%RH 20OC
OK Tubrod 14.3X Series

It is not possible to produce a consumable that operates with equal performance in every situation and the OK Tubrod 14.3X range was introduced especially for welding in the flat and horizontal vertical positions. This range complements the OK Tubrod 14.2X range by designation
Storage period - weeks
15
Productivity
OK 14.3X OK 14.3X
HV Fillet Joint (5mm throat = 0.25 kg weld metal/metre) Process Size Amps Hour Kgs/Arc Arc Time mins/m
MMA AWS: E316L-16 5.0 5mm Solid Wire MIG AWS: ER316L 1.2
200
2.6
5.8
260
3.9
3.8
Cored Wire MIG/MAG OK 14.31 (AWS E316LT-1) 1.6 300 5.8
2.6
Length of completed joint per hour - Duty Cycle 20% MMA Solid MIG OK 14.20 = 2.08 Metres = 3.12 Metres = 4.64 Metres
Shielding gases A variety of shielding gases can be used with the flux cored types due to the greater tolerance available, although the higher the CO2 content the higher the carbon content and the lower the alloy and ferrite content. However, the changes are marginal with C increasing by 0.01% and Cr decreasing by 0.1% progressively between pure Ar through to pure CO2. The influence of shielding gas on mechanical properties is also minimal to the extent that the changes may be disregarded. With regard to running characteristics the CO2 content should not be less than 20% as a lower content will produce inferior arc manipulation.
Product specifications
Flux cored - All Positional All Weld Metal Results (Ar + 20% CO2 Shielding Gas)
Designation Sizes mm
0.9 1.2
Chemical Composition
C Mn Si Cr Ni C Mn Si Cr Ni Mo C Mn Si Cr Ni C Mn Si Cr Ni Mo C Mn Si Cr Ni Mo N C Mn Si Cr Ni Mo N 0.03 1.1 0.7 19.5 10.0 0.03 1.3 0.9 18.5 12.0 2.5 0.03 1.3 0.9 22.5 12.5 0.03 1.2 0.9 18.5 12.5 3.5 <0.04 0.9 0.9 22.0 9.0 3.0 0.15 <0.04 0.9 0.6 25.0 9.0 4.0 0.24
Mechanical Properties
Yield UTS Elong Charpy -196OC Yield UTS Elong Charpy -196OC Yield UTS Elong +20OC Yield UTS Elong +20OC 400 N/mm2 590 N/mm2 45% V 32J 475 N/mm2 615 N/mm2 36% V 26J 460 N/mm2 590 N/mm2 37% 40J 475 N/mm2 630 N/mm2 34% 40J
Classification A5.22-95
E308LT1-4
Polarity Approvals & Shielding Gas

DC+ Ar/CO2 TV Co
OK Tubrod 14.20
OK Tubrod 14.21
0.9 1.2
E316LT1-4
DC+ Ar/CO2
TV Co DNV GL LR TV Co DNV LR GL
OK Tubrod 14.22
0.9 1.2
E309LT1-4
DC+ Ar/CO2
OK Tubrod 14.25
1.2
E317LT1-4
DC+ Ar/CO2
OK Tubrod 14.27
1.2
Yield UTS Elong Charpy -50OC
612 N/mm2 824 N/mm2 33% V 56J
E2209T1-1 E2209T1-4
DC+ CO2 Ar/CO2
INDEX
OK Tubrod 14.28 1.2
DNV RINa TV Co GL LR
Yield UTS Elong Charpy +20OC -46OC
650 N/mm2 820 N/mm2 18% V 55J 39J
E2553T0-4
DC+ Ar/CO2
16
Flux Cored - Downhand All Weld Metal Results (Ar + 20% CO2 Shielding Gas)
Designation Gas
OK Tubrod 14.30 1.2 1.6 C Mn Si Cr Ni C Mn Si Cr Ni Mo C Mn Si Cr Ni C Mn Si Cr Ni Mo C Mn Si Cr Ni Nb 0.03 1.6 0.4 19.0 10.0 0.03 1.4 0.4 19.0 12.0 2.5 0.03 1.6 0.4 24.0 13.0 0.03 1.6 0.4 23.0 13.0 2.3 0.04 1.6 0.4 19.0 10.0 0.5 Yield UTS Elong Charpy +20OC -196OC Yield UTS Elong Charpy +20OC -110OC Yield UTS Elong Charpy +20OC Yield UTS Elong Charpy +20OC Yield UTS Elong Charpy 0OC 390 N/mm2 560 N/mm2 39% V 44J 32J 410 N/mm2 570 N/mm2 33% V 40J 32J 449 N/mm2 594 N/mm2 32% V 42J 526 N/mm2 672 N/mm2 34% V 44J 460 N/mm2 610 N/mm2 41% V 56J E308LTO-1 E308LTO-4 DC+ CO2 Ar/CO2 LR TV DB
Sizes mm
Chemical Composition
Mechanical Properties
Classification A5.22-95
Polarity Approvals & Shielding
OK Tubrod 14.31
1.2 1.6
E316LTO-1 E316LTO-4
DC+ CO2 Ar/CO2
LR TV DB
OK Tubrod 14.32
1.2 1.6
E309LTO-1 E309LTO-4
DC+ CO2 Ar/CO2
LR TV DB
OK Tubrod 14.33
1.2 1.6
E309MoLTO-1 E309MoLTO-4
DC+ CO2 Ar/CO2
LR RINa TV
OK Tubrod 14.34
1.2
E347TO-1 E347TO-4
DC+ CO2 Ar/CO2
Metal Cored
OK Tubrod 15.30 1.2 1.6 C Mn Si Cr Ni FN C Mn Si Cr Ni Mo FN C Mn Si Cr Ni FN C Mn Si Cr Ni C Mn Si Cr Ni Mo N 0.02 1.4 0.7 19.0 10.0 8 0.02 1.4 0.7 18.0 12.0 2.7 8 0.03 1.3 0.6 23.0 13.0 15 0.1 6.0 0.7 18.0 8.0 0.03 0.7 0.7 22.0 9.0 3.0 0.13 Yield UTS Elong Charpy -196OC Yield UTS Elong Charp -196O 360 N/mm2 570 N/mm2 45% V 70J 400 N/mm2 600 N/mm2 37% V 45J EC308L DC+ Ar/2%CO2 Ar/2%O2 TV
OK Tubrod 15.31
1.2 1.6
EC316L
DC+ Ar/2%CO2 Ar/2%O2
TV
OK Tubrod 15.32
1.2 1.6
Yield UTS Elong Charpy -196OC Yield UTS Elong Charpy -60OC Yield UTS Elong Charpy -50OC
380 N/mm2 570 N/mm2 34% V 45J 425N/mm2 625N/mm2 40% V 40J 600N/mm2 780N/mm2 27% V 50J
EC309L
OK Tubrod 15.34
1.2 1.6
EC307

OK Tubrod 15.37 1.2 1.6
TV
EC2209
17
Consumable selection
OK Tubrod 14.20 14.30 15.30 EN 10088-1 X X X X X 10 CrNi 18-8 5 CrNi 18-10 2 CrNi 18-9 6 CrNiNb 18-10 6 CrNiTi 18-10 No 1.4310 1.4301 1.4307 1.4550 1.4541 AISI 302,304 304L,347 321 DIN 17440 X X X X 5 CrNi 18 10 2 CrNi 18 10 10 CrNiNb 18 10 6 CrNiTi 18 10 BS970 302S31 304S31 304S11 347S31 321S31 SS 2331 2332 2352 2338 2337
} } }
14.21 14.31 15.31
X X X X
2 3 2 6
CrNiMo 17-12-3 CrNiMo 17-13-3 CrNiMo 18-14-3 CrNiMoTi 17-12-2
1.4404 1.4436 1.4435 1.4571
316, 316L 316Ti
X X X X
2 5 2 6
CrNiMo 17 13 2 CrNiMo 17 13 3 CrNiMo 18 14 3 CrNiMoTi 17 12 2
316S11 316S31 320S31 316S33 320S31 403S17 410S21 420S37 430S17 347S31 321S31
2348 2347 2343 2350
14.22 14.32 15.32
X X X X
6 Cr13 12 Cr13 20 Cr13 6 Cr17
1.4000 1.4006 1.4021 1.4016 1.4438 1.4550 1.4541
403,410 420,430
X X X X
7 Cr13 10 Cr13 20 Cr13 6 Cr17
2301 2302 2303 2320 2367 2338 2337
14.25 14.34
X 2 CrNiMo 18-15-4 X 6 CrNiNb 18-10 X 6 CrNiTi 18-10
317L 347, 321
X 2 CrNiMo 18 16 4 X 10 CrNiNb 18 10 X 6 CrNiTi 18 10
14.22 14.32 14.33 15.32 15.34 15.34 14.27 15.37 14.28
Buffer layers Dissimilar welding Difficult to weld steels Austenitic manganese steels Corrosion and wear resistance Armour steels Duplex steels including SAF 2205, FAL 223, AF22, NK Cr22, HY Resist 22/5
Super Duplex steels including SAF 2507, UR52N+, XERON 100
18
Robotic welding and cored wires

Metal cored
Traditionally robots offered an increase in duty cycle and a reduction in cycle time but not an increase in welding speed. Solid wire was universally accepted for economy, restriking ability and so on, but actual arcing time remained the same as that with semi automatic MIG/MAG welding. The introduction of metal cored wires has presented the robot user with an opportunity to gain an even greater and quicker return on the comparatively high investment cost. The increase in productivity afforded by metal cored wires are not restricted to semiautomatic equipment and such wires can be readily adapted to robots with no modifications. However, since some applications may benefit from a larger size than 1.2mm which is the most popular size, the fitting of water cooled torches may be necessary. The same may apply to 1.6mm in circumstances where higher currents than those used with the same size of solid wire are envisaged. At the opposite end of the scale and until recently solid wire was the only practical solution with gauge material, for such items as automotive components, office furniture, etc. The availability of 1.0mm metal cored wire has now all but equalled the scope of solid wire but with the added benefits of improved quality with higher productivity. travel between weld runs. Therefore any increase in welding speed is vital, since in most cases welding time is at least 60% of the total cycle time. For example if a component has 320cm of 4mm throat fillet and a 1.2mm solid wire is achieving this at 60cm/min then 5.3 minutes of the cycle is actual arcing time. A change to 1.6mm metal cored wire can achieve welding speeds of 84cm/min for the same size of fillet, which will reduce arcing time to 3.8 minutes and hence total cycle time from 6.0 minutes to 4.5 minutes. This represents a saving of 25% and a theoretical gain of 12 weeks production in a year. Alternatively, the situation can be viewed in terms of metres of weld per year. A 1.2mm solid wire with an arc time of 1.6 min/m and operating at 60% duty cycle for an 1800 hr/yr will produce 40,500 metres of 4mm T fillet. This compares with 54,450 metres for OK Tubrod 14.12 1.6mm at a travel speed of 1.19 min/m or an additional 13,950 metres per year.
Flux cored wires

With regard to flux cored wires as against metal cored wires, some operators and also manufacturers are sceptical of using these due partly to the possibility of poor arc initiation. This is caused by beads of slag on the wire tip, which form between weld runs and cause an insulating effect. There is also the question of deslagging the welds on completion of a component and in the case of basic types the higher levels of spatter which add a further cost dimension in cleaning time. This is not to say that flux cored wires should be disregarded completely for robotic use as they are being used successfully in a variety of cases. Flux cored wires deposit weld metal at a faster rate than metal cored or solid wires especially the rutile EX0T-1 for downhand operation and the EX1T-1 types where positional welding is involved. Provided that the operating parameters are correct the slag from rutile types is self releasing, or if not will generally fall off when cold or through vibration with subsequent handling. Spatter levels will be minimal and restriking can be assisted with a creep feed starting system. The choice therefore depends on the circumstances but flux cored wires would be best suited to joints where larger volumes of weld metal are specified and/or when long uninterrupted run lengths are required.
Summary - 4mm T Fillet

Wire Solid 1.2mm Metal cored 1.6mm
Weld speed cms/min Arc time mins Total cycle time mins Metres of weld/yr
60
84
Cycle time and productivity

A reduction of 1% in total cycle time can make an enormous difference to annual production figures and usually gives an extra half week of output. Once the robot is installed it would be difficult to make a reduction in handling time, i.e. positioning of the work and speed of
5.3
3.8
Marathon Pacs
Non productive time can be minimised further by the use of bulk packs in the form of the Marathon Pac. Unlike any other pack of similar proportions the drum is loaded using a special production technique which ensures that the wire is delivered straight.
6.0
4.5
40,500
54,450
Deposition/Speed Evaluation
Solid Wire E70S-6 Wire Dia mm 1.2 1.2 1.2 Fillet T 2.5 4.0 5.5 Size L 4.0 6.0 8.0 Amps Volts Travel Speed cms/min 50 60 30 Wire Feed cms/min 440 1210 1100 Deposition Rate kgs/hr 2.15 5.9 5.4 Arc Time mins/m 2.0 1.6 3.3
200 290 280
26 30 30
INDEX
OK Tubrod 14.12
1.2 1.2 1.2 1.6 1.6 1.6
2.5 4.0 5.5 2.5 4.0 5.5
4.0 6.0 8.0 4.0 6.0 8.0
250 360 350 330 390 375
28 32 32 30 30 32
110 80 42 120 84 38
1000 1680 1515 690 840 780
4.69 7.88 7.09 5.33 6.50 6.04
0.9 1.25 2.38 0.83 1.19 2.63
19
Shielding gas
Other types of pack or the standard 16kg reels are such that the wire flicks or twists once per revolution. This is a particular disadvantage for robots when the wire has to be in a precise position relative to the joint every time. A Marathon Pac can therefore reduce the incidence of defects and also maintenance as wear on equipment is minimal. At a nominal weight of 200 kg this represents a saving of about 13 normal 15/16 kg reel changes which at 10 minutes each is 2 hours 10 minutes. Considering the example previously described with a 4.5 minute cycle, this represents a further 28 components. A 300 kg pack is also available and using the same example, the time saved will allow production of a further 41 components.
C/Mn & low alloy wires

A variety of shielding gases are now in regular use for the MIG/MAG cored wire process and normally involve CO2, Ar, O2, and He. CO2 is the only gas for use singularly but can be found in mixtures of all the others to bring about various welding characteristics, although Ar is always the principle gas when mixtures are employed.
Single pass gravity fillet joint. - 1.6mm wire, 8mm throat thickness. Welding speed - 40cm/min.
CO2 gas This gas is normally referred to as an active gas as it is not chemically inert, hence the term MAG. It is the least expensive gas, but does have disadvantages when compared to Ar based types.
The case in point

30% increase in welding speed G higher burn off rates than solid wire G faster welding speed G greater return on investment Superior weld finish G obtained from spray transfer mode G max tolerance to plate condition varying from positive to negative polarity G excellent fusion and wetting action minimises defects and risk of undercut, even at high travel speeds G argon rich gas minimises spatter level and gives optimum deposit appearance No restriking problems G with metal cored wire there are no restriking problems with either a hot or cold wire tip G applies to single and multipass applications Tolerance to variances G greater flexibility than solid wire: one current setting may be used for wider variety of weld sizes/travel speeds G greater tolerance to fit-up variations than solid wire, which can be critical if defects are to be avoided
Advantages: G inexpensive G low heat radiation G superior depth to width ratio G lower levels of diffusible hydrogen in the weld metal Single pass HV fillet joint - 1.6mm wire, 3mm throat thickness. Welding speed 120cm/min. Disadvantages: G higher levels of spatter G narrow voltage band - machine setting is critical
The majority of the OK Tubrod flux cored wires may be used with CO2 only and produce good results. The fully basic wires such as OK Tubrod 15.00 and 15.25 will, in fact, produce superior physical characteristics when used with CO2 only. Argon/CO2 mixtures The most popular gas mixture both for C/Mn solid wire and cored wire is that of Argon + 15-20% CO2 and although it is more expensive, generally by a factor of three, the advantages certainly justify its use.
Greater economy G greater penetration allows a reduction in fillet size for a given material thickness, leading to further overall cost benefits
Advantages: G reduced spatter through smoother arc action G lower fume generation G superior weld finish and profile G ability to support a wide voltage range - machine setting less critical G consistent and more favourable penetration, especially with cored wires G faster welding speeds Disadvantages: G greater radiated heat G water cooling sometimes required
20
Modes of weld metal transfer

With the exception of OK Tubrod 14.12 it is essential that all of the OK Tubrod metal cored wires be used with Ar rich gases as the use of CO2 will result in a serious deterioration in weld appearance with unacceptable levels of fume and spatter. With regard to flux cored wires, all except OK Tubrod 15.10 and 15.12 may be used with Ar + CO2 mixtures to enhance operability with reduced spatter and fume levels, but penetration will be decreased. O2 and He additions Although principally used for the MIG welding of stainless steel, the O2 to promote good wetting and He for additional heat as well as cleaning effect, caution should be exercised with O2, for use with C/Mn and low alloy wires. O2 is often mixed with Ar and CO2, on a basis of 80% Ar, 15% CO2, 5% O2. Such a mixture imparts very good wetting and reduces the droplet size and surface tension of the weld metal. However, O2 does have the effect of decreasing alloy transfer across the arc and it is particularly important to be aware of this during welding low alloy steels when a matching composition is required or in the case of Mn when tensile strength is critical. Effect on weld shape The economic advantages to be gained from the use of cored wires are obvious, but consideration should be given to the modes of metal transfer to achieve the maximum benefit, especially as direct comparisons with solid wire are not necessarily applicable. The choice of consumable and size relative to the proposed application are important aspects to be considered in exploiting the advantage of the process. Dip transfer When using standard constant voltage power sources the dip transfer mode will only occur at currents generally below 200A, although will vary depending upon wire size and parameters selected. This method of metal transfer relies on a series of short circuits where the wire actually touches down into the weld pool and consequently the current rises and melts off the end of the wire. Fig 2. A tapped inductance is usually available which can be used to vary the surge of current such that the eruptions taking place immediately after short circuiting do not cause excessive spatter. The dip or short arc method is characterised by a cool arc and so is ideal for sheet material, root passes in open butt joints and especially positional welding, in thinner materials. Close attention to operator technique is required to ensure adequate fusion when positional welding on thicker material. Globular transfer Upon increasing current above 200 amps but again depending on the wire size, there will be a transition to globular transfer where the short circuiting does not occur at a regular frequency. Fig 3. The wire tip will overheat and large globules of molten metal will form. Apart from wandering within the arc, the droplets will not always be directed into the weld pool and so create excessive spatter on impact with the parent material or weld pool. Therefore this type of transfer should be avoided for both solid and all types of cored wires.
Fig 3
Fig 2
Spray transfer The spray transfer mode is established where a constant arc gap is maintained and the droplets which are extremely fine are projected across the arc gap in free flight. Fig 4. The weld appearance is enhanced and the greater heat input and arc force ensures excellent side wall fusion and penetration with a reduced incidence of defects. This mode is usually employed in situations where maximum deposition rates are possible and desirable. There are no restrictions regarding the use of any OK Tubrod cored wires with this method.
Fig 4
100% Ar
80% Ar + 20% CO2
INDEX
100% CO2

Flow rate It is important that flow rate at the torch is maintained within 15-20 litres per minute for flux cored wires and 18-20 litres per minute for metal cored wires.
The rutile E70T-1 and E71T-1 types of cored wires will not operate satisfactorily in dip transfer and so are restricted to spray transfer. This is not a handicap since although two types of rutile wire may be required for flat and vertical to maximise deposition, the OK Tubrod 15.14/15.15 types (E71T-1) can operate in all positions using spray transfer but will not be as fast as the OK Tubrod 15.12 (E70T-1) in the flat position. Except for possibly the overhead position solid wire is confined to dip transfer for positional welding which, in comparison, is slow and liable to give fusion defects unless operator technique is of a consistent high quality. The metal cored OK Tubrod 14.XX wires and OK Tubrod fully basic E71T-5 wires in 1.0mm to 1.4mm are capable of positional welding but only in the dip transfer mode.
Pulsed arc transfer Pulsed arc welding is a controlled method of spray transfer which enables the transfer of droplets by projecting them across the arc gap at a regular frequency. The frequency can be varied at the power source to suit a particular application, type and size of wire. On more advanced equipment the pulse peak current and duration as well as background current can be adjusted. The action is illustrated in Fig 5 and shows a typical wave form together with a diagrammatic view of cyclic events at the wire tip. During the intervals between pulses a background current
21
maintains an arc to keep the wire tip molten but no metal is transferred. In this way transfer of metal occurs at high current but the mean total welding current remains low, thus the heat input and deposition are more easily controlled than with dip transfer.
Fig 5
Although fully basic wires produce the highest integrity weld metal, it is unlikely that their running characteristics will match those of the EX1T-1 or OK Tubrod 15.14/15.15 type wires for positional welding within the foreseeable future. However, depending on the application, the use of synergic pulsed MIG can compensate for the lack of operability with an attendant reduction in spatter and superior fusion characteristics.
and HV applications. The weld crosssection is controlled by the travel speed whereas solid wire would require considerable current resetting to achieve the same flexibility. Plate preparation Due to superior side wall fusion obtained particularly from the metal cored wires the combined angles of preparations can generally be reduced. A V butt joint for instance that would normally need a 60O included angle for manual arc welding can be reduced to 45O thereby saving plate and hence weld metal to fill the joint.
1 2 3
3 CURRENT (AMPS) 2 4 1 5 MODULATED DC WAVE FORM TIME (M' SECS) PULSE TIME CAN BE VARIABLE
Operating conditions
Polarity DC electrode positive is recommended for the rutile flux cored OK Tubrod wires since the use of the negative pole produces inferior running characteristics and can occasionally produce porosity. With the exception of OK Tubrod 14.00, 14.05, 14.06 and 14.12 which will operate on both DC electrode positive and negative polarity, the other OK Tubrod metal cored and basic flux cored wires benefit from the use of the negative polarity giving improved arc action and weld finish with reduced spatter. Voltage Arc voltage has a direct influence on the arc length which controls the weld shape, depth of penetration and spatter level. As the arc voltage is reduced the penetration increases and this is particularly important in V butt joints. An increase in voltage will result in a long arc length and increase the risk of porosity and undercut. When operating on dip transfer for positional welding at comparatively low currents the arc voltage should be kept at the highest practicable level to ensure adequate side wall fusion. Amperage The welding current is directly related to the wire feed speed. The higher the feed speed then the higher the amperage drawn from the power source in order to melt the additional wire going into the weld pool. With flux cored wires the amperage used is ideally in the top half of the range specified for a particular size, except when positional welding with 1.0mm, 1.2mm and 1.4mm wires, and when the dip transfer mode is used at current below 220 amps. OK Tubrod metal cored wires eliminate the need for current variations relative to plate thickness since one current setting for a given wire size will cater for 90% of flat
60 o 45 o
There is no advantage to be gained by using rutile wires with pulsed MIG but it will allow larger sizes of metal cored types to be used at lower current levels than is the case with conventional equipment. The main benefits are to be found with solid wire and in particular stainless steel and aluminium. Synergic MIG welding This process is a sophisticated form of pulsed arc MIG welding where pulse parameters, static and dynamic characteristics are optimised for a given consumable on a pre-programmed basis. This provides for one knob parameter control with improved fusion characteristics and reduced spatter. Synergic pulsed welding with tubular wires is more complicated than with solid wires. The thermal and electrical conductivity of cored wires vary considerably due to differing wall thickness and filling formulations. Those factors lead to a higher peak current requirement for cored wires than for the equivalent size of solid wire. Therefore, not all pulsed power sources available can be used with cored wire although many will operate satisfactorily with metal cored wires due to the lower peak currents required. In addition, power sources have to be pre-set for each type of consumable to be used. Since in the case of cored wires, different manufacturers products will vary in wall thickness and flux formulation and change of supplier, albeit for a wire of the same classification will not necessarily exhibit satisfactory running.
50 o 35 o
Fig 6
The higher level of deoxidants and higher current density available with cored wires allows them to be used where mill scale and primer have to be tolerated. This is particularly so with the metal and basic cored wires, since the rutile types are the least tolerant. However, in the case of primer the degree of success will depend on the type and thickness, but generally OK Tubrod basic wires will achieve porosity free welds at speeds 45% faster than solid wires and the OK Tubrod metal cored wires are approximately 35% faster. Recent advances in the development of the all positional rutile OK Tubrod types have also given added security when welding on primed plate. For optimum radiographic standards with flux cored wires, excessive rust and scale should be removed by grinding which will also serve to reduce slag formation to a minimum when using metal cored wires. Further economies can be achieved from a reduction in weld metal required on single pass fillet joints. The often greater depth of fusion can increase the effective throat thickness and
22
consequently allow a reduction in leg length by up to 20%. The savings in weld metal are considerable as can be seen from Fig 7a and 7b and some certification authorities will permit a reduction of 50% in weld dimensions for single pass fillets when produced fully automatically.
Torch angles and manipulation

Torch angles and manipulation
Vertical but welds
Fig 7a Solid wire
10O 10/20O
1st pass Fill & Cap Fill & Cap
Preparation of root face A torch angle of 10O above the horizontal may be used for root passes to assist arc stability and penetration control.
Preparation with feather edges
Vertical fillet welds
6mm
8mm
Fig 7b Cored wire
Single pass
10
10/20O
INDEX PREVIOUS PAGE

6mm
Triangular weave for single pass fillets. If necessary subsequent weld runs should be deposited using techniques similar to that for filling vertical butt joints. No weaving is necessary for single pass fillets when using OK Tubrod 15.14/15.15
Restrict vertical down technique to thin plate or leg lengths of 6mm maximum. May be used for first pass or multipass joints.
NEXT PAGE
6mm
23
Welding techniques
Torch angles
Flux cored wires With OK Tubrod flux cored wires the torch angle has a significant effect on slag control and weld deposit profile. For both fillet and butt joints the recommended angle between the wire axis and the line of joint is between 60O - 70O and using a backhand technique i.e; pulling, with the wire pointing towards the completed weld. In this way the arc force prevents the slag from running in front of the weld pool and reduces the risk of slag traps. For HV fillets the wire tip should be directed toward the bottom plate at approximately 3mm from the line of the joint with a torch angle of 45O from the vertical plate. In certain circumstances the forehand technique i.e: pushing, can be used to advantage. On small fillet welds where penetration is not of paramount importance, the higher welding speeds required are such that the molten slag is prevented from running ahead of the weld pool. This also has the advantage of producing a mitre fillet where as the backhand method tends to produce a more convex profile. Metal cored wires Maximum penetration is obtained using a backhand (pulling) technique with a torch angle of 70/80O between the wire axis and the joint line. This will also serve to optimise gas coverage and is particularly relevant to multi-pass butt welds. For fillet and lap welds, superior weld appearance is achieved using a torch angle of 60/70O, and a forehand technique (pushing). This results in a more even distribution of weld metal, accompanied by a reduction in penetration. Travel speed Travel speed has an important influence on penetration. For example when using a 1.6mm metal cored wire at 350A an increase in travel speed from 30cm/min to 60cm/min approximately doubles penetration beyond the root of a fillet. At speeds in excess of 80/100 cm/min penetration will decrease. Similarly a reduction in penetration will occur if the welding speed should fall to below 30cm/min, as the arc can impinge on the molten pool in preference to the base material. In addition, the use of slow travel speeds should be avoided when low temperature impact properties are required. While the joint may be filled in fewer passes, the individual weld deposits will be of a large cross-section and therefore impact resistance will be Flux cored wires Flux cored wire
45O 60-70
O
70O 90O
Metal cored wires
Metal cored wire

70-80O 90O
45O 60-70O
45O 60-70
O
24
reduced. Apart from this, in the case of flux cored wires, there is the obvious difficulty of slag control to be considered.
Positional welding
The majority of the OK Tubrod cored wires are capable of positional welding in the smaller sizes. However, the choice of consumable must be given careful consideration in relation to the proposed application because the various ranges require quite different manipulation techniques for optimum results. Rutile types This type of wire allows the use of the spray transfer mode in all positions including overhead and as such affords very high deposition rates. In addition, the exceptional fusion characteristics that result will have significant effect on the production of defect free welds, Fig 8a. This is particularly relevant when compared to solid wire which by necessity can only be used for positional welding in the dip transfer mode. The reduced depth of fusion involved together with the greater degree of skill and concentration demanded will increase the risk of fusion related defects Fig 8b.
In such circumstances the use of nonfusible backing is recommended and this type of wire is eminently suitable for use with these materials and the speed of welding will be significantly higher. Fig 10a and 10b. Metal cored and fully basic types These two groups may be treated as one with regard to positional welding techniques. To maintain optimum control welding is limited to the 1.0mm, 1.2mm and 1.4mm sizes and is restricted to the dip transfer mode where greater welder skill is involved. The manipulation required is similar to that used for solid wire in that initial passes in the vertical position are completed using a triangular weave motion. This is to ensure that the weld profile remains flat and not peaked, which would otherwise occur leading to possible lack of fusion defects at the edges after further welding as in the case of multi-pass joints. The conventional straight weave may be used but only in circumstances when the face of the previous pass is wide enough such that the effect of heat sink will maintain a flat profile automatically. Whilst the dip transfer method is slow and often demanding in terms of operator concentration, the arc energy is greater than with solid wire and the possibility of defects, especially cold lapping is substantially reduced. The root pass in an open butt weld, where full penetration is required from one side, is always the most difficult regardless of welding process or position.
The choice will depend on the thickness of material and degree of root penetration desired. Multi-pass joints should be completed on a similar basis to that of butt welds using the vertical up technique.
Fig 10a Front face
Fig 10b Rear face
Fig 8a
Fig 8b
OK Tubrod types can achieve in excess of 3 kg/hr in the vertical position compared to manual arc at 1 kg/hr max and solid wire at approximately 2 kg/hr. The techniques required for vertical up welding are almost identical to those employed with manual arc Fig 9, both for fillet and butt joints. However, root passes in open butt welds where a uniform bead of penetration is required when welded from one side are not recommended. This is due to the high arc energy and fluidity of the weld pool as well as the need to maintain highly accurate joint preparations which is not considered practical.
Fig 9
However, when using Tubrod metal and basic cored wires the use of dip transfer and vertical down welding can be used to good advantage. Excellent results can be achieved more easily, it is rapid and plate preparation costs can be reduced by dispensing with a root face. Fillet joints may be welded using either the vertical up or vertical down techniques.
25
Electrode extension
This term describes the distance between the contact tip of the torch and the work piece, sometimes described as electrode stickout. The current conditions should be set for the job in hand but during welding it may be necessary to reduce the amount of heat in the weld pool to accommodate poor fit-up or out of position welding. An increase in the stickout length and the extra electrical resistance that results will produce a cooler less fluid weld pool. Similarly any decrease in electrode extension will have the effect of increasing welding current and the characteristic can be of benefit in controlling penetration; especially where inconsistent fit-up is encountered. When operating with dip transfer an extension of 12mm will suffice for most applications, whereas spray transfer produces a greater amount of radiated heat and should have an extension of approximately 20-30mm. During actual welding any large variation will produce an inconsistent weld deposit and excessive electrode extension will reduce for effectiveness of the gas shield. For a given wire feed rate any lengthening of the extension has the effect of reducing the amperage drawn from the power source. Increasing the wire feed speed to compensate for the current drop will result in a significant increase in weld metal deposition. Fig 11.
DIP TRANSFER
Contact tip protrudes beyond the shroud
SPRAY TRANSFER
Contact tip within the shroud
10-12mm Extension
25-30mm Extension
SPRAY TRANSFER IMPROVED ACCESS USING SHORT SHROUD
Fig 11
Electrode extension related to deposition rate
Extension mm Wire feed m/min Current Amps Dep rate kg/Hr
12 5.8 350 4.7
18 5.8 320 4.7
25 5.8 280 4.7
25 8.4 350 6.5
26
Deposition data
OK Tubrod 14.00/14.12
9
1.6mm
OK Tubrod 15.00
9
1.6mm
8
1.4mm
8
1.4mm
7
1.2mm
6 Kgs/Hr 5
1.2mm
6 Kgs/Hr 5
Polarity DCElectrode Extension 1.2mm 1.4mm 1.6mm
Electrode Extension 1.2mm 1.4mm 1.6mm
2 20mm 1
20mm
0 150 200 250 Amps 300 350 400 450
0 150 200 250 Amps 300 350 400 450
OK Tubrod 15.12
11
1.6mm
OK Tubrod 15.14
6
1.6mm 1.2mm 1.4mm
10 5 9 4 8
2.4mm
Kgs/Hr 3
7 2 6 Kgs/Hr 5
1.2mm
Electrode Extension 1.2mm 1.4mm 20mm 1.6mm
4 150 3 Electrode Extension 1.2mm = 20mm 1.6mm = 25mm 2.4mm 200 250 Amps 300 350 400
0 150 200 250 300 Amps 350 400 450 500
OK Tubrod 14.3X
10 Tubrod 14.3X 9
OK Tubrod 15.18
10 9
Stainless Cored Wires
8
1.6mm
8
1.6mm
7
1.2mm
6 Kgs/Hr
6
1.2mm
Kgs/Hr 5 4
Electrode Extension 1.2mm = 20mm 1.6mm = 25mm
100 200 250 300 Amps 350 400 450 500
200
300
400
500
Amps
27
OK Tubrod estimating data

Metal cored wire Tubrod 14.0X Series
Fillet welds
Dia mm
T L mm mm
Amps
Wire feed speed cm/min 1046 1046 1046 954 954 954 780 780 780
Volts
Welding speed cm/min 92 61 37 110 53 35 120 55 35
Arc time min/m
Wire weight kgs/m
Gas litres/m
1.2 1.2 1.2 1.4 1.4 1.4 1.6 1.6 1.6
3 4 6 3 4 6 3 4 6
4 6 8 4 6 8 4 6 8
290 290 290 320 320 320 370 370 370
28 29 29 30 31 31 29 30 30
1.08 1.6 2.7 0.9 1.9 2.8 0.8 1.8 2.8

Wire feed speed cm/min 351 1176 1176 198 708 708 372 675 675 450 675 675 372 744 744 710 710
0.09 0.13 0.23 0.09 0.19 0.28 0.08 0.19 0.29

Welding speed cm/min 20 20 31 14 23 28 46 19 68 40 25 66 17 39 29 24 21 Arc time min.m 5.9 3.6 2.9 7.1 4.3 3.6 2.2 5.3 1.5 2.5 3.9 1.5 5.9 1.9 4.1 4.8 5.6
18.4 27.0 46.0 15.3 32.0 47.6 13.6 30.6 47.6

Wire weight kgs/m 0.17 0.35 0.29 0.16 0.35 0.29 0.12 0.51 0.14 0.16 0.38 0.14 0.31 0.20 0.44 0.49 0.57
Butt welds
60O
2
Dia. mm A 1.2 A 1.4 A 1.6 A B 1.6 B 1.6 C
T mm 13
Run No. 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5
Amps 140 280 280 110 280 280 230 350 350 250 350 350 230 370 370 360 360
Volts 17 31 31 18 31 31 28 30 30 28 30 30 28 30 30 30 30
Gas litres/m 100 61 49 120 73 51 37 90 25 42 66 25 100 32 69 81 95
T
1
13
1.5-3.0mm Root gap
45O
2
13
13
T
1
1.5mm Root face 1.5-2.5mm Root gap
25
45O
3 2
C 3.0mm gap VERTICAL 1.2 25 1 2 3 4 1 2 3 4 1 2 3 4 5 160 160 160 160 130 150 160 160 190 190 190 190 190 408 408 408 408 198 270 270 270 244 244 244 244 244 17 17 17 17 19 18 18 18 15 15 15 15 15 18 5.4 4.9 4.6 13.6 5.3 4.7 4.3 25 5 6 6 5 5.6 18.5 20.5 21.7 7.4 18.9 21.3 23.3 3.9 19.7 15.7 15.7 19.7 0.19 0.63 0.70 0.74 0.17 0.58 0.65 0.72 0.14 0.70 0.57 0.57 0.70 95 314 346 368 125 321 362 396 66 334 266 166 334 V/D V/U V/U V/U V/D V/U V/U V/U V/D V/U V/U V/U V/U
1 4 5
60O 1.4 2.5mm

1 2 3 4 5
25
1.6
20
60O Vertical OVERHEAD 2.4mm
INDEX
T
1 2 4 6 8 10 12 13 3 5 7 9 11
1.6
20
1 2 3-10 11-12 13
150 280 280 280 150
208 579 579 579 208
14 24 23 23 15
16 52 56 70 4
6.1 1.9 1.8 1.4 26.2
0.18 0.16 0.15 0.12 0.80
103 32 30 23 445
60O Overhead
NOTES 1. Shielding gas flow rate 15-20 litres/min. 2. Contact tip to work distance 25-30mm. 3. Pull the torch with an angle of 70o to the line of the joint.
28
Flux cored wire Tubrod 15.XX Series

OK Tubrod 15.00 1.2 and 1.6mm fillet welds HV position Dia mm 1.2
L
1.6
T
T mm 3 4 6 4 6 7
L mm 4 6 8 6 8 10.0
Current amps 280 280 340 350 350 350
Wire feed speed cm/min 1450 1450 1650 840 840 840
Volts 30 31 32 29 32 31
Welding speed cm/min 79 51 30 48 34 25
Arc time min/m 1.2 1.9 3.3 2.1 3.0 3.9
Wire weight kgs/m 0.14 0.22 0.43 0.24 0.34 0.44
Gas litres/m 21 33 56 35 51 66
OK Tubrod 15.00 2.00 and 2.4mm fillet welds - downhand position Dia mm 2.0 T mm 7 7 10 7 7 10 L mm 10 10 12 10 10 12 Current amps 400 500 500 400 550 550 Wire feed speed cm/min 675 925 925 500 700 700 Volts 29 38 38 28 38 38 Welding speed cm/min 27 37 27 32 42 32 Arc time min/m 3.6 2.6 3.6 3.0 2.2 3.0 Wire weight kgs/m 0.47 0.47 0.67 0.42 0.43 0.58 Gas litres/m 61 44 61 51 37 51
2.4
OK Tubrod 15.00 1.2mm vertical up butt weld

4/5mm 1.5mm 20mm
Plate thickness mm 20
Run No. 1 2 3 4 5
Amps
165 140 140 160 160
Wire feed speed cm/min 510 480 480 558 558
Volts
18 19 19 20 20
Welding speed cm/min 13.4 7.8 8.2 8.7 7.0
Arc time min/m 7.4 13.0 12.2 11.5 14.3
Wire weight kgs/m 0.29 0.46 0.44 0.48 0.60
Gas litres/m 126 217 207 195 243 V/D V/U V/U V/U V/U
50O
OK Tubrod 15.00 1.6mm downhand butt weld Plate thickness mm 25 Run No. 1 2 3 4 5 6 Wire feed speed cm/min 150/160 229 350 838 350 838 350 838 350 838 350 838 Amps Volts Welding speed cm/min 13 44 27 24 23 22 Arc time min/m 7.8 2.3 3.7 4.2 4.2 4.5 Wire weight kgs/m 0.24 0.26 0.41 0.47 0.47 0.58 Gas litres/m 132 39 62 71 71 76
60O
2mm
20 32 32 32 32 32
2mm
OK Tubrod 15.00 2.4mm downhand butt weld Plate thickness mm 10 12 Run No. 1 2 1 2 1 2 3 1 2 3 1 2 3 Amps Wire feed speed cm/min 500 500 500 500 325 650 675 500 650 725 450 650 725 Volts Welding speed cm/min 35 22 27 42 32 40 32 42 32 25 42 32 30 Arc time min/m 2.8 2.1 3.6 2.3 3.0 2.5 3.0 2.3 3.0 3.9 2.3 3.0 3.3 Wire weight kgs/m 0.34 0.28 0.49 0.31 0.26 0.44 0.57 0.31 0.55 0.77 0.28 0.55 0.65 Gas litres/m 47 35 61 39 51 42 51 39 51 66 39 51 56
45O
1.5mm

1.5mm 45O
19
25
25
1.5mm
400 400 400 400 300 500 500 400 500 550 380 500 550
27 27 27 26 26 31 28 29 31 32 27 36 36
29
OK Tubrod 15.18 1.2mm fillet welds - HV position Dia mm 1.2 T mm 3 4 6 L mm 4 6 8 Current amps 330 340 340 Wire feed speed cm/min 1650 1780 1780 Volts 30 33 34 Welding speed cm/min 110 66 35 Arc time min/m 0.9 1.5 2.8 Wire weight kgs/m 0.10 0.18 0.34 Gas litres/m 15 25 47
For larger sizes refer to OK Tubrod 15.12 below

L
OK Tubrod 15.12 fillet welds - HV position Dia mm 1.6 2.0 2.4 T mm 4 6 6 7 6 7 L mm 6 8 8 10 8 10 Current amps 350 350 400 400 460 460 Wire feed speed cm/min 1008 1008 894 894 732 732 Volts 34 34 31 31 31 31 Welding speed cm/min 60 36 47 28 46 34 Arc time min/m 1.7 2.8 2.1 3.6 2.2 3.0 Wire weight kgs/m 0.22 0.37 0.37 0.63 0.44 0.59 Gas litres/m 28 47 36 60 36 49
50O
OK Tubrod 15.12 2.4mm downhand butt weld Plate thickness mm 25

3.0mm
Run No. 1 2 3 4 5
Amps
25mm
350 450 450 450 450
Wire feed speed cm/min 300 492 492 492 492
Volts
29 30 30 30 30
Welding speed cm/min 47 42 34 24 25
Arc time min/m 2.1 2.4 3.0 4.2 4.0
Wire weight kgs/m 0.17 0.32 0.40 0.57 0.54
Gas litres/m 36 40 50 70 68
OK Tubrod 15.14/15.15 fillet welds Dia T L mm mm mm Horizontal vertical 1.2 3 4 4 6 1.6 4 6 6 8 Vertical up 1.2 4 6 1.6 6 8 Vertical down 1.2 4 6 1.6 6 8 Current amps 260 260 330 330 180 190 225 240 Wire feed speed cm/min 1500 1500 900 900 684 342 870 504 Volts Welding speed cm/min 67 47 54 37 22 13 37 29 Arc time min/m 1.28 2.14 1.85 2.76 4.46 7.33 2.69 3.43 Wire weight kgs/m 0.14 0.24 0.23 0.34 0.22 0.32 0.17 0.22 Gas litres/m
30 30 30 30 24 24 25 25
22 36 31 46 76 124 45 58
4.0mm
OK Tubrod 15.14/15.15 1.2mm vertical up butt weld Plate thickness mm 20 Run No. 1 2 3 4 5 Amps Wire feed speed cm/min 402 624 672 786 786 Volts Welding speed cm/min 8 12 11 12 10 Arc time min/m 11.8 8.2 8.8 8.2 9.7 Wire weight kgs/m 0.37 0.39 0.45 0.49 0.58 Gas litres/m 200 140 149 140 164
2/3mm 20mm
50O
125 170 180 190 190
20 22 23 23 23
30

25mm
OK Tubrod 15.14/15.15 1.6mm downhand butt weld

50O
Run No. 1 2 3 4 5 6 7 8
Amps
3.0mm
300 350 350 350 350 350 350 350
Wire feed speed cm/min 630 891 891 891 891 891 891 891
Volts
29 31 31 31 31 31 31 31
Welding speed cm/min 30 32 47 44 48 46 37 38
Arc time min/m 3.3 3.0 2.1 2.2 2.2 2.2 2.6 2.6
Wire weight kgs/m 0.27 0.35 0.24 0.25 0.25 0.25 0.30 0.30
Gas litres/m 56 51 36 37 37 37 44 44
OK Tubrod 15.14/15.15 1.6mm horizontal vertical butt weld

2.0mm 45O
Run No. 1-3 4-23
Amps
200 240
Wire feed speed cm/min 387 510
Volts
24 25
Welding speed cm/min 30 43
Arc time min/m 3.2 2.3
Wire weight kgs/m 0.16 0.18
Gas litres/m 55 39
15O
25mm
OK Tubrod 15.14/15.15 1.2mm downhand butt weld Plate thickness mm 20 Run No. 1 2 3 4 5 6 7 8 Amps Wire feed speed cm/min 438 1398 1398 1398 1398 1398 1398 1398 Volts Welding speed cm/min 15 38 31 24 46 46 39 40 Arc time min/m 6.5 2.7 3.2 4.1 2.2 2.2 2.6 2.5 Wire weight kgs/m 0.21 0.27 0.33 0.43 0.22 0.22 0.26 0.25 Gas litres/m 110 45 55 70 36 36 43 41
50O
20mm 2/3mm
130 260 260 260 260 260 260 260
24 31 31 31 31 31 31 31
4mm
OK Tubrod 15.14/15.15 1.6mm vertical up butt weld Plate thickness mm 25

1.5mm
Run No. 1 2 3 4 5 6 7
Amps

60O 25mm
140 180 180 180 200 200 200
Wire feed speed cm/min 252 285 285 285 387 387 387
Volts
22 24 24 24 24 24 24
Welding speed cm/min 15 15 13 10 13 9 9
Arc time min/m 6.3 6.4 7.6 9.3 7.6 10.1 10.5
Wire weight kgs/m 0.21 0.23 0.28 0.34 0.38 0.50 0.53
Gas litres/m 108 108 129 158 129 171 178
31
Mechanical properties
For a variety of reasons fabricators are required to attain progressively higher charpy V notch properties from welded joints using C/Mn weld metal at low temperatures, typically -30OC. The welding consumables have a significant role to play in producing high purity weld metal with controlled S and P levels but unless strict control of heat input and welding procedure are observed the desired results will not be achieved. The heat affected zone (HAZ) hardness will also have an effect although problems in this area cannot be attributed to the welding consumable. High HAZ hardnesses obviously reduce ductility, but under the influence of hydrogen which can be produced via the consumable, premature failure can result. Heat input This is expressed as kilojoules per mm (kJ/mm) and is useful for predicting the welding parameters that may be required. The formula used to establish the heat input value is:
HI(kJ/mm) = Arc Voltage x Amperage x 60 Welding Speed mm/min x 1000
can be such that, although a preheat may have been employed, heat is being taken away at a faster rate than it is being replaced by the welding. This cooling will lead to undesirable hardening of the heat affected zone so that although the weld metal toughness is good the HAZ will be comparatively brittle. In these cases it may be possible to review the welding parameters or as is generally the case continuous external heating will have to be incorporated. Conversely, if the heat input from welding causes a progressive increase in the interpass temperature, welding will have to stop periodically to maintain it within the defined limits. Most high yield C/Mn steels above 25mm thick will require a preheat of 150OC with a maximum interpass temperature of 250OC to ensure satisfactory results. Preheat levels can often be lower with cored wires since they are used at a higher heat input then solid wire or manual metallic arc. Hydrogen It is not proposed to make an in-depth study on the effect of hydrogen in the HAZ as it is already well documented, but comment is needed in relation to cored wires. Basic manual arc electrode coatings can be prone to moisture absorption often necessitating redrying before use. Advances in coating formulations have, however, dramatically improved their tolerance (i.e. Esab VacPac). Rutile electrodes cannot be used for high integrity welding since by nature they contain water bearing agents which are essential to their satisfactory running. Cored wires are not so susceptible as the core is completely enclosed which eliminates the need for re-drying before use. OK Tubrod fully basic wires will produce less than 5ml of diffusible hydrogen per 100g of weld metal and usually less than 3ml straight from the box and OK Tubrod metal cored wires will also produce typically less than 5ml. With the development of rutile based cored wires, use can be made of their attractive operability yet still maintain acceptable hydrogen levels which is not the case with their manual arc equivalents. However, the level of hydrogen produced is related to size of wire and current used. Fig 12 1.2mm 1.2mm 1.6mm up to 200A 200 - 280A 160 - 350A <5mls/100g 5-7mls/100g <10mls/100g
Low alloy wires For test temperatures below -30OC (-40OC) it is necessary to revert to low alloy wires, usually Ni bearing for toughness and Mo for tensile strength or a combination of both. Typically the 2.5% Ni types will move the transition point to below -60OC for the more severe applications. However, in the case of C/Mn steels for test temperatures at -40OC and provided Ni is permissible, use can be made of Tubrod 15.17. This wire contains 1% Ni and is rutile based, but if weld metal from rutile based wires have a higher oxygen level than that of fully basic types, this deficiency is certainly compensated for by the Ni. For temperatures in the region of -20OC increases in productivity can also be achieved by increases in heat input and deposition rate. In this case the drop in toughness that would otherwise occur with C/Mn weld metal will be offset by the 1% Ni. Welding procedure In any welding procedure where low temperature toughness is required, the run sequence will decide the degree of structure refinement produced without necessarily adversely affecting productivity. Large welds and wide weaving should be avoided so the use of a split weave technique must be adopted as soon as practicable after completing the root. Fig 14a. This will ensure maximum grain refinement. Whilst the weld pass sequence in Fig 14b is described as unsatisfactory it may be used if unavoidable, but each layer using the broad weave technique must be as thin as possible. When welding in the vertical position, welding speed is slow and there is a tendency to produce larger weld deposits with attendant higher heat input than in other positions. It is particularly important to restrict their size Fig 14c since the charpy values achieved in the vertical position will generally be lower than the flat or horizontal vertical position Fig 15.
In the case of C/Mn weld metal the heat input levels that can be relied upon to give good results with cored wires are between 1.0 - 2.0 kJ/mm. From this, therefore, the size of wire can be roughly determined together with the electrical parameters and travel speed that must be maintained. It can be seen in Fig 13 that -30OC is the normal transition zone for C/Mn weld metal and also the effect of heat input in moving this transition to a more favourable position. The use of excessive heat input through the use of high amperage and slow travel speeds will produce large weld deposits that will certainly fill the joint rapidly. However, the welds will exhibit a very coarse dendritic structure characterised by low ductility and hence poor low temperature toughness. The heat affected zone The hardness of the heat affected zone, which is in the plate adjacent to the fusion zone, is not directly attributed to the consumable, but the welding activity will have an effect on the inter - pass temperature and therefore hardness. Welding is used to make joints and so cannot be viewed in isolation, therefore, it is necessary to be mindful of the effects of welding on the total joint. It may be that welding is taking place within the laid down procedure relating to run sequence and heat input (kJ/mm) but the plate thickness and joint length
Fig 12
32
Typical transition curves Butt joint

120
100
80 Low Heat Input 60 C/Mn + 2% Ni High Heat Input 40 JOULE
C/Mn
20
0 -60 -50 -40 TEMP OC -30 -20 -10
Fig 13
Fig 14a Satisfactory
Fig 14b Unsatisfactory
Fig 14c Satisfactory
Welding position
Preparation and pass sequence

10 8 6 4 2 1 9 7 5 3
Wire dia mm 1.2 1.6 1.6
No
V Charpy _0OC J/ +
Mechanical properties V Bend test J/-20OC face
120O radius root
Flat (IG)
1 2 3-10
180 200 350
23 25 31 93,105 116,105 75,67 71,71 OK OK
INDEX PREVIOUS PAGE
Vertical up
6 5 3 1 4 2
1.2 1.2 1.2
1 2 3-6
140 180 200
20 21 22 66,76 85,74 39,43 39,39 OK OK
(3G)
NEXT PAGE
Fig 15
33
Welding procedure data

OK Tubrod 14.03
50O
13 10 7 5 3 2 1 9 6 4 12 8 11
OK Tubrod 14.03 1.4mm Material: NQ-1 Thickness: 25mm Parameters: Size mm 1.4 1.4 1.4 Run No 4 2 3/13 Amps 150 290 310 Volts 18 29 32 Position: ASME 1X-1G
Mechanical Properties Transverse tensile test 808 N/mm2 Fractured in plate Charpy V notch energy (J): Test Temp -20OC -40OC Centre line 74 84 82 81 74 73
Transverse tensile test 808 N/mm2 Fractured in plate
OK Tubrod 14.03 Material: OX812E Thickness: 16mm Position: ASME 1X-1G
60O
9 8 6 4 2 1 10 5 3 7
Parameters: Size mm 1.4 1.6 1.6 Run No 1 2 3-10 Amps 200 270 320 Volts 20 27 30 Heat input kJ/mm 1.1 1.2 1.2
Mechanical Properties Transverse tensile test 810 N/mm2 Charpy V notch energy (J): Test Temp -20OC -40OC Centre line 80 78 79 64 69 63
Centre line
OK Tubrod 14.03 Material: OX 812E Thickness: 20mm Parameters: Size mm 1.4 1.4 1.4
9 7 6 5 3 2 1
Position: ASME 1X-1G
60
10 8
11
Run No 1 2-5 6-11
Amps 185 280 320
Volts 20 32 33
Heat input kJ/mm 1.5 1.2 2.0
Mechanical Properties Charpy V notch energy (J): Test Temp 0OC -20OC -40OC -50OC Centre 77 75 71 74 47 44 39 50 line 76 60 49 49
34

13 10 7 5
OK Tubrod 14.03
50O
12 9 6 4 3 2 1 14 11 8
Material: NAXTRA 70 Thickness: 25mm Parameters: Size No 1.4 1.4 1.4 Run mm 1 2 3-14 Amps 150 290 310 Volts 18 29 32
Mechanical Properties Transverse tensile 803 N/mm2 Charpy V notch energy (J): Test Temp -20OC -40OC Cap -2mm 69 63 64 66 63 64
OK Tubrod 14.04
OK Tubrod 14.04 Material: BS4360 - 50E Thickness: 45mm Position: ASME 1X-3G
Parameters: Size mm 1.2 1.6 Run No 1-5 6-33 Amps 150 180 Volts 18 20 Heat input kJ/mm 1.5/2.0 1.5/3.0
CTOD performance (BS 5762) -10OC 0.62 0.46 1.35mm
45O
OK Tubrod 14.04 Material: OX506 Thickness: 13mm Parameters: Size mm 1.2 1.6 1.6 1.6 Run No 1 2 3/4 5/8 Amps 105 230 250 250 Volts 17 23 25 24 Position: ASME 1X-2G
Mechanical Properties Charpy V notch energy (J): Test Temp -54OC *Non-fusible backing Centre line 74 63 51
4 1 2 3
7 6 5
50O
35
OK Tubrod 14.04
1 2 3 4
Material: USITEN 355N2 Thickness: 16mm
Parameters: Size mm 1.2 Run No 1 2/4 Amps 110 130 Volts 17 19
50O
Mechanical Properties Charpy V notch energy (J): Test Temp -54OC Centre line 49 41 43
OK Tubrod 14.04 Material: EH2 Thickness: 30mm Parameters: Size mm 1.2 1.2 1.2 Run No 1 2 3-11 Amps 180 180 200 Volts 18 17 19 Position: ASME 1X-3G
Mechanical Properties Charpy V notch energy (J):
50O
Test Temp -20OC -30OC -50OC
Centre line 100 110 100 98 85 80 55 56 59
36
OK Tubrod 15.00
OK Tubrod 15.00 Material: BS4360: 50E Thickness: 25mm Parameters: Size mm 1.2 2.4 Run No 1 2-15 Amps 150 420 Volts 22 32 Position: ASME 1X-1G Heat treatment: Stress relief 600OC 11/2 hrs
Solid Wire: Autrod 12.51 Mechanical Properties Transverse tensile: UTS 579N/mm2 3.2mm Charpy V notch energy (J): Test Temp -40OC Weld 43 81 89 Root 52 54 62 fracture in plate
OK Tubrod 15.00 1.2mm Material: BS4360: 50D Thickness: 63mm Parameters: Size Run mm No MMA 1 1.6 2-6 2.4 7-21 Back groove 1 MMA 1.6 2-10 2.4 11-36 Amps Volts Heat input kJ/mm 1.0/1.9 Position: ASME 1X-1G Heat treatment: Stress relief 625OC: 21/2 hrs.
250 400
23 27
250 400
23 27
1.0/1.9
Mechanical Properties Charpy V notch energy (J): Test Temp -10OC -20OC -30OC Centre Line 62 96 95 49 100 35 41 83 47
CTOD performance (BS 5762) -10OC 0.39 0.47 0.78mm
OK Tubrod 15.00 Material: BS4360: 50E Thickness: 25mm Parameters: Run No 1 2-10 Size mm 2.4 2.4 Amps 400 420 Volts 32 32 Position: ASME 1X-1G Heat treatment: Stress relief 600OC 11/2 hrs

6mm
Mechanical Properties Transverse tensile: Charpy V notch energy (J): Test Temp -20OC
UTS 562 N/mm2
fracture in plate.
Centre line 70 70 74
37
OK Tubrod 15.00 1.2mm

15 13 11 9 7 5 3 2 16 17 18 19 20 14 12 10 8 6 4
Material: BS4360: 50D Thickness: 50mm
Position: ASME 1X-1G Pre-heat: 100OC lnterpass: 250OC
Parameters: Size mm 1.2 1.6 1.6 1.2 1.2 1.6 1.6 Run No 1-7 8-9 10-15 16-17 18 19 20 Amps 140 160 170 130 130 160 160 Volts 18 18 20 18 18 22 22 Heat input kJ/mm 1.6 1.8 2.4 1.3 2.1 2.4 2.6
Mechanical Properties Longitudinal tensile test TS 595 N/mm2 YS 529 N/mm2 Charpy V notch energy (J): Test Temp -30OC -40OC -50OC -60OC Cap 81 82 21 21 74 50 38 25 98 96 44 28 Root 56 58 44 42 58 50 48 42 60 46 37 38
CTOD performance BS 5762 -10OC 0.97 0.84 0.71mm
32 26
31 25 21 18 15 12
30 24
29 23 20 17 14 11
28
27 22 19
OK Tubrod 15.00 1.2mm Material: BS4360 Thickness: 50mm Parameters: Size mm 1.2 Run No 1-32 Amps 155 Volts 20 Heat input kJ/mm 2.4 Position: ASME 1X-3G
16 13 10 8
9 7 5 3 1 2 6 4
Mechanical Properties Charpy V notch energy (J): Test Temp -20OC Weld 50 59 67 Root 63 78 97
38
OK Tubrod 15.17
OK Tubrod 15.17 1.2mm Material: API: 5L X60 Thickness: 28mm Parameters: Size mm 1.2 1.2 1.2 Run No 1-2 3-10 11-15 Amps 180 200 190 Volts 24 25 24 Heat input kJ/mm 0.9 1.6 2.2 Position: ASME 1X-6G
Mechanical Properties Charpy V notch energy (J): Test Temp -40OC Centre line 130 108 106 119 118 130
OK Tubrod 15.17 1.2mm Material: RAEX 385 Thickness: 16mm Parameters: Size mm 1.2 1.2 Run No 1 2-17 Amps 200 230 Volts 25 26 Position: ASME IX-2G
Mechanical Properties Charpy V notch energy (J): Test Temp -20OC -40OC -50OC Centre line 98 108 98 72 66 58 39 58 46
OK Tubrod 15.17 1.2mm Material: RAEX 385 Thickness: 16mm Parameters: Size mm 1.2 1.2 Run No 1 2-15 Amps 200 220 Volts 25 26 Position: ASME IX-4G
Mechanical Properties Charpy V notch energy (J): Test Temp -20OC -40OC -50OC Centre line 108 121 134 71 93 83 53 29 45
39
OK Tubrod 15.17 1.2mm Material: BS4360: 50D Thickness: 40mm Parameters: Size mm 1.2 1.2 1.2 1.2 Run No 1 2 3-42 43-51 Amps 215 230 230/250 245/255 Volts 23 23 24/26 26 Heat input kJ/mm 1.9 1.6 0.9-1.2 0.8 Position: ASME 1X-2G Preheat: 100OC lnterpass: 250OC max
Mechanical Properties Charpy V notch energy (J): Test Temp -30OC -40OC -50OC Cap 110 101 119 76 104 98 110 84 82 Root 91 98 49 75 84 82 90 75 77 Root (back gouged) 129 121 136 132 104 116 75 93 97
OK Tubrod 15.17 1.2mm Material: BS4360: 50D Thickness: 50mm Parameters: Size mm Run No Amps Volts Weld Speed mm/min 115 138-176 134-197 125-183 Heat Input kJ/mm 1.5 1.4-1.8 1.2-1.7 1.2-2.0 Position: ASME 1X-3G Preheat: 100OC lnterpass: 250OC max.
1.2 1 145 1.2 2-4 180 1.2 5-25 170 Back groove weld 2nd side 26-37 1.2 170 Mechanical Properties Charpy V notch energy (J):
21 23 22 23
Test Temp Cap -30OC 151 115 137 -40OC 120 141 126 -50OC 136 130 97 CTOD performance (BS 5762) - 10OC 0.906 0.551 0.537mm
Root 72 113 124 53 112 52 24 72 55
OK Tubrod 15.17 1.2mm Material: BS4360: 50D Thickness: 40mm Parameters: Size mm 1.2 1.2 1.2 1.2 Run No 1 2-36 37-42 43-47 Amps 180/190 190/200 180 180 Volts 21 23 22 22 Heat input kJ/mm 2.9 1.0-1.2 1.0 1.0 Position: ASME 1X: 3G Preheat: 100OC lnterpass: 250OC max
Mechanical Properties Charpy V notch energy (J): Test Temp -30OC -40OC -50OC Cap 138 142 147 104 108 76 89 54 67 Root 94 94 74 109 109 69 98 63 57 Root (back gouged) 95 104 98 108 96 108 81 84 83
40
OK Tubrod 15.17 1.2mm Material: BS4360: 50D Thickness: 50mm Parameters: Size Run mm No 1.2 1 1.2 2 1.2 3-5 1.2 6-9 Back Grind 1.2 10-16 1.2 17-22 Amps 160 200 210 220 200 210 Volts 23 26 26 26 26 26 Heat input kJ/mm 2.3 2.0 2.4 2.2 2.3 2.2 Position: ASME 1X-3G Preheat: 75OC lnterpass Temp: 250OC Max
Mechanical Properties Charpy V notch energy (J): Cap 1 69 80 94 86 38 (73) CTOD performance (BS5762) - 10OC 0.46 0.49 0.49mm Test Temp -40OC Cap 2 88 84 42 114 102 (86) Root 57 48 23 42 100 (54)
OK Tubrod 15.11
OK Tubrod 15.11 1.2mm Material: CE:0.35% Thickness: 12mm Position: ASME 1X-3G Pre-heat: 20OC Interpass: 250OC Amps 140 180 Volts 21 24 Heat input kJ/mm 2.9 1.0
6 4
7 5 2 1 3
Parameters:
12mm
0-1mm
Size mm 1.2 1.2
Run No 1 2-8
4mm
Mechanical Properties Charpy V notch energy (J): Test Temp -55OC Weld 72 80 92
OK Tubrod 15.11 1.2 mm Material: BS4360: 50D Thickness: 50mm Position: ASME 1X-3G Pre-heat: 120OC Interpass: 180OC
Parameters: Size mm 1.2 1.2 Run No 1 2-45 Amps 145 190 Volts 23 24 Heat input kJ/mm 2.2
Mechanical Properties Charpy V notch energy (J): Test Temp Cap -40OC 90 106 108 -50OC 106 95 64 CTOD performance (BS 5762) -10OC 0.42 0.32 0.37 mm
41
OK Tubrod 15.11 1.2 mm Material: BS4360: 50D Thickness: 20mm Parameters: Size Run Amps Volts mm No 1.2 1 160 24 1.2 2-13 190 25 Mechanical Properties Longitudinal tensile test: TS 602 N/mm2 YS 540 N/mm2 Charpy V notch energy (J): Test Temp -40OC -50OC Cap 74 86 86 66 112 116 Centre Line 90 96 118 112 90 120 Root 114 100 98 64 72 112 Heat input kJ/mm 2.5 1.9 Position: ASME 1X-3G Pre-heat: None Interpass: 250OC
OK Tubrod 15.25
OK Tubrod 15.25 1.6mm Material: BS 4360: 50D Thickness: 63mm Parameters: Size mm Side 1 1.6 2.4 Side 2 1.6 2.4 Run No 2-7 8-22 2-10 11-36 Amps Volts Heat input kJ/mm Position: ASME 1X-1G
250 400 250 400
33 27 1.0-1.9 23 27
Mechanical Properties Charpy V notch energy (J):
Stress relief 625 C - 2.5HRS

O
Test Temp Centre line -10OC 110 99 136 -20OC 127 100 119 -30OC 107 84 102 -40OC 100 77 94 -50OC 75 61 72 CTOD performance (BS5762) -10OC 0.79 0.81 0.84mm
29
28
27
26
OK Tubrod 15.25 Material: BS4360: 50D Thickness: 63mm Parameters: Size Run Amps mm No 1.2 1-3 230/240 1.6 4-10 200/240 2.4 11-22 400 2.4 23-26 400 Back groove 1.2 1 230/240 1.2 2-3 230/240 1.6 4-10 280/300 2.4 11-35 400 2.4 36-41 400 CTOD performance (BS 5762) 1.30 1.61 1.28mm Volts 30 27 32 32 30 30 27 32 32 -10OC Heat input kJ/mm 1.0/2.3 Position: ASME 1X-1G Heat treatment: As welded
10 7 5 3
9 6 4 2
Side 1
INDEX
Side 2
0.9/2.2
36
41
42
OK Tubrod 15.24
OK Tubrod 15.24 1.2 mm Material: BS4360: 55F Thickness: 50mm Parameters: Size mm Run Amps No 1-3 MMA (E8016-G) 1.2 4-57 240 1.2 58-68 210 Mechanical Properties Longitudinal tensile UTS 638 N/mm2 YS 581 N/mm2 Charpy V notch energy (J): Root 136 130 122 79 64 92 Volts Heat input kJ/mm 1.43 1.41 Position: ASME 1X-2G Pre-heat: 100OC Interpass: 200OC
29 28
Test Temp Cap -40OC 150 124 122 -50OC 132 90 98 CTOD performance (BS 5762) -10OC 0.85 1.60 0.80mm OK Tubrod 15.24 1.2mm Material: BS4360: 50D Thickness: 50mm
Position: ASME 1X-2G Pre-heat: 100OC Interpass: 250OC Heat treatment: Stress relief, 600OC 4 hrs Heat input kJ/min
Parameters: Size Run Amps Volts mm No 1.2 1-23 240 27 1.2 24 200 27 1.2 25-31 240 27 Back groove 1.2 32-43 240 27 1.2 44 200 27 1.2 45-50 240 27 Mechanical Properties Longitudinal tensile UTS 592 N/mm2 YS 516 N/mm2 Charpy V notch energy (J): Test Temp Cap -40OC 190 90 134 -50OC 58 122 108 CTOD performance (BS 5762) -10OC 1.57 1.03 1.71 mm Root 120 144 140 136 166 142
OK Tubrod 15.26
OK Tubrod 15.26 1.2mm Material: HY80 Thickness: 30mm Parameters: Size Run Amps mm No 3.2 1 MMA (E9016-G) 1.2 2-18 240 Mechanical Properties Longitudinal tensile: UTS 696 N/mm2 YS 651 N/mm2 Charpy V notch energy (J): Volts Heat input kJ/mm 1.6 Position: ASME 1X-1G Pre-heat: 120OC min Interpass: 150OC max
30
Cap 88 100 90 86 90 104 72 65 64
43
OK Tubrod 15.26 1.2mm Material: HY80 Thickness: 30mm Parameters: Size Run Amps mm No 3.2 1 MMA (E9016 G) 1.2 2-22 230 Mechanical Properties Longitudinal tensile: UTS 675 N/mm2 YS 619 N/mm2 Charpy V notch energy (J): Test Temp -40OC -50OC -60OC Cap 140 118 112 136 94 108 118 108 116 Volts Heat input kJ/mm 1.4 Position: ASME 1X-2G Pre-heat: 120OC min Interpass: 150OC max
28/9
OK Tubrod 15.26 1.6mm Material: Q1 (N) Thickness: 55mm Parameters: Size Run Amps mm No 3.2 1 MMA (E9016-G) 1.6 2-35 290/310 Back groove 1.6 36-53 290/310 Mechanical Properties All weld tensile: Side 1 UTS YS Side 2 UTS YS Charpy V notch energy (J): Test Temp -50OC Weld - Side 1 118 188 86 Weld - Side 2 110 110 130 Volts Heat input kJ/mm 1.22 1.22 N/mm2 N/mm2 N/mm2 N/mm2 Position: ASME 1X-2G Pre-heat: 120OC Interpass: 150OC
23/5 23/5 735 683 756 710
OK Tubrod 15.26 1.2mm Material: HY80 Thickness: 30mm Parameters: Size Run Amps mm No 3.2 1 MMA (E9016-G) 1.6 2-13 350 Mechanical Properties Longitudinal tensile: UTS 619 N/mm2 YS 553 N/mm2 Charpy V notch energy (J): Volts Heat input kJ/mm 1.8 Position: ASME 1X-1G Pre-heat: 120OC min Interpass: 150OC max
31
Cap 94 96 80 74 74 64
106 78 71
44
OK Tubrod 15.27 1.6mm Material: Q2 (N) Thickness: 50mm Parameters: Size mm 1.6 Run Amps No 1 300 2-8 290 9-20 280 21-27 270 Back Groove 28-30 300 31-39 275 Mechanical Properties Longitudinal tensile Side 1 Side 2 Charpy V notch energy (J): Test Temp -50OC Side 1 78 83 87 88 110 Side 2 78 83 98 105 108 Volts 25 25 25 25 25 25 UTS YS UTS YS Heat input kJ/mm 1.4 1.16 1.07 0.86 1.9 1.5 814 763 785 737 N/mm2 N/mm2 N/mm2 N/mm2 Position: ASME 1X-2G Pre-heat: 120OC min Interpass: 150OC max
OK Tubrod 15.27 1.6mm Material: Q2 (N) Thickness: 50mm Parameters: Size mm 1.6 Run No 1 2-5 6-28 Amps 340 340 340 Volts 26 27 27 25 26 27 UTS YS UTS YS Heat input kJ/mm 1.47 1.34 1.40 1.02 1.04 1.30 737 702 757 700 N/mm2 N/mm2 N/mm2 N/mm2 Position: ASME 1X- 1G Pre-heat: 120OC Interpass: 150OC max
Back grind 29 340 31-32 340 33-40 340 Mechanical Properties Longitudinal tensile: Side 1 Side 2 Charpy V notch energy (J): Test Temp -40OC -50OC -60OC Weld Side 115 120 110 122 82 98 1 123 136 110 Weld Side 122 141 140 135 87 92 2 136 148 100
45

15
OK Tubrod 14.04 1.2mm OK Tubrod 14.31 1.2mm OK Tubrod 14.32 1.2mm Material: E32/A1S1 316 Clad Steel Thickness: 47mm Parameters: Size mm Side 1: 1.2 Side 2: 1.2 OK Tubrod 1.2 OK Tubrod 1.2 Run Amps Volts No OK Tubrod 14.04 1-12 185 17 OK Tubrod 14.04 13-14 180 22 14.32 15 180 22 14.31 16 160 21 17 150 21 Mechanical Properties Transverse tensile: Fracture in plate Heat input kJ/mm 2.2 2.2 2.7 2.8 3.4 Position: ASME 1X-3G Pre-heat: Interpass: 150OC max
Charpy V notch energy (J): Test Temp -60OC Bend Test Stainless + C/Mn C/Mn >120O OK >120O OK Side 1 (Cap - 2mm) 46 49 53 Side 2 (Cap - 2mm incl S/S) 66 65 66
OK Tubrod 14.27 1.2mm Material: Duplex Grd S31803 pipe Thickness: 46mm-610mm O.D Parameters:
OK Tigrod 16.88 2.4 mm Position: ASME 1X-2G Pre-heat: 25OC Interpass: 150OC max
Size Run Amps Volts Heat input mm No kJ/mm GTAW 2.4 1 80 12 1.34 2.4 2-5 200 15 1.64 FCAW 1.2 6-55 230 26 1.06 1.2 56-73 210 27 0.79 Mechanical Properties Transverse tensile: 735 N/mm2. Fracture in plate. Charpy V notch energy (J): Test Temp -30OC -45OC Weld Fusion Line Root 46 50 42 78 54 103 45 40 42 48 44 57 76 76 70 63 60 74 Fusion Line 53 59 51 33 41 42
Bend Test Side bends x 4 >120O OK
46
Welding of stainless steel

Types of stainless steel
If chromium is added to carbon steel in amounts exceeding 12% it imparts corrosion and heat resistance and, as such, is the most important alloying element in stainless steel. The presence of chromium causes a film of chromium oxide to be formed on the surface of the steel which affords protection in corrosive environments. However, in less oxidising conditions such as those experienced during exposure to certain acids, insufficient oxygen is present for the protective film to form. Additions of 8-10% nickel will improve corrosion resistance in such circumstances and higher levels up to 15% will serve to maintain strength at elevated temperatures. Frequently molybdenum and smaller amounts of other elements are added to improve further corrosion and/or strength under specific conditions. The variety of stainless steels is enormous but, to simplify the situation, they can be categorised broadly into three main types: Martensitic 13% - 16% Cr These contain from 12% to a maximum of 16% chromium as the main alloying element, with carbon 0.3% maximum. In certain special applications the carbon in this class of steel may exceed 0.3%. These materials are capable of being hardened, consequently their welding presents difficulties unless special precautions are taken. Steels of this type are used for cutlery, spindles, shafts and applications requiring good resistance to corrosion and scaling at elevated temperatures up to approximately 800OC. These steels harden when welded, so to reduce the hardness in the heat affected zone and avoid the danger of cracking, it is necessary to preheat to 200-400OC followed by slow cooling after welding. This should be followed, if possible, by a post-heat at 650-700OC. For ductile joints free from cracks, an austenitic stainless steel consumable is normally used. Weld metal or similar composition is usually employed for limited applications such as overlaying and minor attachments, etc. may be quite tough at red heat at which it operates in service. Steels of this type do not harden when welded. Preheating to 200OC is recommended to ensure safe handling while a post-heat treatment at 750OC helps restore ductility by recrystallisation of the weld. For mildly corrosive applications and where the presence of nickel-bearing weld metal can be tolerated (these steels are frequently used in sulphurbearing atmospheres which attack nickel) an austenitic stainless steel wire is recommended. A weld of this type also provides a joint capable of deformation in further processing operations. Austenitic 19% Cr 9% Ni (+ Mo) The austenitic group represents the largest and most important range used in modern industry and contain a minimum of 18% Cr and 8% Ni. Their austenitic structure ensures that they are soft and ductile with excellent weldability. Welding techniques The welding techniques required for austenitic stainless steel are in many respects similar to those used for mild steels, except that various precautions are essential particularly with regard to distortion. Factors to be considered are: G Poor heat conductivity - 1/3 that of mild steel. Heat is not dissipated from the weld area so rapidly as with mild steel. G High coefficient of expansion - 11/2 times that of mild steel. Shrinkage stresses are increased and hence the risk of distortion. G Higher specific resistance - 5 times that of mild steel. Stainless steel can attain red heat more rapidly, therefore lower currents should be used to avoid overheating of the base material. G Where possible a consumable that matches the composition of the base material should be used. However, fully austenitic weld metal is sensitive to hot cracking, so the weld metal will ideally contain 5-9% ferrite to prevent this.
Duplex stainless steels

The use of Duplex stainless steels is rapidly increasing in preference to the standard fully austenitic steels previously described. In comparison to, for example, a 316L material which will contain 5-9% ferrite, the Duplex steels contain 50% ferrite and 50% austenite, hence the term Duplex. The resulting micro structure produces the following advantages: G Superior resistance to pitting corrosion. G Higher tensile strengths permit the use of thinner sections and consequently reduce overall weight. G Lower risk of stress corrosion cracking. G Comparable weldability to the standard fully austenitic steels. G Excellent mechanical properties in the temperature range -50OC to 280OC.
Table 1
Welding procedures
Weld Process Consumables Metal A B C D E MMA MMA SAW FCAW FCAW OK OK OK OK OK 67.50 67.50 16.86 14.37 14.37 Dia. mm 2.5/3.0 3.0 3.0 1.2 1.2 Weld position 1G 1G 1G 1G 1G Plate thickness 9 mm 13 mm 13 mm 9 mm 13 mm Heat Input 0.4-0.8 0.7-0.8 1.5-2.2 0.8-1.1 0.8-1.1 Ferrite Charpy V FN(AV) +20C(J) 46 31 68 63 56 33 46 135 30 38
Ferritic 16% - 30% Cr Used where very high temperature scaling resistance is required. For example; furnace parts, oil burners, etc. Materials of this group are not hardened by heat-treatment, but are liable to brittleness caused by excessive grain growth at high temperatures above 115OC. This results in a weld which is brittle at ordinary temperatures, though it
OK Autrod 16.86 was used with OK Flux 10.93 OK Tubrod 14.37 was used with CO2 Shielding Gas.
47
Weldability
The essential requirement during the fabrication and welding of Duplex steels is to maintain the balance of ferrite and austenite within the micro-structure to optimise service performance. This can be affected by: G Dilution - Influenced by size of consumable relative to joint geometry and current used, which in turn affects weld metal composition. G Heat Input It should be maintained between 0.5 and 2.5 kJ/mm of weld deposit. G Interpass Temperature - Indicating the maximum temperature between passes, it should not exceed 150OC. G Working Temperature - The material generally should not exceed 300OC. Failure to observe these basic rules results in the formation of brittle phases, a reduction in corrosion resistance or mechanical properties or a combination of all three. It is the ferrite content that provides the strength and austenite the corrosion resistance and it is therefore vital that the balance between the two structures be maintained so far as possible. Dilution has a most marked effect which in turn can be exaggerated by an additional heat input. Manual metal arc will give the least dilution with minimal weld metal Ni loss and will consequently maintain austenite limits.
The submerged arc process will lead to an increase in ferrite content and consequently a reduction in the austenite because of its comparatively higher dilution. It has been noted, however, that the submerged arc process does produce weld metal of excellent notch toughness, especially at room temperature, although this is believed to be attributed to the low O2 content over-riding the effect of the increased ferrite. The precautions indicated may give the impression that the successful welding of Duplex steels is complex with a high risk of compromising the physical properties. This, in fact is not so, as good welding practice with any of the popular welding processes will ensure a heat input within the stipulated range of 0.5 - 2.5 kJ/mm. In selecting a suitable welding process productivity will be an obvious consideration so, if there are any doubts about projected heat input, it can be evaluated by reference to the formula on page 32. Of all the suitable processes when viewed in terms of flexibility, productivity, weld metal composition and mechanical properties, flux cored wires such as OK Tubrod 14.27 and 14.37 produce the most beneficial compromise. (Table 1).
Super duplex stainless steels

The most important elements in duplex steels are Cr, Ni, Mo and N and most super duplex types contain additions of Cu and W. It is the Cr Mo and N that impart the corrosion resistance and in particular resistance to pitting and crevice corrosion in chloride enriched environments. Duplex steels are classified according to their pitting corrosion resistance by a PREN number calculated from the formula %Cr + 3.3 x %Mo + 16 x %Ni. The standard duplex steels will have a PREN rating of between 25 and 38 whereas super duplex steels will exceed 40 - see Table 2. The higher value with super duplex steels is due to the higher alloy and N content and the much improved properties have extended their use considerably.
Table 2
Examples of common duplex stainless steel grades

Steel grade Classification (Old UNS/New UNS/W.Nr) a) 23% Cr - Mo-free duplex stainless steels SAF2304 S 32304 / S 39230 / UR 35 N 1.4362 22% Cr - Standard duplex stainless steels SAF2205 UR 45 N S 31803 / S 39205 / AF 22 1.4462 25% Cr - (0-2.5% Cu) Duplex stainless steels Ferralium 255 S 32550 / S 39253 DP 3 S 31260 / S 39226 25% Cr - Super duplex stainless steels SAF2507 S 32750 / S 39275 UR 52 N+ S 32550 / S 39253 Zeron 100 S 32760 / s 39276 Chemical composition (wt.%)* Cr Ni Mo N Cu W PREN**
23
0.2
0.1
(=25) 25
b)
(30-36) 22 5.3 3 0.17 35
INDEX PREVIOUS PAGE
c)
26
5.5
0.18
1.6
(32-40) 38
d)
NEXT PAGE
25 25 25
7 6 7
3.8 3.8 3.6
0.27 0.26 0.25
1.5 0.7
0.7
(>40) 42 42 41
48
Welding of clad steel

Consumables OK Tubrod 14.28 rutile cored wire is recommended for the welding of super duplex steels and has a similar composition. The Ni content always over matches the base materials, as is also the case with OK Tubrod 14.27/37 to promote austenite during cooling. Table 3. Matching consumables or welding without filler (high dilution) will promote excessive ferrite and possibly embrittlement so this should be avoided unless post weld solution annealing is to be carried out. Wires over alloyed in Ni should, therefore, always be used on welded fabrications for service in the aswelded condition. Although corrosion resistance of duplex weld metals is generally more than adequate, it will normally be lower than that of unaffected base material. It will depend on the phase balance of ferrite and austenite which is affected by cyclic heating during welding, cooling rate and so on. The higher alloyed 25% Cr super duplex steels are especially sensitive and so heat input has to be controlled within closer limits if the higher corrosion resistance is to be maintained and embrittlement avoided. A range of 0.2-1.5 kJ/mm is advisable and the inter-pass temperature controlled within the range 100OC-150OC. If optimum mechanical properties are required the interpass temperature should be 100OC max. Table 4. To improve corrosion resistance of weld deposits in standard 22% Cr duplex steels it is becoming increasingly popular to use super duplex consumables such as OK Tubrod 14.28 which is quite acceptable. Shielding gas It is vital to maintain N levels if corrosion resistance is to be preserved. The shielding gas does have an affect on N content of the weld metal and, for example, in TIG welding N is frequently added from 1-3% to make up for losses and improve corrosion resistance. This is especially relevant in root areas where dilution will be high. With regard to flux cored wires, the rutile OK Tubrod types are recommended for use with Ar+20-25% CO2. The use of a clad-material, consisting of a mild or low-alloy steel backing faced with stainless steel, combines the mechanical properties of an economic backing material with the corrosion resistance of the more expensive stainless facing. This facing usually consists of austenitic stainless steel of the 18/8 or 18/10 type, with or without additions of molybdenum, titanium and niobium, or a martensitic stainless steel of the 13% chromium type. The stainless steel cladding is normally 10 to 20% of total thickness. The welding material which is clad or lined with 13% Cr (martensitic) steels usually requires a preheat of 250C and the use of an austenitic wire of appropriate type. Welding should be followed by a postheat treatment, though satisfactory results can be obtained without these precautions if, during welding, heat dissipation is kept to a minimum. This will help to temper the heat-affected zone by utilising the heat build-up from adjacent weld runs. The carbon steel backing should be welded first making sure that the carbon steel weld metal does not come into contact with the stainless cladding. This
Closed Butt with Root Face
Table 3
Typical chemical composition of all weld metals (wt%)

Wire OK Tubrod 14.27/Ar + CO2 OK Tubrod 14.28/Ar + CO2 C 0.03 0.03 Si 0.90 0.60 Mn 0.90 0.90 Cr 22.5 25 Ni 9.0 9 Mo 3.0 4.0 N 0.15 0.22 PREN 35 41 can be achieved in two ways, either by cutting the cladding away from both sides of the root, or welding with a close butt preparation and a sufficiently large root-face. The joint is then back grooved from the clad side to a sufficient depth to allow the deposition of a high alloy type weld metal, e.g: 309, to compensate for the dilution effect from the two dissimilar steels. Failure to do so will not only result in the depletion of alloy it could also render the clad side weld brittle. It is necessary to weld the cladding with a wire of matching composition to ensure continuity of corrosion resistance and physical requirements. For practical purposes it may be desirable to weld the joint totally from the clad side. In such circumstances
Open Butt
Table 4
Recommended heat input and interpass temperature for welding duplex and super duplex stainless steels
Type Recommended heat input* (kJ/mm) Cr Cr Cr Cr Mo-free duplex Standard duplex (0-2.5% Cu) duplex Super duplex 0.5-2.5 0.5-2.5 0.2-1.5 0.2-1.5 Maximum interpass temperature (C) 150-200 125-200 100-150** 100-150**
23% 22% 25% 25% * **
The heat input should be selected relative to the material thickness. A maximum interpass temperature of 100C is recommended for optimum weld properties.
49
Welding of dissimilar steels

Situations frequently arise when it becomes necessary to weld an austenitic stainless steel to a mild or low alloy ferritic steel. In selecting a suitable electrode, the effect of dilution of the weld metal by the base material must be considered. The weld metal may be diluted from 20-50% depending on the welding technique used. Root runs in butt joints are the most greatly affected since all subsequent runs are only in partial contact with the base material and share dilution with neighbouring runs. If a mild or low alloy steel wire is used to weld stainless to mild steel, the pick-up of chromium and nickel from the stainless steel side of the joint could enrich the weld metal by up to 5% chromium and 4% nickel. This would result in a hardened crack sensitive weld. Austenitic stainless steel electrodes are, therefore, used for joining dissimilar metal combinations of stainless materials to mild and low alloy ferritic steels. However the correct type, which has sufficient alloying to overcome the effects of dilution from the mild or low alloy steel side of the joint, must be selected since if the weld metal does not start with an adequate alloy content the final weld may contain less than 17% chromium and 7% nickel. Weld metal with lower chromium and nickel contents are crack sensitive. Also if as a result of dilution the weld metal is incorrectly balanced with nickel and chromium, there may not be sufficient ferrite present in the weld metal to prevent fissuring and subsequent cracking taking place. For these reasons an austenitic stainless steel wire of the 20/9/3, 25/12 or 19/8/6 should be used. Their composition has been specially balanced to ensure that the total alloy content is adequate to accommodate dilution effects and which have a ferrite content sufficient to provide high resistance to hot cracking.
Schaeffler diagram
A useful method of assessing the general metallurgical characteristics of any stainless steel weld metal is by means of Schaefflers diagram. The various alloying elements are expressed in terms of nickel or chromium equivalents, i.e. elements which like nickel tend to form austenite and elements like chromium which tend to form ferrite. By plotting the total values for the nickel and chromium equivalents on the Schaeffler diagram a point can be found indicating the main phases present in the stainless steel and this provides certain information as to its behaviour during welding. The diagram indicates that the comparatively low alloyed steels are hardenable since they contain the martensitic phase in the as-welded state. As the alloying elements increase, the austenite and ferrite phases become more stable and the alloy ceases to be quench hardenable. Steels with a relatively high level of carbon, nickel and manganese become fully austenitic (Austenite area) while those with more chromium, molybdenum etc. tend to be fully ferritic (Ferrite areas). There is also an important intermediate region of duplex compositions indicated as A + F on the diagram. In this region the welds contain both austenite and ferrite. This leads to the general classification of stainless steels into austenitic, ferritic, and martensitic, according to which phase is predominant. It is especially useful to determine the structure and hence physical characteristics of weld deposits when joining dissimilar steels by plotting the effects of dilution. The actual degree of dilution will depend on the application, plate preparation and thickness as well as the welding parameters used, but the following example will highlight some of the potential problems. Example: Imagine that a high quality C/Mn structural steel is required to be welded to an AISI 308 stainless steel. Experience has shown that a high alloy weld metal with ferrite should be adopted for this application but frequently 316L weld metal is used and this exercise will examine the dangers. Having calculated the Ni and Cr equivalents of the two steels they are plotted on the diagram and a line drawn from the C/Mn steel at point (A) to the 308 at point (B). It is assumed that equal amount of the base material will dilute the weld metal so a point is marked midway along the line (A), (B) and indicated by (C).
Complete welding from clad side
Double V joint
HV fillet joint
welding of the joint should proceed in the normal manner until the carbon steel weld metal is one layer short of the cladding. The high alloy 309 weld metal should be employed for the area of interface with the cladding followed by capping of the joint with a consumable that matches the clad composition.
50
The Ni and Cr equivalents of the proposed weld metals, in this case 316L (OK Tubrod 14.31) and 309L (OK Tubrod 14.32), are now calculated and plotted on the diagram. A line is drawn from each weld metal equivalent to the midway point (C) on line (A), (B). The weld metals will also be diluted by approximately 30% so a point is marked 30% back from the weld metal plots toward the 50% steel dilution mark (C) and denoted (1) and (2). These indicate the structural condition of the weld metal from which a choice will be made. Steels Type AISI 308 BS4360-50D Weld Metals Type 316L 309L
Assessment
1. The C/Mn structural steel to 308 stainless steel using 316L weld metal. The final composition of the weld is indicated by plot (1) which shows that it will be totally austenitic. This structure has a tendency toward hot cracking. In addition, if dilution is increased by up to 45%, such as may occur in root areas of open butt joints, there is a danger of martensitic formation within the austenite and this structure exhibits brittleness at normal temperatures. Clearly, therefore, a 316L weld metal is not the ideal choice in this case. 2. The C/Mn structural steel to 308 stainless steel using 309L weld metal. The weld metal composition in this case indicated by plot (2) will be of austenite plus approximately 5% ferrite which is eminently suitable for the application. The delta ferrite will prevent the risk of hot cracking and dilution can be increased by as much as 50% before there is any danger of martensitic formation.
Equivalents Ni 11.6% - Cr 19.0% Ni 5.2% - Cr 0.45%
Equivalents Ni 14.62% - Cr 23.1% Ni 15.25% - Cr 26.0%
Constitution diagram for stainless steel weld metal

0% 30 10%
Martenisitic cracking below o 400 C Austenite hot cracking above o 1250 C
5%
Nickel equivalent = % Ni + 30 x % C + 0.5 x % Mn
Austentite
20% Percentage of Ferrite 40%

Tubrod 14.31 (316L) 1 B
20
Brittleness after heat treatment o at 500-900 C Ferrite high temperature brittleness
A+M
Tubrod 14.32 (309L) A+F
80%
10
C A+M+F A Martensite M+F F+M Ferrite
100%
10
20
30
40
Chromium equivalent = % Cr + % Mo + 1.5 x % Si + 0.5 x % Nb
51
One sided welding and non fusible backing

Combining the extra deposition available from cored wire with the use of nonfusible backing to permit one sided welding can result in considerable increases in productivity. The labour costs incurred with the application and removal of backing is more than recovered through considerably higher welding speeds over manual arc in particular. A wide variety of shapes and types are available Fig 16 and can be used with the majority of the Tubrod cored wires for welding in all positions. for example, dispensing with the root face for butt welds. G Very low moisture pick-up with ceramic types ensures low hydrogen weld metal and they can be rebaked if necessary. For added insurance glazed types are available for use in extreme conditions. G Mechanical magnetic and adhesive type fixing methods cater for all common joint designs. To achieve full penetration in open butt welds in the flat position and without backing, it is necessary to use the dip transfer mode coupled with a high degree of vigilance on the part of the operator. Dip transfer also restricts the choice of wire types to fully basic E71T-5 OK Tubrod 15.00, or metal cored E70C OK Tubrod 14.12 since rutile types only operate efficiently using spray transfer. The use of ceramic backing eliminates this problem, removing the restriction of choice and allowing the use of spray transfer. The root can, therefore, be completed in a fraction of the time and with minimal operator fatigue. With regard to positional welding and particularly the vertical position, fully basic and metal cored wires are limited to dip transfer throughout the joint. Ceramic backing can do little to improve welding speed in the root since both types of wire are capable of completing satisfactory full root penetration without backing using either the vertical up or downwards techniques. However, although the E71T-1 OK Tubrod 15.14 type wires utilise the spray transfer mode, they are too fluid for adequate control in open butt situations without support. The use of ceramic backing will overcome this difficulty and permit perfect control at very high deposition rates of 3 kg/hr at 180A, in the case of 1.2mm. Fig 17. The higher arc energy available with cored wires also ensures that restarting and remelting of any crater defects is easily accomplished. A hot start device is therefore not required.
Fig 16
G
Penetration is controlled by the backing and not current control hence higher amperage can be used to maximise speed and deposition. G Full fusion and smooth root penetration profile is achieved with no effort, thereby eliminating the need for backgouging and sealing runs. G Plate fit-up and accuracy of edge preparation are not critical. Simplification of joint design is also possible realising further savings,
Fig 17
Recommended edge preparations

40-70o Root gap 4-10mm Preferably 4-6mm 10-35o Root gap 10-25o Root gap Root gap 4-6mm Preferably 4-5mm

Welding position: flat/vertical up
Welding position: horizontal vertical
52
AWS classifications for cored wires

Frequently working drawings specify consumable types to be used with designations taken from a classification system that has been formulated by a standards authority or society. For cored wires the most universally adopted system is that of the American Welding Society. This section is intended to provide the fabricator with a basic understanding of the AWS designations as they apply to Tubrod wires. The system divides cored wires into four sections as follows:AWS A5-18-93 Carbon Steel Electrodes & Rods for Gas Shielded arc welding. Carbon Steel Electrodes for Flux Cored Arc Welding. Low Alloy Steel Electrodes for Flux Cored Arc Welding. Stainless Steel Electrodes for Flux Cored Arc Welding. E 70 C HZ N Y X
Method of classification A5.18-93

This is a relatively new classification for solid wires and rods which now includes metal cored wires. Designates an electrode. Indicates the minimum tensile strength of deposited weld metal in units of 1000 psi. Indicates that the wire is composite i.e. tubular metal cored. Optional supplemented diffusible hydrogen designator. This suffix is only used when the phosphorous, vanadium and copper limits have been changed and indicates that the weld metal is suitable for nuclear reactor applications. Indicates the shielding gas for metal cored tubular wires. CO2 shielding is indicated by C and 75% - 80% Argon plus CO2 is indicated by M. Indicates the chemical composition of the weld metal. The use of the suffix GS will mean that the wire is intended for only single pass welding.
AWS A5.20-95 -
AWS A5.29-80 -
AWS A5.22-95 -
Example: E70C - 6M - OK Tubrod 14.00 E 70 C 6 M = = = = = Electrode Minimum UTS of 70,000 psi Metal Cored (composite electrode) Weld metal composition - A5.18-93 Table 2 75% - 80% Argon + CO2
Method of classification A5.20-95

Designates an Electrode. Indicates the minimum tensile strength of deposited weld metal in units of 10,000 psi. Indicates the primary position for which the electrode is designed. 0 = Flat and horizontal positions. 1 = All positions. Indicates a flux cored electrode. Indicates performance and usability capabilities. Indicates for use with mixed gas. EXXTXM
Example: E71T-1M = Tubrod 15.14 E = Electrode 7 = Minimum UTS of 70,000 psi 1 = All positions T = Flux cored electrode 1 = Electrode classified for use with CO2 or may be used with Argon CO2 mixtures to improve usability, especially for out of position welding. Designed for single and multipass welding and characterised by spray transfer, low spatter loss and a moderate volume of slag. Electrodes of this type are generally rutile bases and operate with DC electrode positive. M = Mixed gas ie. Ar + 20% CO2 Note: the suffix M is omitted when the wire is designed for CO2 only. If the wire is designed for mixed gas and CO2 then both designations will apply, for example, E71T-1M, E71T-1.
53
Performance and Usability Capabilities Tubrod Range

T1 = Tubrod 15.12, 15.14 and 15.18. Characteristics described in example on previous page. Tubrod 14.18. Self shielded electrode for single and multipass welding in the flat and horizontal vertical positions. Using DC electrode positive a globular type metal transfer is produced. Tubrod 15.00. Designed for use with CO2 (Argon based gases may be used as in T1) for single and multi-pass welding in the flat and horizontal positions. Electrodes of this group have a lime fluoride based slag and produce weld metal having improved impact properties and crack resistance in comparison to rutile types. Tubrod 14.17. Self shielded for operation on DC electrode negative, the slag system is designed such that the smaller sizes can be used for all positional welding. Used for single and multi-pass welding.
Low Alloy A5.29.80

This specification is the same as that for carbon steel in respect to mechanical properties, welding positions, usability and performance data. The alloy content is shown by a suffix. Example: Tubrod 15.17 = E81T1-Ni1. Listed below are the suffixes applicable to the Tubrod range.
T4 =
Ni1 Ni2 -
Nickel 0.80/1.10% Nickel 1.75/2.75% C.Mn Low temperature service Nickel 1.25/2.60% Molybdenum 0.25/0.65% High tensile steels Molybdenum 0.40/0.65% High tensile steels Chromium 1.00/1.50% Molybdenum 0.40/0.65% Chromium 2.00/2.50% Molybdenum 0.90/1.20% Creep resisting steels
K3 -
T5 =
A1 -
B2 -
B3 -
T7 =
Stainless Steel A5.22-95

This classification which relates to stainless steel wires is quite easy to understand in that there are only three principal designations. The other parts such as E and T follow the standard pattern in other AWS specifications. The chemical composition is identified by internationally recognised AISI numbering system followed in some cases by an additional letter such as L for low carbon. This classification replaces the A5.22-80 and has been extended to include welding positions as follows: Indicates a welding electrode Designates weld metal composition Designates a cored wire Recommended welding positions 0 = Flat and Horizontal 1 = All positions Indicates shielding gas EXXXTX-X 1 3 4 5 = = = = CO2 None 75-80%Ar+CO2 100% Ar
Note: Some electrodes are designed for all positions in the small sizes with flat and horizontal vertical in the larger sizes. The mandatory section of the specification allows dual classification for the primary positions for these types. An example is Tubrod 15.00 1.2mm - 1.4mm = E71T-5M 2.4mm - 3.2mm = E70T-5M

Example : OK Tubrod 14.20 = E308LT1-4
54
European Standard EN 758: 1997

Tubular cored electrodes for metal arc welding with and without shielding gas of non-alloy and fine grain steels With the introduction of this new standard all EU countries are required to adopt EN 758 and withdraw all individual national standards previously used. In future the standards authorities within the countries which comprise the EU will publish EN 758 with their own prefix. Thus in Germany, for example, it will become DIN EN 857 and BS EN 758 in the UK. The only difference in the contents of the standards will be the language in which they are printed.
Method of Classification
EN 758 T 46 3 1Ni B M 4 H5
optional part hydrogen symbol welding position shielding gas core characteristics chemical composition impact properties strength and elongation tubular electrode standard number
Important: There are two significant differences between the EN standard and the AWS classification system A5.20-95.
Firstly, the designation that relates to strength in the EN system is based on YIELD strength (or 0.2% proof) not the UTS of the deposited weld metal. Secondly, EN 758, although covering cored wires for the welding of non-alloy and fine grain steels up to 500 N/mm2 yield strength, does contain low alloy wires. A number of plain carbonmanganese steels are capable of high impact properties at -40C and below but the toughness given by a wire of similar composition would be extremely procedure-sensitive. For such circumstances Ni and Mo bearing wires are included within this EN standard. In the AWS system, however, there is a separate standard for low alloy wires i.e. A5.29-80.
Compulsory Symbols
Symbol for strength and elongation EN Symbol
Yield strength N/mm2 355 380 420 460 500 min min min min min
Tensile strength N/mm2 440-570 470-600 500-640 530-680 560-720
Elongation %
35 38 42 46 50
22 20 20 20 18
min min min min min
Symbol for toughness EN Symbol Z A 0 2 3 4 5 6
Temperature for 47J, C no requirement +20C 0C -20C -30C -40C -50C -60C
Symbol for alloy content Alloy symbol No symbol Mo MnMo 1Ni 1.5Ni 2Ni 3Ni Mn1Ni 1NiMo Z
1)
Mn 2.0 1.4 1.4-2.0 1.4 1.6 1.4 1.4 1.4-2.0 1.4 Any other composition
Ni 0.6-1.2 1.2-1.8 1.8-2.6 2.6-3.8 0.6-1.2 0.6-1.2
Mo 0.3-0.6 0.3-0.6 -
0.3-0.6
If not specified : Mo<0.2, Ni<0.5, Cr<0.2, V<0.08, Nb<0.05, Cu<0.3 and for electrodes without a gas shield A1<2.0 Single values shown in the table are maximum values
2)
55
Description of core Symbol EN 758
gas-shielded R P B M self-shielded U V W X Y Z S
Rutile base, slow freezing slag Rutile base, fast freezing slag Basic slag Metal powder core
Rutile or basic/fluoride Basic/fluoride, slow freezing slag Basic/fluoride, fast freezing slag Other types
Shielding gas EN 758 Symbol M C N Argon mixture M2 CO2 No shielding gas
Optional symbols
Welding position EN 758 Positions (not used) All positions All positions except vertical down Flat butt welds, flat & HV fillets Flat butt & fillet welds As for (3) and vertical down (not used)
Symbol 0 1 2 3 4 5 9
Symbol for hydrogen content of deposited metal Symbol Diffusible hydrogen, ml/100g deposited metal 5 max 10 max 15 max
H5 H10 H15
When the letter H is included in the classification the manufacturer shall state ... what restrictions need to be placed on the conditions of storage and on current, arc voltage, electrode extension, polarity and shielding gas to remain within [the quoted] limit. Example : OK Tubrod 15.11 = T 50 6 2Ni P M
T 50 6 2Ni P M
= = = = = =
Tubular electrode Yield strength - min 500 N/mm2 Toughness - min 47J at -60C Alloy = 1.8% - 2.6% Ni Positional rutile Mixed gas
56
Cored wire alternatives to manual metal arc

Metal Cored Wire
Manual Arc AWS E6012 E6013 E7024 E7016 E7018 E7028 Metal Cored Wire AWS E70C-3M E70C-6M/6C E706-6M E70C-3M E70C-6M/6C E70C-6M E70C-GM
} } }
E7016-A1 E7018-A1 E8016-G E8016-C3 E8016-C1 E9018 E11018
Note: The weld metal from some unalloyed E7016 manual arc electrodes are capable of high toughness at -40oC and -50oC. In similar circumstances select OK Tubrod 14.05.
Flux Cored Wire

Manual Arc AWS Flux Cored Wire OK Tubrod 15.10 OK Tubrod 15.12 OK Tubrod 15.18 OK Tubrod 15.14 OK Tubrod 15.15 OK Tubrod 15.10 OK Tubrod 15.12 OK Tubrod 15.18 OK Tubrod 15.00 OK Tubrod 15.02 OK Tubrod 15.17 OK Tubrod 15.24 OK Tubrod 15.11 OK Tubrod 15.25 OK Tubrod 15.17 OK Tubrod 15.19 OK Tubrod 15.26 OK Tubrod 15.20 OK Tubrod 15.22 OK Tubrod 15.27 AWS
E6012
E6013
E7024
E7018
E7016 E8016 G E8016-C1
E8016-C3
E9018
E8018-B2 E9018-B3 E11018
Note: Under certain conditions E7016 and E7018 manual arc electrodes may be substituted by OK Tubrod 15.14 or OK Tubrod 15.15. Where an E7016 is used for service at -40oC select OK Tubrod 15.17.
OK Tubrod 14.00 OK Tubrod 14.12 OK Tubrod 14.13 OK Tubrod OK Tubrod OK Tubrod OK Tubrod 14.00 14.12 14.13 14.05
}
}
{
OK Tubrod 14.02
E80C-G
OK Tubrod 14.05 OK Tubrod 14.04 OK Tubrod 14.06 OK Tubrod 14.03
E70C-G E70C-Ni2 E91TX-G E111TX-K3
} } }
E70T-1 E70T-1M, E70T-1 E71T-1, E71T-1M
E70T-1 E70T-1M, E70T-1 E71T-5, E71T-5M E71T-5M E81T1-Ni1 E80T5-Ni1 E81T1-Ni2 E70T5-G E81T1-Ni1 E81T1-Ni1 E90T5-K2 E80T5-B2 E90T5-B3 E110T5-G
57
Cored wire fault finding

FAULT POSSIBLE CAUSE REMEDY
POROSITY
Insufficient shielding gas Excessive electrode extension Gas Nozzle too short Plate condition and impurities Equipment fault on gas control
Check recommended flow rate Reduce extension - refer to notes Replace Remove non-metallic substances Check for leaks and air ingestion
POOR WIRE FEED
Incorrect tip size Damaged liner or tip Incorrect type, size and pressure of feed rolls Spool brake too tight Blocked liner
Check and replace Replace Refer to equipment manual Check tension and slacken if necessary Remove obstruction or replace
SLAG INCLUSIONS
Incorrect welder technique Direction of travel
Refer to notes Refer to recommended technique
UNDERCUT
Travel speed too fast Incorrect torch angle Voltage too high
Reduce travel speed or check parameters Refer to notes on torch angles Reduce voltage
LACK OF PENETRATION
Current too low Electrode extension too long for current being used Incorrect or inconsistent travel speed Torch angle or direction of travel Narrow joint preparation Roof face too large
Increase current Refer to notes on electrode extension Adjust travel speed to suit desired degree of penetration Refer to welding techniques Modify preparation Modify preparation
LACK OF FUSION
Direction and speed of travel Incorrect torch angle Incorrect parameters or torch manipulation
Refer to notes/illustrations Refer to notes/illustrations Check against recommended values for the wire in question and notes on torch manipulation
EXCESSIVE SPATTER
Dirty plate Voltage too high for amperage
Clean plate - wire brush or grinding Check against recommended values Check against recommended flow rates Check size or replace worn contact tip
Shielding gas pressure too high poor current pick-up
58
Cored wire selection

Mild and Medium Tensile Steels Ambient Temps +20OC/0OC
Metal cored high productivity

>4mm 1.0-1.4mm >8mm 1.6mm >12mm 2.4mm
Rutile flux cored general purpose

>4mm 1.2mm >6mm 1.4mm >8mm 1.6mm
Basic flux cored high mech props

>4mm 1.2mm >8mm 1.6mm >12mm 2.4mm
Rutile flux cored heavy deposition

>4mm >12mm 1.2-1.6mm 2.0-2.4mm
Ar+CO2 OK14.00 OK14.12 OK14.13
Ar+CO2 OK15.14 OK15.15
Ar+CO2 OK15.00 OK15.02
CO2 OK15.10 OK15.12
CO2 OK14.12
CO2 OK15.14
CO2 OK15.00 OK15.02 Fully basic. Extra low H2. High purity. X-ray quality. Grade 3. Tolerant to plate condition. DC-.
Ar+CO2 OK15.18
Easy to use. Max versatility. Minimal slag. One current setting. Very low fume. OK14.00 - Grade 2. OK14.12 - Grade 3. DC+, DC-.
Easy to use. All positions. Spray transfer. Ideal on ceramic. Excellent vert' up Grade 3 Low H2 DC+.
Max deposition. Self deslagging. Excellent finish. High welder appeal. Grade 2. DC+.
59
Mild and Medium Tensile Steels Low Temperature Service
-20OC 560 N/mm2
-30OC (-40OC) 560 N/mm2
-60OC 560 N/mm2
Metal
Rutile
Basic
Metal
Rutile
Basic
Metal
Rutile
Basic
OK 14.00 OK 14.12
OK 15.14 OK 15.15
OK 15.00 OK 15.02
OK 14.05
OK 15.17
OK 15.00 OK 15.02
OK 14.04
OK 15.11
OK 15.25
High Yield and Low Alloy Steels
Weathering O +20 -20 C
High Yield 2 >550 N/mm
Creep Resisting
0.5 Mo <12mm >12mm Metal Rutile Basic
Metal
Rutile
Basic
OK 14.01
-20OC OK 14.02 O -40 C OK 14.06
-50OC OK 15.19
-50OC OK 15.24 OK 15.26
OK 14.02
OK 14.12
OK 15.14
OK 15.00
1.25 Cr 0.5 Mo >700 N/mm2 OK 15.20
Ni can be used as sub for Cu
If matching composition demanded Metal Rutile Basic Metal -40OC OK 14.03 Basic -50OC OK 15.27
2.25 Cr 1 Mo
OK 14.01
OK 14.04
OK 15.11
OK 15.25
OK 15.22
60
Welding equipment
When proposing to adopt cored wire welding it is essential to review all aspects of the total process in order to maximise the benefits. Large numbers of MIG equipment are operating in the various fields of metal fabrication, but the majority of these and particularly the earlier types were principly designed for use with solid wire. They produce excellent results in terms of reliability and electrical characteristics relative to this type of wire, but many are not mechanically suitable or electrically versatile enough to optimise the use of cored wires. Equipment considerations G Output of existing equipment - does the power source have sufficient amperage capacity to fully utilise the current range of the proposed wire? The minimum will be around 350A for 1.0, 1.2mm wires and up to 600A for 2.4mm. G The duty cycle of the proposed power source - is it sufficient? Ideally 60% should be the minimum for the largest size of wire likely to be used. G The torch - is the duty cycle of this very important item high enough relative to the operating amperage and particularly in relation to argon rich gas if a change from CO2 is envisaged? G Liners - some users prefer teflon or nylon type liners when operating with solid wires. When welding with cored wires it is recommended that only the steel spiral type are used with an attendant reduction in friction and hence smoother feeding. G Water cooling - could this be an advantage? Modern water cooled torches are smaller, more flexible with less weight and certainly less fatiguing from an operators viewpoint. G Polarity - does the power source have the facility for a change of polarity? Some types of cored wires benefit from the use of negative pole. G Wire feeder - some units only have a single pair of drive rolls which although often satisfactory for 1.0 and 1.2mm wires will almost certainly lead to difficulties if attempts are made to use 1.6mm and 2.4mm sizes. For large sizes tandom and geared four roll drives are preferred. G Feed rolls - smooth grooved rolls are satisfactory for the 10mm, 1.2mm and often 1.4mm but are not considered sufficiently positive for 1.6mm up to 3.2mm. The large sizes benefit from the use of knurled rolls which exert a good grip but with minimum pressure and consequently reduce the risk of crushing or distortion of the wire. Should fume extraction be considered? If the proposed wire is a large diameter flux cored type the volume of fume will be greater than that produced by solid wire. The investment in fume extraction is small compared to the enormous improvement in the working environment. phase AC supply is rectified to form a DC current and then convert back to AC by an inverter, but at a much higher frequency than that of the mains supply. It is then transformed and rectified again to provide a DC supply suitable for welding. The entire process is backed up by a control system that provides the power source with all the necessary static and dynamic properties. Apparent from the low weight and portability there are advantages to be gained from the exceptional welding characteristics provided by an extremely stable arc and minimal spatter loss. Compared to conventional thyristor controlled units, the starting time is almost halved and this relates to the time taken from initial strike to full arc stability. The inverter power sources is particularly beneficial to the jobbing fabricator because of its versatility. With the aid of various add-on units, including pulsing, they can be adapted for MIG/MAG, TIG and MMA which together with the advantage of stepless parameter control can cater for the widest possible range of materials.
Electronic control Modern MIG welding equipment embodies the most advanced electronic control systems and provides significant benefits in efficiency. When viewed against total welding costs (especially labour cost) and weighed against the increased productivity provided by cored wires, the cost of investment in new equipment is less than that for the consumables, and may be paid back in a few months.
G
Automatic electronic feed back control maintains the wire feed at a constant level regardless of voltage conditions. When using dip transfer which is characterised by higher spatter levels than with spray transfer, the improved electronic controlled inductance systems can reduce this weld metal wastage by producing a smoother arc and metal transfer through precise control of peak short circuiting current. Thyristor controlled power sources ensure greater control of output at pre-set levels with steplessly variable voltage control so that parameters can be obtained to suit any application. They can also be controlled remotely. Wire feeders are available with creep starting facilities to assist arc initiation and some have preprogrammable selection once set. In addition this type has the facility to operate at long distances and a wider working radius. Some types also permit the use of 5Kg reels which allow greater portability and accessibility.
Inverters The weight of a conventional MIG/MAG power source is directly related to the frequency of the mains supply. If, therefore, the frequency can be increased, the weight of the transformer will be reduced and it is this fundamental principle that is the basis of inverter power sources. The three-
61
OK Tubrod submerged arc welding

Alloyed cored wires for use with the submerged arc welding process have been available for many years. Cored wires represent the least expensive means of producing a weld metal of complex composition compared with solid wire which may be unavailable, highly expensive or impossible to produce. Hard-surfacing wires are typical examples and to a lesser extent the low alloy joining wires, but the common advantage which is disregarded under such circumstances is productivity. It can be seen that the difference in deposition rate between gas shielded solid and cored wires will widen disproportionately upwards with increases in amperage in favour of cored wire. The normal current range for cored wire across the popular range of semi automatic sizes will be from 140A at the low end of a 1.2mm up to a maximum of 450A with a 2.4mm. In comparison an amperage of 450A with the submerged arc process would be considered low. The potential, therefore, for increased deposition rate with current levels in excess of 800A is enormous and can be up to 30% greater than that of solid wire of equivalent size and similar amperage. Consider the attributes of the OK Tubrod semiautomatic joining wires adapted for use with the submerged arc process in larger sizes. Summary of Benefits G Deposition may be improved by up to 20% with the metal cored OK Tubrod 14.00S and up to 30% with the fully basic flux cored OK Tubrod 15.00S. The effect on productivity is, of course, dramatic, paving the way for considerable cost savings. G The C/Mn wires will produce vastly superior mechanical properties than the standard S1 and S2 type solid wires commonly used throughout industry. Comparatively higher heat inputs, together with fewer passes, can be adopted leading to additional economies in total welding time. In addition, the integrity of OK Tubrod 15.00S weld metal is maintained after stress relief, even down to -30C, which is a significant benefit. G The OK Tubrod wires are universally approved to Grade 3 by all major certification authorities using both AC and DC. Apart from single wire operation they can be used successfully for twin wire, multi-power, single and two sided welding as well as fillet welding. They impose very few limitations with regard to their application, allowing a wide range of industries to enjoy the advantages afforded. An improved tolerance to plate condition with a process that is characterised by significant problems when solid wire is used. Shipbuilders, for example, have the need to weld over shop primers at high travel speeds without porosity. Under such conditions the travel speed achieved with solid wire will generally be surpassed with cored wires, especially the fully basic OK Tubrod 15.00S. Apart from those for mild and medium tensile steels, wires are available for applications required for service down to -60oC and low alloy types for high tensile single sided single pass butt welding, also with good sub-zero notch toughness.
Deposition rate comparison OK 14.00S and OK 12.20 OK flux 10.71
Twin wire deposition comparison OK Tubrod 14.00S + OK 10.71 OK Tubrod 15.00S + OK 10.71 OK Autrod 12.20 + OK 10.71
23 22
18
16
21 20 19
14
18 17
12
16 15 14
10 kg/hr
KG/HR
13 12 11 10 9
6
14.00S 2.4mm 14.00S 3mm 14.00S 4mm 12.20 2.5mm 12.20 3mm 12.20 4mm
8 7 6 5 4 3 2
15.00S 2 x 2.4mm 14.00S 2 x 2.4mm 12.20 2 x 2.5mm
0 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Current (A)
1 0 600 625 650 675 700 725 750 775 800 825 850
875
900
925
950
975
AMPS
Deposition rate comparison OK 15.00S and OK 12.20 OK flux 10.71

20 18
16
14 12 kg/hr
10 8
15.00S 2.4mm 15.00S 3mm 15.00S 4mm 12.20 2.5mm 12.20 3mm 12.20 4mm
4 2
0 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Current (A)
62
1000
OK Tubrod 14.00S
A Metal cored wire designed specifically for use with submerged arc welding process in conjunction with OK 10.71 flux. Classification (with OK 10.71 flux) AWS A5.17-89: F7A2-EC1 Applications OK Tubrod 14.00S is used for the welding of mild and medium tensile steels and is recommended for single and multi-pass fillet welding. Exceptional productivity can be achieved at deposition rates up to 20% higher than with the same size of solid wire at the same current. OK Tubrod 14.00S exhibits excellent mechanical properties compared with equivalent solid wires. This product is suitable for single and twin wire welding applications. OK Tubrod 14.00S can also be used with OK 10.81 flux to give faster welding speeds together with superior weld appearance for fillet welding. Where toughness properties below 0oC are required, then OK 10.71 flux should be used. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 3.0 400-800 28-36 4.0 500-900 28-34 Typical weld metal composition (OK 10.71 flux) C Si Mn 0.05 0.4 1.6 Mechanical properties All weld metal specimens Yield stress 450 N/mm2 Tensile strength 530 N/mm2 Elongation 30% Charpy V impact values Test temp Typical -20oC 120J Approvals (with OK 10.71 flux) ABS 3M, 3YM LR 3M, 3YM DNV IIIYM BV A3YM GL 3YM TUV Eignungsgeprft DB 52.039.13
OK Tubrod 14.02S
A metal cored wire producing a 0.5% Mo weld metal for the submerged arc welding of high tensile steels. Designed for use with OK 10.71 flux it can be used for high speed fillet welding as well as multi-pass butt joints. As an alternative to an S2Mo solid wire, it offers superior deposition rates and mechanical properties, especially notch toughness. Classification (with OK 10.71 flux) AWS A5.23-90: F7AZ-ECA4-A4 Applications All general fabrication of high tensile fine grained steels where submerged arc is appropriate. Boilers, pressure vessels in process plant are typical examples. A typical application within the power industry is the high speed fillet welding of tubes to fins. Suitable for service up to 500oC. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 Typical weld metal composition (OK 10.71 flux) C Si Mn Mo 0.06 0.5 1.3 0.5 Mechanical properties All weld metal specimens Yield stress (0.2% PS) 520 N/mm2 Tensile strength 570 N/mm2 Elongation 28%
OK Tubrod 14.07S
A metal cored wire for the submerged arc welding of 1.25Cr 0.5Mo type creep resisting steels. Used with OK 10.63 fully basic flux the weld metal is of the highest metallurgical integrity for service temperatures up to 500oC. The wire may also be used with OK 10.71 flux for fillet welding applications. Classification (with OK 10.71 flux) AWS A5.23-90: F7AZ-ECB2-B2 Applications Steels of similar composition as used in steam boilers, process plant and piping, together with pressure vessels in the power generation industry. This product has been successfully used in tube to fin applications with OK 10.71 flux. Preheating dependent on thickness up to 300oC is essential followed by post weld heat treatment at 650-700oC. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 Typical weld metal composition (OK 10.71 flux) C Si Mn P 0.05 0.4 0.9 0.015 S Cr 0.010 1.25 Mo 0.5
Mechanical properties All weld metal specimens Yield stress 620 MPa Tensile strength 700 MPa Elongation 26%
63
OK Tubrod 14.08S
A metal cored wire for the submerged arc welding of 2.25Cr 1Mo type creep resisting steels, where creep strength at service temperatures up to 650oC.is required. It is designed for use with OK 10.63 flux for optimum creep rupture strength and minimum hydrogen levels but may also be used with OK 10.71 flux for less critical applications. Applications Highly stressed components of similar composition and required for service at elevated temperatures. These will be found in the construction of process and petrochemical plant, as well as with power generation industry for turbines, pressure vessels and piping. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 3.0 400-800 28-36 4.0 500-900 28-34 Typical weld metal composition (OK 10.63 flux) C Si Mn P 0.08 0.4 1.0 0.010 S Cr 0.010 2.25 Mo 1.0
OK Tubrod 15.00S
A basic flux cored wire especially formulated for use with the submerged arc process and OK 10.71 flux. It produces high impact values from welded joints and compared to those of solid wire can utilise higher heat inputs and fewer passes. Classification (with OK 10.71 flux) AWS A5.17-89: F7A4-EC1 Applications OK Tubrod 15.00S is preferred when high integrity welded joints are required in mild and medium tensile steels. General fabrication, structural engineering and shipbuilding are the principal areas of application. The welding of primed plate at high speeds is of particular benefit. Deposition rates are up to 30% higher than solid wire for the equivalent size and the same current. This wire is suitable for single wire, twin arc and multi-power systems and can also be used with iron powder additions. Where optimal weld appearance and welding speed is required, OK 10.81 flux can be used but is not recommended for applications below -20oC. For optimum low temperature toughness down to -40oC, OK 10.62 flux can be successfully used. Where approvals and classifications are required OK 10.71 flux must be used. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-500 28-38 3.0 400-900 28-36 4.0 500-1000 28-34 Typical weld metal composition (OK 10.71 flux) C Si Mn 0.06 0.5 1.6 Mechanical properties All weld metal specimens Yield stress 460 N/mm2 Tensile strength 540 N/mm2 Elongation 30% Charpy V impact values Test temp Typical -40oC 130J
OK Tubrod 15.21S
A basic flux cored wire used in conjunction with OK 10.71 flux for the submerged arc welding of high tensile steels. The weld metal is alloyed with 0.5% Mo which allows a very wide range of applications including elevated temperatures up to 500oC. The fully basic formulation ensures a very tough, high quality weld deposit. Classification (with OK 10.71 flux) AWS A5.23-90 F7A2-ECA4-A4 Applications Typical examples are structural steelwork, pressure vessels and piping, cranes, contractors plant etc. It is also ideally suitable for the rebuilding of marine engine piston crowns. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-500 27-38 Typical weld metal composition (OK 10.71 flux) C Si Mn P 0.06 0.5 1.2 0.015 S Mo 0.008 0.5 Mechanical properties All weld metal specimens Yield stress 460 MPa Tensile strength 550 MPa Elongation 30% Charpy V impact values Test temp Typical -30oC 120J
Mechanical properties All weld metal specimens Yield stress 600 N/mm2 Tensile strength 670 N/mm2 Elongation 20%
Approvals (with OK 10.71 flux) ABS 3M, 3YM LR 3M, 3YM DNV IIIYM BV A3YM GL 3YM DB 52.039.14 TUV Eignungsgeprft Co
64
OK Tubrod 15.23S
A basic cored wire for the submerged arc welding of 9% Cr creep resisting steels, in conjunction with OK 10.63 low phosphorus fully basic agglomerated flux. This combination will provide a composition compatible with that of the base materials such as ASTM A335 grade P91. The formulation of the wire ensures excellent weldability with high productivity. Applications The principal areas of application are in the power generation and petrochemical industries for high temperature and pressure service. Piping, pressure vessels and turbine diaphragms are typical examples. A minimum preheat of 150oC with a maximum interpass of 300oC is required and post weld heat treatment at 760oC is recommended. Welding data: DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 3.0 400-800 28-36 4.0 500-900 28-34 Typical weld metal composition (OK 10.63 flux) C Si Mn Cr Mo 0.10 0.3 1.0 9.0 1.0 Ni 0.5 Nb 0.05 V 0.2 N 0.04
OK Tubrod 15.24S
A basic flux cored wire for the submerged arc welding of structural steels for service down to -50oC. The weld metal contains a nominal 1% Ni and combines excellent low temperature toughness with a minimum yield of 450 N/mm2 in both the as-welded and stress relieved conditions. Used with OK 10.62 the mechanical properties are maintained at high heat inputs and the CTOD performance is impressive. Deposition rates can be up to 30% higher than with the equivalent size of solid wire at similar currents. Classification (with OK 10.62 flux) AWS A5.23-90: F8A6 EC-G Applications All structural steel applications, particularly offshore constructions and pressure vessels required for service down to -50oC. Using a multipass technique the number of passes may be reduced in comparison to solid wire and the weld metal is equally dependable using single, twin wire or multi-power modes. Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-500 28-38 3.0 400-900 28-36 4.0 500-1000 28-34 Typical weld metal composition (OK 10.62 flux) C Si Mn Ni 0.08 0.3 1.7 0.8 Mechanical properties All weld metal specimens Yield stress (0.2% PS) 530 N/mm2 Tensile strength 620 N/mm2 Elongation 26% Charpy V impact values Test temp Typical -50oC 130J
OK Tubrod 15.25S
A 2.5% Ni basic cored wire introduced for use with the submerged arc process in conjunction with OK 10.62 flux. It is used for welded joints requiring charpy V values down to -60oC combined with the minimum number of passes and high heat inputs. Classification (with OK 10.62 flux) AWS A5.23-90: F7A8-ECNi 2-Ni2 Applications General, structural and offshore fabrication together with shipbuilding are the main application areas where charpy V values down to -60oC are required. It also has a high tolerance to shop primer when welding high speed fillets as well as single-sided, single pass butt joints. The wire has no mode limitations in that it can be used single wire, twin arc and multi-power. Welding data DC+ (Single wire) Diameter Current Amps Volts 3.0 400-900 28-36 4.0 500-1000 28-34 Typical weld metal composition (OK 10.62 flux) C Si Mn Ni 0.06 0.4 1.3 2.2 Mechanical properties All weld metal specimens Yield stress 500 N/mm2 Tensile strength 580 N/mm2 Elongation 28% Charpy V impact values Test temp Typical -60oC 120J
Mechanical properties All weld metal specimens Yield stress (0.2% PS) 610 N/mm2 Tensile strength 720 N/mm2 Elongation 26% Charpy V impact values Test temp Typical +20oC 50J
65
Operating conditions
OK Tubrod 14.53S
A metal cored wire designed especially for submerged arc welding of high dilution fine grained steels of up to 550 N/mm2 yield strength, where excellent toughness is required to -60oC. Used with OK 10.71 flux it has a very high tolerance to heat input and performs well on both thick and thin plate. The results are achieved through controlled alloying and a chemical buffering system for the nucleation of acicular ferrite. As the wire is alloyed to match the parent material properties under conditions of high dilution, the allweld metal yield and tensile strengths exceed those of the base material. Classification AWS A5.23-90 F9A2-EC-G Applications All general fabrications and structural work where good sub-zero toughness is required from high dilution two-pass welding. Such applications will include LNG bulk carriers and ice-breaking ships. Welding data DC+ (Single wire) Diameter Current Amps Volts 3.0 400-800 28-36 4.0 500-900 28-34 Typical weld metal composition (OK 10.71 flux) C Si Mn Ni Mo 0.06 0.6 1.5 2.1 0.3 Mechanical properties All weld metal specimens Yield stress 0.2% 620 N/mm2 Tensile strength 690 N/mm2 Elongation 25% Charpy V impact values (all weld metal) Test temp Typical -30oC 60J In a high dilution butt joint -60oC 40J
OK Tubrod 14.54S
A metal cored tubular wire developed for submerged arc welding of structural steels, having a minimum yield strength 550 N/mm2. Used with OK 10.62 flux it has a very high tolerance to heat input variations, the weld metal producing 100J at -40oC even at 6kJ/mm. With a nominal composition of 1.3 Ni, 0.5 Mo it also contains non-metallic additions to improve performance and reduce hydrogen levels. Applications All structural work involving high yield steels of not less than 550 N/mm2. These steels will include NQ1, OX540E, OX542, OX602, SE500, DOMEX 480 and HY80. Typical examples involving these steels will be bridges, offshore jack-up structures, earth moving equipment and cranes. Classification AWS A5.23-90 F9A4-EC-G Welding data DC+ (Single wire) Diameter Current Amps Volts 2.4 250-450 28-38 3.0 400-800 28-36 4.0 500-900 28-34 Typical weld metal composition (OK 10.62 flux) C Si Mn Ni Mo 0.07 0.2 1.6 1.3 0.5 Mechanical properties All weld metal specimens Yield stress 0.2% 580 N/mm2 Tensile strength 690 N/mm2 Elongation 28% Charpy V impact values Test temp Typical -40oC 130J
The operation of OK Tubrod cored wires with the submerged arc process is similar to that of solid wire from a practical point of view. There are, however, various factors to keep in mind when selecting parameters, as the same amperage, voltage and speed used for a given size of solid wire will not necessarily be the same for the cored wire. The principal reason for this is the fact that the amperages used for submerged arc will cause the cored wire to burn off at a significantly faster rate. Prospective users will obviously want to capitalise on this feature yet maintain the weld deposit geometry achieved with solid wire. An appreciation of the effect of variables is, therefore, desirable. Voltage Fundamentally, variations in voltage have the same effect on cored wires and solid wires, in respect of weld deposit profile and surface appearance. For example increasing voltage for a given amperage will produce:
G
G G
G G
A flat deposit of increased width in butt joints and a concave profile in the case of fillet joints. Less penetration in all situations. Increased flux consumption and in extreme cases the Mn content depending on the flux type. Improve tolerance to fit-up variances. Difficult slag removal especially in the root area of butt joints due to undercutting.
A progressive reduction in voltage will have the opposite effect producing a narrower bead with excessive reinforcement and deeper penetration. It is the latter, very important, feature that differs in respect to cored wires in that for a given voltage the penetration will be less and will have to be kept in mind when establishing parameters and plate preparation. This is particularly important for square edge butt joints and will be discussed later. There are occasions, however, when making high speed HV fillet joints that a high reinforcement will require a reduction in voltage to flatten the weld. The need is usually recognised by a high reinforcement accompanied by intermittent undercut when, for example, establishing parameters for a 3mm T fillet at a travel speed in excess of 1 metre per minute. Conversely, if the profile has excessive reinforcement with continuous undercut it is normally an indication that increased voltage will smooth out the profile.
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Amperage Cored wires in the OK Tubrod 14.XXS and 15.XXS series may be used with either DC+, DC- or AC. DC+, however, is the most popular current type and is the preferred choice for cored wires. A high deposition rate and superior penetration can be achieved with DC+. Solid wire will give a higher deposition rate in the medium current range than cored wires using DC- but this is not used for joining under normal circumstances. The benefit with DCpolarity is in surfacing applications where dilution with the base material is minimal but build-up is optimised. The third type of current used with submerged arc is AC but it has few advantages and is in the minority except for when it is used as a necessity in multi-wire situations. At low currents, with single wire operation, the arc has a tendency for instability, particularly with the more basic fluxes, although it can be used to advantage if arc blow becomes a problem with DC. This is a phenomena caused by an interaction of magnetic fields pushing the arc in differing directions and normally associated with fabrications of complex design. Penetration The depth of penetration per amp with OK Tubrod submerged arc wires will always be less than that achieved with solid wire. Due consideration must be given to this when establishing suitable parameters for the root area of joints and also for square edge butt joints. An increase in amperage or reduction in voltage will not produce the same depth of penetration as solid wire of equivalent size. Increased amperage with solid wire will give deeper penetration but with an attendant progressive reduction in width Fig 18 which results in an unacceptable depth to width ratio. Such a profile is highly susceptible to solidification cracking.
It can be seen in Fig 19 that the penetration profile with cored wire has a much rounder appearance and as such has a superior depth to width ratio and is therefore highly resistant to cracking. A study of columnar crystal formation of both weld deposits clearly shows the difference in the angles of convergence in the center of the weld. The cored wire pattern of solidification is less inclined to promote center line segregation of harmful residual elements which causes the cracking, especially under conditions of restraint.
in the included angles and depth of preparation. This in turn saves weld metal to fill the joint. The softer less penetrating arc with its more favourable width will ensure superior tolerance to fit-up variances allowing better control and consistency of penetration with a more acceptable profile Fig 21.
Fig 21
Submerged Arc Fluxes All OK Tubrod wires for submerged arc are specially formulated for use with the process i.e. with modified silicon and manganese contents, but they should not be viewed in isolation as in the case with MIG/MAG types. The wires with submerged arc must be considered in combination with a flux and the type chosen for a given physical characteristic might not necessarily produce satisfactory mechanical properties. Alternatively, the tensile and yield strength are as required but the charpy V toughness is not adequate. It can be seen for example that when OK Tubrod 15.25S is used with OK Flux 10.71 which has a basicity index of 1.6 the impact properties at -50oC will be an average of 72J. If, however, this wire was used in conjunction with OK Flux 10.62 with a basicity index of 3.4 the impact properties at the same -50oC will be an average of 150J. This combination also exhibits exceptional CTOD performance - see typical welding procedure page 77. A small increase in tensile strength will occur from around 510 N/mm2 up to 560 N/mm2 but this is not significant since most authorities specify a minimum level, not a maximum. In the case of general fabrication where the user often satisfies himself that a particular combination attains mechanical properties for the intended purpose, then there are few limitations on fluxes. A case for consideration would be mass produced items for the automotive industry where OK Tubrod 14.00S might be used with OK Flux 10.81.
Fig 19
The rounded penetration profile of the cored wire can also be turned to practical advantage in the case of the two sided square edge butt joints Fig 20. If the joint tracking and preparation are inconsistent then the finger type penetration shape of solid wire could miss in the middle resulting in an unwelded area. The shape of the cored wire penetration with its greater width will have a margin for error in this regard and eliminate expensive repairs.

Fig 18
Fig 20
One sided welding on non consumable backing is becoming increasingly popular because of the savings in plate turning and welding of the second side. A wider gap is obviously required to ensure adequate penetration on the under side which also allows a reduction
67
Welding equipment
In single pass applications the maximum speed would be faster and the weld appearance superior than in the case of either OK Flux 10.71 or 10.62. If, however, this combination was used on thick V butt joints where unlimited multipass filling is used the result would be an unacceptable increase of Mn within the weld metal, since OK Flux 10.81 is a Mn alloying flux. Consequently, this would have a deleterious effect on impact toughness and raise the tensile strength. To ensure maximum flexibility with regard to welding speed, mechanical properties and scope of application, the semi-basic OK Flux 10.71 has been selected as the most versatile type. It is for use with this flux that the OK Tubrod wires have been approved by the major certification authorities. Consumable selection is also simplified. All OK Tubrod flux cored wires for submerged arc are compatible with all machines originally designed for solid wire and without the need for special accessories. Some equipment may be fitted with smooth feed rollers which are generally satisfactory but the larger diameter wires may benefit from the knurled type as with semi-automatic MAG welding. On the subject of feeding, particularly the smaller sizes, cored wires will feed at faster rates at a given amperage than solid wire. It is for this reason that before changing to a cored wire the speed of the gearbox needs to be checked to ensure that it is capable of feeding at the required rates specified in the table below. When using the highly popular Esab A6 system it is conceivable that for 4mm - 5mm solid wire it will have a gearbox with a ratio of 156:1. If a solid wire of 5mm is being used at 750A, a change to 4mm cored wire will affect the amperage available from the power source which would probably be as low as 550A at maximum wire feed speed. This situation is even more noticeable when converting to 2.4mm in twin wire mode at 850A when the wire feed speed required will be up to 7 metres per minute. A 74:1 ratio gearbox is, therefore, essential if optimum performance is to be achieved.
Wire feed speeds

Type Size mm Mode Amperage Weight of wire kg/hr Wire feed speed m/min
OK Tubrod 14.00S
2.4 2.4 3.0 4.0
Single Twin Single Single Single Twin Single Single
450 900 700 900 450 900 700 900
7.87 19.00 14.17 16.27 9.70 21.60 16.90 20.70
4.5 5.5 5.0 3.5 6.0 6.5 6.5 4.5
OK Tubrod 15.00S
2.4 2.4 3.0 4.0
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Welding techniques
Single wire welding OK Tubrod submerged arc wires may be used in all situations covered by solid wires both for HV fillet welding, single sided single pass and two pass two sided as well as multi-pass butt welding. Productivity is not the highest attainable but deposition rates in comparison to solid wire will be greater for a given current and wire diameter. Single wire may be adopted for the following reasons:
G
positioning is accurate as, obviously, the weld pool is not seen once welding is under way. The edges are the most critical but a general guide is to set the outside of the wire surface one diameter from the fusion face which will make sure of fusion and avoid an otherwise expensive repair. Twin wire welding This technique involves the use of two wires approximately 12mm apart within one contact jaw or tip, the power for both being provided by one power source and one wire feed motor. Both wires are fed into the weld pool and allows the use of currents and welding speeds of twice those associated with a single wire - Fig 22.
To obtain maximum possible charpy V impact values where heat input and individual weld size limitations are essential to ensure maximum grain refinement. G Circumferential work where the diameter of the work piece is such that higher deposition would result in inadequate control of the weld pool. G When minimum dilution and depth of penetration is required. G In HV fillet welding on certain types of shop primer for porosity free welded joints in preference to higher welding speeds, attainable via twin wire welding. G Where current capacity available from the power source precludes the use of higher productivity methods. The operation of the cored wires is otherwise similar to that of solid wire from the practical point of view. When welding HV fillet joints the top surface of the wire should be directed at the corner of the joint at an angle of 30o/40o to ensure a fillet weld of equal leg length. Penetration is often greater dependent on welding speed and this wire positioning will serve to ensure maximum depth in the correct areas. With multi-pass butt welding, especially in thicker material with low included angles of preparation, normal running voltages and welding speed should be reduced in the root region where access is more confined. This will restrict the heat to a narrow zone and allow the weld metal to spread out to the fusion faces without undercut which will greatly assist slag removal. It is particularly relevant to the high basicity fluxes. During the welding of a V butt a point will be reached, usually after the second or third pass when overlapping will be required. As the joint is filled and depending on plate thickness preparation and impact properties required it may be that up to six or even ten passes per layer will be necessary, the need being to keep each layer flat. It is important, therefore, that wire
Fig 22
Contact jaws DC+ polarity
Wire electrodes
Direction of travel Molten slag Granular flux Solidified slag
Arc cavity Plate Solidified weld metal Molten weld pool Penetration
Swivelling the nozzle can produce a gap between the wires relative to the joint line and as such can be used to spread the weld deposit and reduce penetration, whilst maintaining the same deposition rate - Fig 23b. This facility can also be used to advantage in the root of butt joints to increase tolerance to inconsistent fit-up where a reduction in current would be necessary with a single wire. The accessories required to convert a standard machine are relatively inexpensive in comparison to the advantages gained. All that is required for the Esab A6 system is an additional reel holder together with a twin wire straightener drive roll and contact jaws. When using wires of 2.4mm or smaller two brass support tubes should ideally be fitted between the feed rolls and contact jaws to assist feedability and prevent buckling of the wire. Other manufacturers equipment will have similar conversion kits as standard accessories. Power sources should be DC with cables connected for electrode positive polarity and have sufficient capacity to provide double the amperage for the proposed size of wire when used singly. Multi-power welding
Although this method is used for butt welding it is used more often for high speed fillet welding. OK Tubrod 14.00S 2.4mm, for example, when used in conjunction with OK 10.81 flux can produce a 3mm T HV fillet at speeds approaching 2 metres per minute. This is a benefit which will be attractive to shipbuilders for welding stiffeners. The technique also permits greater flexibility in terms of weld width and penetration depth. In the case of fillet welding the wires will normally be in line with the joint Fig 23a - which will give good penetration with minimum width.
Fig 23a
Two wire This process differs from twin wire welding in that it uses two wires driven by separate feed systems and power sources, albeit going into the same weld pool. The two wire system which is popular, for example in shipyards, uses DC/AC. The higher penetrating arc produced by DC+ is used for the lead wire to ensure optimum penetration into the root and the AC for the trail to provide the filling and capping function. In general a higher current will be used for the lead wire and whilst giving deep penetration will leave a narrow weld deposit with excessive reinforcement. This, however, is not a problem as it will be smoothed out by the trailing wire which will have a lower current and positioned 12mm to 50mm behind the lead Fig 24. Fig 24
Fig 23b
DC+ (AC)
AC
AC
AC
20O-25O
10O-15O
20O-25O
15-30mm 50-55mm 15-20mm
69
The DC, AC system is normally used for single and two pass applications but AC/AC can be used for multi-pass welding where high penetration is of no benefit. The two wire multi-power process can more than double the welding speed of a single wire. A point will be reached, however, when the amperage for the size of wire and also the travel speed will exceed the maximum levels at which a satisfactory weld deposit will be achieved. This will result in severe gouging by the lead arc and insufficient filling by the trailing wire to the extent that undercutting will occur leaving a weld with an excessively peaked profile.
There are many variations that may be used depending on the weld geometry required. The angles and spacing of the wires will be adjusted in consideration of the function that each wire has to perform. For example, in two pass butt joints (one each side) in heavy plate the wires are often positioned close together to maximise the benefit of the extra heat available. In addition, the lead wire will have a trailing angle and the middle wire will be a 90o, with the trailing wire having a pushing angle similar to that of the lead Fig 26.
Fig 26
Three wire If faster welding speeds are required it will be necessary to employ three wires which can give welding speeds more than four times those of a single wire. In this case three separate feed units and three power sources are needed with all three wires being fed into the same weld pool. The most common systems use DC/AC/AC although the AC/AC/AC is popular, for example, in pipe mills. In the former system the DC lead connected to positive pole will provide the penetration. The second AC wire will perform the filling function and the trailing AC wire, usually operating at lower current, will smooth out the cap profile. To ensure that there is no interaction between the arcs the power sources must be Scott connected to ensure that the two AC welding currents are out of phase with each other such that the one phase lags the other by 90o through each full AC cycle of 360o Fig 25. In a typical arrangement the lead wire will be 90o to the plate whilst the second wire will be 10o-15o toward the direction of travel and approximately 50-55mm behind the lead. The third wire at a distance of 15mm - 20mm behind the middle wire will be at an angle of 20o-25o Fig 24. Fig 25
1000 800 600
A change to 4.0mm OK Tubrod 14.53S in the same situation with the multipower process would ensure an increase in travel speed to 1300mm/min for the same total current. As a direct result the heat input is reduced to 3.9 kJ/mm. The faster burn-off rate of the cored wire has allowed an increase of 23% in travel speed which is considerable, especially in a mass production situation where productivity is vital. This clearly demonstrates that feeding three wires into the same weld pool at such high total currents does not increase heat input beyond acceptable limits because of the high welding speeds available. Consequently the flux is also being used at well below its maximum limits and hence weld pool control is optimised. Butt welding high yield steels The availability of the new fine grain high yield steels has allowed designers to substantially reduce the weight of structures yet maintain the same design criteria. Generally, having yield strength of >550 N/mm2 these steels have excellent weldability and many are also less sensitive to heat input than conventional steels. These qualities are brought about by advanced thermomechanical processing and enhanced cooling techniques rather than alloying to produce an excellent combination of strength and toughness. The relatively lean chemical composition and hence lower carbon equivalent of the steels has also led to the additional advantage of reduced preheat temperatures. If full advantage is to be gained from the attributes provided, the weld metal for joining these materials must also be capable of deposition at high heat inputs with minimal degradation of mechanical properties. High heat input The more traditional submerged arc wires, even the low alloy types, require strict control of heat input and interpass temperature to ensure good notch toughness from the welded joint. As a result the potential of the process in terms of productivity is not fully exploited. The micro-structure of the weld metal used for these high yield steels is required to have a high proportion of fine acicular ferrite which will remain regardless of heat input even as high at 6 kJ/mm. OK Tubrod 14.54S, when used in conjunction with the fully basic OK Flux 10.62, will produce the required weld metal microstructure. Especially developed for welding high strength steels it has a nominal composition of 1.3% Ni, 0.5 Mo and it can achieve
AC
AC
AC
15-25o
15-25o
Middle Trail
Welding current, A
400 200 0 0 -200 -400 -600 -800 -1000 90 180 270 360
Degrees of cycle
Heat input & productivity The attainment of good mechanical properties with a single wire will be heavily dependent on the heat input during welding. In the case of butt joints in C/Mn steels, for example, a heat input not exceeding 4 kJ/mm would be considered sensible. To compete with three wire multipower welding a single wire would require excessive amperage to produce a weld deposit of the same crosssection at a much reduced travel speed. Imagine a procedure for welding a two pass butt joint in 22mm plate using a single solid wire. To complete one side of the joint would require a 3.0mm wire running at 1000A or a 4mm wire running at 1400A with a travel speed of 280mm/min. Using the formula previously described on page 32, we can calculate that the heat input will be an unacceptable 10.5 kJ/mm. In comparison a three wire multipower procedure with 4mm solid wires would require a DC+ lead at 950A/30V and an AC middle wire at 800A/36V together with a trail also on AC at 700A/40V travelling at 1000mm/min. The heat input in this case will be 5.1 kJ/mm for a total current of 2450A which, under some circumstances, may still be considered to be on the high side. On the other hand the heat input has been reduced by 50% and the travel speed increased by 78%.
70
considerable increases in productivity. Page 79 details a welding procedure in 35mm thick SE 500 plate using this wire in 3.0mm diameter and the joint was completed in only 11 passes at a heat input of 6 kJ/mm. The mechanical properties show more than adequate toughness, both in the root and cap areas. High dilution As a consequence of welding any plate thickness with the minimum of passes, a comparatively greater amount of dilution will occur. This is especially relevant with the submerged arc process in the thickness range 10mm - 15mm where 1-3 passes will be required to complete the joint. In such cases the weld metal composition has to be formulated to account for this high dilution for the maintenance of mechanical properties. OK Tubrod 14.53S for use with OK Flux 10.71 has been developed for welding high strength steels using high heat input and high dilution methods. It can be seen from the product data (page 66) that the all-weld tensile and yield strengths are too high for steels of, say, 550 N/mm2 yield and the charpy properties are the opposite and might be described as marginal. Compare then the all-weld metal figures with the welding procedure used for joining NV 2-4 plate (page 79) and it will be seen that the yield and tensile strengths have been reduced to acceptable levels and the notch toughness has increased considerably, even down to -60oC. It is for this reason that OK Tubrod 14.53S is not recommended for conventional multipass welding in thick butt joints, for example.
HV fillet joint data

OK Tubrod 14.00S 2.4mm Throat mm 2.5 3.0 4.0 Wire Mode Twin Twin Twin Flux Amps Volts Speed cm/min 180 170 120
OK 10.71 OK 10.71 OK 10.71
800 800 850
27 28 27
OK Tubrod 14.00S 3.0mm Throat mm 3.0 4.0 Wire Mode Single Single Flux Amps Volts Speed cm/min 140 120
OK 10.71 OK 10.71
620 620
30 30
OK Tubrod 15.00S 2.4mm Throat mm 2.5 3.0 3.0 4.0 Wire Mode Single Single Twin Twin Flux Amps Volts Speed cm/min 140 130 160 120
OK OK OK OK
10.71 10.71 10.71 10.71
360 360 800 700
27 27 28 27
OK Tubrod 15.00S 3.0mm Throat mm 3.0 4.0 5.0 Wire Mode Single Single Single Flux Amps Volts Speed cm/min 150 120 60
OK 10.71 OK 10.71 OK 10.71
650 590 575
32 32 30
Note : All fillet joints were produced with clean mild steel. Travel speeds will be significantly reduced when welding on primed plate.
71
Selected welding procedures

OK Tubrod 15.00S + OK Flux 10.71
Material: BS4360 Thickness: 12mm Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm 2.8 3.3 Position: ASME 1X-1G Pre-heat: None Interpass:
4.0 1 680 29 41 4.0 2 700 33 41 Mechanical Properties Transverse tensile test Fractured in plate Adjust gap to optimise weld surface profile and reinforcement Charpy V notch energy (J): Test Temp -40oC Centre 90 106 84

Material: BS4360 43A Thickness: 22mm Position: ASME 1X-1G Pre-heat: None Interpass:
Parameters: Size mm Run No Amps Volts Speed cm/min 45 45 Heat input kJ/mm 3.4 3.6
3.0 1 720 3.0 2 750 Mechanical Properties Charpy V notch energy (J): Test Temp -20oC
36 36
Side 1 120 122 160
Side 2 116 124 160
Root 40 50
62

Material: BS4360: 50D Thickness: 50mm Interpass: 250oC Parameters: Size mm Run No Amps Volts Speed cm/niin Heat input kJ/mm 1.39 1.46 1.70 1.50 YS 428 N/mm2 Position: ASME 1X-1G Pre-heat: 150oC Heat treatment: 620oC 2 hours
3.2 1 (MMA E7016) 3.0 2 400 29 50 3.0 3-4 420 29 50 3.0 5-40 450 29 46 3.0 41-48 450 30 54 Mechanical Properties Longitudinal tensile TS 534 N/mm2 Charvy V notch energy (J): Test Temp -20oC o -30 C Cap 110 116 112 110 95 104
Centre 124 106 118 95 98 90
Root 110 108 78 97
84 94
72

Material: BS 4360: 50D Thickness: 25 mm Interpass: 250oC Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm 1.53 1.76 1.55 YS 509 N/mm2 Position: ASME 1X-1G Pre-heat: 150oC Heat treatment: 600oC 1 hour
3.2 1 (MMA E7016) 3.0 2-3 420 28 46 3.0 4-9 450 30 46 3.0 10-12 450 30 52 Mechanical Properties Longitudinal tensile TS 596 N/mm2 Charpy V notch energy (J): Test Temp -20oC -30oC Cap 108 84 122
Centre 138 100 120 92 60 70
Root 84 68
74

Material: BS 4360: 50D Thickness: 25 mm Position: ASME 1X-1G Pre-heat: 100oC Interpass: 250oC
Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm
3.0 1 (MMA E7016) 4.0 2 (MMA E7016) 4.0 3 520 28 50 4.0 4-5 550 29 50 4.0 6-13 610 30 50 Mechanical Properties Longitudinal tensile TS 610 N/mm2 Charpy V notch energy (J): Test Temp -20oC -50oC -60oC Centre line 162 164 170 112 146 140 86 146 96
1.8 1.9 2.3 YS 507 N/mm2
Root 156 184 160 130 100 110 112 118 106
73

Material: BS 4360: 50D Thickness: 25mm Interpass: 250oC Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm Position: ASME 1X-1G Pre-heat: 100oC Heat treatment: 600oC 4 hours
3.0 1 (MMA E7016) 4.0 2 (MMA E7016) 4.0 3 520 28 50 4.0 4-5 550 29 50 4.0 6-13 610 30 50 Mechanical Properties Longitudinal tensile TS 588 N/mm2 Charpy V notch energy (J): Test Temp -20oC -50oC -60oC Centre line 160 152 154 124 94 140 108 70 126
1.8 1.9 2.3 YS 494 N/mm2
Root 124 156 140 96 132 106 98 100 112

Material: BS 4360: 50D Thickness: 25mm Position: ASME 1X-1G Pre-heat: 100oC Interpass: 250oC
3.0 1 (MMA E7016) Side 1 4.0 2 450 28 50 4.0 3-4 500 29 50 4.0 5-16 550 30 50 Side 2 4.0 17 470 28 50 4.0 18-20 500 28 50 4.0 21-31 550 30 50 Mechanical Properties Longitudinal tensile TS 701 N/mm2 Charpy V notch energy (J): Test Temp Cap -20oC 154 146 148 -40oC 130 118 102 CTOD performance -10oC Weld >1.37* >1.62* *Test stopped - max clip
1.51 1.74 1.98 1.57 1.68 1.98 YS 623 N/mm2
Root 154 182 200 108 140 150 CL >1.70*
74

Root & Hot Pass MMA E7016 Side 1 3.0 3 460 29 50 3.0 4-5 460 30 45 3.0 6-45 510 30 45 Sealing Passes 3.0 17 470 28 50 Mechanical Properties Longitudinal tensile TS 643 N/mm2 Charpy V notch energy (J):
1.6 1.8 2.0 1.57 YS 568 N/mm2
Test Temp Cap Centre line -20oC 144 152 148 128 126 142 -40oC 106 122 140 88 89 90 CTOD performance -10oC Weld CL >2.44* 0.72 >1.68* *Test stopped - max clip
Root 154 131 108 116
168 114
OK Tubrod 15.24S + OK Flux 10.62 Multi-power

Parameters: Size mm 3.2 4.0 4.0 4.0 Run No 1 2 3 Amps Volts Speed cm/min Heat input kJ/mm
} }
MMA E7016 29 30 30 50 1.6 3.99
500 DC+ 600 DC+ 600 AC+ Mechanical Properties 4-15 Charpy V notch energy (J): Test Temp -40oC -50oC Cap 80 82 76 64 78 60
55
Centre line 160 128 138 106 106 104
Root 84 86 78 54
80 56
75
Material: BS4360 50D Thickness: 50mm Interpass: 250oC Parameters: Size Run Amps mm No 3.2 1 (MMA 3.0 2 450 3.0 3 500 3.0 4-5 600 3.0 6-27 680 Punch through 3.0 28 680 Mechanical Properties Charpy V notch energy (J): Test Temp -40oC -50oC Cap 136 134 136 122 142 106 Centre 160 140 176 146 86 134 Volts E7016) 28 28 30 32 32 Speed cm/min 55 48 48 48 48
Position: ASME 1X-1G Pre-heat: 150oC Post-heat: 620oC-2 hrs
Heat input kJ/mm 1.3 1.7 2.2 2.7 2.7
Root 110 112 94 96
98 94

Material: BS4360 50D Thickness: 50 mm Interpass: 250oC Parameters: Size Run Amps Volts mm No 3.2 1 (MMA E7016) 3.0 2 450 28 3.0 3 550 28 3.0 4-5 600 32 3.0 6-21 650 34 Punch through 3.0 22 650 34 OK 21.85 neutral metal powder added Mechanical Properties Charpy V notch energy (J): Test Temp Cap -40oC 116 170 146 -50oC 126 118 132 Speed cm/min 50 47 47 47 Heat input kJ/mm 1.5 1.9 2.4 Position: ASME 1X-1G Pre-heat: 150oC Post-heat: 620oC-2 hrs
47 2.8 at l00g/min from pass No 6
Centre 152 172 132 134 166 142
Root 98 104 58 78
92 62
76
Material: Grade 350 Thickness: 7.5mm
Position: ASME 1X-1G Pre-heat: 20oC Interpass: 250oC
Parameters:
3mm
Size mm
Run No
Amps
Volts
Speed cm/min 42
3.0 1 650 Mechanical Properties Charpy V notch energy (J): Test Temp 0 oC -40oC
36
Heat input kJ/mm 3.3
Centre 60 61 66 42 39 49

Material: BS 4360 : 50D Thickness: 50mm Interpass: 120-180oC Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm Position: ASME 1X-1G Pre-heat: 150oC Heat treatment
Side 1 3.2 1 (MMA) 3.0 2 450 26 3.0 3 450 28 3.0 4-14 500 30 3.0 15-18 500 30 Side 2 3.0 19 450 26 3.0 20 450 28 3.0 21-30 500 30 3.0 31-34 500 30 Mechanical Properties Longitudinal tensile TS 668 N/mm2 Charpy V notch energy (J): Test Temp Cap -50oC 134 116 134 -60oC 90 88 80 CTOD performance BS 5762 -10oC 1.96 2.02 1.79
50 50 40 56 50 50 40 56
1.4 1.5 2.2 1.6 1.4 1.5 2.2 1.6 YS 594 N/mm2
Root 172 176 178 147 180 170
77
Material: BS4360 50D Thickness: 15mm
Position: ASME 1X-1G Pre-heat: None Interpass: 150-200oC
Parameters: Size Run Amps mm No 3.2 1 650 3.2 2 650 Mechanical Properties Charpy V notch energy (J): Test Temp -40oC -50oC Centre 172 119 89 132 165 103 Volts 28 32 Speed cm/min 50 60 Heat input kJ/mm 2.2 2.0

Material: NV2-4 Thickness: 12mm Position: ASME 1X-1G Pre-heat: None Interpass: 150/200oC
Parameters: Size Run Amps Volts mm No 3.2 1 600 32 3.2 2 600 32 Mechanical Properties Longitudinal tensile: TS 679 N/mm2 Charpy V notch energy (J): Test Temp -20oC -40oC -60oC Centre 272 254 231 210 230 204 142 102 91 Speed cm/min 60 60 Heat input kJ/mm 1.9 1.9
YS 599 N/mm2
78
OK Tubrod 14.53S + OK FLUX 10.71

Material: NV2-4 Thickness: 12mm Position: ASME 1X-1G Pre-heat: Interpass: 150-200oC
Parameters: Size Run Amps mm No 3.2 1 550 3.2 2 550 Mechanical Properties Longitudinal tensile: TS 655 Charpy V notch energy (J): Test Temp -20oC -40oC -50oC Centre 183 201 184 92 137 91 192 118 Volts 32 32 Nmm2 Speed cm/min 60 60 Heat input kJ/mm 1.9 1.9
YS 586 N/mm2
OK Tubrod 14.54S + OK FLUX 10.62

Material: Supereslo 500 Thickness: 35mm Position: ASME 1X-1G Pre-heat: None Interpass: 250oC max
Parameters: Size mm Run No Amps Volts Speed cm/min Heat input kJ/mm 5.1 5.9
4.0 1 585 4.0 2-11 590 Mechanical Properties Longitudinal tensile: Charpy V notch energy (J): Test Temp -20oC -40oC
29 20 30 18 Root TS 677 N/mm2 YS 612 N/mm2
Cap TS 672 N/mm2 YS 565 N/mm2
Cap 110 105 114 76 89 82
Root 118 140 125 106 87 117
79
Electrogas welding
Initially this process was developed from the electro-slag process using solid wire and CO2 shielding gas. Its success, however, like electro slag welding, was limited as it was restricted to heavy plate with parallel gaps. A consequence of this was very large weldments which suffered from coarse grain solidification due to the very high heat input. This had an adverse effect on mechanical properties, especially notch toughness, so if the potential of the process was to be fully realised a significant reduction in heat input was required. A capability to weld thinner plate would also increase the scope of applications. High speed electrogas welding Except for a few users the process has been in the doldrums for many years. Through it all, however, the process still had much to recommend it for inexpensive high productivity welding and is about to undergo a revival. Many of the problems previously associated with its limitation have been addressed and research is continuing in Europe and the USA. These developments include: Smaller diameter cored wires i.e. 1.6mm and 2.4mm are now available which have permitted an increase in the resistive heating effect per amp. This has resulted in higher deposition rates and consequently faster welding speeds with an overall reduction in heat input. G The above mentioned improvements have ensured consistent notch toughness down to -20oC but the use of alloying and micro alloying have now made -40oC a realistic target depending on procedure. G Weld preparations have been modified from the old parallel gap system to single and double V types. Weld metal volumes have, therefore, been decreased which, for given deposition rate, has further increased welding speeds. G Metal powder may be added to the weld pool which will increase deposition but at the same time reduce welding temperature and heat loading of the plate adjacent to the fusion zone. G These developments have combined to facilitate the electrogas welding of reduced plate thickness so much so that 8mm presents no difficulty, although using an integral backing strip on one side even 6mm has been successfully joined.
G
Process description The basic principle of the process can be seen in Fig 27 where the molten pool is contained within the joint by water cooled copper shoes. These move upwards with the pool at a controlled rate and are shaped such that they mould the weld reinforcement until solidification is complete. The molten pool is protected from the atmosphere by a gas shield which can be either CO2 or Ar + CO2 mixtures, Additional protection is afforded by de-oxidants and a thin layer of slag from the cored wire
defects will occur within the first 20mm, that is until the weld pool is complete and stable. Intermediate stops should, therefore, be avoided and the work planned so that the total joint can be welded without intermediate pauses. It is also advisable to use run-on and runoff pieces which are removed after welding, complete with the aforementioned defects. The process, once started, is continuous until completion of the joint and this must be considered before actual welding is commenced. Is there
Wire guide nozzle
CO2 or Arc 20%CO2 Gas shield
Cored wire electrode
Welding arc
Molten weld pool Mobile water cooled copper shoes
Completed weld
Fig 27 Principle of Electrogas Process
consumable. The slag will also help to prevent damage to the weld reinforcement when plastic by forming a lubrication barrier between the copper shoes and weld. Heat from the molten pool and the arc fuse the edges of the plates being joined, almost like a casting process which continues until the joint is completed. An inevitable consequence of solidification when welding stops is a pipe or shrinkage cavity. At the start of welding it is also highly probable that
sufficient wire and shielding gas to complete the joint for example? On the equipment side it should be maintained in good running order both mechanically and electrically and the power source adopted must have sufficient amperage for the appropriate joint and size of wire at a duty cycle of 100%. Reference to Tables 1 & 2 will provide useful estimating data regarding wire feed speeds, total weights of weld metal and speeds of travel for given joint designs.
80
Electrogas welding
V preparation Vertomax 2MG
Table 1
6 8 15 16 32.0o 26.6o 21.7o 6 6 16 5 10 6 12
15 10
20
10 18
18.4o 16.6o
Plate th. s (mm) a (mm)
Gap size b Bevel angle (mm) (deg) min max max min 5 5 5 5 5 9 9 9 9 9 35 29 25 20 18 24 19 16 13 13 Voltage (V)
Welding Current (A) Speed (m/h)
Wire Dia (mm) Needs (kg/m)
8 10 12 15 20
16 16 16 16 18
32 32 35 32 34
350 350 350 420 480
9 8 7 6 4.5
1.6 1.6 1.6 2.4 2.4
1.5 1.7 1.9 2.2 2.9
arc time 30 min/m

V-prep, 1 pass X-prep, 2 passes
b
Electrogas process
Mini Vertomatic NC Vertomatic Mini T
s a a
20 10 0 0 10 20 30 40
thickness (mm)
angle
81
Electrogas welding
X preparation Vertomax 2MG
Table 2
o 19o 22
19o 15 3 15 3
30 30
15 15
35
15 15 18o
Plate th. s (mm)
Pass nr
Groove depth (mm)
a (mm)
Gap size b Bevel angle (mm) (deg) min max max min 3 3 3 3 5 5 5 5 22 22 19 18 18 18 16 16
Voltage (V)
Welding Current (A)
18
Speed (m/h)
Wire Dia Needs (mm) (kg/m)
30
1 2 1 2
15 15 17 18
15 15 15 15
32 32 32 32
420 420 450 450
6 6 5.5 5.5
2.4 2.4 2.4 2.4
1.9 1.9 2.1 2.1
35
a b
arc time 30 min/m
V-prep, 1 pass X-prep, 2 passes
a b
Electrogas process
Mini Vertomatic NC Vertomatic Mini T
1 s
1 s
20 10 0 0 10 20 30 40
2
thickness (mm)
copper strip angle
angle
82
Electrogas welding
X preparation Vertomax 2MG
Table 2 continued
o 18.8 18.8o
o 15.2 15.2o o 17.6 17.6o
20 20.0
22 22.0 3 3.0
22 22.0 3 3.0
3 3.0
50 50.0
60 60.0
Plate th. s (mm)
Pass nr
Groove depth (mm)
a (mm)
Gap size b (mm) min max 3 3 3 3 3 3 5 5 5 5 5 5
Bevel angle (deg) max min 19 19 18 18 15 13 17 17 16 16 14 12
Voltage (V)
Welding Current (A)
70 70.0
Speed (m/h)
Wire Dia Needs (mm) (kg/m)
Oscillation Ampl. Speed Dwell (mm) (m/min) (s)
50
1 2 1 2 1 2
25 25 30 30 35 40
20 20 22 22 22 22
32 32 33 33 34 35
600 600 610 610 620 630
3.8 3.8 3 3 2.6 2.4
3.2 3.2 3.2 3.2 3.2 3.2
3.2 3.2 4 4 4.6 5.1
0 0 15 15 20 25
0 0 0.8 0.8 0.8 0.8
0 0 1.5 1.5 1.5 1.5
60
75
a b b
60 arc time 50 min/m 40
a a
b b
1 1 s s
X-prep, 2 passes Electrogas process V-prep, 1 pass

Vertomatic NC, SG, T
1 1 s
30 20 10
2 2
0 10 20 30 40 50 60 70 80 thickness (mm)
copper copper strip strip angle angle
a a
angle angle
Fig 28
83
Applications The electrogas process is specifically designed for vertical up and inclined vertical (45o maximum) welding of plate thickness in a range 8-40mm thick and larger if multi-pass techniques are used. With any fully automatic welding system, setting up the equipment occupies a major part of the total operation. A joint length of 2-5m, therefore, depending to some extent on the joint design and plate thickness is considered the minimum for economic welding. Initially the electrogas process was chiefly associated with tank farm construction for oil storage etc. The more recent developments regarding the reduction in heat input, increased speed and better mechanical properties have seen the process enter shipbuilding for hull section welding, civil engineering for penstocks, bridges, and mountain thaw drains as well as blast furnace shells. The process is not, however, restricted to outside use and machines are available for fabrication shop use. Any general fabrication work with long vertical seams may be welded with the
process. In certain situations items such as drums or heavy fabricated beams and even specially designed railway crossings have been turned to the vertical position in order to take advantage of the productivity provided by Electrogas. Steels Corresponding with the process development the steel industry has introduced steels which are relatively insensitive to heat input in the range 60-200 kJ cm yet retaining high joint toughness. Since high heat input has hitherto been the largest single restricting factor for Electrogas welding, this development is seen as a major benefit in providing greater scope for its use. These steels contain second phase particles such as Titanium oxide and Titanium carbides which pin grain boundaries and restrict grain growth in the HAZ during welding.
Multi-pass welding In the thickness range 30mm-50mm where heat input is critical due to the type of steel being joined, a multi-pass technique can be used. The crosssectional area of the preparation will be reduced as too will the heat input but the productivity will remain high even compared to conventional single pass electrogas. The high speed development technology can still be adopted and incorporates all the additional benefits previously described. A double V preparation is used with a gap to ensure complete root fusion and the joint completed in two passes. When welding the first side the molten weld metal is prevented from falling through to the reverse side by a copper dam Fig 28. The dams will be shaped so as to match fit the plate preparation and are mechanically attached to the reverse side of the joint. They will be approximately 50cm long and as the joint cools after the welding head has passed they are removed and placed in front again and so on.
84
Calculating electrode consumption

Using the tables showing weld metal areas and the formula below it is possible to calculate the weight of electrode/filler wire required for a particular joint configuration/welding process. W = DxAxL Efficiency When calculating consumable requirements allowances must be made for wastage i.e. stub ends from electrodes, Tigrod etc. Example; calculating consumable requirements. 10mm Fillet weld, 100m long. 1) M.M.A. process Weight of electrode/Filler wire required, kg. Density of weld metal, kg/m3. Cross sectional area of joint to be filled, m2. Length of joint, m. W = 7870 x 50 x 10-6 X 100 = 60.54kg 0.65 2) M.I.G./M.A.G. Efficiency = Efficiency Factor for various welding process used i.e. 1.0 = 100% efficient. To assist in calculating consumable requirements the following efficiency factors may be used. Manual metal arc M.I.G./M.A.G. wires Metal cored wires Flux cored wires TIG SAW* 0.65 0.95 0.95 0.85 1.00 1.00 W = 7870 x 50 x 10-6 x 100 = 40.57kg 0.95 *See relevant pages of main body of catalogue for flux consumption data.
Where; W = D = A = L =
Stress and energy units conversions

The following table is reproduced by courtesy of British Standards Institution N/mm 2 (MN/m2 )
1700 1650 105 1600 1550 1500 1450 1400 1350 1300 1250 1200 1150 1100 1050 1000 950 60 900 850 800 50 750 700 650 600 550 500 450 400 30 450 25 20 400 350 300 40 000 15 250 200 10
2
tonf/in 2
110
N/mm 2
1700 1650 1600
lbf/in 2
250 000
N/mm 2
1700
kgf/mm2
175
ft lbf
120
kgf m
240 000 230 000 220 000
1650 1600
170 165 160
160
160 16
100
1550 1500
1550 155 1500 150 1450 145 1400 200 000 1350 190 000 180 000 170 000 135 1300 130 1250 125 1200 120 1150 115 160 000 150 000 140 000 130 000 120 000 1100 110 1050 105 1000 950 900 850 800 110 000 100 000 90 000 750 700 650 600 550 500 450 60 000 50 000 400 350 300 250 200 150 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15
2
95 1450 90 1400 1350 85 1300 80 1250 1200 75 1150 1100 1050 65 1000 950 900 55 850 800 750 45 700 650 40 600 35 550 500 80 000 70 000 210 000
140 100
140 14
140
120
120 12
80
70
100
100
10
80
60
80
60 40
60
40
40
20 20 20
350 300 250 200 150
30 000 20 000
2
150
2
0
2
N/mm (MN/m2 )
tonf/in
N/mm
lbf/in
N/mm
kgf/mm
ft lbf
kgf m
CONVERSION FACTORS Conversion Factors 2 2 2 2 2 2 2 2 2 2 1N/mm 1MN/m 0.075tonf/in 145lbf/in 0.102kgf/mm 1N/mm 1MN/m 0.075tonf/in 145lbf/in 0.102kgfmm 1J (joule) 0.738ft lbf 0.102kgfm For more detailed conversions see BS 350 Conversion factors and tables
85
Welding data tables - Filler metal requirements (kg/m)

SINGLE V JOINT - 60o included angle FILLET WELD
PLATE THK. mm 4 5 6 7 8 9 10 11 12 14 15 16 18 20 25
ROOT GAP mm 1 1 1 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2
THEORETICAL VOLUME cm3/m 13 19.5 27 39 49 60.5 77.5 92 107 141 160 180 223 271 411
WELD cm3/m 12.5 19 25.5 38 46.5 56 72 83.5 97.5 130 146 157 204 247 375
WEIGHT WELD METAL/m kg/m 0.1 0.15 0.2 0.3 0.37 0.44 0.57 0.66 0.77 1.02 1.15 1.23 1.6 1.94 2.94
FILLET SIZE T mm 2 3 4 6 8 10 12 15 18 20 25
THEORETICAL WELD VOLUME cm3/m L T 6.0 12.5 21.0 42.0 73.5 114.0 162.0 248.0
WEIGHT WELD METAL/m kg/m L T 0.05 0.10 0.16 0.33 0.58 0.89 1.27 1.95
4.5 8.0 18.0 32.0 50.0 72.0 112.5 162.0 200.0 312.5
0.036 0.064 0.142 0.252 0.394 0.567 0.887 1.277 1.576 2.463
The figures above are for accurate weld volumes of exact dimensions. In practice it is difficult to obtain mitre shaped fillet welds, actual welds are generally convex in profile and an allowance of approximately 15% should be made when calculating consumable requirements
Conversions and information

ELECTRODE SIZE EQUIVALENTS
Diameters mm SWG 1.6 16 2 14 2.5 12 3.25 10 4 8 5 6 6 4 8 in 1/16 5/64 3/32 1/8 5/32 3/16 1/4 5/16 Lengths mm 250 300 350 400 450 600 700 in 10 12 14 16 18 24 28
BASIC CONVERSION FACTORS

To Convert: into (N.B. Factors ending in 0 are exact) in mm mm in ft m m ft lb kg kg lb ton (long) tonne tonne kg gallon (imp) I (litre) l ml ml cm3 cu ft l Multiply by: 25.40 0.0393 701 0.304 8 3.280 839 8 0.453 592 370 2.204 62 1.016 05 1000.0 4.545 96 1000.0 1.000 028 28.3161
APPROXIMATE METAL DENSITIES

(g/cm3 at 20OC) Steel, 0.06% C/0.4% Mn Steel, 0.1% C/5% Cr Steel - 0.15% C/13% Cr Steel: 0.2% C/26% Cr Stainless Steel 19% Cr/10% Ni/0.03% C Stainless Steel 25% Cr/20% Ni/0.2% C Aluminium, Commercial Purity Al/1.3% Mn Al/11 % Si Copper, O.F.H.C. Cu/7.5% Sn/0.2% P 7.87 7.81 7.74 7.66 7.93 7.9 2.7 2.74 2.65 8.94 8.9
COMPOUND CONVERSION FACTORS

tonf/in2 lbf/in2 N/mm2 N/mm2 ft lbf kgf m kgf m ft lbf J in/min m/hr cu ft/hr I/min lb/cu ft g/cm3 N/mm2 N/mm2 tonf/in2 lbf/in2 J (joules) J ft lbf kgf m ft lbf m/hr in/min I/min cu ft/hr g/cm3 lb/cu ft 15.444 3 0.006 894 777 0.064 749 145.037 76 1.355 82 9.806 650 7.233 01 0.138 255 0.737 562 1.524 0 0.656 168 0.471 95 2.118-936 0.016 02 62.43
SYMBOLS FOR CHEMICAL ELEMENTS
Al C Cb Co Cr Cu H Fe Mg Mn Mo N
Aluminium Carbon Columbium (Niobium) Cobalt Chromium Copper Hydrogen Iron Magnesium Manganese Molybdenum Nitrogen
Nb Ni O p Pb s Si Sn Ta Ti V W Zn
Niobium Nickel Oxygen Phosphorus Lead Sulphur Silicon Tin Tantalum Titanium Vanadium Tungsten Zinc
86
INDEX PREVIOUS PAGE
ESAB AB Box 8004 S-402 77 GOTEBORG SWEDEN Phone + 46 31 509000 Tgm esabsales Telex 20625 Telefax: 010 46 31 509 480
ESAB Group (UK) Limited Hertford Road, Waltham Cross Herts EN8 7RP England Telephone: Lea Valley (01992) 768515 Telex:25743 Telefax: (01992) 715803
In the interest of continuous improvement ESAB reserves the right to change the specifications or design of any of its products without prior notice.
Member of The Esab Group
PWX 165/3/99
87

Cored Wires - ESAB - OK Tubrod

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Cored Wires - ESAB - OK Tubrod

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OK TUBROD CORED WIRES PRODUCT BRIEF

OK TUBROD CORED WIRES PRODUCT BRIEF

OK TUBROD CORED WIRES PRODUCT BRIEF

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The cored wire process

Cored Wire Cross-sections

OK Tubrod cored wires

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EX0T-1 Downhand and HV

EX1T-1 All Positional

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Note: All classifications referred to are AWS see page 53 and 54

EX0T-1 Downhand and HV

EX1T-1 All Positional

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Note: All classifications referred to are AWS see page 53 and 54

OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 690 N/mm2 760 N/mm2 15%

Minimum 500 N/mm2 560 N/mm2 22%

INDEX PREVIOUS PAGE NEXT PAGE

OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 420 N/mm2 530 N/mm2 22%

Minimum 540 N/mm2 620 N/mm2 20%

Minimum 420 N/mm2 510 N/mm2 22%

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OK Tubrod self-shielded range

Minimum 400 N/mm2 480 N/mm2 22%

Minimum 400 N/mm2 480 N/mm2 22%

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OK Tubrod flux cored range

Minimum 420 N/mm2 510 N/mm2 22%

Minimum 420 N/mm2 510 N/mm2 22%

Minimum 420 N/mm2 510 N/mm2 22%

INDEX PREVIOUS PAGE NEXT PAGE

OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 420 N/mm2 510 N/mm2 22%

Minimum 460 N/mm2 530 N/mm2 22%

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SG 52.2 42.039.05 3S 3YS

OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 550 N/mm2

Minimum 470 N/mm2 560 N/mm2 22%

Minimum 510 N/mm2 570 N/mm2 20%

CO2 3SA,3YSA SA 3YM HH 3S, 3YS, H15 E51 5R(H)

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OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 420 N/mm2 530 N/mm2 22%

Minimum 420 N/mm2 510 N/mm2 22%

Minimum 54J 47J

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OK TUBROD CORED WIRES PRODUCT BRIEF

Minimum 550 N/mm2 620 N/mm2 17%

Minimum 420 N/mm2 530 N/mm2 22%

Minimum 690 N/mm2 760 N/mm2 15%

INDEX PREVIOUS PAGE NEXT PAGE

OK TUBROD CORED WIRES PRODUCT BRIEF

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OK Tubrod stainless cored wires

MMA AWS: E308L-16 3.2

OK Tubrod 14.2X Series

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OK Tubrod 14.3X Series

Storage period - weeks

OK TUBROD CORED WIRES PRODUCT BRIEF