Professional Documents
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644
Technical Reference Data 656
Deposition Data 657
11
General Consumable Data 660
Technical Data
AU : IPRM 2007 : Section 11 : technical data 643
11 Technical Data
Classification Tables
AS/NZS 1553 Part 1-1995 Low Carbon Steel Electrodes for Manual
Metal Arc Welding of Carbon Steels and Carbon Manganese steels
Tensile Strength Minimum Yield Minimum
Weld Metal No. Range (MPa) Strength (MPa) Elongation
Optional Indicators
48 500-620 (1) 420 (1) 22% for notch toughness,
lower hydrogen status and
moisture absorption resistance
E 48 Designates approximately 1/10th of the minimum tensile strength in MPa.
E 4 8 1 8 – 4 H5 R
Welding position,
welding current Designates the coating is moisture
18 and covering. resistant. Tested electrodes
shall exhibit not >10‑ml H2/100
Designates the impact
See Table 1 for details. 4 energy grade number. R g of DWM after exposure to
an environment of 27° C and
80%‑relative humidity for a period
of not less than 9 hours.
Impact Minimum average CVN
Energy impact‑values
Grade no.
Z Not required.
A 47J @ + 20°C
0 47J @ 0°C
Designates the diffusible hydrogen
2 47J @ -20°C H5 content of deposited weld metal
(DWM)
(1) Designates that, for each increase of 1% in the value 3 47J @ -30°C
of elongation over the minimum, a decrease of 10 MPa
in tensile and yield strength is allowed to the following 4 47J @ -40°C
H5 ≤ 5 ml H2/100 g of DWM
minimum values, (e.g. E41XX, tensile: 410 MPa/ yield: 330 5 47J @ -50°C
MPa and E48XX, tensile: 480 MPa/yield: 400 MPa).
6 47J @ -60°C
H 10 ≤ 10 ml H2/100 g of DWM
AS/NZS 1553 Part 1-1995 Covered Electrodes for Welding Low Carbon Steel
AS/NZS 1553.1 Electrode Classification Summary – Table 1
DC +
EXX10 F,V, OH, H High Cellulose Deep
Fluid Slag
AC and DC +
EXX11 F,V, OH, H High Cellulose Deep
Fluid Slag
AC and DC + or –
EXX12 F,V, OH, H High Titania, Stiff Slag Medium
(Viscous)
AC and DC + or –
EXX14 F,V, OH, H Low Iron Power, Titania Low
Stiff Slag (Viscous)
DC +
EXX15 F,V, OH, H Basic Medium
Hydrogen controlled
AC and DC +
EXX16 F,V, OH, H Basic Medium
Hydrogen controlled
AC and DC +
EXX18 F,V, OH, H Basic Hydrogen controlled Medium
Low Iron Powder
AC and DC + or –
EXX19 F,V, OH, H Iron Oxide Titania Medium
Potassium
AC and DC + or –
EXX24 F and H/V-FILLET High Iron Powder Low
Titania
AC and DC + or –
EXX27 F and H/V-FILLET High Iron Powder Deep
Iron Oxide
AC and DC +
EXX28 F and H/V-FILLET Basic Hydrogen controlled Medium
High Iron Powder
F,V, OH, H,
EXX46 AC and DC + Basic Hydrogen controlled Medium
V-DOWN
As specified by the
EXX99 As specified by the manufacturer As described by the manufacturer As specified
manufacturer
Designates
70 Designates the minimum required tensile strength in ksi. 1 Welding Positions
Electrode
Optional
Designators
E
E 7 0 1 8 – 1 H4 R
1) Yield on E6022 electrodes is not specified and E7018M\ may have a range of 53-72 ksi for (2) Minimum elongation for E6012, E6013, E7014 and E7024 types is 17%. Elongation on
all diameters other than 3/32< (2.4mm) which is 53-77 ksi. E6022 electrodes is not specified.
AWS 5.1-1991 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
Notes:
b) The term ‘DC +’ refers to direct current electrode positive (dc, reverse polarity).
The term ‘DC –’ refers to direct current electrode negative (dc, straight polarity).
c) Electrodes of the E6022 classification are intended for single-pass welds only.
d) Elecrodes with supplemental elongation, notch toughness, absorbed moisture, and
diffusible hydrogen requirements may be further identified.
* For electrodes 3/16 in. (4.8mm) and under, except 5/32 in. (4.0mm) and under for
classifications E7014, E7015, E7016, E7018, E7018M.
AWS A5.5-96 Specification for Low Alloy Steel Electrodes for Shielded metal arc welding
E110 Series, 100,000 psi (760 MPa) and E120 Series, 120,000 psi (830 MPa)
ER70S-2 CO2 70,000 480 58,000 400 22 20ft Lb @ -20°F (27J @ -30°C)
ER70S-3 CO2 70,000 480 58,000 400 22 20ft Lb @ 0°F (27J @ -20°C)
ER70S-4 CO2 70,000 480 58,000 400 22 Not Required
ER70S-6 CO2 70,000 480 58,000 400 22 20ft Lb @ -20°F (27J @ -30°C)
ER70S-7 CO2 70,000 480 58,000 400 22 20ft Lb @ -20°F (27J @ -30°C)
ER70S-G * 70,000 480 58,000 400 22 As agreed between supplier and purchaser
E70C-3X † 70,000 480 58,000 400 22 20ft Lb @ 0°F (27J @ -20°C)
E70-6X Arg 70,000 480 58,000 400 22 20ft Lb @ -20°F (27J @ -30°C)
E70C-G(X) * 70,000 480 58,000 400 22 As agreed between supplier and purchaser
E R 7 0 S – 6 H4
Designates ‘Mixed Gas’ and is
M classified for use with Argon +
20–25% CO2 gas
Wire Class Carbon (C) Manganese (Mn) Silicon (Si) Other Elements Allowable % Range
E Electrode
Weld Metal No. Tensile Strength Min. Proof Stress at Minimum
Range (MPa) 0.2% offset (MPa) Elongation
T Tubular
P All Positional W40 430-550 310 22%
W50 490-650 360 22%
D Flat and H/V Fillets
W55 550-690 470 19%
S Single run only
W62 620-760 540 16%
Construction and W69 690-830 610 15%
Group
recommended W76 760-900 680 14%
1 welding position W83 830-970 750 13%
Heat Treatment
Condition
A As welded condition
P Post-welded heat treatment
H5 ≤ 5 ml H2 / 100 g of DWM
H10 ≤ 10 ml H2 / 100 g of DWM
H15 ≤ 15 ml H2 / 100 g of DWM
Designates Weld
Metal‑Chemistry
E Electrode
Optional
Designators
E 7 1 T – 1 M J H4
AWS A5.20 Class Polarity No. of Weld Passes Discernible Features and Applications
T-1 and T-1M DC + Multiple Larger diameters (2 mm [5/64″] and larger) are used for flat and H/V welding
only.Very smooth/quiet arc with low spatter loss, flat to slightly convex weld
bead contour, full covering easy removed slag, and high deposition rates.
T-2 and T-2M DC + Single Essentially the same as T-1/T-1M types, but with higher manganese or silicon
or both. Higher levels of deoxidisers allow welding of heavily oxidised steels
such as, rimmed, rusty and mill scaled steels. SINGLE pass only.
T-3* DC + Single # High speed gasless welding in flat and H/V and 20° down inclined positions
on sheet metal. Limited mech. props.
T-4* DC + Multiple Very low Sulphur weld deposits (resistant to hot cracking) and very high
deposition rates. Bridging of poor fit-up joints.
T-5 and T-5M DC +/- Multiple Larger diameters (>2mm) are used for flat and H/V welding. Good
mechanical properties (e.g. impacts 27J @ -29°C/20ft Lb @ -20°F). Slightly
convex weld bead contour, easy removed thin slag, resistant to hot and cold
cracking.
T-6* DC + Multiple Good low temperature impact properties (e.g. 27J @ -29°C/20ft Lb @
-20°F). Slightly convex weld bead contour, easy removed thin slag, resistant
to hot and cold cracking.
T-7* DC - — Dia. (>2mm) used for flat and H/V welding. High deposition rates and very
Fluoride low sulphur weld metal resistant to cracking.
T-8* DC - Multiple Very good low temperature strength, notch toughness and crack resistance
(e.g. 27J @ -29°C/20ft Lb @ -20°F).
T-9 and T-9M DC + Multiple Essentially the same as T-1/T-1M types, but deposit weld metal with improved
impact properties (e.g. 27J @ -29°C/20ft Lb @ -20°F). To obtain X-Ray
quality, joints are to be relatively clean and free of oil, excessive oxide and
mil-scale.
T-10* DC - Single High speed gasless welding in flat and H/V and 20° vertical inclined positions
on larger thickness than the T-3 class.
T-11* DC - Multiple General purpose wire for use on material less than 20mm (3/4) unless
preheat and interpass temp’s are maintained.
T-12 and T-12M DC + Multiple Essentially the same as T-1/T-1M types, but modified to increase impact
properties and to meet lower manganese requirements of the ASME Boiler
and pressure Vessel code section IX, A-1 analysis group of 1.6% Mn.
T-13* DC - Single Root pass welding only on circumferential pipe welds.
T-14* DC - Single # High speed all positional welding of sheet metal such as, galvanised, zinc
and other coated steels < 6mm (1/4)
T-G DC +/- Multiple For electrodes not covered by any present classification. The wire must
meet the chemical requirements to ensure a carbon steel deposit and the
specified tensile strength.
T-GS DC +/- Single For single pass electrodes not covered by any present classification. The
wire must meet the specified tensile strength requirements. No other
requirements are specified.
* Self shielded wire types.
AWS A5.20-95 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding
Technical
Reference Data
Deposition Data
Deposition Rates, Electrode Efficiency
Deposition rates are calculated using the following methodology. Oxy-Acetylene welding 99.99%
They show the formula for measuring deposition rates. GMAW – Pulse Arc 98%
m2 – m1
RN(%) =
m3 – m4
Where:
m1 = mass of test plate before welding
m2 = combined mass of test plate and the weld
m3 = mass of the core of the wire of the 5 electrodes
m4 = mass of the core of the wire in the five stubs after welding
For example, an E6013 type electrode has an approximate efficiency
of 91 percent while an E7024 will have around 150 percent efficiency.
Approximate Fraction
Metric (mm) International inches Lengths* (mm) Gauge No. inches
— — 200 — —
1.6 0.0625 250 16 1/16
2 0.0787 300 14 5/64
— — 250 — —
2.5 0.0984 300 12 3/32
— — 350 — —
3.2 — 350 10 1/8
4.0 0.1250 380 — —
— 0.1575 450 — —
4.8 0.1576 350 8 5/32
5 0.1969 380 6 3/16
5.6 0.2205 450 — —
6 0.2362 500 4 7/32
6.3 0.2481 600 — 1/4
8 0.3150 700 0 5/16
10 0.3937 900 — 3/8
* Length will depend on manufacture and market preference and not all sizes will be available.
Joining Suitable
BOC Cigweld Process Materials Features Suitable Flux Comments
Tobin Bronze Tobin Bronze Braze Welding Brass & Bronzes Low Fume Tenacity 20 With mild steel, low strength applications
Fusion Welding Mild Steel only (e.g. car panel filling)
Ferrous Materials
Nickelcoat Nickel Bronze Braze Welding Steel High Strength Self Fluxing Fusion welding of similar copper alloys
Fusion Welding Cast Iron Wear Resistant Brazing of nickel based alloys
Malleable Iron
Nickel Bronze Nickel Bronze Braze Welding Steel High Strength Tenacity 20 Fusion welding of similar copper alloys
Fusion Welding Cast Iron Wear Resistant Brazing of nickel based alloys
Malleable Iron Build up of worn ferrous components
Mangcoat Comcoat C Braze Welding Steel Low Fume Self Fluxing Due to dezincification, not suitable for
Cast Iron High Strength copper pipes carrying hot water or
Malleable Iron sea water
Mang Bronze Manganese Braze Welding Steel Low Fume Tenacity 20 Due to dezincification, not suitable for
Bronze Cast Iron High Strength copper pipes carrying hot water or
Malleable Iron sea water
Tungsten Electrodes
Tungsten Electrodes are usually identified by a colour on the end of BOC Tungstens
the electrode.
Thoriated
In Australia/NZ, the AWS standard is generally referred to as the
compliance standard for this product, although the colour of the Red Tip DC straight polarity for copper, nickel alloys, titanium, mild
tungstens sold by various suppliers may not match that of the steels and stainless steels. This tungsten is usually sharpened to a
standard, due to various manufacturers conforming to European point. The length of taper should be 2 times the diameter of the
standards. tungsten. Thoriated tungsten emits a small amount of radioactivity.
To help clarify, the charts below show those that are classified under Zirconiated
AWS: A5: 12 and those that are sold by BOC. White Tip AC polarity for the welding of aluminium and magnesium.
Tungsten should be used in the ball form.
Note: When sharpening tungstens, they should be sharpened so that the grinding lines travel
down the length of the tungsten. This allows the ions to travel down the tungsten without
having to cross circumferential lines that would cause them to leave the tip in an erratic Lanthiated
manner and affect the weld quality.
Gold Tip for AC high frequency and DC Straight Polarity currents.
Suitable for automated TIG applications due to its high current
carrying capacity and has good multi-strike capability. Lanthiated
is radiation free. Lanthiated tungstens are normally sharpened the
same as thoriated.
Ceriated
Grey Tip for low DCSP on materials that are welded with the
thoriated tungstens. Cerium is radiation free. Ceriated tungstens are
normally sharpened as per the thoriated tungstens.
AWS: A5:12 Colour Code and Alloying Elements for Various Tungsten Electrode Alloys
Nominal Weight of
AWS Classification Coloura Alloying Element Alloying Oxide Alloying Oxide %
EWP Green — — —
EWCe-2 Orange Cerium CeO2 2
EWLa-1 Black Lanthanum La2O3 1
EWTh-1 Yellow Thorium ThO2 1
EWTh-2 Red Thorium ThO2 2
EWZr-1 Brown Zirconium ZrO2 0.25
EWG Grey Not Specifiedb — —
Note: Colours may vary
a
Colour may be applied in the form of bands, dots etc, at any point on the surface of the electrode.
Recommended Tungsten Electrodes and Gas Cups for Various Welding Currents
SI Metric System
Length
1 millimetre (mm) — 0.0393 701 inch
1 centimetre (cm) 10 millimetres 0.393 701 inch, 0.032 208 4 feet
1 decimetre (dm) 10 centimetres 3.937 01 inches
1 metre (m) 10 decimetres (100 cm) 39.370.1 inches, 3.280 843 feet, 1.093 614 yards
1 decametre (dam) 10 metres 10.936 14 yards
1 hectometre (hm) 10 decametres (100 m) 109.361 4 yards
1 kilometre (km) 10 hectometres (1,000 m) 3 280.843 feet, 1.093.614 yards, 0.621 371 mile
Area
1 square millimetre (mm2) — 0.001 550 sq. inch
1 square centimetre (cm2) 100 sq. millimetres 0.155 sq. inch, 0.001 076 39 sq. feet
1 square decimetre (dm ) 2
100 sq. centimetres 15.50 sq. inches
1 square metre (m ) 2
100 sq. decimetres (10,000 cm )2
10.763 915 sq. feet, 1.195 99 sq. yards
1 are 100 sq. metres (1 sq. decametre) 119.599 sq. yards
1 hectare (ha) 100 ares (10,000 sq. metres) 11 959.9 sq. yards, 2.471 05 acres
1 square kilometre (km ) 2
100 hectares (1,000,000 sq. metres) 0.386 102 sq. mile
Volume (cubic)
1 cubic millimetre (mm3) — 0.000 061 024 cubic inch
1 cubic centimetre (cm3) 1,000 cubic millimetres 0.061 024 cubic inch
1 cubic decametre (dm ) 3
1,000 cubic centimetres (1 litres) 61.024 cubic inch
1 cubic metre (m ) 3
1,000 cubic decimetres (1,000 litres) 35.317 76 cubic feet, 1.307 95 cubic yards
Volume (fluid)
1 millimetre (ml) — 0.035 195 fluid oz
1 centilitre (cl) 10 millilitres 0.351 95 fluid oz
1 decilitre (dl) 10 centilitres 3.519 5 fluid oz, 0.175 975 pint
1 litre (L) 10 decilitres 1.759 75 pints, 0.219 969 gallon, 0.264 18 US gallon
Mass
1 milligram (mg) (1,000 micrograms) mg 0.015 432 36 grain
1 centigram (cg) 10 milligrams 0.154 323 6 grain
1 decigram (dg) 10 centigrams 1.543 236 grains
1 gram (g) 10 decigrams (1,000 milligrams) 15.432 36 grains, 0.035 274 avoir oz
1 decagram (dag) 10 grams 0.352 74 avoir oz
1 hectogram (hg) 10 decagrams 3.527 4 avoir oz, 15,432.358 grains
1 kilogram (kg) 10 hectograms (1,000 grams) 2.204 622 6 litres, 2.204.622 6 lbs
1 tonne 1,000 kilograms 19.684 1 cwts, 0.984 207 ton, 1.102 311 short tons (2,000 lb ton)
These tables can also be found on page 18 of this manual.
°C °F °C °F °C °F °C °F °C °F °C °F
300 572 92 197.6 64 147.2 36 96.8 8 46.4 -20 -4.0
290 554 91 195.6 63 145.2 35 95.0 7 44.6 -21 -5.8
280 536 90 194.0 62 143.6 34 93.2 6 42.8 -22 -7.6
270 518 89 192.2 61 141.8 33 91.4 5 41.0 -23 -9.4
260 500 88 190.4 60 140.0 32 89.6 4 39.2 -24 -11.2
250 482 87 188.6 59 138.2 31 87.8 3 37.4 -25 -13.0
240 464 86 186.8 58 136.4 30 86.0 2 35.6 -26 -14.8
230 446 85 185.0 57 134.6 29 84.2 1 33.8 -27 -16.6
220 428 84 183.2 56 132.8 28 82.4 0 32.0 -28 -18.4
210 410 83 181.4 55 131.0 27 80.6 -1 30.2 -29 -20.2
200 392 82 179.6 54 129.2 26 78.8 -2 28.4 -30 -22.0
190 374 81 177.8 53 127.4 25 77.0 -3 26.6 -31 -23.8
180 356 80 176.0 52 125.6 24 75.2 -4 24.8 -32 -25.6
170 338 79 174.2 51 123.8 23 73.4 -5 23.0 -33 -27.4
160 320 78 172.4 50 122.0 22 71.6 -6 21.2 -34 -29.2
150 302 77 170.6 49 120.2 21 69.8 -7 19.4 -35 -31.0
140 284 76 168.8 48 118.4 20 68.0 -8 17.6 -36 -32.8
130 266 75 167.0 47 116.6 19 66.2 -9 15.8 -37 -34.6
120 248 74 165.2 46 114.8 18 64.4 -10 14.0 -38 -36.4
110 230 73 163.4 45 113.0 17 62.6 -11 12.2 -39 -38.2
100 212 72 161.6 44 111.2 16 60.8 -12 10.4 -40 -40.0
99 210.2 71 159.8 43 109.4 15 59.0 -13 8.6 -45 -49.0
98 208.4 70 158.0 42 107.6 14 57.2 -14 6.8 -50 -58.0
97 206.6 69 156.2 41 105.8 13 55.4 -15 5.0 -55 -67.0
96 204.8 68 154.4 40 104.0 12 53.6 -16 3.2
95 203.0 67 152.6 39 102.2 11 51.8 -17 1.4
94 201.2 66 150.8 38 100.4 10 50.0 -18 -0.4
93 199.4 65 149.0 37 98.6 9 48.2 -19 -2.2
Force
Pounds Force Newtons Newtons Pounds Force Tons Force Kilonewtons Kilonewtons Tons Force
(lbf) (N) (N) (lbf) (tonf) (kN) (kN) (tonf)
1 4.448 22 1 0.224 809 1 9.964 02 1 0.100 361
2 8.896 44 2 0.449 618 2 19.928 04 2 0.200 722
3 13.344 67 3 0.674 427 3 29.892 06 3 0.301 083
4 17.792 89 4 0.899 236 4 39.856 08 4 0.401 444
5 22.241 11 5 1.124 045 5 49.820 10 5 0.501 805
6 26.689 33 6 1.348 854 6 59.784 12 6 0.602 166
7 31.137 55 7 1.573 663 7 69.748 14 7 0.702 527
8 35.585 78 8 1.798 472 8 79.712 16 8 0.802 888
9 40.034 00 9 2.023 281 9 89.676 18 9 0.903 249
10 44.482 22 10 2.248 090 10 99.640 20 10 1.003 610
Note: 1 MPa and 1 N/mm2 are the same. These tables can also be found on page 19 of this manual.
Austenitic SS Classifications
Common Austenitic stainless steel grades and their applications
Welding Chart SS
Consumables for dissimilar stainless steel
304, 347 347 347 347 347 347 347 309MoL 309MoL Duplex 309MoL
304L 308L 309MoL 310 318 318 308L 308L 309L 309MoL 309L
308L 308L 308L 308L 309L
309L
309, 309MoL 309MoL 309MoL 309L 347 Match above 309MoL 309MoL Duplex 309MoL
309S 309L 309L 318 316L 309MoL 309MoL 309L 309L 309MoL 309L
310 316 318 347 309L
309L
310, 310 316L 316L 347 Match above 309MoL 309MoL Duplex 309L
310S 318 318 310 309L 309L 309L 309MoL 309MoL
310 310 310 316L 310 309L 310
317, 318 316L 347 Match above 309MoL 309MoL Duplex 309MoL
316 316L 318 316L 309MoL 309L 309L 309MoL 309L
316L 309L
Carbon Matching
and Low
Alloy
Steels
NOTES
(1) Consumables listed against a steel may not achieve matching corrosion resistance or mechanical properties.
(2) Welding procedure qualification should be carried out prior to welding in critical applications.
(3) Consult your BOC welding process specialist or visit BOC’s Inform website (subscription required) for more detailed information.
General
The following tables have been produced from the product of the
joint volume and the density of mild steel. The values are accurate
enough to cater for the variations in weld profiles that occur.
For most joints, at least two tables must be read in conjunction Flat Convex Concave
with each other and the resulting values added together:
Table A
The following example demonstrates the ease of applying the tables 16 1.2 1.4 1.4
to a complex weld: 19 1.8 2.1 1.9
Section 1 from Table C 22 2.4 2.8 2.7
Section 2 from Table D 25 3.1 3.7 3.6
Section 3 from Table E Note
Section 4 from Table B Values are taken for leg lengths 10% oversize, consistent with normal shop practice. This
results in about 20% excess weld metal being required.
Total weight is the sum of all these four values.
Underbead Penetration
11
22 22
33
44
Table B
These tables can also be used for other materials, but applying Underbead
Width
factors are proportional to the densities of these materials relative (mm) Weld Metal Weights (kg/m)
to that of mild steel:
2 .03
1 Stainless steels: multiply the weights of mild steel weld metal
by 1.017, which gives an increase of less than 2% 3 .12
2 Aluminium alloys: divide the weights of mild steel weld metal by 3 5 .28
6 .49
3 Copper alloys: multiply the weights of mild steel weld metal
by 1.14, which gives an increase in value of 14% 8 .79
9 1.12
11 1.49
12 1.93
Notes
1 The underbead width is taken as twice the radius of the penetration bead
2 This table can be used for the radiused section in multi-pass butt joints with U or J
preparations
Reinforcements V Section
A B
Table C Table D
Table E Table F
Note
This table should be read in conjunction with Table C (reinforcement) and the weights added
together.
Process
Material Manual MIG-MAG Manual MIG-MAG Mechanised
Thickness Manual Metal Arc Dip Transfer Spray Transfer MIG-MAG Submerged Arc
20 SWG
10 SWG
3 mm
2mm 2mm
4 mm
6 mm
10 mm
Single V preparation
12 mm
20 mm
25 mm
38 mm
Double V preparation
75 mm
30°
6mm
12mm r
30°
Effect of Overwelding
If a 6 mm filletweld is specified and it is over-welded by 1.5 mm, it
will add 56 percent volume to the joint. Overwelding this by 3 mm
will add 125 percent weld volume.
Not
Required
25
24 Excess 56%
16 23
15 22
9 14 21
8 13 20
4 7 12 19
3 6 11 18
1 2 5 10 17
Not
Not Required
Required 36
35
25 34
24 Excess 56% 33 Excess 125%
23 32
22 31
21 30
20 29
19 28
18 27
17 26
Not
Required
36
35
34
33 Excess 125%
32
31
30
29
28
27
26
9 mm Fillet
36 Triangles
36/16 = 225%