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Classification Tables

644
Technical Reference Data 656
Deposition Data 657

MMA Electrode Sizes 658

Deposition Rate (GMAW) 659

11
General Consumable Data 660

Tungsten Electrodes 661

SI Metric System 662

Austenitic SS Classifications 664

Martensitic Ferritic SS Classifications 665

Welding Chart SS 666

Weld Metal Calculator 667

Joint Preparations Summary Chart 670

Effect of Overwelding 671

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

41 430-550 (1) 350 (1) 22%


Electrode

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

644 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AS/NZS 1553 Part 1-1995 Covered Electrodes for Welding Low Carbon Steel
AS/NZS 1553.1 Electrode Classification Summary – Table 1

Electrode Welding Type of Current Type of Flux Covering Penetration


Classification Positions and Polarity and Slag Type

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)

EXX13 F,V, OH, H AC and DC + or – High Titania, Fluid Slag Medium

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

EXX20 F and H/V-FILLET AC and DC + or – High Iron Oxide Deep

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

F,V, OH, H, Basic Hydrogen controlled,


EXX48 AC and DC + Medium
V-DOWN Low Iron Powder

As specified by the
EXX99 As specified by the manufacturer As described by the manufacturer As specified
manufacturer

AU : IPRM 2007 : Section 11 : technical data 645


11 Classification Tables

AWS 5.1-1991 Specification for Carbon Steel


Electrodes for Shielded Metal Arc Welding

Minimum Tensile Minimum Yield Minimum Especially good


Weld Metal No. Strength (psi) Strength (ksi) Elongation 4 Vertical-Down

60 60,000 48 (1) 22% (2) 2 Flat and H/V Fillets

70 70,000 58 (1) 22% (2) 1 All Positional

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

Designates the flux type Designates the coating is moisture


and welding current/polarity resistant. Tested electrodes as
to be used. (e.g. hydrogen
Applicable to E7016, E7018 and received or conditioned shall exhibit
controlled low iron powder
8 AC and DC+, medium E7024 type electrodes only. R not > 0.3% (by Wt) of moisture
after exposure to an environment of
penetration).
Designates that the electrode 80% relative humidity for a period
1 meets the requirements for of not less than 9 hours.
See Table 2 for details.
improved impact toughness.
In the case of an E7024 ductility
‘elongation’ is also improved
from 17%.

Average minimum results


Grade CVN impact requirements Designates the diffusible hydrogen
H4 content of deposited weld metal
(DWM)
E7016-1 20ft Lb @ -50°F (27J @ -46°C)
E7018-1 20ft Lb @ -50° F(27J @ -46°C)
H4 ≤ 4 mls H2/100g of DWM
E7024-1 20ft Lb @ 0°F (27J @ -18°C)

H8 ≤ 8 mls H2/100g of DWM

H16 ≤ 16mls H2/100g of DWM

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.

646 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AWS 5.1-1991 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding

Electrode Classification – Table 2

AWS Welding Positionsa Type of Currentb Type of Covering AWS Classification

E6010 F,V, OH, H DC + High Cellulose Sodium E6010

E6011 F,V, OH, H AC or DC + High Cellulose Potassium E6011

E6012 F,V, OH, H AC or DC – High Titania Sodium E6012

E6013 F,V, OH, H AC, DC + or – High Titania Potassium E6013

E6019 F,V, OH, H AC, DC + or – Iron Oxide Titania Potassium E6019

E6020 F AC, DC + or – High Iron Oxide E6020

E6022c F, H AC or DC – High Iron Oxide E6022c

E6027 H/V-FILLET AC or DC – High Iron Oxide, Iron Powder E6027

E6027 F AC, DC + or – High Iron Oxide, Iron Powder E6027

E7014 F,V, OH, H AC, DC + or – Iron Powder,Titania E6014

E7015d F,V, OH, H DC + Low Hydrogen Sodium E6015d

E7016d F,V, OH, H AC, DC + Low Hydrogen Potassium E6016d

Low Hydrogen Potassium,


E7018d F,V, OH, H AC, DC + E6018d
Iron Powder

E7018M F,V, OH, H DC + Low Hydrogen Iron Powder E7018M

E7024d F, H/V-FILLET AC, DC + or – Iron Powder,Titania E7024d

E7027 H/V-FILLET AC, DC – High Iron Oxide, Iron Powder E7027

E7027 F AC, DC + or – High Iron Oxide, Iron Powder E7027

Low Hydrogen Potassium,


E7028d F, H/V-FILLET AC, DC + E7028d
Iron Powder

F, OH, H Low Hydrogen Potassium,


E7048d AC, DC + E7048d
V-DOWN Iron Powder

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.

AU : IPRM 2007 : Section 11 : technical data 647


11 Classification Tables

AWS A5.5-96 Specification for Low Alloy Steel


Electrodes for Shielded Metal Arc Welding

Weld Minimum Tensile Yield Weld 60Minimum Tensile Yield


Metal No: Strength (psi) Strength (ksi) Metal No: Strength (psi) Strength (ksi)
7010-P1 70,000 60 100 100,000 87
70 70,000 57 10018M 100,000 88-100 Especially good
4 Vertical-Down
70xx-B2L 75,000 57 110 100,000 97
80 80,000 67 11018M 100,000 98-110
2 Flat and H/V Fillets
80xx-C3 80,000 68-80 120 120,000 107
90 90,000 77 12018M 120,000 108-120
1 All Positional
9018M 90,000 78-90 12018M1 120,000 108-120
Designates
80 Designates the minimum required tensile strength in ksi. 1 Welding Positions

Designates the flux type and welding current/polarity to be


E 8 0 1 8 – C 1 8 used. (e.g. hydrogen controlled low iron powder AC and
DC+, medium penetration). See Table 3 for details.

Classification Suffixes by Major Chemical Analysis (%)


E Electrode
Type C Mn Ni Cr Mo V
Carbon-Molybdenum Steel Electrodes
A1 0.12 0.60-1.00 — — 0.40-0.65 —
Chromium-Molybdenum Steel Electrodes

B1 0.05-0.12 0.90 — 0.4-0.65 0.40-0.65 —


B2 0.05-0.12 0.90 — 1.00-1.50 0.40-0.65 —
B2L 0.05 0.90 — 1.00-1.50 0.40-0.65 —
B3 0.05-0.12 0.90 — 2.00-2.50 0.90-1.20 —
B3L 0.05 0.90 — 2.00-2.50 0.90-1.20 —
B4L 0.05 0.90 — 1.75-2.25 0.40-0.65 —
B5 0.07-0.15 0.40-0.70 — 0.40-0.60 1.00-1.25 0.05
B6 0.05-0.10 1.00 — 4.00-6.00 0.45-0.65 —
B6L 0.05 1.00 — 4.00-6.00 0.45-0.65 —
B7 0.05-0.10 1.00 — 6.00-8.00 0.45-0.65 —
B7L 0.05 1.00 — 6.00-8.00 0.45-0.65 —
B8 0.05-0.10 1.00 — 8.00-10.50 0.85-1.20 —
B8L 0.05 1.00 — 8.00-10.50 0.85-1.20 0.05
B9 0.08-0.13 1.25 — 8.00-10.50 0.85-1.20 0.15-0.30

Nickel Steel Electrodes


(1) Yield on E7010-P1 and E7018- C1 0.12 1.25 2.00-2.75 — — —
W1 is required to be 60ksi
C1L 0.05 1.25 2.00-2.75 — — —
(451MPa).
C2 0.12 1.25 3.00-3.75 — — —
(2) * G classifications require the C2L 0.05 1.25 3.00-3.75 — — —
weld deposit to exhibit only a
minimum of one (1) element
C3 0.12 0.40-1.25 0.80-1.10 0.15 0.35 0.05
listed. C3L 0.08 0.40-1.40 0.80-1.10 0.15 0.35 0.05
C4 0.10 1.25 1.10-2.00 — — —
(3) # M classification chemical
limits can vary widely in C5L 0.05 0.40-1.00 6.00-7.25 — — —
the case of Mn, Ni, Cr and
Nickel-Molybdenum Steel Electrodes
Mo. Refer to page 5 of AWS
A.5-96 for details. EX018-M NM1 0.10 0.80-1.25 0.80-1.10 0.10 0.40-0.65 0.02
electrodes are intended Manganese-Molybdenum Steel Electrodes
to meet most military
requirements and have D1 0.12 1.00-1.75 0.90 — 0.25-0.45 —
greater toughness, lower D2 0.15 1.65-2.00 0.90 — 0.25-0.45 —
coating moisture content, D3 0.12 1.00-1.80 0.90 — 0.40-0.65 —
both as received and after
exposure, and also conform Pipeline Electrodes
to mandatory diffusable
hydrogen limits for deposited P1 0.20 1.20 1.00 0.30 0.50 0.10
weld metal. G=General and M = Military
G* — 1.0 Min 0.50 Min 0.30 min 0.20 min 0.10 min
M# 0.10 0.60-2.25 1.25-2.50 0.15-1.50 0.25-0.55 0.05
M1 0.10 0.80-1.60 3.00-3.80 0.65 0.20-0.30 0.05

648 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AWS A5.5-96 Specification for Low Alloy Steel Electrodes for Shielded metal arc welding

AWS A5.5 Electrode Classification Summary – Table 3


Electrode Type of Current Type of Flux Covering
Welding Positions Penetration
Classification And Polarity And Slag Type or ‘Use’
E70 Series, 70,000 psi (480 MPa)

E7010-X F,V, OH, H DC + High Cellulose Sodium Deep


E7011-X F,V, OH, H AC and DC + High Cellulose Potassium Deep
E7015-X F,V, OH, H DC + Low Hydrogen Sodium Medium
E7016-X F,V, OH, H AC and DC + Low Hydrogen Potassium Medium
E7018-X F,V, OH, H AC and DC + Iron Powder, Low Hydrogen Medium
E7020-X F and H/V-FILLET AC and DC + or - High Iron Oxide Medium to Deep
E7027-X F and H/V-FILLET AC and DC + or - High Iron Oxide, Iron Powder Medium

E80 Series, 80,000 psi (550 MPa)

E8010-X F,V, OH, H D. C. + High Cellulose Sodium Deep


E8011-G F,V, OH, H AC and DC + High Cellulose Potassium Deep
E8013-G F,V, OH, H AC and DC + or – High Titania Potassium Medium
E8015-X F,V, OH, H DC + Low Hydrogen Sodium Medium
E8016-X F,V, OH, H AC and DC + Low Hydrogen Potassium Medium
E8018-X F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium

E90 Series, 90,000 psi (620 MPa)

E9010-G F,V, OH, H DC + High Cellulose Sodium Deep


E9011-G F,V, OH, H AC and DC + High Cellulose Potassium Deep
E9013-G F,V, OH, H AC and DC + or – High Titania Potassium Medium
E9015-G F,V, OH, H DC + Low Hydrogen Sodium Medium
E9016-X F,V, OH, H AC and DC + Low Hydrogen, Potassium Medium
E9018-X F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium
E9018M F,V, OH, H DC + Low Hydrogen, Iron Powder Medium

E100 Series, 100,000 psi (690 MPa)

E10010-G F,V, OH, H DC + High Cellulose Sodium Deep


E10011-G F,V, OH, H AC and DC + High Cellulose Potassium Deep
E10013-G F,V, OH, H AC and DC + or – High Titania Potassium Medium
E10015-X F,V, OH, H DC + Low Hydrogen Sodium Medium
E10016-X F,V, OH, H AC and DC + Low Hydrogen, Potassium Medium
E10018-X F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium
E10018M F,V, OH, H DC + Low Hydrogen, Iron Powder Medium

E110 Series, 100,000 psi (760 MPa) and E120 Series, 120,000 psi (830 MPa)

E11010-G F,V, OH, H DC + High Cellulose Sodium Deep


E11011-G F,V, OH, H AC and DC + High Cellulose Potassium Deep
E11013-G F,V, OH, H AC and DC + or – High Titania Potassium Medium
E11015-G F,V, OH, H DC + Low Hydrogen Sodium Medium
E11016-G F,V, OH, H AC and DC + Low Hydrogen, Potassium Medium
E11018-G F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium
E11018M F,V, OH, H DC + Low Hydrogen, Iron Powder Medium
E12010-G F,V, OH, H DC+ High Cellulose Sodium Deep
E12011-G F,V, OH, H AC and DC + High Cellulose Potassium Deep
E12013-G F,V, OH, H AC and DC + or – High Titania Potassium Medium
E12015-G F,V, OH, H DC + Low Hydrogen Sodium Medium
E12016-G F,V, OH, H AC and DC + Low Hydrogen Potassium Medium
E12018-G F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium
E12016M F,V, OH, H AC and DC + Low Hydrogen Potassium Medium
E12018M1 F,V, OH, H AC and DC + Low Hydrogen, Iron Powder Medium

AU : IPRM 2007 : Section 11 : technical data 649


11 Classification Tables

AWS A5.18-2001 Specification for Carbon Steel Electrodes


and Rods for Gas Shielded Arc Welding

As Welded Mechanical Properties


Tensile Strength Yield Strength
AWS Class Shielding Gas % Elong. Charpy-V-Notch (CVN) Impact Requirements
Psi MPa Psi 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

E70-GS (X) * 70,000 480 Not Specified Not Required


*Shielding gas shall be agreed to between purchaser and supplier
† 75-80% Ar/balance CO2 or CO2

Optional – designates the


H4 diffusable hydrogen content of
deposited weld metal (DWM)

H4 < 4 mls H2 / 100g of DWM


H8 < 8 mls H2 / 100g of DWM
H 16 < 16 mls H2 / 100g of DWM

E R 7 0 S – 6 H4
Designates ‘Mixed Gas’ and is
M classified for use with Argon +
20–25% CO2 gas

Designates ‘Carbon Dioxide’ and is


E 7 0 C – 6 M H4 C classified for use with 100% CO2 gas
or the wire is self shielded

M Designates ‘Shielding Gas’

E = Electrode, R = Rod, S = Solid Wire, C = Composite Metal Cored Wire,


followed by a hyphen then a number or letter which defines the chemical composition of the wire.

Wire Class Carbon (C) Manganese (Mn) Silicon (Si) Other Elements Allowable % Range

ER70S-2 0.07 0.90-1.40 0.40-0.70 0.05-0.15Ti/0.02-0.127r/0.05-0.15Al


ER70S-3 0.06-0.15 0.90-1.40 0.45-0.75 0.05Cu*
ER70S-4 0.06-0.15 1.00-1.50 0.60-0.85 0.05Cu*
ER70S-6 0.06-0.15 1.40-1.85 0.80-1.15 0.50Cu*
ER70S-7 0.07-0.15 1.50-2.00 0.50-0.80 0.50Cu*
ER70S-G G = General, composition is not specified and is agreed between the supplier and the customer.
ER70C-3X 0.12* 1.75* 0.90* 0.50Cu*
ER70C-6X 0.12* 1.75* 0.90* 0.50Cu*
ER70C-G(X) G = General, composition is not specified and is agreed between the supplier and the customer.
ER70C-GS(X) G = General, Single Pass Only, composition is agreed between the supplier and the customer.
* Single values are maximum. X represents shielding gas indicators (e.g. ‘C’ indicates CO2). (X) is optional for these classifications.

650 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AS 2203.1-1990 Cored Electrodes for Arc Welding


Part 1: Ferritic Steel Electrodes

W40 Weld Metal

Designates approximately 1/10th of the minimum tensile strength in MPa.

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%

Group 3 Properties of the weld metal

Heat Treatment
Condition

A As welded condition
P Post-welded heat treatment

Designates the diffusable


H10 hydrogen‑content of deposited weld
E T P – G C p – W5 0 4 A . C M I H 10 metal (DWM).

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

See Table 4 for details


Group Shielding requirements
2 and current type
G Gas shielding
C Carbon dioxide CO2
M Mixed gas
N No external shielding gas
4 Designates the impact energy grade number:
DC constant potential
p electrode positive Minimum average
Impact energy Minimum average Impact energy CVN impact
grade no: CVN impact values grade no:
DC constant potential values
n electrode negative 0 Not required. 9A.K1 27J @ -40°C
a AC current 1 47J @ + 20°C 508A.K2 27J @ -20°C
2 47J @ 0°C 509A.K2 27J @ -30°C
3 47J @ - 20°C 559A.K2 27J @ -30°C
4 47J @ -40°C 628A.K2 27J @ -20°C
5 47J @ -60°C 629A.K2 27J @ -50°C
9A.Ni1 27J @ -30°C 698A.K3 27J @ -20°C
9P.Ni1 27J @ -50°C 699A.K3 27J @ -50°C
9P.Ni2 27J @ -60°C 768A.K3 27J @ -20°C
9A.Ni2 27J @ -40°C 769A.K3 27J @ -50°C
9P.Ni3 27J @ -73°C 769A.K4 27J @ -50°C
9A.D1 27J @ -40°C 9A.K6 27J @ -30°C
629P.D2 27J @ -50°C 9A.K7 27J @ -50°C
699P.D2 27J @ -40°C 9A.W 27J @ -30°C
Agreed between
9A.D3 27J @ -30°C X.G the purchaser
and supplier

AU : IPRM 2007 : Section 11 : technical data 651


11 Classification Tables

AS 2203.1-1990 Cored Electrodes for Arc Welding


Part 1: Ferritic Steel Electrodes
AS 2203.1 Weld Metal Chemistry Wt% Summary – Table 4

Weld Carbon Manganese Silicon Nickel Chromium Molybdenum Other


Metal No. (C) (Mn) (Si) (Ni) (Cr) (Mo) Elements

Carbon Steel Cored Wires

CM1 0.20 1.75 0.90 0.50 0.20 0.30 0.08V/1.8Al


CM2 > 0.20 1.75 0.90 0.50 0.20 0.30 0.08V/1.8Al

Carbon-Molybdenum Steel Cored Wires

A1 0.12 1.25 0.80 — — 0.40–0.65 —

Chromium-Molybdenum Steel Cored Wires

B1 0.12 1.25 0.80 — 0.40–0.65 0.40–0.65 —


B2L 0.05 1.25 0.80 — 1.00–1.50 0.40–0.65 —
B2 0.12 1.25 0.80 — 1.00–1.50 0.40–0.65 —
B2C 0.10–0.15 1.25 0.80 — 1.00–1.50 0.40–0.65 —
B3L 0.05 1.25 0.80 — 2.00–2.50 0.90–1.20 —
B3 0.12 1.25 0.80 — 2.00–2.50 0.90–1.20 —
B3C 0.10–0.15 1.25 0.80 — 2.00–2.50 0.90–1.20 —
5Cr 0.10 1.50 1.00 0.40 4.00–6.00 0.45–0.65 0.50Cu
7Cr 0.10 1.50 1.00 0.40 6.00–8.00 0.45–0.65 0.50Cu
9Cr 0.10 1.50 1.00 0.40 8.00–10.50 0.85–1.20 0.50Cu

Nickel Steel Cored Wires

Ni1 0.12 1.50 0.08 0.80–1.10 0.15 0.35 0.05V/1.8Al


Ni2 0.12 1.50 0.08 1.75–2.75 — — 0.05V/1.8A1
Ni3 0.12 1.50 0.08 2.75–3.75 — — —

Manganese-Molybdenum Steel Cored Wires

9X.D1 0.12 1.25–2.00 0.80 — — 0.25–0.55 —


9X.D2 0.15 1.65–2.25 0.80 — — 0.25–0.55 —
9X.D3 0.12 1.00–1.75 0.80 — — 0.40–0.65 —

Other Low Alloy Steel Cored Wires

9X.K1 0.15 0.80–1.40 0.80 0.80–1.10 0.15 0.20–0.65 0.05V


9X.K2 0.15 0.50–1.75 0.80 1.00–2.00 0.15 0.35 0.05V/1.8Al
9X.K3 0.15 0.75–2.25 0.80 1.25–2.60 0.15 0.25–0.65 0.05V
9X.K4 0.15 1.20–2.25 0.80 1.75–2.60 0.20–0.60 0.30–0.65 0.05V
9X.K5 0.10–0.25 0.60–1.60 0.80 0.75–2.00 0.20–0.70 0.15–0.55 0.05V
9X.K6 0.15 0.50–1.50 0.80 0.40–1.10 0.15 0.15 0.05V/1.8Al
9X.K7 0.15 1.00–1.75 0.80 2.00–2.75 — — —
G — 1.00 min. 0.80 min. 0.50 min. 0.30 min. 0.20 min. 0.10 min./1.8Al
9X.W 0.12 0.50–1.30 0.35–0.80 0.40–0.80 0.45–0.70 — 0.30–0.75Cu

Single values shown are maximum.

652 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AWS A5.20-95 Specification for Carbon Steel


Electrodes for Flux Cored Arc Welding

Weld Minimum Tensile Strength 0 Flat and Horizontal T Tubular


Metal No. psi (MPa) 1 All Positional
6 60,000 (415) Designates the
Designates the T
1 Electrode is Flux‑cored.
7 70,000 (480) Welding Positions

Designates the minimum tensile strength in


7 psi x 10,000.

E Electrode
Optional
Designators

E 7 1 T – 1 M J H4

Position of welding, shielding, The second letter and sixth number


1 designates the diffusable hydrogen
to polarity, H4 content of deposited weld metal
and application
14 requirements. (DMW)

H4 ≤ 4 mls H2 / 100g of DWM


‘General’ classification and
means that the electrode H8 ≤ 8 mls H2 / 100g of DWM
G shielding, polarity and impact
properties are not specified.
H16 ≤ 16 mls H2 / 100g of DWM

‘Single’ pass welding only.


S
See Table 5 for details.

The fourth letter designates that


the electrode meets the following
requirements of improved
J impact‑toughness,
20ft Lb @ -40°F‑(27J @ -40°C).

See Table 6 for details.

Designates ’Mixed Gas’ and


is classified for use with
Argon + 20–25% CO2.
M If no ‘M’ is shown, then
the electrode is used with
either CO2 or the electrode
is self shielded.

AU : IPRM 2007 : Section 11 : technical data 653


11 Classification Tables

AWS A5.20-95 Specification for Carbon Steel


Electrodes for Flux Cored Arc Welding
Table 5

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.

654 AU : IPRM 2007 : Section 11 : technical data


Classification Tables 11

AWS A5.20-95 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding

Shielding Gas Types


E7XT-1 E7XT-1M
These electrodes are designed primarily for use with CO2 shielding These electrodes are designed primarily for use with Argon +
gas. Argon based gases may be used to improve out-of-position 20–25% CO2 shielding gases.
characteristics when recommended by the manufacturer. Warning: Higher levels of CO2 above those recommended, in
Warning: By using Argon-based gas mixtures with these electrode Ar/CO2 gases or the use of 100% CO2 gas with these types of
types, the following problems may occur: electrodes may result in the following:
1) Deoxidiser levels in weld deposits may increase; 1) Deterioration of arc and out-of-position characteristics;
2) Weld deposit hardness levels may increase, 2) Resultant weld deposits may show decreased levels of manganese
3) Weld deposit manganese and silicon levels will increase, which and silicon, which will reduce yield and tensile strength and may
will raise yield and tensile strength, and may degrade impact degrade impact properties.
properties.

As Welded Mechanical Properties – Table 6

Tensile Strength Yield Strength


%
AWS Class ksi MPa ksi MPa Elong. Charpy-V-Notch (CVN) Impact Requirements
T-1/1m 70 480 58 400 22 20ft lb @ 0°F (27J @ -18°C)
T-2/2m 70 480 n.s. n.s. n.s. not specified
T-3* 70 480 n.s. n.s. n.s. not specified
T-4* 70 480 58 400 22 not specified
T-5/5m 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)
T-6* 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)
T-7* 70 480 58 400 22 not specified
T-8* 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)
T-9/9m 70 480 58 400 22 20ft lb @ 0°F (27J @ -29°C)
T-10* 70 480 n.s. n.s. n.s. not specified
T-11* 70 480 58 400 20 not specified
T-12/12m 70-90 480-620 58 400 22 20ft lb @ 0°F (27J @ -29°C)
E6XT-13* 60 415 n.s. n.s. n.s. not specified
E7XT-13* 70 480 n.s. n.s. n.s. not specified
T-14* 70 480 n.s. n.s. n.s. not specified
E6XT-G 60 415 48 330 22 not specified
E7XT-G 70 480 58 400 22 not specified
E6XT-GS 60 415 n.s. n.s. n.s. not specified
E7XT-GS 70 480 n.s. n.s. n.s. not specified
The above designations may be classified with the ‘J’ indicator, provided the lower CVN Impact requirements of 20ft Lb @ -40°F (27J @ -40°C), are met for
T-1/1M, T-5/5M, T-6, T-8, T-9/M and T-12/12M types.
* Self shielded wire types.

AU : IPRM 2007 : Section 11 : technical data 655


11 Technical Data

Technical
Reference Data

656 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

Deposition Data
Deposition Rates, Electrode Efficiency

Deposition Rates Weld Metal Recovery


When welding with a consumable (electrode, wire or rod), it will This should not be confused with an electrode efficiency.
have a deposition rate at which weld metal is deposited (melted) Weld metal recovery measures the amount of weld metal that will
onto a metal surface. The deposition rate is expressed in kilograms be deposited on the work piece.
per hour (kg/h).
For example, if you purchase a 5 kg packet of MMAW E6012
Deposition rate is based on a 100% duty cycle (continuous operation). electrodes, which will produce a weld metal recovery of around
This is not a true reflection on an actual welding workshop, as 60 percent, you will end up throwing away 2 kg as slag and stubs.
it does not allow for stops and starts such as electrode change In a GMAW solid wire at 93 percent you will lose 0.35 kg.
overs, chipping slag, cleaning spatter, machine adjustments or other
occurrences, but is used to establish the consumable ability to The following are an indication only, as an operator and welding
deposit weld metal. envelope will influence these figures.
Therefore it must be noted that, when calculating actual deposition Various Process Efficiencies
rate for costing of a welded structure, you must take into consideration the
duty cycle of equipment and the operator factor. Welding processes vary in both the deposition rates and deposition
efficiencies. Below are tables that give an indication only of the
For example, it is accepted as a general rule that an operator using various processes. The GTAW and Oxy-Acetylene assume that the
MMAW will only weld at around 30 percent operator factor (on a stubs are joined together to have no waste.
good day) and a GMAW will be around 60 percent.
Generally, when welding current is increased, so is the deposition Approximate process deposited weld metal recovery
rate. When electrical stick out is increased in the case of GMAW (Not electrode efficiency)
and FCAW, the deposition rate will also increase.
Welding Process Average Efficiency
Electrical stick out is the distance from the end of the contact tip to
the work piece (ETWD). GTAW 100%

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%

Deposition Rate = GMAW – Spray Arc 95%


GMAW – Short (Dip) Arc 93%
Weight (Test plate before welding - test plate after welding)
FCAW – E70C-6M types 92%
Measured period of time (normally 60 seconds)
FCAW – E70T-5 types 88%
(e.g. Plate before welding: 4 kg and 4.80 kg after welding = 80 grams,
welded in 60 seconds, 80 grams x 60/1000 = 4.8kg/h) FCAW – E71T-1 types 85%

Deposition Rate Example = FCAW – Tubular Hard-facing wires 80–85%

4 kg - 4.8 kg 80 g FCAW – E70T-4 types 82%


= = 4.8 kg/h
60 sec 60 sec x 60/1000 MMAW – Hard-facing types 62–72%
MMAW – E7014 types 63%
Electrode Efficiency (Deposition Efficiency)
MMAW – E7016 types 61%
Electrode efficiency, to AS/NZS 1553.1: 1995, is the difference between
the weight of the weld metal deposited and the weight of the filler metal MMAW – E7024 types 60%
consumed (not including flux and stub ends) in making the weld.The MMAW – E6012 types 60%
efficiency of an electrode is calculated by using the following formula by MMAW – E7018 types 58%
running 5 electrodes in a 1G position:

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.

AU : IPRM 2007 : Section 11 : technical data 657


11 Technical Reference Data

MMA Electrode Sizes


AS/NZ 1553.1.1995

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.

British and United States Electrode Size Comparison Table

Metric (mm) International inches Gauge No. Approximate Fraction inches


2 0.0787 14 5/64
2.5 0.0984 12 3/32
3.15 0.1240 10 1/8
3.25* 0.1280 — —
4 0.1576 8 5/32
5 0.1969 6 3/16
6* 0.2362 4 7/32
6.3 0.2481 — 1/4
8 0.3150 0 5/16
10 0.3937 — 3/8
*The British Standard Institution in the Specifications for Covered Electrodes (BS 639:1969) proposes that, with the exception of the 3.15 and 6 mm sizes, the metric sizes in the first column
become standards.
The 3.25 mm diameter is, at present widely, used and will be retained until such a time as it can be dropped through its lesser usage.
The 6 mm diameter is not a preferred size, but it is included because the existing capacities of some welding equipment may make the use of 6.3 mm impractical.

658 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

Deposition Rate (GMAW)


Solid Mild Steel Wire

Wire Size Wire Feed Speed Deposition Rate


(mm) Welding Current (A) ARC Voltage (V) (m/min) (kg/h)
0.8 60* 16* 3.3 0.7
80* 17* 4.4 1.0
100* 18.5* 5.9 1.3
120* 20* 7.0 1.6
140* 20* 9.9 2.2
160* 22* 12.4 2.8
180 30 14.3 3.2
0.9 70* 15* 3.7 1.1
100* 19* 6.0 1.7
120* 19* 6.9 2.0
150* 20* 8.7 2.5
180* 21* 11.5 3.3
180 29 12.0 3.4
200 31 14.0 4.0
1.2 120* 18* 2.7 1.4
150* 18* 3.5 1.8
170* 19* 3.9 2.0
220 30 6.2 3.2
250 32 9.1 4.7
310 34 11.3 5.8
340 36 12.9 6.6
1.6 140* 19* 1.7 1.6
200* 19* 2.4 2.2
250* 21* 3.1 2.8
300 30 4.9 4.5
350 34 6.2 5.7
400 34 7.5 6.8
* Short arc transfer conditions
Note:
Deposition rate data is determined using:
• DCEP (reverse polarity) with a conventional constant potential power source
• Ar 16–18% CO2 shielding gas
• An electrode stick out length of 8–10 mm for short arc transfer conditions and 15 mm for spray transfer conditions
• A process efficiency of 96% for both short arc transfer and spray arc transfer conditions.

AU : IPRM 2007 : Section 11 : technical data 659


11 Technical Reference Data

General Consumable Data


Gas/TIG Rods per kg (approx) GMAW Consumable Lengths (m/kg) (approx)

Size (mm) Dia. (mm) Metre


Length
Description 1.6 2.4 3.2 5.0 6.0 (mm) Mild Steel MIG Wire
Aluminium 196 94 53 — — 915 0.6 525
ProFill Mang 83 38 21 8 7 750 0.8 277
Bronze
0.9 204
ProFill Nickel — — 20 8 — 750
Bronze 1.0 164

Cast Iron — — — 9 — 700 1.2 123

Mild Steel 70 29 18 5 — 915 1.6 64

Stainless Steel 69 31 16 — — 915 Flux Cored Wires


1.2 140
Low Temperature Alloys Rods per kg (approx) 1.6 70
2.0 53
Size (mm)
Length 2.4 38
Description 1.5 2.5 3.0 (mm)
Aluminium Welding Wire (5356)
ProSilver 2 83 31 22 750
0.8 739
ProSilver 5 84 30 18 750
0.9 595
ProSilver 15 80 29 20 750
1.2 356
ProSilver 34 69 31 18 750
1.6 185
ProSilver 40 69 32 18 750
2.4 84
ProSilver 42 67 32 18 750
3.2 47
ProSilver 50 66 24 18 750
Stainless Steel MIG Wire
ProSilver 55 66 25 18 750
ProSilver 56 64 23 17 750 0.6 450

ProSilver 503 65 24 18 750 0.8 275

Silbralloy 2 83 30 21 750 0.9 200

Copperflo 2 84 31 22 750 1.2 115


1.6 63
BOC ProFill Gas Welding Rods – Applications

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

660 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

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

Direct Current (Amps) Alternating Current (A)


Electrode Diameter Use Gas Straight Reverse Unbalanced Balanced
(mm) Cup (mm) Polarity (DCEN) Polarity (DCEP) Wave Wave
0.25 6.4 <15 — <15 <15
0.50 6.4 5–20 — 5–15 10–20
1.00 10 15–80 — 10–60 20–30
1.6 10 70–150 10–20 50–100 30–80
2.4 12 150–250 15–30 100–160 60–10
3.2 12 250–400 25–40 150–210 100–180
4.0 12 400–500 40–55 200–275 160–240
4.8 16 500–750 55–80 250–350 190–300
6.4 20 750–1100 80–125 325–450 325–450
Note: All values are based on the use of argon as the shielding gas.

AU : IPRM 2007 : Section 11 : technical data 661


11 Technical Reference Data

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

1 decalitre (dal) 10 litres 2.199 69 gallons


1 hectolitre (hl) 10 decalitres (100 litres) 21.996 9 gallons
1 kilolitre (kl) 1,000 litres (1 m3) 219.969 gallons

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.

662 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

SI Metric System (cont.)


Celsius to Fahrenheit

°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.

AU : IPRM 2007 : Section 11 : technical data 663


11 Technical Reference Data

Austenitic SS Classifications
Common Austenitic stainless steel grades and their applications

Typical Analysis (%)


UNS
AISI No. No. Forms Available C Cr Ni Mo Ti Other Typical Applications
301 S30100 Steel & Coil 0.08 17.0 7.00 — — — General purpose steel with good corrosion resistance for most
applications. Employed where the high work-hardening exponent
is desirable. Can be supplied cold worked to give high strength
and ductility. Used for structural applications such as rail carriages
and wagons.
302 S30200 Sheet & Coil, Bars 0.08 18.0 9.0 — — — General purpose steel with good corrosion resistance for most
applications. Used for architecture, food processing, domestic sinks
and tubs and deep drawing applications.
303 S30300 Bars 0.12 18.0 9.0 — — 0.25 S Free machining steel used where extensive machining is required.
Corrosion‑resistance and weldability inferior to 302.
304 S30400 Sheet & Coil, Plate 0.06 18.5 9.0 — — — Similar corrosion resistance to 302. Used where higher resistance
& Bars to weld decay is needed in brewing, etc.
304L S30403 Sheet & Coil, Plate 0.03 18.5 9.5 — — — Chemical plant and food processing equipment, where freedom
from sensitisation is required in plate.
305 S30500 Sheet & Coil, Wire 0.08 18.0 12.0 — — — Spun sheet parts, cold headed screws.
309 S30900 Sheet & Coil, Plate, 0.15 23.0 13.5 — — — High temperature, oxidation resistant. Furnace parts.
Bar
309S S30903 Sheet, Plate, Bar, 0.08 23.0 13.5 — — — A low carbon version of 309. Used where superior corrosion
Tube & Pipe resistance to 316 is required.
310 S31000 Sheet & Coil, Plate 0.12 25.0 20.0 Furnace parts and equipment. Resistant to temperature 900–
& Bars 1100°C.
— S30815 Sheet, Plate, Bar, 0.10 21.0 11.0 — — 0.15 N Used for furnace parts, radiant shield, fluidised beds. Resistant to
Tube & Pipe 0.4 Ce temperatures up to 1150°C. Possesses high strength and resistance
to sigma‑phase formation.
310S S31003 Sheet, Plate, Bar, 0.08 25.0 20.0 — — — A low carbon version of 310 used to restrict nitric acid corrosion.
Tube & Pipe
316 S31600 Sheet & Coil, Plate, 0.06 17.0 12.0 2.25 — — Used where higher corrosion resistance is required (e.g. marine
Seamless welded equipment). Can be welded up to 3mm without subsequent heat
tube pipe treatment.
316L S31603 Sheet & Coil Plate, 0.03 17.0 12.0 2.25 — — A low carbon modification of 316 where heavy section weldments
Seamless welded are required without the risk of intergranular corrosion.
tube pipe
316Ti S31608 Plate, Pipe, Tube 0.08 17.0 12.0 2.25 0.5 — A titanium stabilised version of 316, used where good resistance to
intergranular corrosion and high temperature strength is required.
317 S31700 Sheet & Coil Plate 0.07 19.0 13.0 3.25 — — For chemical plant – has a greater corrosion resistance than 316
in certain applications, notably in contact with brines and halogen
salts. Also available in the low carbon ‘L’ grade.
904L N08904 Sheet, Plate, Bar, 0.02 20.0 25.0 4.5 — 1.5 Cu High resistance to: general corrosion (e.g. in sulphuric and acetic
Pipe, Tube, acids); crevice corrosion; stress corrosion cracking; pitting in
chloride bearing solutions. Good weldability.
— N08028 Sheet, Plate, Tube, 0.02 27.0 31.0 3.5 — 1 Cu Used against all types of corrosion under severe conditions.
Pipe, Bar Used in sour oil and gas production pipe, heat exchangers, heat
exchangers for acid concentration, piping evaporation.
— 31254 Sheet, Plate, Tube, 0.02 20.0 18.0 6.0 — 0.2 N Used where high resistance to chloride pitting and crevice
Pipe, Bar corrosion is required (e.g. seawater heat exchangers, bleach vats
and washers in the pulp and paper industry).
321 S32100 Sheet & Coil, Plate 0.06 18.0 10.0 — 0.5 — Heavy weldments in chemical and other industries. Suitable
& Bar for heat resisting applications to 800°C. Not suitable for
bright polishing.
201 S20100 Sheet & Coil, Plate 0.12 17.0 4.5 — — 6.5 Mn Lower cost, reduced nickel version of Type 301.
0.15 N
202 S20200 Sheet & Coil, Plate 0.08 18.0 5.0 — — 9.0 Mn Lower cost, reduced nickel version of Type 302.
0.15 N

664 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

Martensitic Ferritic SS Classifications


Common Martensitic stainless steel grades and their applications

Typical Analysis (%)


AISI UNS Forms
No. No. Available C Cr Ni Mo Other Typical Applications
410 S41000 Bars 0.10 12.5 — — — General purpose grade for use in mildly corrosive environments.
403 S40300 Bars 0.15 13.0 — — — Capable of attaining higher hardness than 410.
416 S41600 Bars 0.10 12.5 — — 0.20 S Free machining variation of 410.
420 S42000 Bars 0.25 12.5 — — — General engineering uses, such as pump and valve shafts.
420C — Sheet & Coil, 0.30 12.5 — — — Developed for high hardness after heat treatment. Used for cutting tools,
Plate & Bars surgical knives etc.
431 S43100 Bars 0.18 16.0 2.0 — — Hardenable steel with corrosion resistance approaching 302. Used for
pump shafts etc. Should be double tempered after hardening.
440C S44004 Bars 1.10 17.0 — 0.40 — Capable of being hardened to 60Rc. Highest harness and abrasion
resistance of all the stainless steels. Corrosion resistance similar to 410.

Common Ferritic stainless steel grades and their applications

Typical Analysis (%)


AISI UNS Forms
No. No. Available C Cr Ni Mo Other Typical Applications
405 S40500 Sheet & Coil 0.06 12.0 — — 0.2A1 Welded fabrications for mildly corrosive environments and in heat
resistant applications.
409 S40900 Sheet & Coil 0.06 11.5 — 0.5 — Heat resistant steel, easily formed and welded. Mainly used for
automotive exhausts or welded applications where superior performance
to galvanised steel is required.
446 S44600 Tube, Pipe 0.08 26.0 — — — Used for severe heat resistant applications up to 1200°C. In
recuperators, highly resistant to sulphidation and oil ash corrosion.
410S S41008 Sheet & Coil, 0.06 12.5 — — — Used for heat resistant applications up to 650°C in power plant and oil
Plate & Bar refineries, where high strength at elevated temperatures is not required.
430 S43000 Sheet & Coil, 0.08 17.0 — — — Interior architecture component, stove and automotive trim. Welds tend
Plate & Bar to be brittle.
444 S44400 Sheet & Coil 0.02 18.5 2.0 0.4 — Heat exchanger and hot water tanks, and in chloride containing water.
Not prone to cloride stress corrosions. Superior resistance to pitting,
crevice and intergranular corrosion. Possesses excellent deep drawing
properties.
182 S18200 Bar 0.07 18.25 2.0 – 0.20S Free machining bar variant of 444. Superior machinability to 303.

Common Ferritic-Austenitic stainless steel and their applications

Typical Analysis (%)


AISI UNS Forms
No. No. Available C Cr Ni Mo Other Typical Applications
329 S32900 Bars 0.08 26.0 4.5 1.5 — Shafting for pumps, boats. Superior corrosion resistance and strength to
316L, poor weldability.
— S31500 Sheet, Plate 0.03 18.0 4.9 2.7 — Superior corrosion resistance to 316L, high resistance to stress
Bar, Pipe, Tube, corrosion. General fabrication in chemical industry equipment. Suitable
Fitting for welding in heavy sections without risk of intergranular corrosion.
— S31803 Sheet, Plate 0.03 22.0 5.5 3.0 0.14N Superior corrosion resistance to 317L. Excellent stress corrosion
Bar, Pipe, Tube, resistance. Typically used in heat exchangers, scrubbers, calorifiers, fans,
Fitting in chemical process tanks, oil and gas and refining industries where
outstanding corrosion resistance is required. Suitable for welding heavy
sections without risk of intergranular corrosion.
— S32304 Sheet, Plate Bar, 0.03 23.0 4.0 — 0.1N Similar corrosion resistance to 316L. High resistance to stress corrosion
Pipe, Tube and erosion, high yield strength. Used where high corrosion resistance
is required (e.g. marine, mining, chemical, food, metallurgy and power
industries).

AU : IPRM 2007 : Section 11 : technical data 665


11 Technical Reference Data

Welding Chart SS
Consumables for dissimilar stainless steel

S30815, 409, Duplex


Base Metal 317L, (253MA), 430, S31500 Carbon
ASTM, AISI, 201, 304, 309, 310, 317, 316L, 321, 904L, 446, 410, S31803 and Low
UNS 202 304L 309S 310S 316 316Ti 347 (N08904) 5CR12 420 S32304 Alloy Steels
201, 347 347 347 347 318 308L 347 347 309MoL 309MoL Duplex 309MoL
202 308L 308L 309MoL 310 347 316L 309MoL 309L 309L 309MoL
309MoL 347

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

317L, 316L 347 Match above 309MoL 309MoL Duplex 309MoL


316L, 316L 309MoL 309L 309L 309MoL 309L
316Ti
309L 309L

321, 347 Match above 309MoL 309MoL Duplex 309MoL


347 309MoL 309L 309L 309MoL 309L
347 347

S30815, Matching 309MoL 309MoL Duplex 309MoL


(253MA), 309L 309L 309MoL 309L
904L,
309L
(N08904)

409, 309L 309MoL Duplex 309MoL


430, 309MoL 309L 309MoL 309L
446,
309L
5CR12

410, Matching Duplex 309MoL


420 or 309MoL 309L
309MoL 309L
309L

Duplex, Matching Duplex


S31500, 309MoL
S31803,
309L
S32304

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.

This table can also be found on page 383 of this manual.

666 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

Weld Metal Calculator


Weights of mild steel weld metal are given in kilograms per metre Fillet Welds
length of joint, based on joint design.

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

Table/s Shape of Fillet


Leg Length
Fillet welds (down-hand and horizontal/ A (mm) Flat Convex Concave
vertical)
3 .04 .06 .06
Square edge close butts C
5 .10 .13 .12
Square edge open butts C E
6 .19 .24 .22
V and double V butts B C D
8 .30 .36 .34
V close butts (partial penetration) C D
9 .43 .52 .49
Butt joints with copper backing bard B C D E 11 .58 .72 .67
U and J groove butt welds F 12 .76 .92 .88
Multi-pass butt welds F 14 .96 1.2 1.1

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

AU : IPRM 2007 : Section 11 : technical data 667


11 Technical Reference Data

Reinforcements V Section

A B

Table C Table D

Height of Reinforcement (mm) Included Angle of V


Bead width Depth of V
(mm) 2 3 5 6 (mm) 14° 20° 60° 70° 90° 45°
5 .04 - - - 3 .01 .013 .04 .055 .08 .04
6 .05 - - - 5 .022 .031 .10 .125 .18 .09
8 .065 - - - 6 .04 .06 .18 .22 .32 .16
9 .07 .16 - - 8 .06 .09 .28 .34 .50 .25
11 .09 .18 .28 - 9 .09 .12 .42 .49 .72 .36
12 .10 .21 .31 - 11 .12 .18 .57 .68 .98 .49
14 .12 .24 .36 - 12 .15 .22 .73 .89 1.3 .64
16 .13 .27 .40 - 14 .19 .28 .92 1.12 1.6 .80
18 .15 .30 .43 .58 16 .24 .34 1.15 1.4 2.0 .98
19 .16 .33 .48 .63 18 .30 .42 1.4 1.6 2.4 1.2
22 .18 .37 .55 .71 19 .34 .51 1.6 1.9 2.9 1.4
25 .21 .42 .63 .85 21 .42 .60 1.9 2.4 3.3 1.6
29 .24 .48 .71 .95 22 .48 .68 2.2 2.7 3.9 1.9
32 .27 .52 .79 1.06 25 .63 .89 3.0 3.6 5.1 2.5
35 .30 .58 .88 1.2 29 .79 1.13 3.7 4.5 6.6 3.3
38 .31 .64 .95 1.3 32 .97 1.4 4.6 5.5 8.0 4.0
41 .34 .68 1.03 1.4 35 1.2 1.6 5.5 6.7 9.6 4.8
45 .37 .74 1.1 1.5 38 1.4 2.1 6.5 8.0 11.4 5.7
50 .42 .85 1.3 1.6 45 1.9 2.7 8.9 10.9 15.4 7.7
Notes 50 2.5 3.6 11.8 14.1 20.2 10.1
1 See Table E for square edge butts with a gap between faces
2 These weights must be doubled for 2-pass butts Notes
3 Normal shop practice would give reinforcements of 2 mm for thicknesses up to 20 mm, 1 This table should be read in conjunction with Tables B, C and E and the weights
and 3 mm on thicker plates except for 2-pass square edge close butts, where the added together
reinforcement can be greater 2 This table can be used for V butt joints with gaps, the gap value being obtained from
4 Bead width is usually the same as plate thicknesses ±3 mm, depending upon preparation, Table E
except in multi-pass welding where the bead width is approximately the maximum weld 3 The final column (45°) only applies to Figure B , the figures being half those applicable to
preparation width plus 6 mm the 90° V

668 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

Square Edge Open Butts Multi-Pass Groove Butt Joints

Table E Table F

Plate Width of Separation (mm) Groove


thickness Depth (mm) Weight of Weld Metal (Kg/m)
(mm) 2 3 5 6 10 12
11 1.34
3 .04 .07 .12 .16 .24 .31
12 1.5
5 .06 .12 .18 .24 .36 .48
16 1.8
6 .07 .16 .24 .31 .48 .64
19 2.1
8 .10 .19 .30 .40 .58 .79
22 2.4
9 .12 .24 .36 .48 .71 .95
25 2.7
11 .13 .28 .42 .55 .83 1.1
32 3.6
12 .16 .31 .48 .64 .95 1.3
38 4.5
14 .18 .36 .54 .71 1.1 1.4
45 5.4
16 .19 .40 .60 .79 1.2 1.6
50 6.6
18 .22 .43 .65 .86 1.3 1.8
57 7.9
19 .24 .48 .71 .95 1.4 1.9
63 9.2
22 .28 .55 .83 1.1 1.6 2.2
70 10.7
25 .31 .64 .94 1.3 1.9 2.5
76 12.4
29 .36 .71 1.1 1.4 2.1 2.8
Note
32 .40 .79 1.2 1.6 2.4 3.1
This table is compiled from Tables B, C, D and E.
35 .43 .86 1.3 1.8 2.7 3.4
38 .48 .95 1.4 1.9 2.8 3.9
41 .52 1.03 1.5 2.1 3.1 4.2
45 .55 1.10 1.6 2.2 3.3 4.5
48 .58 1.2 1.8 2.4 3.6 4.8
50 .64 1.3 1.9 2.5 3.9 5.1

Note
This table should be read in conjunction with Table C (reinforcement) and the weights added
together.

AU : IPRM 2007 : Section 11 : technical data 669


11 Technical Reference Data

Joint Preparations Summary Chart


Typical preparations for a range of material thicknesses

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°

670 AU : IPRM 2007 : Section 11 : technical data


Technical Reference Data 11

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

6 mm Fillet 7.5 mm Fillet


16 Triangles 25 Triangles
= 100% 25/16 = 156%

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

7.5 mm Fillet 9 mm Fillet


25 Triangles 36 Triangles
25/16 = 156% 36/16 = 225%

Not
Required
36
35
34
33 Excess 125%
32
31
30
29
28
27
26

9 mm Fillet
36 Triangles
36/16 = 225%

AU : IPRM 2007 : Section 11 : technical data 671

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