| Process: SAW |
Base Metal: Carbon Steel, Mild Steel, Low Alloy Steel |
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| Flux Types and
AWS Code Point of View: |
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| Neutral flux (fused) can be used
on multipass for unlimited thicknesses, as it produce good |
| impact
properties, but it is not usually the best choice for single pass, as it has
little or no |
| resistance
to cracking and/ or porosity. Neutral flux can be used again (crushed slag),
as it |
| doesn't
absorb moisture, compare with Active flux (bonded); For electrode-flux
combination |
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be considered neutral, it should have a Wall Neutrality Number of 40 or
less. |
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| Active flux is recommended for
single pass fillet weld (voltage must be more tightly controlled |
| for multipass). It is good on material thickness of maximum
25 mm (1 in). |
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| Active flux
consume 20% less because of it's lower density than neutral flux. |
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| Alloy flux used with plain carbon
steel, selected to add alloy to weld deposits as to welding |
| low alloy
steels. |
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| AWS Classification numbers do not
indicate whether a flux and electrode combination is |
| Neutral
or Active. AWS Classification numbers for electrodes do not specify the
results obtained |
| when
used with a particular flux. The Classification of electrode should only be
used as a guide |
| to
determine whether an electrode is suitable for a specific application. |
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| Base Metal: Carbon Steel, Mild Steel, Low Alloy Steel |
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| Process: SAW |
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| Position: Flat (Groove welds), Flat/Horizontal (Fillet welds) |
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| Current/Polarity: DCRP (DCEP) |
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| Nozzle Cup
Size: 5/8 in. |
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| Arc
Travel Speed (in/min): 10 to 20 (Fillet), 12 to 22 (Groove) |
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| Flux Type: Neutral flux or Active flux |
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| Note: |
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| DCRP
used for most application because it produces smooth welds and greater
penetration. |
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| AC
usually used in Full Automatic (Machine) process type. Increase voltage about
2 volts when |
| using
AC current compare with DCRP voltages.
Also in AC current, wire feed speed and |
| deposition rate increase about 15 to 25% for given
Amperage, compare with DCRP parameters. |
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| Deposition rate
may vary about 10% depends on type of flux being used. |
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| Increase
voltage will increase flux consumption. |
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| Parameters are
based on manufacturers' recommendation survey. |
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| Use lower end
data for thinner metal and higher end data for thicker metals |
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| Filler Metal
Electrode-Flux Combinations (AWS A5.17): |
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| AWS A5.17: F7AX-EM12K, F7AX-EM13K (X=0, 2, 4, 5, 6, 7) like:
F7A0-EM12K, F7A2-EM12K, F7A2-EM12K-H8, |
| F7A4-EM12K,
F7A4-EM12K-H8, F7A5-EM12K, F7A6-EM12K, F7A6-EM12K-H8, F7A0-EM13K,
F7A0-EM13K-H8, |
| F7A2-EM13K,
F7A2-EM13K-H8, F7A4-EM13K, F7A4-EM13K-H8, F7A5-EM13K-H8, F7A6-EM13K,
F7A6-EM13K-H8 |
| Or similar
carbon steel electrodes and flux combinations like: |
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| AWS A5.17: F7A6-EH11K-H8, F7A4-EH14, F7A2-EH14, F7A0-EL12,
F7A0-EL12-H8, F7A2-EL12, F7A2-EL12-H8 |
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| Filler Size:
5/64 in. (2 mm) |
Process Type: |
Semi-Automatic (Hand Held) |
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| ESO: 3/4 to
1-1/8 in. (20 to 28 mm) |
ESO: Electrical Stick Out |
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| A |
V * |
W ** (in/min) |
A: Current, V: Voltage, W: Wire Feed Speed |
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| 350-400 |
27-30 |
85-100 |
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| 400-450 |
29-32 |
100-120 |
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| 450-500 |
33-35 |
120-145 |
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| Filler Size:
3/32 in. (2.4 mm) |
Process Type: |
Semi-Automatic (mechanized) |
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| ESO: 3/4 to
1-1/8 in. (20 to 28 mm) |
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| A |
V * |
W ** (in/min) |
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| 400-450 |
26-28 |
76-86 |
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| 450-500 |
28-32 |
86-100 |
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| 500-550 |
30-33 |
100-120 |
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| Filler Size:
1/8 (3.20 mm) |
Process Type: |
Full-Automatic (Machine) |
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| ESO: 1 to 1-1/2
in. (25 to 38 mm) |
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| A |
V * |
W ** (in/min) |
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| 550-600 |
30-33 |
62-70 |
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| 600-650 |
30-34 |
70-78 |
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| Filler Size:
5/32 (4.0 mm) |
Process Type: |
Full-Automatic
(Machine) |
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| ESO: 1 to 1-1/2
in. (25 to 38 mm) |
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| A |
V * |
W ** (in/min) |
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| 500-550 |
28-32 |
38-42 |
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| 550-600 |
30-32 |
42-46 |
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| 600-650 |
30-32 |
46-52 |
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| 650-700 |
32-34 |
52-58 |
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| Filler Size: 3/16 (4.8 mm) |
Process Type: |
Full-Automatic
(Machine) |
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| ESO: 1 to 1-1/2
in. (25 to 38 mm) |
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| A |
V * |
W ** (in/min) |
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| 650-750 |
32-34 |
35-45 |
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| 750-850 |
32-35 |
45-55 |
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| 850-950 |
33-36 |
55-60 |
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| 950-1100 |
33-36 |
60-70 |
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| Important Notes: |
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| Above parameters are for DCRP (DC +) current (see also
notes above for AC current). |
| * Voltages
shown above are for Neutral flux, reduce 1 volt for Active flux |
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| **
Wire feed speeds shown above are based on ESO of 1 in. (25 mm) |
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| Also recommend
to set ESO (Electrical Stick Out) around 8 times of wire size |
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| When
increasing ESO when using an extention, increase voltage about 2 to 4 volts
per an inch increase |
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