W E L D I N G W I R E

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1 WELDING WIRE a n d E L ECTRODES

2 1 WELDING WIRE a n d ELECTRODES Quality it s what we re all about. The company that is today known as Techalloy Welding Products was founded in 1919 and is devoted to the manufacture and sale of welding consumables for shielded metal arc welding (SMAW), submerged arc welding (SAW), tungsten inert gas welding (TIG) and gas metal arc welding (MIG). The product range consists of welding wires and coated electrodes in stainless steel, nickel and nickel-based alloys, special purpose types together with a number of low alloy steels. The original company, Reid Avery, stood for great craftsmanship and expertise. Since adopting the Techalloy name, a pledge has been made to continue the fine legacy established by Reid Avery and to pursue innovative product developments. As part of this effort, Techalloy became the first company in the United States to produce imprinted TIG rods, saving welders hours of wasted time with traditional tags. New production equipment and technological advancements in the last few years have focused on ensuring the manufacture of premium quality welding consumables. The company has received ISO 9001 and certification to complement its existing significant number of certifications and registrations. / / 2009 / Techalloy Welding Products

3 WELDING WIRE a n d ELECTRODES 2 TECHALLOY and Central Wire Group Techalloy is a member of the Central Wire Group, one of North America s largest and most highly regarded drawers of specialty wire. This affords Techalloy significant advantages in terms of financial, technical, and operational resources on a global basis. Techalloy produces its welding consumables in Baltimore, Maryland and Perth, Ontario, and supports its sales and marketing activities with strategically located warehouse locations throughout North America. Important Notice Techalloy Welding Products sells all of its products subject to the Terms and Conditions of Sale which are issued by Techalloy Welding Products and are available for review upon request. These Terms and Conditions of Sale are incorporated for all purposes as if fully set forth in this handbook. There are no warranties whatsoever, whether written, oral, implied, express, or statutory, other than those specified in these Terms and Conditions of Sale. There is no warrant of merchantability of fitness for a particular purpose. The data contained in this handbook is intended for general information only, and not for specification purposes. Applications suggested for these alloys are made to permit you to make your own evaluation and decision, and are not to be construed as either express or implied warranties of fitness for these or other applications. All analyses should be considered as typical or average values, and are minimum or maximum only where indicated. They are not intended for specification purposes.

4 3 WELDING WIRE a n d ELECTRODES CERTIFICATIONS Certifications are important to a company because they represent the hard work and diligence that has gone into creating a quality product. Certifications are important to you, the buyer, because they represent quality, dependability, and peace of mind. Techalloy holds certifications of ISO 9001, ASME Section III Certification American Bureau of Shipping Canadian Welding Bureau Military Qualified Products TUV (Germany) Brazil Welding Foundation (FBTS) DHV (Norway) ISO 9001:14001 CERTIFIED American Bureau of Shipping L L L 347 Canadian Welding Bureau L 308LHS L 309LHS L 316LHS 317L CB FE EN606 HC NiMo Weld A Techrod 112 Techrod 276 Techrod 122 Techrod 182 Military Qualified Product List L L L L L MOT MOT L Techalloy 418 Techalloy 413 Techalloy 606 Techalloy 625 Tech-Rod 182 Tech-Rod 190

5 WELDING WIRE a n d ELECTRODES 4 CONTENTS CERTIFICATIONS...3 NICKEL ALLOY FILLER METAL...5 Nickel and High Nickel Alloy Welding Wires... 5 Recommended Welding Parameters... 8 Typical Chemical Composition... 8 Nickel and High Nickel Alloy Electrodes... 9 Typical Electrode Sizes & Currents Typical Chemical Composition Suggestions for Welding Nickel and High Nickel Alloys STAINLESS STEEL FILLER METAL...14 Stainless Steel Welding Wires Recommended Welding Parameters Typical Chemical Composition Stainless Steel Electrodes Typical Chemical Composition Typical Electrode Sizes & Currents Suggestions for Welding Stainless Steels LOW ALLOY STEEL FILLER METAL...28 Low Alloy Steel Wires Typical Chemical Composition Recommended Welding Parameters Suggestions for Welding Low Alloy Steels PACKAGING OPTIONS...32 TABLES AND CHARTS...33

6 5 WELDING WIRE a n d ELECTRODES NICKEL & HIGH NICKEL ALLOY WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 55 No AWS Specification Techalloy 72 AWS A5.14 ERNiCr-4 Techalloy 99 AWS A5.15 ERNiCl Techalloy 208 FM 61 AWS A5.14 ERNi-1 Techalloy 276 AWS A5.14 ERNiCrMo-4 Techalloy 413 FM 67 AWS A5.7 ERCuNi Techalloy 55 is used for TIG and MIG welding of cast iron. This filler metal is extensively employed to overlay cast iron rolls. It is also used to repair castings. The weld metal of Techalloy 55 is harder than that of Techalloy 99. However, machining can be accomplished by using carbide tipped tools. A preheat and interpass temperature of 350 F (175 C) minimum is recommended during welding, without which the weld and heat affected zones could develop cracks. High Chromium Nickel alloy used for joining, repair and overlay cladding of Ni-Cr and Ni-Fe-Cr components. Material is resistant to high temperature corrosion including fuel-ash corrosion and erosion in atmospheres containing sulpher. This material is primarily used for boiler tube overlay in coal fired boiler systems. Techalloy 99 is used for TIG and MIG welding of cast iron. This wire is extensively employed to repair gray iron casting. It can also be used for overlay and buildup. Dilution from the casting influences the mechanical properties of the metal. The welds are easily machinable. A preheat and interpass temperature of 350 F (175 C) minimum is recommended during welding. Techalloy 208 is used for TIG, MIG, and SAW welding of nickel 200 or 201. This filler metal is also employed for overlaying on steel as well as repairing cast iron castings. It can also be used for dissimilar joints between nickel or nickel alloys to stainless or ferritic steels. Techalloy 276 is used for welding of materials of similar chemical composition (UNS Number N10276), as well as dissimilar materials of nickel base alloys, steels and stainless steels. This wire also can be used for cladding steel with nickel-chromium-molybdenum weld metal. This alloy, due to its high molybdenum content, offers excellent resistance to stress corrosion cracking, pitting, and crevice corrosion. Techalloy 413 is used for TIG, MIG, and oxyfuel welding of 70/30, 80/20 and 90/10 copper-nickel alloys. This filler metal can be used for MIG overlay on steel after a first layer with Nickel 208 (Filler Metal 61). Dissimilar-welding applications include joining copper-nickel alloys to Nickel 200 or nickel-copper alloys. Carbon.05 Tensile Strength Manganese.25 89,500 PSI 620 MPA Silicon.15 Iron 43.6 Yield Strength Nickel ,000 PSI 430 MPA Elongation 35% Carbon.03 Tensile Strength Titanium ,000 PSI 740 MPA Chromium 43.6 Nickel Elongation 30% Carbon.05 Tensile Strength Manganese.22 66,500 PSI 460 MPA Silicon.05 Nickel 99.6 Yield Strength 36,000 PSI 250 MPA Elongation 40% Carbon.06 Tensile Strength Manganese.30 66,500 PSI 460 MPA Silicon.40 Aluminum.5 Yield Strength Titanium ,000 PSI 260 MPA Nickel 95.5 Elongation 28% Carbon.01 Tensile Strength Manganese ,000 PSI 720 MPA Silicon.04 Chromium Yield Strength Molybdenum ,000 PSI 560 MPA Tungsten 3.65 Vanadium.15 Elongation 40% Nickel Iron 5.5 Nickel 31.0 Tensile Strength Manganese.75 53,000 PSI 360 MPA Silicon.10 Iron.55 Yield Strength Titanium.35 21,000 PSI 140 MPA Copper Elongation 32%

7 WELDING WIRE a n d ELECTRODES 6 NICKEL & HIGH NICKEL ALLOY WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 418 FM 60 AWS A5.14 ERNiCu-7 Techalloy 606 FM 82 AWS A5.14 ERNiCr-3 Techalloy 617 AWS A5.14 ERNiCrCoMo-1 Techalloy 622 AWS A5.14 ERNiCrMo-10 TECHALLOY 652 AWS A5.14 ERNiCrFe-7A Techalloy 418 is used for TIG or MIG welding of nickel copper alloys (ASTM B127, B163, B164, and B165 UNS Number N04400). This filler metal can be used for MIG overlay on steel after a first layer with nickel 208 (Filler Metal 61). Dissimilar welding applications include joining nickel-copper alloys to Nickel 200 copper-nickel alloys. Techalloy 606 is used for TIG, MIG and SAW welding of base metals such as ASTM B163, B166, B167 and B168 alloys which have UNS Number N It is one of the most used nickel alloys whose applications range from cryogenic to high temperatures. This filler metal can also be used for dissimilar welding applications between various nickel alloys and stainless or carbon steels, as well as for overlaying. Techalloy 617 is used for TIG, MIG, and SAW welding of nickel-chrome-cobalt-molybdenum alloys as well as between themselves and dissimilar metals, such as stainless, carbon or low alloy steels. This filler wire also can be used to overlay welding where similar chemical composition is desired. The weld metal provides optimum strength and oxidation resistance from 1500 F (815 C) up to 2100 F (1150 C). Techalloy 622 is an alloy of nickel with chromium, molybdenum and tungsten as principal alloying elements. It is used to weld alloys of similar composition as well as dissimilar joints between nickel-chromium-molybdenum alloys and stainless or carbon or low alloy steels. It can also be used for cladded overlay as well as spraying applications. Techalloy 622 offers excellent corrosion resistance in oxidizing as well as reducing media in a wide variety of chemical process environments. It offers an outstanding resistance to stress corrosion cracking, pitting, and crevice corrosion. Techalloy 652 is used to weld base metal Alloy 690, and used extensively in the power boiler and nuclear power industries. This filler metal contains high levels of Chromium to resist stress corrosion cracking and increased Niobium to resist ductility dip cracking. Techalloy 652 can be used to overlay low alloy and stainless steels. Carbon.05 Tensile Strength Manganese ,500 PSI 530 MPA Silicon.77 Titanium 2.25 Yield Strength Nickel ,500 PSI 360 MPA Copper Elongation 34% Carbon.03 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.22 Chromium 20.4 Yield Strength Columbium + Tantalum ,000 PSI 360 MPA Nickel 72.9 Elongation 38% Carbon.06 Tensile Strength Manganese ,000 PSI 770 MPA Silicon.11 Chromium 21.8 Yield Strength Cobalt ,000 PSI 610 MPA Molybdenum 9.05 Aluminum 1.25 Elongation 28% Titanium.25 Nickel Carbon.008 Tensile Strength Manganese ,000 PSI 790 MPA Iron 3.1 Chromium 21.5 Yield Strength Molybdenum ,000 PSI 570 MPA Tungsten 3.5 Nickel Elongation 38% Carbon.03 Tensile Strength Manganese.25 92,000 PSI 634 MPA Silicon.30 Sulfur/Phosphorus.01/.01 Yield Strength Chromium ,000 PSI 360MPA Nickel Molybdenum.01 Elongation 45% Niobium/Tantalum.75 Iron 9.00 Copper.10 Cobalt.02 Aluminum.60 Titanium.70 Aluminum + Titanium 1.30 Boron.002 Zirconium.005

8 7 WELDING WIRE a n d ELECTRODES NICKEL & HIGH NICKEL ALLOY WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 625/ 625HWT AWS A5.14 ERNiCrMo-3 TECHALLOY 625 FCA AWS A5.34 ENiCrMo3T1 Techalloy 718 AWS A5.14 ERNiFeCr-2 Techalloy 825 AWS A5.14 ERNiFeCr-1 Techalloy 625 is used for TIG, MIG, and SAW welding of nickel-chrome-molybdenum alloys. This filler metal is very versatile in its applications. It can be used for welding of dissimilar joints between nickel-chrome-molybdenum alloys and stainless or carbon or low alloy steels. It can also be used for cladding as well as for spraying applications. Techalloy 625 with low iron (less than 0.8%) is preferred in various applications where dilution of iron must be controlled to the minimum. The high alloy content of Techalloy 625 enables it to withstand highly corrosive environments. The combination of nickel and chromium provides the resistance to oxidizing conditions and the combination of nickel and molybdenum provides resistance to reducing conditions. Due to its molybdenum content, this alloy offers resistance to stress corrosion cracking, pitting, and crevice corrosion. Techalloy 625HWT is engineered to work with the standard Gas Tungsten Arc process with an AC power source to preheat the welding wire before introduction to the GTA heat source. This enables automated systems with continuous wire feed to achieve a high quality, high deposition rate overlay. Techalloy 625FCA is a gas shielded, all position flux cored wire that provides a final weld chemistry equivalent to the compostion requirements of AWS A5.14 ERNiCrMoT-3 solid wire. Used for dissimilar welding of NiCrMo Alloys to Steel, for surfacing Carbon & Low Alloy Steels, and for joining Ni-Cr-Mo alloys. Techalloy 718 is used for TIG welding alloys 718, 706, and X-750. It is mainly used for welding high-strength aircraft components, and liquid rocket components involving cryogenic temperatures. This alloy can be age hardened to higher strengths. Techalloy 825 is used for TIG, MIG, and SAW welding of nickel-iron-chromium-molybdenum-copper alloys. This can also be used to overlay cladding where similar chemical composition is required. Carbon.009 Tensile Strength Manganese , MPA Silicon.12 Chromium 21.9 Yield Strength Molybdenum ,000 PSI 590 MPA Columbium + Tantalum 3.7 Nickel Elongation 27% Iron.40 Carbon.04 Tensile Strength Manganese PSI 786 MPA Silicon.30 Chromium 21.5 Yield Strength Columbium PSI 550 MPA Molybdenum 9.0 Nickel 59 Elongation 30% Carbon.04 Tensile Strength Manganese ,000 PSI 860 MPA Silicon.2 Chromium 19.0 Yield Strength Molybdenum ,000 PSI 630 MPA Columbium + Tantalum 5.05 Titanium.9 Elongation 27% Aluminum.4 Nickel Iron Carbon.01 Tensile Strength Manganese.45 88,500 PSI 610 MPA Silicon.25 Iron 29.0 Yield Strength Chromium ,000 PSI 420 MPA Molybdenum 3.1 Copper 2.0 Elongation 34% Nickel 42.6 Titanium 1.0 Techalloy is a registered trademark of Techalloy Welding Products

9 WELDING WIRE a n d ELECTRODES 8 NICKEL & HIGH NICKEL ALLOY WELDING WIRES RECOMMENDED WELDING PARAMETERS FOR TIG, MIG, & SAW WELDING OF NICKEL ALLOYS Process diameter of Wire Voltage (V) Amperage (A) Gas TIG.035 inches (0.9 mm) % Argon.045 inches (1.2 mm) % Argon 1/16 inches (1.6 mm) % Argon 3/32 inches (2.4 mm) % Argon 1/8 inches (3.2 mm) % Argon MIG.035 inches (0.9 mm) % Argon + 25% Helium.045 inches (1.2 mm) % Argon + 25% Helium 1/16 inches (1.6 mm) % Argon + 25% Helium SAW 3/32 inches (2.4 mm) Suitable Flux may be used 1/8 inches (3.2 mm) Suitable Flux may be used 5/32 inches (4.0 mm) Suitable Flux may be used TYPICAL CHEMICAL COMPOSITION OF NICKEL & HIGH NICKEL WIRES Product Specification C Mn Si Fe Cr Mo Ni Cb W S P Al Ti Cu AWS A5.14 +Ta Techalloy 55 None Techalloy 72 ERNiCr Bal 0.50 Techalloy 99 ERNiCl (AWS A5.15) Techalloy 208 (FM 61) ERNi Techalloy 276 ERNiCrMo BAL Techalloy 413 (FM 67) ERCuNi (AWS A5.7) BAL Techalloy 418 (FM 60) ERNiCu BAL Techalloy 606 (FM 82) ERNiCr Techalloy 617 (FM 617) ERNiCrCoMo BAL Co Techalloy 622 ERNiCrMo BAL Techalloy 652 ERNiCrFe-7A Techalloy 625/625HWT ERNiCrMo (FM 625) Techalloy 625FCA* ENiCrMo3T Techalloy 718 (FM 718) ERNiFeCr Techalloy 825 (FM 65) ERNiFeCr *Specification: AWS A5.34

10 9 WELDING WIRE a n d ELECTRODES NICKEL & HIGH NICKEL ALLOY ELECTRODES Techalloy s extensive line of nickel alloy coated electrodes blends weld-appeal with proper metallurgy for optimum performance. mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 55 AWS A5.15 ENiFe-Cl Tech-Rod 99 AWS A5.15 ENi-Cl Tech-Rod 112 AWS A5.11 ENiCrMo-3 Tech-Rod 55 is used for welding of cast irons to themselves as well as for joining cast irons to mild steels. It is also employed for the repair of castings. The welds are moderately hard and require carbide tipped tools for machining. A preheat and interpass temperature of not less than 350 F (175 C) is required during welding. Tech-Rod 99 is designed for welding of gray iron castings to themselves as well as joining them to mild steels or stainless steels. It is also used extensively to repair castings. The welds are quite machinable. A preheat and interpass temperature of not less than 350 F is recommended during welding. Tech-Rod 112 is a covered electrode which is used to weld nickel-chromium-molybdenum alloys. It is also used extensively in overlay cladding where similar chemical composition is required on the clad side. Its applications include dissimilar joints between nickel-chromium-molybdenum alloys to either stainless steels, carbon, or low alloy steels. These electrodes are used in applications where the temperature ranges from cryogenic up to 1800 F. Carbon.9 Tensile Strength Manganese.74 84,000 PSI 580 MPA Silicon 2.09 Iron 40.2 Yield Strength Copper ,500 PSI 410 MPA Nickel 54.5 Elongation 8% Carbon.85 Tensile Strength Manganese.25 72,000 PSI 500 MPA Silicon 1.73 Iron 4.2 Yield Strength Copper ,500 PSI 390 MPA Nickel Elongation 5% Carbon.03 Tensile Strength Manganese ,500 PSI 790 MPA Silicon.34 Iron 1.5 Yield Strength Chromium ,500 PSI 620 MPA Molybdenum 9.2 Columbium + Tantalum 3.55 Elongation 34% Nickel

11 WELDING WIRE a n d ELECTRODES 10 NICKEL & HIGH NICKEL ALLOY ELECTRODES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 117 AWS A5.11 ENiCrCoMo-1 Tech-Rod 122 AWS A5.11 ENiCrMo-10 Tech-Rod 135 No AWS Specification Tech-Rod 141 AWS A5.11 ENi-1 TECH-ROD 152 AWS A5.11 ENiCrFe-7 Tech-Rod 182 AWS A5.11 ENiCrFe-3 Tech-Rod 117 is a covered electrode which is used for welding of nickel-chromium-cobaltmolybdenum alloys (UNS number N06617). This electrode can also be used for overlay cladding where similar alloy is required. Weld metal provides optimum strength and oxidation resistance above 1500 F up to 2100 F, especially when welding on base metals of nickel-iron-chromium alloys. Tech-Rod 122 electrodes are used for welding of nickel-chromium-molybdenum alloys as well as for overlay cladding on carbon, low alloy, or stainless steels. They are also used for dissimilar joints between nickel-chromium-molybdenum alloys and stainless, carbon, or low alloy steels. Typical specifications for the nickel-chromium-molybdenum base metals are ASTM, F574, B619, B622, and B626 all of which have UNS Number N Tech-Rod 122 offers excellent corrosion resistance in oxidizing as well as reducing media in a wide variety of chemical process environments. It offers an outstanding resistance to stress corrosion cracking, pitting, and crevice corrosion. Tech-Rod 135 is a covered electrode which is used for nickel-iron-chromium-molybdenum-copper alloys. This can also be used for overlay cladding where similar chemical composition is required. Tech-Rod 141 is used for welding of cast and wrought forms of commercially pure nickel. These electrodes can also be used for surfacing as well as dissimilar welding between nickel and steel or stainless steel. Tech-Rod 152 electrodes are used for welding Nickel-Chromium-Iron alloys such as Alloy 690. The weld metal contains high Chromium that imparts excellent resistance to general corrosion and stress corrosion cracking. The higher Niobium content provides resistance to ductility dip cracking. The electrode can be used for overlays of low alloy and stainless steels. Tech-Rod 182 electrodes are used for welding of nickel-chromium-iron alloys to themselves, and for dissimilar welding between nickel-chromium-iron alloys and steels or stainless steels. The applications include surfacing as well as clad-side welding. High manganese of this weld deposit reduces the possibility of micro fissures. High manganese reduces creep strength, which limits its usage up to 900 F. Carbon.06 Tensile Strength Manganese ,000 PSI 760 MPA Silicon.35 Iron 1.5 Yield Strength Chromium ,000 PSI 600 MPA Molybdenum 8.8 Cobalt Elongation 26% Aluminum.65 Nickel Impact Strength 600 ft. lbs. at Room Temperature Carbon.014 Tensile Strength Manganese ,000 PSI 790 MPA Silicon.16 Chromium 21.2 Yield Strength Molybdenum ,500 PSI 540 MPA Tungsten 3.3 Nickel Elongation 36% Iron 3.9 Impact Strength 60 ft. lbs at Room Temperature Carbon.02 Tensile Strength Manganese ,000 PSI 600 MPA Silicon.40 Iron 27.4 Yield Strength Chromium ,000 PSI 490 MPA Molybdenum 3.2 Copper 1.8 Elongation 33% Nickel 35.2 Carbon.04 Tensile Strength Manganese.45 64,500 PSI 500 MPA Silicon.50 Iron.35 Yield Strength Titanium ,500 PSI 400 MPA Nickel 97.6 Elongation 26% Carbon.03 Tensile Strength Manganese ,000 PSI 620 MPA Silicon.40 Sulfur/Phosphorus.01/.01 Yield Strength Chromium ,000 PSI 379 MPA Nickel Molybdenum.32 Elongation 40% Niobium + Tantalum 2.25 Iron 9.50 Carbon.03 Tensile Strength Manganese ,500 PSI 580 MPA Silicon.42 Iron 7.4 Yield Strength Chromium ,500 PSI 370 MPA Columbium + Tantalum 1.75 Nickel Elongation 36%

12 11 WELDING WIRE a n d ELECTRODES NICKEL & HIGH NICKEL ALLOY ELECTRODES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 187 AWS A5.6 ECuNi Tech-Rod 190 AWS A5.11 ENiCu-7 Tech-Rod 276 AWS A5.11 ENiCrMo-4 Tech-Rod Weld A AWS A5.11 ENiCrFe-2 Tech-Rod 187 is a copper-nickel, all-position electrode for shielded metal arc welding of wrought or cast alloys of similar composition as well as 80 Cu + 20 Ni and 90 Cu + 10 Ni alloys. It is also used for the clad side of copper-nickel clad steels. This filler metal is widely used in marine applications because of its good resistance to the corrosive elements of sea water. Tech-Rod 190 is used for welding materials of nickel-copper-alloys to themselves (such as ASTM, B127, B163, B164, B165 all of which have UNS Number N04400). They also can be used for overlay welding as well as for welding of clad steels where nickel-copper surfacing is required. Dissimilar welding applications including joining nickel 200 and copper-nickel alloys. Tech-Rod 276 is used for welding materials of similar composition. This low carbon nickelchromium-molybdenum filler metal can also be used for dissimilar welding between nickel base alloys and stainless steels, as well as for surfacing and cladding. Due to high molybdenum content this alloy offers excellent resistance to stress corrosion cracking and pitting and crevice corrosion. Tech-Rod Weld A electrodes are used for welding of nickel-chromium-iron alloys to themselves as well as for dissimilar welding between various nickel alloys and carbon or stainless steels. These electrodes can also be used for overlay cladding where similar alloy is needed. These electrodes have wide applications ranging from cryogenic temperatures up to 1500 F. Nickel 30.5 Tensile Strength Manganese ,500 PSI 380 MPA Silicon.35 Iron.62 Yield Strength Titanium.2 37,500 PSI 260 MPA Copper Elongation 28% Carbon.03 Tensile Strength Manganese ,500 PSI 520 MPA Silicon.9 Iron.95 Yield Strength Titanium.65 52,000 PSI 360 MPA Copper 28.2 Nickel 67.6 Elongation 39% Carbon.015 Tensile Strength Manganese.4 106,000 PSI 730 MPA Silicon.14 Iron 5.5 Yield Strength Molybdenum ,500 PSI 540 MPA Tungsten 3.25 Chromium 15.5 Elongation 39% Nickel 59.1 Carbon.04 Tensile Strength Manganese ,000 PSI 610 MPA Silicon.32 Chromium 15.5 Yield Strength Molybdenum ,000 PSI 500 MPA Columbium + Tantalum 1.25 Iron 8.5 Elongation 36% Nickel Techalloy, Tech-Rod is a registered trademark of Techalloy Welding Products.

13 WELDING WIRE a n d ELECTRODES 12 NICKEL & HIGH NICKEL ALLOY ELECTRODES TYPICAL ELECTRODE SIZES & CURRENTS FOR SMAW WELDING OF NICKEL ALLOYS Amperage (A) Process diameter of Wire Voltage (V) Flat Vertical & Overhead SMAW 3/32 inches (2.4 mm) /8 inches (3.2 mm) /32 inches (4.0 mm) /16 inches (4.8 mm) TYPICAL CHEMICAL COMPOSITION OF NICKEL & HIGH NICKEL COVERED ELECTRODES Product Specification C Mn Si Fe Cr Mo Ni Cb W S P Ti Al Other AWS A5.11 +Ta Tech-Rod 55 ENiFe-Cl (AWS A5.15) Cu Tech-Rod 99 ENiCl (AWS A5.15) Cu Tech-Rod 112 ENiCrMo Tech-Rod 117 ENiCrCoMo BAL Co Tech-Rod 122 ENiCrMo BAL Tech-Rod 135 None Cu Tech-Rod 141 ENi Tech-Rod 152 ENiCrFe Tech-Rod 182 ENiCrFe Tech-Rod 187 ECuNi (AWS A5.6) Bal Cu Tech-Rod 190 ENiCu Cu Tech-Rod 276 ENiCrMo Tech-Rod WELD A ENiCrFe

14 13 WELDING WIRE a n d ELECTRODES SUGGESTIONS FOR WELDING NICKEL & HIGH NICKEL ALLOYS Nickel and High Nickel Alloys are used in fabrication of equipment which has to withstand highly corrosive environments. Often the corrosion is enhanced by the operating conditions of high pressure and temperature. Various high nickel alloys are developed and are being developed to meet these demanding conditions. In some cases the mild and low alloy steel equipment and vessels are clad by nickel alloys to combat corrosion. Techalloy Welding Products manufactures nickel and nickel alloy welding consumables for TIG, MIG, SAW and SMAW processes. The products and process parameters are provided in the tables on pages 8 and 12 for easy reference. Welding of nickel is different from welding other metals and alloys. Two characteristics contribute to this difference: Nickel could form a tenacious viscous oxide during welding which restricts the wettability and flow of the weld metal. Nickel is highly susceptible to embrittlement by sulfur, phosphorus, lead and other lowmelting substances. The weld metal flow problem can be reduced by: Selecting an appropriate joint design. Choosing the correct type of gas and gas flow rate to ensure proper protection from atmospheric oxygen. Clean welding consumables which do not contain any lubricants or oxides or contaminants. Selecting a superior formulated covered electrode to ensure proper flow and cleanliness. The weld area on both sides of the weld joint must be lightly ground to remove oxide from the surface. Interpass cleaning is essential to ensure complete slag removal as well as fusion between the weld beads. Weld joint designs used for nickel alloy welding should be different from those used for welding steels. The sluggish nature of the weld metal calls for more open joint, which will provide better accessibility to the welder. Another characteristic of nickel alloy weld metal is the lower penetration. This necessitates the use of a smaller land at the root of the joint. For joining tubes and pipes, they should be purged and filled with inert gas before welding to avoid oxidation at the root. For manual welding, appropriate current ranges should be used to avoid overheating. Overheating of the electrode could result in loss of deoxidizers and breakdown of the binder of the flux, leading to defective welding. MIG welding calls for helium additions to argon to improve the wetting of the weld metal. For TIG welding, argon or argon-helium mixtures are generally used. Gas flow rates of 30 to 50 CFH are required to obtain high quality welds. With submerged arc welding, the flux may need to be pre-baked before welding to reduce the chances of weld defects due to moisture. A procedure test is generally required to assure that the proposed welding parameters and filler metals result in sound and acceptable chemical and mechanical properties of the welds. As the cleanliness of the welding consumables is of paramount importance, Techalloy Welding Products has incorporated in-line cleaning systems to ensure the requisite degree of cleanliness. Should you need to have more information or discuss applications or welding parameters, do not hesitate to call us at Electrode Storage & Reconditioning Coated electrodes just removed from sealed containers are intended for use as is out of the container. Electrodes from open containers should be stored in a holding oven at 215 F 240 F. Open cans of electrodes exposed to a high humidity atmosphere for more than four hours or low humidity for more than eight hours should be reconditioned before using by baking in a drying oven for 1-2 hours at 400 F 500 F.

15 WELDING WIRE a n d ELECTRODES 14 STAINLESS STEEL WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 307 Techalloy 308/308H AWS A5.9 ER308H AWS A5.9 ER308 Techalloy 308/308L AWS A5.9 ER308L AWS A5.9 ER308 Techalloy 308LHS AWS A5.9 ER308LSi Techalloy 309/309L AWS A5.9 ER309L AWS A5.9 ER309 Techalloy 309LHS AWS A5.9 ER309LSi Techalloy 309LMo Techalloy 310 AWS A5.9 ER310 A popular European grade used for automotive exhaust applications and dissimilar stainless grades. Techalloy 308/308H is used for TIG, MIG, and submerged arc welding of unstabilized stainless steels such as Types 301, 302, 304, 305, 308. This filler metal is the most popular grade among stainless steels, used for general-purpose applications where corrosion conditions are moderate. Can also be certified as ER308H. Techalloy 308/308L has the same analysis as type 308 except the carbon content has been held to a maximum of.03% to reduce the possibility of intergranular carbide precipitation. Ideal for welding Types 304L, 321, and 347 stainless steels. This is a suitable wire for applications at cryogenic temperatures. Techalloy 308LHS is a stainless steel welding wire for MIG welding. This wire is used to weld equipment made with 304 and 308 stainless grades. Welding speed is higher than 308 or 308L due to improved wettability of weld metal. Techalloy 309/309L is of similar composition as Techalloy 309 except for the carbon content being lower than.03%. The lower carbon content reduces the possibility of intergranular corrosion. Techalloy 309L is preferred over 309 for cladding over carbon or low alloy steels, as well as for dissimilar joints that undergo heat treatment. Techalloy 309LHS is of the same chemical composition as 309L, with higher silicon content to improve the bead appearance and increase welding ease. The weld beads are exceptionally smooth due to good wetting. Techalloy 309LMo is of the same composition as ER309L, with the addition of percent Molybdenum to improve pitting corrosion properties in chloride containing environments. Techalloy 309LMo can be used to join base metals of similar composition, dissimilar ferrous alloys and is most often used to overlay carbon and low alloy base metals. Techalloy 310 is used for the welding of stainless steels of similar composition in wrought or cast form. The weld deposit is fully austenitic and calls for low heat during welding. This filler metal can also be used for dissimilar welding. Carbon.07 Manganese 6.6 Silicon.90 Chromium 18.7 Nickel 8.9 WRC FN 5 Carbon.05 Tensile Strength Manganese ,500 PSI 610 MPA Silicon.46 Chromium Yield Strength Nickel ,500 PSI 410 MPA WRC FN 8 Elongation 39% Carbon.019 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.46 Chromium 20.8 Yield Strength Nickel ,000 PSI 390 MPA WRC FN 8 Elongation 40% Carbon.016 Tensile Strength Manganese ,500 PSI 600 MPA Silicon.85 Chromium Yield Strength Nickel ,000 PSI 410 MPA WRC FN 8 Elongation 39% Carbon.021 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.51 Chromium Yield Strength Nickel ,000 PSI 400 MPA WRC FN 12 Elongation 36% Carbon.019 Tensile Strength Manganese ,500 PSI 620 MPA Silicon.84 Chromium Yield Strength Nickel ,500 PSI 420 MPA WRC FN 10 Elongation 34% Carbon.01 Tensile Strength Manganese ,000 PSI 585 MPA Silicon.40 Sulfur/Phosphorus.01/.02 Yield Strength 310 MPA Chromium ,000 PSI Nickel Molybdenum 2.60 Elongation 40% Copper.10 Nitrogen.05 WRC FN 9 Carbon.11 Tensile Strength Manganese ,500 PSI 620 MPA Silicon.40 Chromium Yield Strength Nickel ,500 PSI 420 MPA WRC FN 0 Elongation 34%

16 15 WELDING WIRE a n d ELECTRODES STAINLESS STEEL WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 312 AWS A5.9 ER312 Techalloy 316/316L AWS A5.9 ER316L AWS A5.9 ER316 Techalloy 316LHS AWS A5.9 ER316LSi Techalloy 317L AWS A5.9 ER317L Techalloy 320LR AWS A5.9 ER320LR Techalloy 330 AWS A5.9 ER330 Techalloy 347 AWS A5.9 ER347 Techalloy 312 is used to weld cast alloys of similar composition and is used to weld dissimilar metals and weld overlays. This alloy has very high ferrite. When welding similar cast alloys, limit welding to two or three layers only. Techalloy 316/316L has the same analysis as ER316, except that the carbon content is limited to a maximum of 0.03% in order to reduce the possibility of formation of intergranular carbide precipitation. This filler metal is primarily used for welding low carbon molybdenum-bearing austenitic alloys. This low carbon alloy is not as strong at elevated temperatures as ER316H. Techalloy 316LHS is similar to 316L, with higher silicon content for optimum ease in welding and smooth bead appearance. Higher productivity could be realized in MIG welding. Techalloy 317L is used for welding stainless steels with similar composition. Due to its higher molybdenum content, this alloy offers high resistance to pitting and crevice corrosion. Lower carbon makes the weld metal less susceptible to intergranular corrosion. Techalloy 320LR has a composition similar to Techalloy 320, except that carbon, silicon, phosphorus, and sulfur levels are kept at lower levels as well as the columbium and manganese being specified at a narrower range. The low melting residuals are limited in this alloy to reduce the possibility of microfissuring. It is for this reason that this alloy is often used for welding Type 320 stainless steels. Techalloy 330 is used to weld cast and wrought material of similar chemical composition. The weld metal provides excellent heat and scale resistance up to 1800 F. However, high sulfur environments may adversely affect elevated temperature performance. This being a fully austenitic alloy, heat input is necessary. Techalloy 347 is a columbium-stabilized stainless steel welding wire used to weld Types 321 and 347. Addition of columbium reduces the possibility of chromium carbide precipitation and consequent intergranular corrosion. Carbon.11 Tensile Strength Manganese ,500 PSI 760 MPA Silicon.44 Chromium 29.6 Yield Strength Nickel ,500 PSI 540 MPA Molybdenum.08 WRC Ferrite 30 min Elongation 45% Carbon.016 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.48 Chromium Yield Strength Nickel ,000 PSI 400 MPA Molybdenum 2.25 WRC FN 6 Elongation 36% Carbon.022 Tensile Strength Manganese ,500 PSI 600 MPA Silicon.85 Chromium Yield Strength Nickel ,500 PSI 400 MPA Molybdenum 2.45 WRC FN 8 Elongation 36% Carbon.017 Tensile Strength Manganese , MPA Silicon.44 Chromium 19.4 Yield Strength Nickel ,000 PSI 400 MPA Molybdenum 3.25 WRC FN 6 Elongation 35% Carbon.025 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.05 Chromium 19.6 Yield Strength Nickel ,500 PSI 400 MPA Molybdenum 2.5 Columbium + Tantalum.25 Elongation 35% Sulfur.001 Phosphorus.007 Copper 3.4 WRC FN 0 Carbon.23 Tensile Strength Manganese ,000 PSI 580 MPA Silicon.42 Chromium Yield Strength Nickel ,500 PSI 390 MPA WRC FN 0 Elongation 29% Carbon.04 Tensile Strength Manganese ,500 PSI 600 MPA Silicon.52 Chromium 19.9 Yield Strength Nickel ,000 PSI 390 MPA Columbium.72 WRC FN 10 Elongation 35%

17 WELDING WIRE a n d ELECTRODES 16 STAINLESS STEEL WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 385 AWS A5.9 ER385 (904L) Techalloy 409Cb AWS A5.9 ER409Cb Techalloy 385 is used for welding materials of similar chemical composition which are used for fabrication of equipment and vessels for handling of sulfuric acid and many chloride containing media. This filler metal may also find applications for joining Type 317L material where improved corrosion resistance in specific media is needed. In order to reduce the propensity for fissuring and hot cracking, the low melting constituents such as carbon, silicon and phosphorus are controlled to lower levels in this alloy. Techalloy 409Cb is a ferritic stainless steel welding wire which is used to weld type 409 and 409Ti base materials. Addition of columbium leads to a preferential reaction with carbon, saving chromium from forming carbides. This improves corrosion resistance, increases strength at high temperatures, and promotes ferritic micro-structure. Carbon.019 Tensile Strength Manganese ,500 PSI 600 MPA Silicon.35 Chromium 20.5 Yield Strength Nickel ,500 PSI 410 MPA Copper 1.6 Molybdenum 4.6 Elongation 36% WRC FN 0 Carbon.05 Tensile Strength Manganese.62 67,000 PSI 460 MPA Silicon.48 Chromium 11.5 Yield Strength Columbium.35 50,500 PSI 350 MPA Elongation 26% Techalloy 410 AWS A5.9 ER410 Techalloy 410 is used to weld Types 403, 405, 410, and 416. It is also used for welding overlay on carbon steels to resist corrosion, erosion, or abrasion. This material, being an air hardening type, calls for preheating of the joint to 350 F before welding. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld heat treatment between 1350 F and 1400 F for one hour. Carbon.11 Tensile Strength Manganese.45 89,000 PSI 620 MPA Silicon.39 Chromium 12.5 Yield Strength 78,500 PSI 540 MPA Elongation 24%

18 17 WELDING WIRE a n d ELECTRODES STAINLESS STEEL WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 410NiMo AWS A5.9 ER410NiMo Techalloy 420 AWS A5.9 ER420 Techalloy 430 AWS A5.9 ER430 Techalloy 430LCb Techalloy 630 AWS A5.9 ER630 (17-4PH) Techalloy 410NiMo is used primarily to weld cast and wrought material of similar chemical composition. Preheating and interpass temperature of not less than 300 F are required. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld heat treatment between 1100 F and 1150 F for one hour. Techalloy 420 has a higher carbon content than Techalloy 410. This alloy is often used for surfacing applications which call for superior resistance to abrasion. It requires preheat and interpass temperatures of not less than 400 F, followed by slow cooling. Post weld heat treatment is used to temper the weld deposit. NOTE: Mechanical properties are greatly influenced by changes in welding parameters such as preheat and interpass temperatures. Techalloy 430 is a ferritic stainless steel which offers good ductility in heat treated condition. In addition to the applications of welding similar alloys, it is also used for overlays and thermal spraying. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld heat treatment between 1400 F and 1450 F for two hours. Techalloy 430LCb is stabilized ferritic steel, which offers superior mechanical properties to 430 grade. In addition its fatigue resistance is also higher, the fact that lead to its spontaneous popularity in the automotive industry. This product is also used for overlay cladding as well as in thermal spray applications. Preheating of the joint to a minimum of 300 F is recommended. Welding must be done with very low heat input. NOTE: Mechanical properties reflect the heattreated specimen at 1400 F to 1450 F for two hours. Techalloy 630 is a precipitation hardening stainless steel used for welding of materials of similar chemical composition. Mechanical properties of this alloy are greatly influenced by the heat treatment. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld heat treatment between 1875 F and 1925 F for one hour, followed by precipitation hardening between 1135 F and 1165 F for four hours. Carbon.02 Tensile Strength Manganese ,500 PSI 820 MPA Silicon.4 Chromium 11.8 Yield Strength Nickel ,000 PSI 630 MPA Molybdenum.55 Elongation 20% Carbon.29 Tensile Strength Manganese ,000 PSI 1000 MPA Silicon.35 Chromium 13.2 Yield Strength 120,000 PSI 830 MPA Carbon.07 Tensile Strength Manganese.44 77,500 PSI 530 MPA Silicon.36 Chromium 16.5 Yield Strength 59,000 PSI 410 MPA Elongation 25% Carbon.01 Tensile Strength Manganese.51 74,000 PSI 510 MPA Silicon.40 Chromium Yield Strength Columbium.40 60,000 PSI 40 MPA Elongation 25% Carbon.03 Tensile Strength Manganese ,000 PSI 1030 MPA Silicon.43 Chromium Yield Strength Nickel ,000 PSI 930 MPA Copper 3.6 Columbium + Tantalum.22 Elongation 10%

19 WELDING WIRE a n d ELECTRODES 18 STAINLESS STEEL WELDING WIRES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 2209 AWS A5.9 ER2209 (Duplex Grade) Techalloy 2594 AWS A5.9 ER2594 (Super Duplex Grade) Techalloy 2209 is a filler material designed to weld duplex stainless steels such as UNS Number N The welds are characterized by high tensile strength and improved resistance to stress corrosion cracking and pitting. The wire is lower in ferrite compared to that of base metal in order to obtain improved weldability. Techalloy 2594 provides matching chemistry and mechanical property characteristics to wrought superduplex alloys such as 2507and Zeron 100, as well as to superduplex casting alloys (ASTM A890). The welding wire is overalloyed 2-3 percent in Nickel to provide the optimum ferrite/austenite ratio in the finished weld. This structure results in high tensile/yield strength and superior resistance to SCC and pitting corrosion. Carbon.016 Tensile Strength Manganese ,000 PSI 720 MPA Silicon.45 Chromium 22.4 Yield Strength Nickel ,500 PSI 560 MPA Molybdenum 3.2 Nitrogen.18 Elongation 26% WRC FN 40 min. Carbon.02 Tensile Strength Manganese PSI 850 MPA Silicon 1.00 Chromium Yield Strength Nickel PSI 650 MPA Copper.50 Molybdenum 3.90 Elongation 28% Nitrogen.250 Recommended Welding Parameters for Stainless Steels Process diameter of Wire Voltage (V) Amperage (A) Gas TIG.035 inches (0.9 mm) % Argon.045 inches (1.1 mm) % Argon 1/16 inches (1.6 mm) % Argon 3/32 inches (2.4 mm) % Argon 1/8 inches (3.2 mm) % Argon MIG.030 inches (0.8 mm) % Argon + 1% Oxygen or 97% Argon + 3% CO inches (0.9 mm) % Argon + 1% Oxygen or 97% Argon + 3% CO inches (1.1 mm) % Argon + 1% Oxygen or 97% Argon + 3% CO inches (1.6 mm) % Argon + 1% Oxygen or 97% Argon + 3% CO 2 SAW 3/32 inches (2.4 mm) Suitable Flux must be used 1/8 inches (3.2 mm) Suitable Flux must be used 5/32 inches (4.0 mm) Suitable Flux must be used

20 19 WELDING WIRE a n d ELECTRODES STAINLESS STEEL WELDING WIRES Typical Chemical Composition of Stainless Steel Wires Product Specification C Mn Si Fe Cr Mo Ni Cb N S P Cu FN +Ta Techalloy BAL Techalloy 308/308H AWS A5.9 ER308H BAL Techalloy 308/308L AWS A5.9 ER308L BAL Techalloy 308LHS AWS A5.9 ER308LSi BAL Techalloy 309/309L AWS A5.9 ER309L BAL Techalloy 309LHS AWS A5.9 ER309LSi BAL Techalloy 309LMo Techalloy 310 AWS A5.9 ER BAL Techalloy 312 AWS A5.9 ER BAL min Techalloy 316/316L AWS A5.9 ER316L BAL Techalloy 316LHS AWS A5.9 ER316LSi BAL Techalloy 317L AWS A5.9 ER317L BAL Techalloy 320LR AWS A5.9 ER320LR BAL Techalloy 330 AWS A5.9 ER BAL Techalloy 347 AWS A5.9 ER BAL Techalloy 385 AWS A5.9 ER BAL Techalloy 409Cb AWS A5.9 ER409Cb BAL Techalloy 410 AWS A5.9 ER BAL Techalloy 410NiMo AWS A5.9 ER410NiMo BAL Techalloy 420 AWS A5.9 ER BAL Techalloy 430 AWS A5.9 ER BAL Techalloy 430LCb BAL Techalloy 630 AWS A5.9 ER BAL Techalloy 2209 AWS A5.9 ER BAL min Techalloy 2594 AWS A5.9 ER BAL min

21 WELDING WIRE a n d ELECTRODES 20 STAINLESS STEEL ELECTRODES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 308/308L AWS A5.4 E308L-16 AWS A5.4 E308L-17 Tech-Rod 309/309L AWS A5.4 E309L-16 AWS A5.4 E309L-17 Tech-Rod 310 AWS A5.4 E Tech-Rod 312 AWS A5.4 E Tech-Rod 316/316L AWS A5.4 E316L-16 AWS A5.4 E316L-17 Tech-Rod 317L AWS A5.4 E317L-16 Tech-Rod 308/308L is a low carbon electrode used to weld Types 304L and 347. The weld deposit contains a maximum of.04% carbon, which minimizes the formation of chromium carbides, and consequent susceptibility to intergranular corrosion. The weld deposit, with controlled ferrite, gives excellent notch toughness at -320 F (-196 C). Tech-Rod 309/309L gives a weld deposit similar to 309, with reduced carbon levels (0.04% maximum) that offer increased resistance to intergranular corrosion. Type 309/309L is ideal for joining stainless steel to themselves or to carbon or low alloy steels. Tech-Rod 309L is preferred to Tech-Rod 309 for cladding over carbon or low alloy steels, as well as for dissimilar joints which undergo heat treatment. Tech-Rod 310 electrodes are used to weld stainless steels of similar composition in wrought and cast form. The weld deposit is fully austenitic, and as such calls for minimum heat input during welding. Tech-Rod 312 electrodes are used for welding wrought and cast alloys of similar composition as well as for welding dissimilar metals. The weld deposits exhibit high tensile strength and offer good resistance to abrasion. The weld deposit of Tech-Rod 316L electrodes is similar to that of Type 316, except the carbon is limited to a maximum of 0.04%. Precise control of the carbon content in Tech-Rod 316/316L electrodes provides a weld deposit matching the corrosion resistant qualities of Type 316/16L stainless steel. The extra low carbon content reduces the possibility of carbide precipitation and consequent intergranular corrosion. The weld deposit of Tech-Rod 317L is similar to that of Type 317, except the carbon is limited to a maximum of 0.04%. In addition to the resistance to pitting and crevice corrosion, this consumable offers good resistance to intergranular corrosion. Carbon.03 Tensile Strength Manganese ,500 PSI 580 MPA Silicon.43 Chromium 19.4 Yield Strength Nickel ,000 PSI 380 MPA Iron WRC FN 7 Elongation 40% Carbon.035 Tensile Strength Manganese ,500 PSI 555 MPA Silicon.53 Chromium Yield Strength Nickel ,000 PSI 410 MPA Iron WRC FN 8 Elongation 36% Carbon.11 Tensile Strength Manganese ,500 PSI 625 MPA Silicon.52 Chromium 26.2 Yield Strength Nickel ,500 PSI 425 MPA Iron WRC FN 0 Elongation 34% Carbon.12 Tensile Strength Manganese ,000 PAS 750 MPA Silicon.56 Chromium 29.3 Yield Strength Nickel ,000 PSI 540 MPA Iron WRC FN 30 min Elongation 23% Carbon.035 Tensile Strength Manganese ,800 PSI 590 MPA Silicon.52 Chromium 18.7 Yield Strength Nickel ,000 PSI 400 MPA Molybdenum 2.30 Iron Elongation 36% WRC FN 7 Carbon.035 Tensile Strength Manganese ,500 PSI 570 MPA Silicon.55 Chromium Yield Strength Nickel ,000 PSI 400 MPA Molybdenum 3.4 Iron Elongation 38% WRC FN 7

22 21 WELDING WIRE a n d ELECTRODES STAINLESS STEEL ELECTRODES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 320LR AWS A5.4 E320LR-16 Tech-Rod 330 AWS A5.4 E Tech-Rod 347 AWS A5.4 E Tech-Rod 385 AWS A5.4 E (904L) Tech-Rod 410 AWS A5.4 E Tech-Rod 410NiMo AWS A5.4 E410NiMo-16 Tech-Rod 320LR is similar in composition to Tech-Rod 320, with carbon, silicon, phosphorus, and sulfur controlled to lower limits and columbium and manganese kept to a narrower range. This composition is designed to reduce the possibility of microfissuring; however, low heat input is advisable for welding. Tech-Rod 330 electrodes are used to weld wrought and cast forms of stainless steel of similar chemical composition, which offer good heat and scale resistance above 1800 F (980 C). However, high sulfur environments adversely affect the high temperature performance. The heat input has to be kept to a minimum during welding to avoid the possibility of microfissuring. Tech-Rod 347 electrodes are columbium stabilized stainless steel electrodes used for welding Types 347 and 321 stainless and stainless clad steels. The columbium content is approximately ten times the carbon content, and when this product is used to weld stabilized Type 347 or 321 parent metal, it precludes intergranular corrosion under severe operating conditions. Tech-Rod 385 is used for welding materials of similar chemical composition (UNS Number N08904). These materials are used in fabrication of equipment and vessels for handling and storing sulfuric acid and phosphoric acid. The weld metal is fully austenitic and, as such, the low melting constituents such as carbon, silicon, and phosphorus should be kept low. Welding must be done with low heat input, using stringer bead technique. Tech-Rod 410 is designed to weld stainless steels of similar chemical composition as well as to overlay carbon steels to impart corrosion, erosion, and abrasion resistance. This material, being an airhardening type, calls for a preheat and interpass temperature of not less than 400 F (200 C) during welding. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld heat treatment between 1550 F and 1650 F for two hours. Tech-Rod 410NiMo is designed to weld materials of similar chemical composition in cast and wrought forms. Preheat and interpass temperatures of not less than 300 F (150 C) are recommended during welding. NOTE: Mechanical properties listed to the right reflect utilization of a post-weld treatment between 1100 F and 1150 F for one hour. Carbon.024 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.24 Chromium 19.8 Yield Strength Nickel ,000 PSI 390 MPA Molybdenum 2.4 Columbium + Tantalum.27 Elongation 34% Copper 3.55 Sulfur.011 Iron WRC FN 0 Carbon.21 Tensile Strength Manganese ,500 PSI 580 MPA Silicon.48 Chromium Yield Strength Nickel ,000 PSI 390 MPA Iron WRC FN 0 Elongation 26% Carbon.050 Tensile Strength Manganese ,000 PSI 590 MPA Silicon.52 Chromium Yield Strength Nickel ,000 PSI 390 MPA Columbium.6 Iron Elongation 35% WRC FN 7 Carbon.015 Tensile Strength Manganese ,000 PSI 610 MPA Silicon.45 Chromium 20.5 Yield Strength Nickel ,500 PSI 450 MPA Molybdenum 4.6 Copper 1.75 Elongation 32% Iron WRC FN 0 Carbon.12 Tensile Strength Manganese.68 78,500 PSI 540 MPA Silicon.52 Chromium 12.1 Yield Strength Iron 63,000 PSI 430 MPA Elongation 23% Carbon.03 Tensile Strength Manganese ,500 PSI 800 MPA Silicon.45 Chromium 12.1 Yield Strength Nickel ,000 PSI 630 MPA Molybdenum.52 Iron Elongation 17%

23 WELDING WIRE a n d ELECTRODES 22 STAINLESS STEEL ELECTRODES mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE DEPOSIT (AS WELDED) Tech-Rod 430 AWS A5.4 E Tech-Rod 2209 AWS A5.4 E (Duplex Grade) Tech-Rod 2594 AWS A5.9 E (Super Duplex Grade) TECH-ROD WELD-ALL Tech-Rod 430 is designed to weld materials of similar chemical composition as well as overlay on carbon steels. The undiluted weld metal is ferritic, but with the dilution from mild or low alloy steel, it could become martensitic. Therefore, preheating and interpass temperatures of 300 F (150 C) during welding are recommended. Tech-Rod 2209 is used to weld duplex stainless steels such as UNS Number N The welds offer excellent resistance to stress corrosion cracking, and pitting. The micro-structure of the weld metal consists of austenite and ferrite. The ferrite of weld metal will be lower than the ferrite of Type 2205 base metal. Welding of duplex stainless steels calls for controlled parameters to achieve specified mechanical and corrosion resistance properties. Tech-Rod 2594 is a superduplex grade electrode that provides matching chemistry and mechanical property characteristics to wrought superduplex alloys such as 2507 and Zeron 100, as well as to superduplex casting alloys (ASTM A890). The electrode is overalloyed 2% to 3% in nickel to provide the optimum ferrite/austenite ratio in the finished weld. This structure results in high tensile and yield strengths and superior resistance to SCC and pitting corrosion. This electrode is used for joining and overlaying a variety of steels such as carbon and spring steels, tool and die grades, stainless steels and dissimilar steels. Deposits are of high strength with satisfactory elongation and resistance to wear, corrosion, and impact. Not heat treatable. WELDING PROCEDURES: Clean weld area and bevel heavy sections. Hold a short arc and run stringer beads for high alloy tool steels. Preheat to 400 F. Peen to relieve stresses. Weld AC or DC. Carbon.05 Tensile Strength Manganese.65 74,000 PSI 530 MPA Silicon.42 Chromium 16.4 Yield Strength Iron 58,500 PSI 400 MPA Elongation 23% Carbon.02 Tensile Strength Manganese ,000 PSI 700 MPA Silicon.52 Chromium 22.4 Yield Strength Nickel ,000 PSI 600 MPA Molybdenum 3.3 Nitrogen.16 Elongation 22% Iron WRC FN 35 min Carbon 0.02 Tensile Strength Manganese PSI 900 MPA Silicon 1.00 Chromium Yield Strength Nickel PSI 695 MPA Copper 0.50 Molybdenum 3.90 Elongation 31% Nitrogen 0.25 Iron WRC FN 40 min Tensile Strength 120,000 PSI 830 MPA Yield Strength 65,000 PSI 450 MPA Elongation is % Hardness BHN

24 23 WELDING WIRE a n d ELECTRODES STAINLESS STEEL ELECTRODES Typical Chemical Composition of Stainless Steel ELECTRODEs Product Specification C Mn Si Fe Cr Mo Ni Cb N S P Cu FN +Ta Tech-Rod 308/308L AWS A5.4 E308L BAL * AWS A5.4 E308L-17 Tech-Rod 309/309L AWS A5.4 E309L BAL * AWS A5.4 E309L-17 Tech-Rod 310 AWS A5.4 E BAL * Tech-Rod 312 AWS A5.4 E BAL * min Tech-Rod 316 AWS A5.4 E BAL * Tech-Rod 316/316L AWS A5.4 E316L BAL * AWS A5.4 E316L-17 Tech-Rod 317L AWS A5.4 E317L BAL * Tech-Rod 320LR AWS A5.4 E320LR BAL * Tech-Rod 330 AWS A5.4 E BAL * Tech-Rod 347 AWS A5.4 E BAL * Tech-Rod 385 AWS A5.4 E BAL * Tech-Rod 410 AWS A5.4 E BAL * Tech-Rod 410NiMo AWS A5.4 E410NiMo BAL * Tech-Rod 430 AWS A5.4 E BAL * Tech-Rod 2209 AWS A5.4 E BAL min Tech-Rod 2594 AWS A5.9 E BAL min Tech-Rod Weld-All * Nitrogen in these weld deposits is usually between.04% and.08% TYPICAL ELECTRODE SIZES & CURRENTS FOR SMAW WELDING OF Stainless Steels Amperage (A) Process diameter of Wire Voltage (V) Flat Vertical & Overhead SMAW 3/32 inches (2.4 mm) /8 inches (3.2 mm) /32 inches (4.0 mm) /16 inches (4.8 mm)

25 WELDING WIRE a n d ELECTRODES 24 SUGGESTIONS FOR WELDING STAINLESS STEELS Stainless steels were primarily developed to render corrosion resistance. There are certain other requirements that must be met in every stainless application. They may include corrosion resistance in a particular medium, avoidance of contamination of product, resistance to oxidation and carburization at elevated temperatures as well as the ability to provide requisite mechanical strength. There are several grades of stainless steels which can be broadly grouped into 300 Series, 400 Series and others. 300 Series stainless steels contain iron, chromium, nickel and carbon as principal ingredients. 400 Series stainless steels contain iron, chromium, and carbon as principal ingredients. Not all 400 Series are weldable. Weldable 400 Series stainless steels are also called straight chromium steels, since their major alloying element is chromium. The 400 Series can be divided into ferritic grades and martensitic grades. Each grade calls for different preheat and interpass welding temperatures. The martensitic grades contain chromium from 11-14% and are air hardenable unless modified with an addition of aluminum, titanium, columbium, or carbon levels below 0.1%. These modified grades and the higher chromium grades up to 30% have markedly decreased hardenability and are called ferritic stainless steels. The second group of stainless steels is the 300 Series. These grades are very popular in the fabrication industry, as they can withstand a variety of corrosion media. The chromium content of these steels ranges from 16% to 30%, and the nickel content from 5% to 35%. These are called austenitic steels, as the microstructure of these grades is predominantly austenite. Nonetheless, there is some ferrite in several grades. The other grades which do not contain any ferrite are called fully austenitic grades. A small amount of ferrite is necessary to stop cracking during solidification of welds. However, in certain media, ferrite reduces corrosion resistance, and the only choice for such media is to opt for fully austenitic grades. Fully austenitic grades give rise to micro-fissuring during welding, which could be eliminated by choosing low heat input processes along with restricted low melting constituents in the weld metal. Welding Requirements To weld stainless steels, three factors are to be considered: The type of stainless steel material that is to be welded. The process of welding. The distortion caused by welding. Welding 300 Series Stainless Steels The 300 Series consists of two types of material: those which contain ferrite and austenite, and those which contain only austenite. None of the above requires any preheat or interpass temperature or post weld heat treatment. However, heating up to 150 F before welding is advisable to evaporate any condensed moisture in the joint. The stainless steels which do not contain any ferrite are called fully austenitic steels. These materials are prone to develop micro-fissures during welding. Formation of micro-fissures could be avoided by selecting the low heat input process of welding such as TIG or shielded metal arc with up to 1/8 diameter electrodes. The consumables selected for welding these materials should be able to deposit weld metal with low levels of impurities and low melting constituents. Welding of austenitic stainless steels with more than 10% ferrite should be done with low interpass temperature in order to avoid temper embrittlement, which could occur between 800 F and 1100 F. Some grades such as 309L, 309LSi and 312, which contain higher ferrite are used for welding dissimilar metals, in which case the resulting ferrite in the weld deposit, after dilution from the base materials, should be taken into consideration. If the ferrite after dilution is too low say, 2FN or less there could be a problem of microfissuring in the welds. If the resulting ferrite is too high, such welds undergo faster embrittlement and it is advisable to limit such welds to one or two layers.

26 25 WELDING WIRE a n d ELECTRODES SUGGESTIONS FOR WELDING STAINLESS STEELS Welding 400 Series Stainless Steels Welding most of the 400 Series stainless steels calls for maintaining preheat and interpass temperatures, and in some cases post-weld heating to avoid formation of brittle structure called martensite. Techalloy 409Cb, 430 and 430LCb grades which are ferritic do not require preheat, but it is advisable to heat to 200 F to avoid condensation in the joint. Techalloy 410 calls for a preheat and interpass temperature of 400 F to avoid possible formation of martensite. Techalloy 420 is a martensitic grade, and is extremely sensitive to air hardening, and should be preheated and welded above 600 F and subjected to post-weld heating at 500 F for one hour. Welding Duplex and Super Duplex Stainless Steels Duplex and super duplex stainless steels were developed to combine the best properties of austenitic and ferritic steels. They have higher yield strength, 65 Ksi (450 N/ mm 2 ), and higher tensile strength, 100 Ksi (69 N/mm 2 ), compared to 300 Series stainless steels. These steels are resistant to corrosion as well as to stress corrosion cracking and pitting from hydrocarbon compounds. Filler metals to weld duplex and super duplex stainless steels will have similar chemical composition to that of the parent metal except that the nickel is higher by 3% to 4%. Higher nickel is required to reduce ferrite in order to obtain optimum mechanical properties. Duplex and super duplex stainless steels are sensitive to embrittlement around 900 F and could rapidly form brittle inter-metallic phases (such as CHI and SIGMA ) between 1300 F and 1500 F. Control of heat input during welding is essential to avoid formation of intermetallic phases. Heat input in the range of KJ/inch is recommended for welding. Duplex stainless steels typically have a pitting index between 35 and 38, and super duplexes typically have a pitting index above 40. Pitting index is calculated with the following formula: PITTING INDEX = %Cr +3.3 (%Mo) +16(%N) Welding Processes Influence of welding processes and parameters also are to be considered for welding stainless steels. The major welding processes are: Shielded metal arc welding (SMAW) Submerged arc welding (SAW) TIG welding MIG welding FCAW SMAW Welding In shielded metal arc welding, the consumable used for welding is a coated electrode. The coating flux contains various minerals in order to impart different characteristics to welding. Some principal functions of the flux are: To ionize the arc atmosphere and improve metal transfer To generate shielding gases, and thus protect the molten weld metal from atmospheric oxidation To provide slag coverage to the molten weld metal To provide deoxidants to react with dissolved oxygen in the weld metal and protect alloying elements To provide alloying elements to the weld To make a clean slag-metal separation on solidification. The electrodes should be transferred to a holding oven when the package is opened to stop them from absorbing moisture from the atmosphere. Electrode Storage & Reconditioning Coated electrodes just removed from sealed containers are intended to be used as is from the container. Electrodes from open containers should be stored in a holding oven at 215 F 240 F. Open cans of electrodes exposed to a high humidity atmosphere for more than four hours or low humidity for more than eight hours should be reconditioned before using by baking in a drying oven for 1-2 hours at 400 F 500 F.

27 WELDING WIRE a n d ELECTRODES 26 SUGGESTIONS FOR WELDING STAINLESS STEELS SAW Welding In submerged arc welding, the flux is separately fed into the joint where the consumable wire establishes an arc beneath the flux. In the heat generated from the arc, the wire as well as some part of the flux melts. As the welding head moves along the joint, slag and metal separate by virtue of the difference in their specific gravities, and on solidification, the weld metal makes the joint, and the slag will be chipped off. The functions of the flux are similar to those in shielded metal arc welding. Heat input is high in SAW leading to higher productivity. TIG Welding In TIG welding, the arc is struck between the workpiece and a non-consumable electrode like thoriated tungsten for welding ferrous materials, and zirconiated tungsten for aluminum. The consumable wire is melted in the arc atmosphere and the inert gases like argon or helium or their mixture are used as shielding gases. TIG is extremely suitable for joining thin sheets and tubes, and for making root pass welding in pipes, since the heat input in this process is minimal. TIG welds do not cause any undercuts or excessive penetration, and the distortion is the lowest of any welding process. TIG welds provide superior quality weld metal, but the productivity is low. MIG Welding Gas-Metal-Arc welding is generally called MIG (metal inert gas) welding. In this process, the consumable travels through a nozzle and a tip before it strikes an arc with the workpiece. The arc atmosphere is shielded by gases like: 100% argon 99% argon with 1% oxygen 97% argon with 3% carbon dioxide assume an important role. Shielding gases are chosen taking quality, cost and operability into consideration. Control of Distortion Due to Welding Two factors contribute to distortion: The thermal coefficient of expansion of austenitic stainless steels is very high compared to that of mild steels. The conductivity of heat of stainless steels is much less than that of mild steels. Due to the combination of the above factors, stainless steels undergo distortion, which must be controlled by using suitable jigs, fixtures, and balanced heat input during welding. Estimation of Delta Ferrite in Austenetic Stainless Steel There are three methods of estimating ferrite in stainless steels: By measuring with instruments like Magna- Gauge, which work on the principle of measuring the magnetic strength. By calculating from the chemical composition with the help of diagrams developed by Schaeffler, DeLong, and Welding Research Council. By metallographic methods. Of the above, the first two items are popular, while the third approach is laborious and time-consuming. Ferrite can be measured from an undiluted weld metal employing a calibrated instrument. Ferrite can also be estimated from the chemical composition of undiluted weld metal using multiple regression charts. Measured ferrite and estimated ferrite could differ to a certain extent. The welding parameters, thermal experience, and the size, shape, and orientation of ferrite could influence the accuracy of measurements. MIG welding is a high-productivity process. MIG welding doesn t need expensive machinery, and the welding machines are easily transportable, making this process very popular on construction sites. In MIG welding, shielding gas, welding parameters, and the consumable

28 27 WELDING WIRE a n d ELECTRODES SUGGESTIONS FOR WELDING STAINLESS STEELS 18 WRC-1992 DIAGRAM FOR STAINLESS STEEL WELD METAL Nieq = Ni + 35C + 20N+ 0.25Cu A FA AF F Cr eq = Cr + Mo Cb NICKEL EQUIVALENT = % Ni + 30 X % C + 30 X % N X % Mn SCHAEFFLER A + M LINE DELONG (FN) DIAGRAM FOR STAINLESS STEEL WELD METAL AUSTENITE PRIOR MAGNETIC PERCENT FERRITE 2% WRC FERRITE NUMBER 0% 0 4% 6% 7.6% 9.2% 10.7% 12.3% 13.8% CHROMIUM EQUIVALENT = %Cr + %Mo x %Si x %Cb AUSTENITE PLUS FERRITE DELONG DIAGRAM: Calculate the nickel and chromium equivalents from the weld metal analysis. If nitrogen analysis of the weld metal is not available, assume 0.06% for GTA and covered electrode, or 0.08% for GMA weld metals. The DeLong diagram predicts the WRC Ferrite Number within plus or minus 3 in approximately 90% of the tests for the 308, 309, 316, and 317 families.

29 WELDING WIRE a n d ELECTRODES 28 Low Alloy STEEL Wires A strong tradition has helped position Techalloy as a leading supplier of Low Alloy solid wires for critical fabrications. mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 80S-B2 AWS A5.28 ER80S-B2 Techalloy 80S-B6 (Techalloy 502) AWS A5.2 ER80S-B6 Techalloy 80S-B2 is designed for the gas metal arc welding of 1-1/4 Cr / 1/2 Mo steels, which are used for high temperature service. Preheating and interpass temperatures of not less than 300 F must be used during welding. NOTE: Mechanical properties (listed to the right) reflect utilization of a post-weld heat treatment between 1125 F and 1175 F for one hour. Techalloy 80S-B6 is designed to weld materials of similar chemical composition, for high temperature service applications. This is an air-hardening material and as such calls for preheat and interpass temperatures of 350 F minimum during welding. NOTE: Mechanical properties (listed to the right) reflect utilization of a post-weld heat treatment between 1550 F and 1600 F for two hours. Carbon.09 Tensile Strength Manganese.55 85,000 PSI 590 MPA Silicon.48 Chromium 1.35 Yield Strength Molybdenum.55 71,500 PSI 490 MPA Elongation 21% Impact 32 F (0 C) 60 ft-lbs 80 Joules Carbon.07 Tensile Strength Manganese.44 78,500 PSI 540 MPA Silicon.36 Chromium 5.45 Yield Strength Molybdenum.55 60,500 PSI 420 MPA Elongation 32% Techalloy 80S-B8 (Techalloy 505) AWS A5.28 ER80S-B8 Techalloy 90S-B3 AWS A5.28 ER90S-B3 Techalloy 90S-B9 AWS A5.28 ER90S-B9 Techalloy 80S-B8 is designed for welding materials of similar composition. This alloy, being an air-hardening type, calls for preheat and interpass temperatures of not less than 350 F during welding. NOTE: Mechanical properties (listed to the right) reflect utilization of a post-weld heat treatment between 1550 F and 1600 F for two hours. Techalloy 90S-B3 is designed for gas metal arc welding of 2-1/4 Cr / 1 Mo steels, which are used for high temperature applications. A preheat and interpass temperature of not less than 350 F should be maintained during welding. NOTE: Mechanical properties (listed to the right) reflect utilization of a post-weld heat treatment between 1250 F and 1300 F for one hour. For welding 9 CrMo P91 grade steels. Requires controlled preheat, interpass and post weld heat treatment. NOTE: Mechanical properties (listed to the right) reflect utilization of a post-weld heat treatment of 1400 F for two hours. Carbon.08 Tensile Strength Manganese.45 79,000 PSI 550 MPA Silicon.34 Chromium 9.15 Yield Strength Molybdenum ,000 PSI 430 MPA Elongation 30% Carbon.10 Tensile Strength Manganese.62 94,500 PSI 650 MPA Silicon.48 Chromium 2.55 Yield Strength Molybdenum ,500 PSI 550 MPA Elongation 19% Impact 68 F (20 C) 80 ft-lbs 105 Joules Carbon.11 Tensile Strength Manganese ,000 PSI 772 MPA Silicon.19 Chromium 9.0 Yield Strength Nickel.5 100,000 PSI 690 MPA Molybdenum.95 Vanadium.18 Elongation 17% Columbium.07 Iron Impact Strength 40 ft-lbs at room temp. 54 Joules

30 29 WELDING WIRE a n d ELECTRODES Low Alloy STEEL Wires mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy 110S-1 AWS A5.28 ER110S-1 Techalloy 110S-1 is intended for applications where high strength, combined with low temperature ductility are prime considerations. Applications include welding of HY100 and other high strength, low alloy steels. A preheat and interpass temperature of not less than 300 F is required during welding. NOTE: Mechanical properties of welds (listed to the right) are greatly influenced by the preheat, interpass temperature, the heat input, and the postweld heat treatment. Carbon.07 Tensile Strength Manganese ,500 PSI 790 MPA Silicon.45 Chromium.30 Yield Strength Nickel ,000 PSI 680 MPA Molybdenum.42 Iron Elongation 17% Impact -60 F / -51 C 60 ft-lbs 87 Joules Techalloy 120S-1 AWS A5.28 ER120S-1 Techalloy 120S-1 is a high strength, low alloy steel welding wire developed for welding HY100 and other high strength steels. The weld deposits also give adequate low temperature toughness down to -60 F. A preheat and interpass temperature of not less than 300 F is recommended during welding. NOTE: Mechanical properties of welds (listed to the right) are greatly influenced by the preheat, interpass temperature, the heat input, and the postweld heat treatment. Carbon.08 Tensile Strength Manganese ,000 PSI 860 MPA Silicon.48 Chromium.35 Yield Strength Nickel ,500 PSI 730 MPA Molybdenum.50 Iron Elongation 15% Impact -60 F / -51 C 60 ft-lbs 80 Joules Techalloy 515 AWS A5.23 EB2 Techalloy 521 AWS A5.23 EB3 Techalloy 4130 Techalloy 515 is a 1-1/4 Cr /.5 Mo wire for submerged arc welding applications of steels with similar chemical composition. A preheat and interpass temperature of not les than 300 F should be maintained during welding. NOTE: Mechanical properties (listed to the right) of welds are greatly influenced by the flux used as well as the heat input and the post-weld heat treatment. Mechanical properties listed to the right reflect utilization of a post-weld heat treatment of 1125 F to 1175 F for one hour. Techalloy 521 is a 2-1/2 Cr / 1 Mo wire for submerged arc welding applications of steels with similar chemical composition. A preheat and interpass temperature of not less than 350 F should be maintained during welding. NOTE: Mechanical properties of welds (listed to the right) are greatly influenced by the flux used as well as the heat input and the post-weld heat treatment. Mechanical properties reflect utilization of a postweld heat treatment of 1250 F to 1300 F for one hour. Techalloy 4130 is a high strength, low alloy welding wire for joining steels of similar chemical composition, as well as for overlays where moderate hardness is required. This wire can be used for TIG, MIG and submerged arc welding applications. A preheat and interpass temperature of not less than 400 F is required during welding. NOTE: Mechanical properties of welds (listed to the right) are governed by the heat treatment undergone by the weld metal. Mechanical properties are for weld metal oil quenched from 1550 F and tempered at 1050 F. Carbon.10 Tensile Strength Manganese.65 84,500 PSI 580 MPA Silicon.25 Chromium 1.45 Yield Strength Molybdenum.54 71,000 PSI 490 MPA Iron Elongation 22% Carbon.09 Tensile Strength Manganese.69 94,500 PSI 650 MPA Silicon.22 Chromium 2.55 Yield Strength Molybdenum ,500 PSI 560 MPA Iron Elongation 19% Carbon.31 Tensile Strength Manganese ,000 PSI 1,000 MPA Silicon.28 Chromium.93 Yield Strength Molybdenum ,000 PSI 900 MPA Iron Elongation 11%

31 WELDING WIRE a n d ELECTRODES 30 Low Alloy STEEL Wires mechanical typical CHEMICAL PROPERTIES OF composition ALL WELD METAL PRODUCT uses of THE WIRE (AS WELDED) Techalloy AK-10* AWS A5.28 ER100S-G *This grade can also be used for submerged arc welding, where its relevant classifications is AWS A5.23 EG Techalloy AK-10 is a low alloy steel welding wire developed for welding of high strength steels with adequate ductility at low temperatures. The hardness of the undiluted weld will be less than 235 BHN. The requirement of preheat and interpass temperatures should be determined taking the base plate chemistry and thickness into consideration. NOTE: Mechanical properties (listed to the right) of welds are greatly influenced by the preheat, interpass temperature, the heat input, and the post- weld heat treatment. Carbon.12 Tensile Strength Manganese ,000 PSI 720 MPA Silicon.60 Chromium.30 Yield Strength Nickel.95 88,000 PSI 610 MPA Molybdenum.40 Iron Elongation 25% Impact -75 F/-59 C 50 ft-lbs 67 Joules TYPICAL CHEMICAL COMPOSITION OF low alloy wires Product Specification C Mn Si Fe Cr Mo Ni V Techalloy 80S-B2 AWS A5.28 ER80S-B BAL Techalloy 80S-B6 AWS A5.2 ER80S-B BAL Techalloy 80S-B8 AWS A5.28 ER80S-B BAL Techalloy 90S-B3 AWS A5.28 ER90S-B BAL Techalloy 90S-B9 AWS A5.28 ER90S-B BAL Techalloy 110S-1 AWS A5.28 ER110S BAL Techalloy 120S-1 AWS A5.28 ER120S BAL Techalloy 515 AWS A5.23 EB BAL Techalloy 521 AWS A5.23 EB BAL Techalloy BAL Techalloy AK-10 AWS A5.28 ER100S-G BAL RECOMMENDED WELDING PARAMETERS FOR TIG AND MIG WELDING OF LOW ALLOY STEELS Process diameter of Wire Voltage (V) Amperage (A) Gas tig.035 inches % Argon.045 inches % Argon 1/16 inches % Argon 3/32 inches % Argon 1/8 inches % Argon MIG Spray Transfer.035 inches % Argon + 2% Oxygen.045 inches % Argon + 25% CO 2 1/16 inches % CO 2 MIG Short Circuiting Transfer.035 inches % CO 2 *.045 inches % Argon + 25% CO 2 *With 100% CO 2 gas shielding, weld metal undergoes globular transfer.

32 31 WELDING WIRE a n d ELECTRODES suggestions for welding Low Alloy STEELs Low alloy steels are used for higher strengths and service environments of high and low temperatures. They contain carbon, manganese, chromium, molybdenum, and nickel and in some specific types vanadium and copper appear as alloying elements. Low alloy steels with chromium and molybdenum are designed for moderately high temperature applications, since they have high creep resistance. For still higher temperatures, ferritic and martensitic stainless steels are used. TIG WELDING In TIG welding, the arc is struck between the workpiece and the non-consumable electrode like thoriated tungsten for welding of ferrous materials and zirconiated tungsten for aluminum. The consumable wire is melted in the arc atmosphere and the inert gases like argon or helium or their mixture are used as shielding gases. TIG is extremely suitable for joining thin sheets and tubes, and for making root pass welding in pipes, since the heat input in this process is minimal. TIG welds do not cause any undercuts or excessive penetration, and the distortion is the lowest of any welding process. TIG welds provide superior quality weld metal, but the productivity is low. MIG WELDING Gas-Metal-Arc welding is generally called MIG (metal inert gas) welding. In this process, the consumable travels through a nozzle and a tip before it strikes an arc with the workpiece. The arc atmosphere is shielded by gases such as 100% argon, 98% argon with 2% oxygen, 75% argon with 25% carbon dioxide, and 100% carbon dioxide. The smooth functioning of MIG welding depends on welding parameters, shielding gases, and the consumables. The welding parameters are amperage, voltage, feed of the wire, speed of welding, and flow rate of the shielding gas. The feed of the wire has to be adjusted to suit the voltage and amperage. Voltage, amperage, and speed determine the heat input. If these parameters are not synchronized, the welding does not perform well. There could be burnback fusing the tips, or there could be insufficient melting of the wire, resulting in improper fusion. If the gas pressure is insufficient, the metal gets oxidized, leaving inclusions and porosity in weld metal. There are two different techniques in MIG welding Spray transfer Droplet transfer/short-circuit type In spray type, the liquid weld metal travels from the tip of the consumable in the form of tiny globules to the workpiece. Spray transfer is achieved with higher current densities. In droplet transfer, the liquid metal travels in the form of droplets, and operates at lower current densities. Usually the droplet or short-circuiting technique is used in root pass welding, followed by spray transfer for the rest of the welding.

33 WELDING WIRE a n d ELECTRODES 32 PACKAGING OPTIONS Unless a customer specifies that exact metric size is required, standard imperial size will be substituted. For example,.045 standard will be supplied instead of 1.2 mm wire unless otherwise specified at the time of the order. STANDARD DIAMETERS GMAW (MIG) /16 GTAW (TIG) 1/16 3/32 1/8 5/32 SAW (Sub-Arc) 1/16 3/32 1/8 5/32 SMAW (Electrodes) 3/32 1/8 5/32 3/16 PACKAGING OPTIONS item Standard Package GMAW GTAW SAW SMAW 2# Spool 20 spools 40#/box A 10# Spool 4 spools 40# /box A 33# Plastic Spool 1 spool 33#/box S 33# Wire Spool 1 spool 33#/box S 60# Spool 1 spool 60#/box A 60# Coil 1 coil 60#/box S 10# Tubes (36 ) 3 tubes-30#/box S 50# Bulk (36 ) 60 cartons/skid S 250# Reel 3 reels/skid A 500# Reel 3 reels/skid A 250# Tech Pak 2 paks/skid A 500# Tech Pak 2 paks/skid A 500# Pay-off Pak 4 paks/skid A 700# Pay-off Pak 4 paks/skid A 8# Poly Tube (3/32 x 12 ) 3 tubes - 24#/box S 10# Poly Tube (3/32 x 14 ) 3 tubes 30#/box S S Standard Packaging (may vary by alloy) A Available upon request # Pounds

34 33 WELDING WIRE a n d ELECTRODES tables and charts LINEAR MEASUREMENTS WEiGHT MEASUREMENTS Linear Measures Metric Equivalents Weight Measures Metric Equivalents 1 centimeter inches 1 inch 2.54 centimeters 1 decimeter inches / foot 1 foot decimeters 1 meter inches / yards 1 yard meter 1 dekameter rods 1 rod dekameter 1 kilometer mile 1 mile kilometers 1 gram ounce 1 ounce grams 1 kilogram pounds 1 pound kilogram 1 metric ton English ton 1 English ton metric ton TEMPERATURE CONVERSIONS Fahrenheit Celsius Fahrenheit Celsius SQUARE MEASUREMENTS Square Measures Metric Equivalents 1square centimeter square inches 1 square inch square centimeters 1 square decimeter square foot 1 square foot square decimeter 1 square meter square yards 1 square yard square meter 1 acre 160 square rods 1 square rod acre 1 hectare 2.47 acres 1 acre hectare 1 square kilometer square mile 1 square mile 2.59 square kilometers MEASURE OF VOLUME Volume Measures Metric Equivalents 1 cubic centimeter cubic inch 1 cubic inch cubic centimeter 1 cubic centimeter cubic foot 1 cubic foot cubic decimeters 1 cubic yard cubic meter 1 stere cord 1 cord steres 1 liter quart dry / quarts liq. 1 quart dry liters 1 quart liquid liter 1 dekaliter gallons / pecks 1 gallon dekaliter 1 peck dekaliter 1 hektoliter bushels 1 bushel hektoliter 212 F 100 C 59 F 15 C 122 F 50 C 50 F 10 C 113 F 45 C 41 F 5 C 104 F 40 C 32 F 0 C 98.6 F 37 C 23 F -5 C 95 F 35 C 14 F -10 C 86 F 30 C 5 F -15 C 77 F 25 C -4 F -20 C 68 F 20 C -13 F -25 C FRACTION/DECIMAL EQUIVALENTS Fraction Decimal Fraction Decimal Fraction Decimal 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

35 WELDING WIRE a n d ELECTRODES 34 tables and charts WIRE GAUGE TABLE Gauge inches millimeters Gauge inches millimeters Other useful conversions Measurements Conversions Temperature F = 1.8 x C + 32 Coating Weight 1 oz./ft. 2 = 305.5g/m 2 Draw Speed Feet per minute / = meters per second Stainless Steel Diameter 2 x 2.7 = pound per lineal foot Metric Distance 1 Foot x.3048 = 1 meter 1 inch / 25.4 = 1 millimeter 1 Micron =.001 millimeter = inches Tensile Strength PSI = mpa / Weight 1 kg = 2.2 pounds

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