SOLID WIRE AND ROD PRODUCTS

The information contained herein is based on data and information developed in the laboratories of The Esab Group, Inc. (Seller), but is presented without guarantee or warranty and the Seller makes no recommendation for and disclaims any liability incurred from any use thereof, including without limitation, any use in a commercial process not controlled by the Seller, and any use in violation of any existing patent, foreign or domestic, or of applicable laws and regulations. THE SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, EXCEPT AS EXPRESSLY STATED IN SELLER'S SALES CONTRACT OR SALES ACKNOWLEDGMENT FORM.

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SOLID WIRE PRODUCTS TABLE OF CONTENTS

Description Introduction
Weldability Process ....................................................................7-4 Features ...................................................................7-5

Page

Description

Page

Spoolarc MIG Wires

Carbon Steel Wires Spoolarc Easy Grind (No AWS Class) .....................7-6 Spoolarc 65 (ER70S-2) ............................................7-6 Spoolarc 29S (ER70S-3) ..........................................7-7 Spoolarc 82 (ER70S-3) ............................................7-7 Spoolarc 85 (ER70S-4) ............................................7-8 Spoolarc 86 (ER70S-6) ............................................7-8 Spoolarc 87HP (ER70S-7) .......................................7-9 Manganese-Molybdenum (Mn-Mo) Wires Spoolarc 83 (ER80S-D2)..........................................7-9 High Strength Wires Spoolarc 95 (ER100S-1) ........................................7-10 Spoolarc 120 (ER120S-1) ......................................7-10

Special Purpose Wires Spoolarc WS (ER80S-G) ........................................7-10 Spoolarc 140 (No AWS Class) ...............................7-10 Gas Welding Rods Oxweld 1HT (RG60) ...............................................7-11 Oxweld 7 (RG45)....................................................7-11 Oxweld 32CMS (RG65)..........................................7-11

Wire Chemistries .....................................................7-12 Packaging Specifications ......................................7-13 Bulk Packaging ........................................................7-13 Spoolarc Deposition & Welding Data .................7-14

Spoolarc MIG Wires (contd.)

All ESAB MIG wire products are manufactured under ISO 9002 Certified Quality Management System.
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SOLID WIRE SELECTION

Weldability
Welding performance of a MIG wire is described by the following: Weld metal soundness Weld puddle fluidity Bead shape and edge wetting Spatter tendency

Here is a guide to choosing wires with the proper deoxidizer level for your job.

AS YOU INCREASE OXYGEN CONTENT OF BASE METAL PLATE and/or CURRENT and/or WELD PUDDLE SIZE and/or AMOUNT OF MILL SCALE OR RUST and/or OXIDIZING LEVEL OF SHIELDING GAS

Weld Metal Soundness

Soundness in weld metal is characterized by a lack of porosity, good fusion, and freedom from cracking. Porosity, the most frequently cited cause of poor weld soundness, is caused by excess oxygen from the atmosphere, the shielding gas, and any base plate contamination combining with carbon in the weld metal to form bundles of carbon monoxide (CO) gas. Some of the CO can become trapped as the weld cools forming pores called porosity. Typically, the MIG wire process is recognized as having very low hydrogen in the deposit. Factors, such as moisture in the shielding gas, atmospheric conditions, and plate condition, may have a varying degree of adverse effect on the actual diffusible hydrogen in the weld deposit.

YOU SHOULD USE WIRE WITH HIGHER DEOXIDIZER CONTENT TO OBTAIN WELD METAL WITH LEAST POROSITY

Process

Control Of Porosity
Sufficient deoxidation of the weld puddle is needed to minimize CO formation and porosity. To accomplish this, Spoolarc wires contain elements with which oxygen combines in preference to carbon to form harmless slags. These elements, called deoxidizers, are manganese (Mn), silicon (Si), titanium (Ti), aluminum (Al), and zirconium (Zr). Aluminum, titanium and zirconium are very powerful deoxidizers perhaps five times as effective as manganese and silicon. The following table shows the relative deoxidizer level for Spoolarc plain carbon steel and alloy steel MIG wires:
Wires % Mn % Si Deoxidizer Level

Weld Puddle Fluidity, Bead Shape And Spatter

Fluidity of the molten weld puddle is important for several reasons. Fluid puddles tend to wet out smoothly at the edges and produce a flat, smooth bead shape, especially on fillet welds. This is important on multi-pass, short arc welds where lack-of-fusion defects can occur if bead shape is poor. Flat, well-wet-in beads are also desirable where appearance is a primary concern and where post weld grinding may be necessary to meet job requirements. Caution: Excessive puddle fluidity can cause performance difficulties in out-of-position welding or in making concave horizontal fillets.

Spoolarc 86 1.46 0.85 Spoolarc 83 1.37 0.65 Spoolarc 87 HP 1.55 0.55 Spoolarc 85 1.20 0.70 Spoolarc 65* 1.10 0.50 Spoolarc 82 1.20 0.60 Spoolarc 29S 1.15 0.55 Determining Required Oxidizer Level In Wire
*Contains .08 Al, .052Zr, .08T. Note: Mn and Si values are based on CO2 Shielding.

highest

Influence Of Manganese And Silicon

Choosing the manganese and silicon content of a MIG wire is usually the major decision an operator must make. Increasing manganese and silicon affects puddle fluidity, bead shape and other factors as follows:

lowest

7-3

SOLID WIRE SELECTION

2. Spoolarc HI DEP III (copper-coated) wire has a mattefinish with a low (typically 0.05% wt.) copper coating that is thin and tightly adherent - eliminating troublesome copper flaking. The matte-finish on the Spoolarc wire contrasts with many conventional MIG wires that are shiny in appearance. These shiny wires do not have any enhanced welding performance. In fact, these wires are generally higher in copper coating level (up to 0.30% wt.) and are prone to copper flaking which detracts from their performance. Higher tensile strength wire has a greater resistance to buckling under compression. ESAB draws most MIG wires directly from rod to final size resulting in a high tensile strength product that resists birdnesting when restrictions in the feed system occur.

INCREASING Mn and Si

3.

BEAD SHAPE Less edge wetting Crown in middle Coarse freeze lines Tends to Spatter

BEAD SHAPE Smooth, wet-in edges Flat bead surface Smooth, uniform freeze lines Minimum spatter

4.

The Al, Ti and Zr deoxidizers in Spoolarc 65 wire tend to make its puddle somewhat sluggish. The stiff puddle characteristic makes this wire ideal for pipe especially small diameter pipe and many other out-of-position welding jobs.

Excellent Arc Characteristics

Quick starting with Spoolarc wire from ESAB minimizes weld spatter - a common problem with other MIG wires. Spoolarc wires produce excellent spray arcs at lower voltages, providing precise control of the welding process, lower weld metal hydrogen levels and better penetration. Spoolarc wires increase contact tip life. ESABs proprietary manufacturing process results in better current transfer, less arcing, reduced contact tip erosion - especially at high current and wire feed speeds. Fewer worn out contact tips can mean a sizable saving not only in replacement parts but also in labor and downtime required to change them.

Influence Of Shielding Gas and Arc Voltage

CO2 shielding causes more turbulent wire-to-base plate metal transfer and tends to create a more crowned bead with greater spatter loss. Argon-based shielding gases provide more stable, uniform wire-to-base plate metal transfer, well-shaped beads, minimal spatter loss and a lower fume generation rate. Increasing arc voltage tends to increase puddle fluidity, flatten the weld bead, increase edge wetting and increase spatter. Higher voltages also reduce penetration and may cause additional loss of alloying elements. Spoolarc wires are processed either copper-coated using the proprietary ESAB HI DEP III manufacturing process, or as bare (uncoppered) product. Spoolarc wires are available in a variety of alloys, diameters and packages to meet the most demanding customer applications. Spoolarc wires, either copper-coated or bare, provide excellent feedability and arc stability under the roughest shop conditions and most demanding applications even at high wire feed speedsthat means less downtime, greater productivity. Note: Spoolarc bare wires are a standard product for customers requiring or preferring no copper coating.

ESAB Spoolarc Wires For Low Hydrogen Welds

Hydrogen normally gets into welds through moisture on the electrode surface, particularly when stick electrodes are used. Spoolarc MIG wires have no absorbent coating and no moisture pickup. Tight control of surface residuals results in a high quality weld with no hydrogen problems. There is no need for drying ovens to recondition electrodes that may have absorbed moisture.

CAUTION: Dont Forget to Test The Weld

Most of the data in this booklet are based on AWS tests performed under standard conditions. In normal practice, however, the results usually differ to the extent that the job conditions differ from the standard. The following factors can affect the results produced by any wire/gas combination: Base plate chemistry Base plate thickness Weld bead size Dilution of base plate with weld metal Heat input (affects weld cooling rate) That is why it is important to test the selected wire/gas combination in the same joint and under the same condition to be used during actual production. Depending on the job, the test may simply be to evaluate welding performance. It may also involve a full check on the welds service properties.

Features Why Feedability Is So Improved With ESAB Spoolarc Wires

1.

All Spoolarc MIG wires are cleaned after the final drawing process to remove residual drawing lubricants and are then treated with a proprietary ESAB process to insure good feeding, arc stability and low weld deposit hydrogen.

7-4

CARBON STEEL WIRES

Spoolarc Easy Grind
No AWS Class
Description:
Spoolarc Easy Grind is a fully deoxidized wire designed to weld over moderate levels of rust and paint as are commonly encountered in auto body repair work. Easy Grind produces welds that easily exceed the tensile requirements of ER70S class wires. Easy Grind is produced in small diameters and are appropriate for the low current welding machines commonly used in body shops.

Spoolarc 65

AWS Class ER70S-2 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 Military - MIL 70S-2, MIL-E-23765/1 ABS - ER70S-2 CWB-CSA W48.4-M, ER480S-2

Description:
Spoolarc 65 is a triple deoxidized (aluminum, titanium, zirconium) welding wire designed for welding over rust and mill scale. The less fluid weld puddle of Spoolarc 65 makes it easy to control when used out of position. Spoolarc 65 is the preferred wire for all position welding of small diameter pipe.

Typical Mechanical Properties

As Welded 75% Ar/25% CO2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 72,000 (497) 80,000 (552) 24 As Welded ft.-lbs. (J) 40 (54)

Typical Mechanical Properties

Testing Temp. As Welded GMAW 98% Ar/2% O2 CO2 GTAW Argon

Typical Charpy V-Notch Impact Properties

Testing Temp. -20F (-29C)

Yield Strength, psi (MPa) 68,000 (469) 70,700 (487) 67,500 (466) Tensile Strength, psi (MPa)82,000 (566) 80,000 (552) 77,500 (534) % Elongation in 2" (51 mm) 28 26 31

Standard Diameters and Packages

.023" (0.6 mm) x 12# (5.4 kg) spl .030" (0.8 mm) x 12# (5.4 kg) spl

Typical Charpy V-Notch Impact Properties

As Welded GMAW 98% Ar/2% O2 CO2 ft.-lbs. (J) ft.-lbs. (J) 45 C 0.06 0.06 (61) Mn 0.75 1.05 35 Si 0.27 0.45 (47) P GTAW Argon ft.-lbs. (J) 170 (230) S

Testing Temp. -20F (-29C) Gas/Process CO2 /GMAW Argon/GTAW

Typical Undiluted Weld Metal Analysis (%)

0.011 0.007 0.011 0.009

Standard Diameters and Packages

MIG:
.030" (0.8 mm) x 12, 33 & 44# (5.4, 15 & 20 kg) spl .035" (0.9 mm) x 12, 33 & 44# (5.4, 15 & 20 kg) spl, 65# (29 kg) coil & 700# (318 kg) reel .045" (1.2 mm) x 12, 33 & 44# (5.4, 15 & 20 kg) spl, 65# (29 kg) coil & 700# (318 kg) reel 1/16" (1.6 mm) x 44# (20 kg) spl & 65# (29 kg) coil 3/32" (2.4 mm) x 65# (29 kg) coil

TIG:
1/16" (1.6 mm) x 12, 18 & 36" (305, 457 & 914 mm) lengths 3/32" (2.4 mm) x 12, 18 & 36" (305, 457 & 914 mm) lengths 1/8" (3.2 mm) x 12, 18 & 36" (305, 457 & 914 mm) lengths *TIG rod available flagged or unflagged

Recommended Welding Parameters pg. 14

7-5

CARBON STEEL WIRES

Spoolarc 29S Spoolarc 82

AWS Class ER70S-3 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 ABS - ER70S-3, 3SA, 3YSA

AWS Class ER70S-3 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 Military - MIL 70S-3, MIL-E-23765/1 ABS - ER70S-3, 3SA, 3YSA Lloyds - 3SA, 3YSA

Description:
Spoolarc 29S is an economy priced general purpose MIG wire suitable for many carbon steel welding applications. It provides sufficient deoxidation to allow welding over light mill scale. Spoolarc 29S is used in a wide variety of applications including heavy equipment, automotive parts, railcars, farm implements, and sheet metal.

Description:
Spoolarc 82 is a premium quality, general purpose MIG wire subjected to the stringent quality control procedures required for certification to military, Lloyds, and ABS specifications. Spoolarc 82 is recommended for pressure vessel and pipe fabrication, HVAC duct work, and general carbon steel structural welding.

Typical Mechanical Properties

As Welded CO2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 60,100 (415) 75,000 (518) 32

Typical Mechanical Properties

As Welded 98% Ar/2% O2 CO2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 66,200 (457) 79,400 (548) 28 60,000 (414) 72,800 (502) 28

Typical Charpy V-Notch Impact Properties

Testing Temp. 0F (-18C) As Welded CO2 ft.-lbs. (J) 95 (129)

Typical Charpy V-Notch Impact Properties

Testing Temp. As Welded 98% Ar/2% O2 CO2 ft.-lbs. (J) ft.-lbs. (J) 110 (149) 64 (87)

Typical Undiluted Weld Metal Analysis (%)

Gas CO2 C 0.07 Mn 0.67 Si 0.30 P S 0.004 0.009

0F (-18C)

Typical Undiluted Weld Metal Analysis (%)

Gas 98% Ar/2% O2 CO2 C 0.10 0.07 Mn 0.90 0.76 Si 0.41 0.32 P S Cu 0.16 0.15 0.013 0.009 0.004 0.010

Standard Diameters and Packages

.030" (0.8 mm) x 33 & 44# (15 & 20 kg) spl .035" (0.9 mm) x 33, 44 & 60# (15, 20 & 27 kg) spl, 65 & 600# (29 & 272 kg) coil, 700# (318 kg) reel, & 500 & 900# (227 & 408 kg) Marathon Pac .045" (1.2 mm) x 33, 44 & 60# (15, 20 & 27 kg) spl, 65 & 600# (29 & 272 kg) coil, 700# (318 kg) reel, & 600 & 900# (272 & 408 kg) Marathon Pac .052" (1.4 mm) x 65 & 1000# (29 & 454 kg) coil, 1000# (454 kg) reel, & 600 & 900# (272 & 408 kg) Marathon Pac 1/16" (1.6 mm) x 65 & 1000# (29 & 454 kg) coil, 1000# (454 kg) reel, & 900# (408 kg) Marathon Pac

Standard Diameters and Packages

.030" (0.8 mm) x 12, 33 & 44# (5.4, 15 & 20 kg) spl .035" (0.9 mm) x 12, 33, 44 & 60# (5.4, 15 & 20 kg) spl, 65# (29 kg) coil, 300, 700 & 1000# (136, 318 & 454 kg) reel & 500# (227 kg) Marathon Pac .045" (1.2 mm) x 12, 33, 44 & 60# (5.4, 15 & 20 kg) spl, 65# (29 kg) coil, 300, 700 & 1000# (136, 318 & 454 kg) reel & 500# (227 kg) Marathon Pac .052" (1.4 mm) x 1000# (454 kg) reel 1/16" (1.6 mm) x 33, 44 & 60# (15, 20 & 27 kg) spl, 60# (27 kg) coil, 300 & 700# (136 & 318 kg) reel, & 500# (227 kg) Marathon Pac

Recommended Welding Parameters pg. 14

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CARBON STEEL WIRES

Spoolarc 85 Spoolarc 86

AWS Class ER70S-4 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 Military - MIL 70S-4, MIL-E-23765/1 ABS - ER70S-4

AWS Class ER70S-6 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 Military - MIL 70S-6, MIL-E-23765/1 ABS - ER70S-6 Lloyds - 3SA, 3YSA CWB-CSA W48.4-M, ER40S-6

Description:
Spoolarc 85 contains more manganese and silicon for greater deoxidation capability when compared to ER70S-3 wire. The higher level of deoxidizers provides for better rust and scale tolerance and it also improves bead wetting. Spoolarc 85 is typically used for applications including welding of farm machinery, material handling equipment, and piping.

Description:
Spoolarc 86 contains higher levels of manganese and silicon than the other standard grades of MIG wire. This wire features excellent tolerance of rust and scale, excellent wetting, and a highly fluid weld puddle. It also produces the highest deposit strength of all the carbon steel MIG wires. Spoolarc 86 is used for butt and fillet welding of sheet and plate of a variety of thickness. Applications include HVAC duct work, heavy equipment, structural, and general carbon steel fabrication.

Typical Mechanical Properties

As Welded 98% Ar/2% O2 CO2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) Gas 98% Ar/2% O2 CO2 C 0.08 0.07 Mn 1.20 0.78 69,000 (476) 83,500 (576) 24 Si 0.73 0.42 P 65,300 (451) 78,900 (544) 26 S Cu 0.16 0.16

Typical Mechanical Properties

As Welded 75% Ar/25% CO2 CO2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 72,000 (497) 86,000 (593) 27 68,000 (469) 81,600 (563) 30

Typical Undiluted Weld Metal Analysis (%)

0.011 0.012 0.004 0.011

Standard Diameters and Packages

.030" (0.8 mm) x 44# (20 kg) spl .035" (0.9 mm) x 12 & 44# (5.4 & 20 kg) spl, 65# (29 kg) coil, 1000# (454 kg) reel, & 500 & 900# (227 & 408 kg) Marathon Pac .045" (1.2 mm) x 12 & 44# (5.4 & 20 kg) spl, 65# (29 kg) coil, 1000# (454 kg) reel, & 600 & 900# (272 & 408 kg) Marathon Pac 1/16" (1.6 mm) x 44# (20 kg) spl, 65# (29 kg) coil, & 900# (408 kg) Marathon Pac

Typical Charpy V-Notch Impact Properties

Testing Temp. -20F (-29C) As Welded 75% Ar/25% CO2 CO2 ft.-lbs. (J) ft.-lbs. (J) 67 (91) 31 (42)

Typical Undiluted Weld Metal Analysis (%)

Gas C Mn 1.19 1.03 Si 0.62 0.51 P S Cu -0.26 75% Ar/25% CO2 0.07 CO2 0.08 0.012 0.011 0.011 0.012

Recommended Welding Parameters pg. 14

Standard Diameters and Packages

.023" (0.6 mm) x 12 & 33# ( 5.4 & 15 kg) spl .030" (0.8 mm) x 12, 33 & 44# (5.4, 15 & 20 kg) spl .035" (0.9 mm) x 12, 33, 44 & 60# (5.4, 15, 20 & 27 kg) spl, 65# (29 kg) coil, 500 & 900# (227 & 408 kg) Marathon Pac & 700 & 1000# (318 & 454 kg) reel .045" (1.2 mm) x 33, 44 & 60# (15, 20 & 27 kg) spl, 65# (29 kg) coil, 500 & 900# (227 & 408 kg) Marathon Pac & 700 & 1000# (318 & 454 kg) reel .052" (1.4 mm) x 500# (227 kg) Marathon Pac 1/16" (1.6 mm) x 33, 44 & 60# (15, 20 & 27 kg) spl, 65# (29 kg) coil & 700# (318 kg) reel

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CARBON STEEL WIRES MANGANESE-MOLYBDENUM (Mn-Mo) WIRES

Spoolarc 87 HP Spoolarc 83

AWS Class ER70S-7 Code and Specification Data:

AWS A5.18, ASME SFA 5.18 CWB-CSA W48.4-M, ER480S-7

AWS Class ER80S-D2 Code and Specification Data:

AWS A5.28, ASME SFA 5.28 Military MIL-80S-3, MIL-E-23765/2 CWB-AWS A5.28, ER80-D2

Description:
Spoolarc 87 HP is a high manganese carbon steel wire. It features an optimized manganese to silicon ratio to produce excellent appearing welds over a wide range of welding parameters. It also produces excellent weld metal mechanical properties. Spoolarc 87 HP is suitable for welding over moderate amounts of rust and scale. This wire is widely used for robotic welding applications in the automotive industry, and fabrication of heavy equipment and farm implements. Spoolarc 87 HP is also available as a TIG rod.

Description:
Spoolarc 83 contains 1/2% Mo to provide higher deposit strength in both the as welded and stress relieved conditions. It contains high levels of manganese and silicon to provide good wetting and good rust and scale tolerance. Spoolarc 83 also is used for all position welding of high tensile pipe and tubing commonly found in earthmoving and construction equipment. It is available in forms suitable for MIG and TIG welding.

Typical Mechanical Properties

As Welded MIG 75% Ar/25% CO2 CO2 TIG Argon

Typical Mechanical Properties

Relieved (621C) Testing Temp. O2 As Welded 98% Ar/2% O2 CO2 Stress 8 hrs. @1150F 98% Ar/2%

Yield Strength, psi (MPa) 66,800 (461) 59,900 (413) 69,000 (476) Tensile Strength, psi (MPa)79,100 (546) 72,600 (501) 82,000 (566) % Elongation in 2" (51 mm) 29 22 33

Typical Charpy V-Notch Impact Properties

As Welded MIG TIG 75% Ar/25% CO2 CO2 Argon ft.-lbs. (J) ft.-lbs. (J) ft.-lbs. (J) 62 (84) 55 (75) 127 (172)

Yield Strength, psi (MPa) 95,000 (656) 77,000 (531) 75,000 (518) Tensile Strength, psi (MPa)110,000(759) 92,000 (634) 89,000 (614) % Elongation in 2" (51 mm) 22 23 29

Typical Charpy V-Notch Impact Properties

Relieved (621C) As Welded 98% Ar/2% O2 ft.-lbs. (J) 87 (118) CO2 ft.-lbs. (J) 44 (60) Stress 8 hrs. @1150F 98% Ar/2% ft.-lbs. (J) 31 (42)

Testing Temp. -20F (-29C)

Typical Undiluted Weld Metal Analysis (%)

Gas/Process 75% Ar/25% CO2/MIG CO2/MIG Argon/TIG C 0.08 0.08 0.11 Mn 1.75 1.30 1.80 Si 0.65 0.27 0.70 P S 0.015 0.014 0.005 0.010 0.016 0.014

O2 Testing Temp. -20F (-29C)

Typical Undiluted Weld Metal Analysis (%)

Gas 98% Ar/2% O2 CO2 C 0.09 0.08 Mn 1.65 1.16 Si 0.60 0.34 P S Mo 0.43 0.39 0.013 0.012 0.008 0.012

Standard Diameters and Packages

MIG:
.023" (0.6 mm) x 12# (5.4 kg) spl .030" (0.8 mm) x 12 & 44# (5.4 & 20 kg) spl .035" (0.9 mm) x 44 & 60# (20 & 27.2 kg) spl, 65# (29 kg) coil, 500# (227 kg) Marathon Pac, & 700 & 1000# (318 & 454 kg) reel .045" (1.2 mm) x 44 & 60# (20 & 27.2 kg) spl, 65# (29 kg) coil, 500# (227 kg) Marathon Pac, & 700 & 1000# (318 & 454 kg) reel .052" (1.4 mm) x 500 & 600# (227 & 272 kg) Marathon Pac 1/16" (1.6 mm) x 60# (27.2 kg) spl, 65# (29 kg) coil, 1000# (454 kg) reel

Standard Diameters and Packages

MIG:
.030" (0.8 mm) x 12 & 44# (5.4 & 20 kg) spl .035" (0.9 mm) x 12, 44 & 60# (5.4, 20 & 27.2 kg) spl, 65# (29 kg) coil, & 1000# (454 kg) reel .045" (1.2 mm) x 12, 44 & 60# (5.4, 20 & 27.2 kg) spl, 65# (29 kg) coil, & 1000# (454 kg) reel 1/16" (1.6 mm) x 44 & 60# (20 & 27.2 kg) spl & 65# (29 kg) coil

TIG:
1/16" (1.6 mm) x 36" (914 mm) lengths 3/32" (2.4 mm) x 36" (914 mm) lengths 1/8" (3.2 mm) x 36" (914 mm) lengths

TIG:
1/16" (1.6 mm) x 36" (914 mm) lengths 3/32" (2.4 mm) x 36" (914 mm) lengths 1/8" (3.2 mm) x 36" (914 mm) lengths *TIG rod available flagged or unflagged

*TIG rod available flagged or unflagged

Recommended Welding Parameters pg. 14

7-8

HIGH STRENGTH WIRES SPECIAL PURPOSE WIRES

Spoolarc 95 Spoolarc WS

AWS Class ER100S-1 Code and Specification Data:

AWS A5.28, ASME SFA 5.28 Military - MIL 100S-1, MIL-E-23765/2

AWS Class ER80S-G Code and Specification Data:

AWS A5.28, ASME SFA 5.28

Description:
Spoolarc 95 is Military grade high strength wire used to weld HY-80 steels. Applications for Spoolarc 95 include military tanks, ships and submarines.

Description:
Spoolarc WS is a special purpose wire designed to weld weathering grade steels. The weld metal properties provide the color matching characteristics desired for ASTM A588, A242, Cor-Ten and Mayari R steels. The mechanical properties meet the Federal Highway (AASHTO) Charpy impact standards of 25 ft.-lbs. (34 J) @-20F (-29C). Applications include butt and fillet welds on structural support members and other fabrication requirements for welding weathering grade steels.

Typical Mechanical Properties

As Welded 98% Ar/2% O2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 95,000 (656) 105,000 (725) 23 As Welded 98% Ar/2% O2 ft.-lbs. (J) 93 (126) 65 (88) C Mn Si P S Cr Ni Mo

Typical Charpy V-Notch Impact Properties

Testing Temp. 0F (-18C) -60F (-51C) Gas 98% Ar/2% O2

Typical Mechanical Properties

As Welded 98% Ar/2% O2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 72,500 (500) 78,500 (542) 24

Typical Undiluted Weld Metal Analysis (%)

0.07 1.40 0.35 0.008 0.007 0.20 1.80 0.35

Typical Charpy V-Notch Impact Properties

Testing Temp. -20F (-29C) As Welded 98% Ar/2% O2 ft.-lbs. (J) 25 (34)

Spoolarc 120

AWS Class ER120S-1 Code and Specification Data:

AWS A5.28, ASME SFA 5.28 Military - MIL 120S-1, MIL-E-23765/2

Typical Undiluted Weld Metal Analysis (%)

Gas 98% Ar/2% O2 C Mn Si P S Cr Ni Cu 0.10 0.55 0.23 0.014 0.009 0.45 0.55 0.45

Description:
Spoolarc 120 is a Military grade of high strength wire used to weld HY-100 and other similar steels. Applications for Spoolarc 120 include military tanks, ships and submarines.

Standard Diameters and Packages

.035" (0.9 mm) x 44# (20 kg) spl .045" (1.2 mm) x 44# (20 kg) spl 1/16" (1.6 mm) x 44# (20 kg) spl

Typical Mechanical Properties

As Welded 98% Ar/2% O2 Yield Strength, psi (MPa) Tensile Strength, psi (MPa) % Elongation in 2" (51 mm) 112,000 (773) 123,000 (849) 19 As Welded 98% Ar/2% O2 ft.-lbs. (J) 100 (136) 75 (102) C Mn Si P S Cr Ni Mo

Spoolarc 140
No AWS Class
Description:
Spoolarc 140 is a high strength wire designed to weld HY-130 steels. Meets MIL 140S-1 chemistry requirements. Applications include Military grade material, as well as castings and some heat-treatable steels.

Typical Charpy V-Notch Impact Properties

Testing Temp. 0F (-18C) -60F (-51C) Gas

Standard Diameters and Packages

.035" (0.9 mm) x 35# (15.9 kg) spl .045" (1.2 mm) x 35# (15.9 kg) spl 1/16" (1.6 mm) x 35# (15.9 kg) spl

Typical Undiluted Weld Metal Analysis (%)

98% Ar/2% O2/AW 0.07 1.30 0.35 0.007 0.008 0.40 2.60 0.45

Standard Diameters and Packages

.030" (0.8 mm) x 35# (15.9 kg) spl .035" (0.9 mm) x 35# (15.9 kg) spl .045" (1.2 mm) x 35# (15.9 kg) spl 1/16" (1.6 mm) x 35# (15.9 kg) spl Recommended Welding Parameters pg. 14

7-9

GAS WELDING RODS

Oxweld 1 HT
Description:
Oxweld 1 HT is an oxy-fuel rod for steel pipe, castings and wrought iron applications. Deposit strengths in excess of 60 ksi (414 MPa) can be achieved.

AWS Class RG60 (AWS A5.2)

Oxweld 32 CMS
Description:

AWS Class RG65 (AWS A5.2)

Oxweld 32 is a low alloy oxy-fuel rod designed for high speed fusion welding of pressure vessels, tanks and piping. Weld metal strengths average 70-80 ksi (483-552).

Standard Diameters and Packages

1/16" (1.6 mm) x 36" (914 mm) lengths 3/32" (2.4 mm) x 36" (914 mm) lengths 1/8" (3.2 mm) x 36" (914 mm) lengths 5/32" (4.0 mm) x 36" (914 mm) lengths 3/16" (4.8 mm) x 36" (914 mm) lengths

Standard Diameters and Packages

1/16" (1.6 mm) x 36" (914 mm) lengths 3/32" (2.4 mm) x 36" (914 mm) lengths 1/8" (3.2 mm) x 36" (914 mm) lengths 5/32" (4.0 mm) x 36" (914 mm) lengths 3/16" (4.8 mm) x 36" (914 mm) lengths

Oxweld 7
Description:

AWS Class RG45 (AWS A5.2)

Oxweld 7 is a low carbon, low manganese oxy-fuel designed for improved machinability on steel plate, pipe and wrought iron.

Standard Diameters and Packages

1/16" (1.6 mm) x 36" (914 mm) lengths 3/32" (2.4 mm) x 36" (914 mm) lengths 1/8" (3.2 mm) x 36" (914 mm) lengths 5/32" (4.0 mm) x 36" (914 mm) lengths 3/16" (4.8 mm) x 36" (914 mm) lengths

Straight Length Rods

Size lb. (kg) 15 20 (6.8) (9.1) in. 1/16 x 36 - 2 Flags 3/32 x 36 - 2 Flags 1/16 x 36 - 1 Flag 1/8 x 36 - 2 Flags 3/32 x 36 - 1 Flag 1/8 x 36 - 1 Flag 1/16 to 1/4 x 36 For Rod Size (mm) (1.6 x 914) (2.4 x 914) (1.6 x 914) (3.2 x 914) (2.4 x 914) (3.2 x 914) (1.6-6.4 x 914) Package Dimensions in. 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 37 x 3-1/4 x 2-3/4 (mm) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) (940 x 82.4 x 70.1) Features For Flag Identified Carbon Steel Rods - Both Ends For Flag Identified Carbon Steel Rods - Both Ends For Flag Identified Carbon Steel Rods - One End For Flag Identified Carbon Steel Rods - Both Ends For Flag Identified Carbon Steel Rods - One End For Flag Identified Carbon Steel Rods - One End Standard Package for Carbon Steel Rods

25 (11.3) 30 (13.6) 30 (13.6) 40 (18.1) 50 (22.7)

7-10

WIRE CHEMISTRIES
Typical Undiluted Weld Metal Analysis
Type C-Mn Spoolarc AWS Wires Classification 65 29S 82 85 86 87HP Mn-Mo 83 Hi-84 High Strength Special Purpose 95 120 WS 140 ER70S-2 ER70S-3 ER70S-3 ER70S-4 ER70S-6 ER70S-7 ER80S-D2 ER80S-D2 ER100S-1 ER120S-1 ER80S-G None Typical Analysis (%) Gas CO2 CO2 CO2 98/2 CO2 98/2 CO2 75/25 CO2 75/25 CO2 98/2 CO2 98/2 98/2 98/2 98/2 98/2 C 0.06 0.07 0.07 0.10 0.07 0.08 0.08 0.07 0.08 0.08 0.08 0.09 0.08 0.10 0.07 0.07 0.10 0.11 Mn 0.75 0.67 0.76 0.90 0.78 1.10 1.03 1.19 1.30 1.18 1.16 1.65 1.17 1.70 1.40 1.30 0.55 1.60 Si 0.27 0.30 0.32 0.41 0.42 0.62 0.51 0.62 0.27 0.53 0.34 0.52 0.38 0.53 0.35 0.35 0.23 0.35 P 0.011 0.004 0.004 0.013 0.004 0.011 0.011 0.012 0.005 0.015 0.008 0.013 0.010 0.011 0.008 0.007 0.005 0.014 S 0.007 0.009 0.010 0.009 0.011 0.012 0.012 0.011 0.010 0.014 0.012 0.012 0.011 0.009 0.007 0.008 0.009 0.008 Cr 0.20 0.40 0.45 0.70 Ni 1.80 2.60 0.55 2.58 Mo 0.38 0.43 0.36 0.45 0.35 0.45 0.90 0.26 0.15 0.16 0.16 0.16 0.26 0.45 Cu Other Al, Ti & Zr

Typical Wire Analysis

Type C-Mn Spoolarc Wires 65 29S 82 85 86 87HP Mn-Mo 83 Hi-84 High Strength Special Purpose 95 120 WS 140 AWS Classification ER70S-2 ER70S-3 ER70S-3 ER70S-4 ER70S-6 ER70S-7 ER80S-D2 ER80S-D2 ER100S-1 ER120S-1 ER80S-G None Typical Analysis (%) C 0.06 0.08 0.08 0.10 0.08 0.09 0.09 0.11 0.06 0.07 0.08 0.11 Mn 1.09 1.03 1.20 1.20 1.50 1.65 1.83 1.86 1.62 1.60 0.49 1.60 Si 0.53 0.50 0.60 0.70 0.86 0.60 0.60 0.60 0.32 0.32 0.25 0.35 P 0.009 0.013 0.009 0.009 0.011 0.012 0.011 0.008 0.005 0.005 0.018 0.007 S 0.008 0.012 0.009 0.010 0.010 0.012 0.010 0.007 0.008 0.006 0.011 0.006 Cr 0.03 0.11 0.31 0.65 0.70 Ni 0.04 1.72 2.33 0.64 2.60 Mo 0.48 0.50 0.33 0.48 0.90 Cu 0.45 Other Al, Ti & Zr

7-11

PACKAGING SPECIFICATIONS
Arbor Hole Diameter in. (mm) 5/8 2-1/16 2-1/16 2-1/16 2-1/16 2-1/16 (16) (52.3) (52.3) (52.3) (52.3) (52.3)

SIZE lb. (kg)

O.D. in. (mm) 4 8 12 12 12 12 (102) (203) (305) (305) (305) (305)

Width in. (mm) 1-3/4 2-1/4 4 4 4 4 (44.5) (57) (102) (102) (102) (102)

Type of Spool Plastic Fiber Board Plastic Fiber Board Fiber Board Fiber Board

Features Designed for use in spool-onguns - aluminum wire only Designed for portable suitcasetype welders Aluminum wire only Designed for use on military orders. Can save 3/lb in use cost over 30 lb (13.5 kg) spool by reducing change-out time; under 50 lb (23.5 kg) lifting load restriction. Easier, quicker change-out than 65 lb (30 kg) coil

Spools
1 12 13.2 33 35 44

(0.45) (5.4)

(6) (15) (15.9) (20)

60

(27)

14

(356)

2-1/16

(52.3)

(102)

Fiber Board

Reels
300 700 1000

(136) (318) (454)

22 30 30

(559) (762) (762)

1-5/16 1-5/16 1-5/16

(33.3) (33.3) (33.3)

12-1/2 12-1/2 16

(318) (318) (406)

Wood Wood Wood

Excellent for high production, continuous welding; large size minimizes change-out time cost.

Coils
65

(29)

16-1/4

(413) For Wire Size in. (mm)

12

(305) O.D. (mm) (584) (584) (584)

(102) Core Dia. in. (mm) 16 13 16 (406) (330) (406)

Wire tied Height in. (mm) 34 30.5 34 (864) (775) (864)

Most widely used package

Size lb. (kg)

in. 23 23 23

Features Excellent for high production, continuous welding with fewer changeouts required

Drums

700 (318) 700 (318) 1000 (454)

1/16 to 5/64 3/32 to 3/16 1/16 to 3/16

(1.6-2.0) (2.4-4.8) (1.16-4.8)

Marathon Pac Drums

500 (227) 600 (272) 900 (408)

.035 to .052 (0.9-1.4) .045 (1.2) .035 & .045 (0.9 & 1.2)

(29s, 82, 86, 87 HP Wires Only)

20-1/4 20-1/4 23 (514) (514) (584) 11.5 11.5 11.5

(292) (292) (292)

32.5 32.5 34

(826) (826) (864)

Wire pays out straight without twisting or flipping Results in precise bead placement.

Bulk Packaging
Bulk Packages Save Money
Bulk packages that is 300, 700, and 1000-lb. (136, 318 and 450 kg) reels, 500, 600 & 900-lb. (227, 272 & 408 kg) Marathon Pacs save in several ways: 1. Reduces wire change-out labor cost. 2. Increases production through time saved in number of change-outs. 3. Reduces wire scrap loss. 4. Usually costs less per pound than wire in smaller packages.

Cost Of Change-Out
Change-out cost in $/lb (kg) = (Change-out-time in minutes) X (Labor cost + overhead rate in $/ hr) (Wire package size in lbs/kg) X (60)

The graph below shows change-out costs for ESAB wire packages. Typical change-out time for spools is 10 minutes, for coils 11-12 minutes and for reels and drums, 20 minutes. Labor is figured at $35 per hour, including overhead.

Change-Out Time Is Part of Your Real Wire Cost

Price of the wire is not the only factor to consider when buying wire. Cost of the labor required to replace an empty package can often be equivalent to 10% to 20% of the purchase price of the wire. The total cost of your wire, therefore, is the price plus the change-out cost. 7-12

WELDING DEPOSITION & PARAMETER DATA

Spoolarc Recommended Welding Parameters
SHORT ARC Electrode Diameter in. (mm) .023 (0.6) .030 (0.8) .035 (0.9) .045 (1.2) .052 (1.4) Electrode Unit Length/Wt. in./lb (m/kg) 8505 (476) 5000 (280) 3670 (206) 2220 (124) 1665 ( 93) RANGE: Amps 45-90 60-140 90-160 130-200 150-200 Volts 14-16 14-16 15-19 17-19 17-20 IPM (cm/min) 150-380 (381-965) 150-350 (381-889) 180-300 (457-762) 125-200 (318-508) 135-190 (343-483) OPTIMUM: Amps 70 100 130 160 160 Volts 15 15 17 18 18 IPM (cm/min) 300 (762) 220 (559) 250 (635) 150 (381) 140 (356)

SPRAY ARC .023 (0.6) .030 (0.8) .035 (0.9) .045 (1.2) .052 (1.4) .062 (1.6) 8505 (476) 5000 (280) 3670 (206) 2220 (124) 1665 ( 93) 1150 ( 64) 100-125 160-200 180-230 260-340 275-400 290-400 23-25 24-26 25-27 25-30 26-33 26-36 400-620 (1016-1575) 500-650 (1270-1651) 400-550 (1016-1397) 300-500 (762-1270) 265-390 (673-991) 180-280 (457-711) 110 180 200 300 325 340 23 25 26 27 28 27 450 (1143) 520 (1321) 480 (1219) 350 (889) 310 (787) 200 (508)

Note: DCEP (Electrode Positive); Flow rates of 25-45 CFH is required.

Deposition and Efficiency Data for MIG Welding Wires

Electrode Diameter in. (mm) .030 (0.8) Amps 75 100 150 200 80 100 150 200 250 100 125 150 200 250 300 350 250 275 300 350 400 450 98% A 2% O2 *98% Eff. 2.0 (0.91) 2.6 (1.18) 4.1 (1.86) 6.8 (3.08) 2.2 (1.00) 2.7 (1.22) 4.2 (1.90) 6.2 (2.81) 9.0 (4.08) 2.1 (0.95) 2.8 (1.27) 3.6 (1.63) 5.6 (2.54) 7.8 (3.58) 10.2 (4.63) 13.2 (5.99) 6.5 (2.95) 7.7 (3.49) 9.0 (4.08) 11.3 (5.13) 14.0 (6.35) 17.4 (7.89) Deposition Rate lbs./hr (kg/hr) 75% A 25% CO2 *96% Eff. 1.9 (0.86) 2.6 (1.18) 4.0 (1.81) 6.7 (3.04) 2.1 (0.95) 2.7 (1.22) 4.1 (1.86) 6.0 (2.72) 8.8 (3.99) 2.0 (0.91) 2.8 (1.27) 3.5 (1.59) 5.5 (2.49) 7.6 (3.45) 10.0 (4.53) 12.9 (5.85) 6.4 (2.90) 7.6 (3.45) 8.8 (3.99) 11.0 (4.99) 13.7 (6.21) 17.1 (7.76) Straight CO2 *93% Eff. 1.8 (0.82) 2.5 (1.13) 3.9 (1.77) 6.5 (2.95) 2.0 (0.91) 2.6 (1.18) 4.0 (1.81) 5.9 (2.68) 8.6 (3.90) 1.9 (0.86) 2.7 (1.22) 3.4 (1.54) 5.3 (2.40) 7.4 (3.36) 9.7 (4.40) 12.5 (5.67) 6.2 (2.81) 7.3 (3.31) 8.5 (3.86) 10.7 (4.85) 13.3 (6.03) 16.5 (7.48)

.035 (0.9)

.045 (1.2)

1/16 (1.6)

*Use this figure as the deposition efficiency in the weld metal cost per lb. (kg) calculations.

7-13

7-14