SELECTION OF WELDIND CONSUMABLES FOR HEAVY FABRICATION
SELECTION OF WELDIND CONSUMABLES FOR HEAVY FABRICATION
R.D.Pennathur MAILAM INDIA LIMITED
EVALUTION OF WELDING
HOW ?
WHEN ?
WHERE ? TUBAL CAIN FORGE WELD KJELLBERG METAL ARC 1910 BERNADO CORBON ARC 1885 BC FUNCTION OF FLUX MATERIALS Deoxidation of Scavengers- Helps to Purify The Weld Metal Slag Formers -Slag Protects Weld Puddle From Atmosphere During Solidification Arc Stabilisers - Produce a Smooth Arc & Help Reduce Spatter & Smoke Alloying Elements - Provide the Necessary mechanical Properties Gasifier - Provide a Shielding Gas CRITERIA FOR SELECTION
METALLURGICAL
MECHANICAL
PROCESS METALLURGICAL BASE MATERIAL CHEMICAL COMPOSITION MECHANICAL PROPERTIES CORROSION REQUIREMENTS PHYSICAL PROPERTIES SOUNDNESS &STRUCTURAL STABILITY HEAT TREATMENT
MECHANICAL
THICKNESS OF MATERIAL
DIMENTION & NO. OF COMPONENTS PROCESS
AVAILABLE FORM OF CONSUMABLES
ADAPTABILITY TO JOB
WELDING PROCESS SELECTED SMAW Advantages Variety of electrodes with different features Most versatile in use all position joints /joints with limited access Suitable for most alloys Equipment simple,inexpensive & portable. Disadvantages Finite length High dependence on welder skill Not amenable for automation
GAS METAL ARC WELDING GMAW/MIG-MAG/CO2/SOLID WIRE Advantages Continuous electrode Higher currents possible Minimal post weld cleaning required Highly amenable to automation Disadvantages Equipment more complex & Costlier than SMAW Welder skill dependence still high,especially for out-of position welding Not amenable for customisation SUBMERGED ARC WELDING SAW Advantages Highest deposition rate Most suited for automation Consumables can be customised Lower operator fatigue Disadvantages Not versatile-no positional capability Generally not used for thin section Joint fit-up very critical Arc not visible FLUX CORED WIRE- FCAW FCAW Consumable is Often known as Inside Out as flux is inside & metal is outside . Modern Technology of Manufacture of FCAW wire involves Strip & Dry Premixed Flux as Basic Raw Materials The Quantum of Flux Addition & Flux Fill Ratio are Continuously Monitored to deliver Consistent Quality Products. ` FCAW -CORED WIRE ADVANTAGES High productivity of Continuous Wire Welding Metallurgical Benefit of Flux Higher Current than Solid Wire Versatile Use-All Positional ,Wide Thickness Range Visible Arc -Easy to Use DISADVANTAGES Equipment more complex & Costlier than SMAW FCAW Wires more Expensive on Weight Basis but compensated by higher Productivity `TYPES OF CORED WIRES CS/LAS SS Gasless (Self Shielded) A 5. 20 5.22
Gas Shielded Flux Cored A 5.20 5.22
Composite Submerged Arc
Gas Shielded Metal Cored A5.18 GASLESS (SELF SHIELDED) Generates its Own Protective Shielding Gas. Normally used in Flat & Horizontal Positions only . For CS most commonly used for Out Door Fabrication & also extensively used for Repair & Maintenance application For SS Mainly used for Joining & Overlay Welding Application GAS SHIELDED FLUX CORED WIRES For CS/LAS Currently Available in Two Types Positional Welding type - Rutile Slag Flat/ Horizontal type - Basic Slag Both Types Typically Run with Ar- 25%Co2 or 100% CO2 Diameter Down to 0.9 mm Available For SS Positional Welding Type available in all grades suitable for CO2 Shielding CLASSIFICATION OF FCAW CONSUMABLES For Metal Cored Wires as per AWS A 5.18 E 70 C X Y N HZ For FCAW Wires as per AWS A 5.20 E XXT XMJ HZ For SS FCAW Wires as per A 5.22 E XXX T X-X COMPOSIT SUBMERGED ARC FCAW Consumables used mainly with Neutral Flux to give desired Weld metal Chemistry Typical Application include High Alloy Steel Compositions with special TDC Required in Small Quantity.(Tailor Made Product) GAS SHIELDED METAL CORED Composit or Metal Cored FCAW consumables most commonly used for robotic application in view of Higher Deposition Efficiency Bead on Bead Welding (NO Slag ) Better Wire Feeding.
` FCAW -CORED WIRE ADVANTAGES High productivity of Continuous Wire Welding Metallurgical Benefit of Flux Higher Current than Solid Wire Versatile Use-All Positional ,Wide Thickness Range Visible Arc -Easy to Use DISADVANTAGES Equipment more complex & Costlier than SMAW FCAW Wires more Expensive on Weight Basis but compensated by higher Productivity COMMOMLY AVAILABLE FCAW PRODUCTS FCAW Product for Positional Welding of CS / LAS With Gas Shielding. Self Shielded FCAW Product for CS Self Shielded for HF Products Gas Shielded SS Small Dia.Cored Wire Product for Fabrication Self shielded SS Cored Wire for SS Overlay /Cladding
WHY FCAW FCAW AS PROCESS HAS GREAT ADVANTAGE OVER OTHER CONVENTIONAL PROCESS
FCAW IS THE FUTURE PROCESS WITH TECHNO COMMERCIAL EDGE OVER OTHER EXSISTING PROCESSES
FCAW HAS WIDE RANGE OF PRODUCT TO MEET INDUSTRIAL NEEDS & ALSO EASE OF APPLICATION MAKES IT USER FRIENDLY. SELECTION CRITERIA Chemical & Mechanical Properties Commercial Availability of Product Suitability for Restraint Welds - Hydrogen Level in Weld Metal Type of Gas Shielding to be used Feasibility of Application Cost Factor
ACID vs BASIC vs METAL CORED vs RUTILE BASIC E70T-1 vs E70T-5 vs E70C-6M vs E70T-1 ACID BASIC METALCORED RUTILE BASIC UTS,Mpa YS Mpa %E 585 518 23 535 450 28 575 517 27 585 497 27 IMPACT J -18 DeG C -29 Deg C 40-65 20-45 110-160 80-135 75-100 25-55 80-125 65-100 HYDROGEN Ml/100 GMS 5-10 2-5 3-8 2-5 OPE.CHARAC. BEAD SHAPE FLAT CONVEX FLAT FLAT WETTING ACTION VERY GOOD FAIR GOOD VERY GOOD STORAGE & RECONDITIONING FOR SMAW /FCAW SMAW Low Hydrogen Store 100-150 Deg C Recondition at 400 Deg C- 1Hr Stainless Recondition at 200 Deg C- 1Hr FCAW Plastic Recondition at 50 Deg C- 48Hr Min Coils Store 100-125 Deg C Recondition at 150 Deg C- 6-8Hrs Wire Spool Store 150 Deg C Basket Recondition at 250 Deg C- 2-3Hrs Higher Rebake Temperature , Faster Reconditioning
SHIELDING GASES Arc Characteristics Penetration Profile Mode Of Transfer Spatter Level Alloy Recovery Material Types SHIELDING GAS COMPARISON E 81T-1-Ni1 VERTICAL UP @21 KJ/CM 95Ar/5CO2 75Ar/25CO2 50Ar/50CO2 100CO2 TYPICAL CHEMICAL ANALYSIS C Mn Si .059 1.29. .44 .055 1.29 .44 .042 1.24 .39 .041 1.16 .31 TYPICAL MECH. PROP(Mpa) YS UTS 540 603 531 586 502 568 457 565 TYPICAL IMPACT PROP(J) 0 Deg C -40Deg C 123 91 125 84 109 48 104 40 BEAD SHAPE FLAT FLAT CONVEX CONVEX PROCESS SHARE FOR VARIOUS COUNTRIES INDIA USA SMAW 80% SMAW 35% GMAW 55% SAW8% GTAW2% SAW 8% GMAW 10% GTAW 2% GTAW SMAW SAW GMAW GTAW SMAW SAW GMAW EUROPE JAPAN GMAW 60% SMAW 30% SAW 8% GTAW 2% SMAW 20% GTAW 2% SAW8% GMAW 70% GLOBAL PROCESS SHARE OF WELD METAL JAPAN EUROPE USA INDIA SMAW 20% 30% 35% 80% SAW 8% 8% 8% 8% GTAW 2% 2% 2% 2% GMAW 70% 60% 55% 10% PROCESS SHARE IN GLOBAL PERSPECTIVE Steady Increase in Solid & Core Wire Consumption Covered Electrode Consumption will Decline & Stabilise around 30% In Developed Countries, CO2 Welding Accounts for more than 50% In Developing Countries like China & Korea CO2 Process Share is already around 15% ESTIMATING WELD METAL DEPOSITION COSTS
MATERIAL COST
ELECTRODE
SHIELDING GAS FIXED COST Joint Preparation
Fixturing
Tacking Preheating
Cleaning
Inspection
Rs COSTING Power & 2- 5% Equipment
Electrode Cost 8- 15 %
Labour & 80- 85 % Overhead Cost LABOUR & OVERHEAD ELECTRODE COST POWER & EQUIP. INCREASED WELDING PRODUCTIVITY REDUCED WELDING COST ELECTRODE EFFICIENCY & STUB END LOSS DATA ON EFFECT OF STUB END LOSSES TYPE -E7018 ELECTRODES
EFFICIENATY AT 50 mm STUB LOSS -70 % EFFICIENATY AT 75 mm STUB LOSS -64.5% EFFICIENATY AT 100 mm STUB LOSS -59.1% EFFICIENATY AT 125 mm STUB LOSS -54.5% EFFICIENATY AT 150 mm STUB LOSS -49.1% 450 mm WELD METAL COST FORMULAS 1 Labour & Labour & Overhead Cost/Hr Overhead = ---------------------------------------- Deposition Operating Rate (Kg/Hr) X Factor Electrode Cost / Kg 2 Electrode: = --------------------------------- Deposition Efficiency Gas Flow Rate Cu.Meters/ Hr. X Gas Cost / litre 3 Gas = ------------------------------------ Deposition Rate (Kg/Hr) Flux Cost/kg X 1.4 4 Flux = ------------------------------------- Deposition Efficiency Cost Rs/KWH x Volts x Amps 5 Power Cost = ---------------------------------- 1000 X Deposition Rate (kg/Hr) Total Cost per kg = Sum of 1-5 , Above of Deposited Weld Metal WELD METAL COST WORKSHEET FCAW AS COMPARED TO SMAW - WELDING POSITION - FLAT CALCULATING COST CAL. COST CAL FCAW COST PER KG FCAW SMAW Vs. DEP. WELD E 71T-1 / 1.6 DIA. E 7018 / 5mm SMAW AT 300 A/28 V AT 250 A/28 V * COST RED.- Labour & Overhead 150/5X0.45 66.67 150/2.5 X0.30 200 -133.33 Electrode: 150/0.87 172.4 60 /0.65 92.3 80.4 Gas 990 x 0.04 /5 7.92 NA 7.92 Power Cost 4 x 300 x 28 / 4 x 250 x 28 / 1000 x 5 6.72 1000 x 2.5 11.2 -4.48 Sum of Total Variable 253.7 Total Variable 304 -49.29 the Above cost/kgDeposite Cost/kg Deposite : Rework at 3% at 15% COST 253.72 /0.97 261.56 303.51 /0.85 357 -95.54 Basic Cost Saving per Kg with FCAW = 49.29 Actual Cost Saving pr Kg with FCAW = 95.54 ONE MINUTE WELD VERTICAL UP POSITION-6MM FILLET One Minute Welds made using SMAW 3.2mm 70mm, GMAW-0.9mm 105 mm FCAW 1.2mm 300 mm Cost aspect based on above productivity.
FCAW SMAW GMAW 900 1300 2900 DEP. COST PER KG C O S T
I N
R S .
LABOUR &OVERHEAD-RS.500 SMAW FCAW GMAW FCAW CONSUMABLES AVILABILITY WITH AWS SPECIFICATION E70T-1 FOR E71T-1 BOILER E70T5 QUALITY E81T1-W WHEATHERING E80T1-A1 FOR E80T1-B2 LOW ALLOY E80-T1-B3 STEEL E80T5-G FOR E90T5-K2 HSLA E100T5K3 STEELS E110T5-K4 E308TX-X FOR SS E316TX-X POSITIONAL E312TX-X WELDING E309TX-X E308.T0-3 FOR E309T0-3 CLADDING APPLICATION
FABRICATION INDUSTRIES
CORROSION RESISTANCE OVERLAYS
HARD FACING/REPAIR & MAINTAINANCE
PROCESS INDUSTRIES BOILER &PRESSURE VESSELS HEAVY STRUCTURAL OFFSHORE FABRICATION RAIL &ROAD BRIDGES SHIP BUILDING ROAD TANKERS RAIL WAGONS TRANPORTATION REPAIR &MAINTAINANCE SUPER CONDITIONING HOW WELDING SMARTER SAVED 120,000 MAN-HOURS Walking Dragline - 12,000 MT Weight Boom Height : 95 M Hoist Depth : 55 M Bucket Load :325 MT Cylindrical Steel Base 32 M Dia. 2.5 M Wide & 140 MT Weight Replacement of the Base Estimated 160,000 Man- Hour with SMAW(80 Months) Estimated 40,000 Man- Hour with FCAW (20 Months) 32M 2.5M Wedge Shaped Segments Make Up Dragon Base 150 mm SS FCAW TO RESCUE OF ASPRIN MAKERS HEAD ACHE SS Half Coil Reactor Found Leaking. Leak Spots Identified as likely restart points in OH Position. Small Dia. SS FCAW made it possible to reduce restart points Better approach made improved Fusion Possible.
HALF COIL REFINARY Oil is King!
Tosco, Martinez oil refinery
OFF SHORE APPLICATION PRESENT STATUS FCAW ACCEPTED AS FABRICATION PROCESS AVAILABILITY,COSISTANT QUALITY,EASE OF APPLICATION WILL HELP IN INCRESING PROCESS SHARE PRESENT MARKET SHARE OF 12%(GMAW+FCAW) EXPECTED TO INCESE RAPIDLY TO 20% BY 2010 AS AGAINST 50% OF ADVANCED COUNTRIES. INDIAN MANUFACTURES GEARING UPTO CHALLENGE OF OFFERING IMPROVED QUALITY & QUANTITY AT MOST COMPETATIVE PRICE. FCAW PROCESS TO BE CLASSIFIED AS PROCESS CAPABLE OF PROVIDING HIGHER PRODUCTIVITY,QUALITY,CONSISTANT CHEMISTRY,POSITIONAL CAPABILITY & EASE OF APPLICATION. CONCLUTION
Industries are adopting FCAW as production process which can give desired quality. The availability of CS/LAS,SS & HF consumables in India has improved. The present share of GMAW +FCAW which is at present 12% is expected to reach 20% by 2010 As industrial application of SAW has reached 100% utilisation level ,the FCAW application will have rapid growth. The improved availability of FCAW product to AWS specification &as well as Custom built products will ensure adoption of FCAW as process where in productivity & consistant quality are basic requirement