Welder Guide Book - ESAB Welding & Cutting Products
Contents
1. ESAB Miggytrac ESAB Railtrac ESAB Railtrac Orbital for circumferential joints 25 26 Grinding Grinding may be necessary to correct weld metal sagging or beads which are too convex Remove only the most obvious irregularities and avoid making deep grooves They can lead to slag traps and lack of fusion when welding subsequent passes Correct Incorrect Always grind stop start areas Root pass treatment When welding double sided joints ensure that grinding is done to remove the root pass from the first side to sound metals before welding the first pass on the second side Correct Incorrect Grinding wheel pushed into root resulting in a deep groove The narrow joint is almost inaccessible to the torch Troubleshooting Process faults Although good equipment maintenance and good welder training will help prevent process faults they can never be avoided completely In such cases understanding the most common causes will help the welder to solve any problems quickly Listed below are the most common process faults and their likely causes 1 wire stubbing 2 wire burn back 3 excess spatter 4 erratic wire feed 5 unstable arc incorrect parameters Volts too low for wire feed speed or wire feed speed too high for volts spool brake too tight incorrect parameter settings damaged worn contact tip incorrect machine burn back setting slipping in feed rolls incor2. Welder Guide Book Contents Introduction Before you start welding Contact tip and gas nozzle Polarity and inductance Welding parameter setting ASME and EN ISO positions Choice of wire size Recommended parameter settings Split weave and stringer beads 23 3 Direction of travel 4 Welding positions 8 Vertical up 10 welding techniques 11 13 Mechanized welding ia Grinding Troubleshooting 16 Dual Shield 710X Dual Shield 710 X M Dual Shield Il 711X Dual Shield Il 712X Dual Shield 7100 Ultra Dual Shield Il 70 Ultra Dual Shield Il 71 Ultra Dual Shield Il 70T 12H4 Dual Shield Il 80 Ni1H4 Dual Shield 810X Ni1 Dual Shield 8000 Ni2 Dual Shield 8000 B2 Dual Shield II 101 TC Dual Shield Il 101H4M Dual Shield 9000 C1 Dual Shield 9000 D1 Dual Shield 9000 M E71T 1C DH8 T 1M T 9C DH8 T 9M E71T 1C T 1M DH8 T 9C T 9M DH8 E71T 1C JH8 T 12C JH8 E71T 1M JH8 T 12M JH8 E71T 1C DH8 T 1M DH8 T 9C DH8 T 9M DH8 E71T 1M T 9M T 12M ET1T 1C J T9CJ T 12C J E71T 1M JH4 T 9M JH4 T 12M JH4 E81T1 Ni1M JH4 E81T1 Ni1C H8 E81T1 Ni2C T1 Ni2M E81T1 B2C T1 B2M E91T1 K2C E91T1 GM H4 E91T1 Ni2C T1 Ni2M E91T1 D1C T1 D1M E91T1 K2C T1 K2M CO 2 CO 2 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO 75 Ar 25 CO Introductio
3. check positioning of contact tip distance too long relative to gas cup readjust parameters gas flow too low adjust flow rate Slag inclusions Slag inclusions occur when molten penetration Slag is allowed to run ahead of the welding arc and gets trapped To obtain sufficient penetration below the solidifying weld pool welders must use the correct All positional rutile flux cored wires stick out and arc length If the are prone to this because of their arc voltage is too high and or the fast freezing slag and their easy stick out length too short then weldability penetration will be reduced Also travel speed has an important The most likely welding positions for influence on penetration and must slag inclusions to occur are the be fast enough to secure good 1G PA and 2G PC positions penetration and to avoid slag particularly in joint preparations running ahead of the weld pool with a small included angle It 1G amp 2G and weld metal sagging is IMportant is to control the 2G Slag inclusions welding current too low arc voltage too high travel speed too low forehand technique torch angle too small convex beads Centerline cracking on ceramic backing When welding root passes on ceramic backing strips centerline cracking hot cracks may occur in 1G PA position If the current and voltage are too high a concave bead shape may be formed which combined with high shrinkage forces can result in
4. the gas nozzle diameter is changed Contact tip and gas nozzle Incorrect Contact tip too recessed Incorrect Contact tip protruding beyond gas nozzle Ideal stick out for wire diameters 045 and 052 in 1 2 and 1 4mm 3 4 1 in for 1 16 in 20 25mm for 1 6mm It is essential to fit the gas nozzle and contact tip at the right distance relative to each other The ideal distance of the contact tip is 5 64 in 2mm recessed A longer distance will force the welder to use too long of a stick out resulting in poor weldability This may lead to lack of fusion and slag entrapment particularly in narrow joints Contact tips protruding beyond the gas nozzle can result in insufficient gas shielding Correct stick out length The stick out is the distance between the contact tip and workpiece and must be kept between 1 2 to 3 4 in 15 to 20mm for 045 and 052 in diameters 81 2 and 1 4mm Excessive stick out results in too short of an arc length larger droplets unstable arc and splatter which causes poor weldability If the stick out is too short the current will increase and possibly cause undercut Gas nozzle diameter Various nozzle diameters must be available to allow satisfactory access to the joint to maintain the above recommended stick out and to ensure proper shielding gas protection Small diameter gas nozzles are used for the first layers only Revert to the standard gas nozzl
5. 0 240 470 6 0 12 0 25 31 2G Root 180 210 240 330 6 0 8 5 23 26 Fill 180 260 240 400 6 0 10 0 25 29 3G Root 180 220 240 330 6 0 8 5 23 27 rw Fill 180 240 240 350 6 0 9 0 24 28 4G Root no yw Fill 180 260 240 400 6 0 10 0 24 28 5G Root no Fill 180 240 240 350 6 0 9 0 24 28 6G Root no S Fill 180 240 240 350 6 0 9 0 24 28 Arc voltage valid for 75 Ar 25 CO mixed gas Increase arc voltage 1 2V for CO On ceramic backing Not recommended Current A 190 340 190 240 kkk 190 340 180 210 190 300 180 210 190 240 KKK 190 240 kkk 190 240 kkk 190 240 WFS ipm WFS m min Volts 180 420 180 240 175 420 155 200 175 340 155 220 175 245 180 240 180 240 180 240 4 5 10 5 4 5 6 0 4 4 10 5 4 0 5 0 4 4 8 5 4 0 5 5 4 4 6 2 4 5 6 0 4 5 6 0 4 5 6 0 24 32 24 28 24 32 23 27 24 32 23 27 24 29 24 28 24 28 24 28 Current A 200 400 3F 220 250 4F 200 250 kkk 210 400 190 220 210 320 kkk 220 250 WFS ipm WFS m min Volts 155 420 200 230 155 230 180 420 145 200 180 320 200 240 4 0 10 5 5 0 5 8 4 0 5 8 4 5 10 5 3 7 5 0 4 5 8 0 5 0 6 0 25 35 24 28 29 29 25 35 25 28 25 33 24 28 17 Direction of travel To ensure good penetration and to prevent slag running ahead of the weld pool Always weld with a backhand angle A forehand weld can deliver a reasonabl
6. al torch positioning Vertical up welding techniques Full width weaving LA li Travel direction ci Full width weaving is commonly practiced with ESAB all positional rutile flux cored wires However care must be taken to ensure that the heat input is not excessive otherwise weld metal impact properties may deteriorate The weaving technique involves crossing the joint from edge to edge in a straight line while gradually moving upwards in the direction of travel Split weave and stringer beads The split weave and stringer toughness properties are required bead techniques should be used e g offshore fabrication where optimal subzero weld metal 77 Claw Seay Wy Full width weaving high heat input Split weave medium heat input better toughness Stringer beads low heat input best toughness Full width weaving 2 5 3 5 kJ mm Split weave 1 5 2 5 kJ mm Stringer bead 1 0 1 5 kJ mm 23 24 Mechanized welding Mechanized welding is a great way to fully benefit from the productivity of ESAB all positional rutile flux cored wires It allows higher welding currents and travel speeds which are not manageable in manual welding while monotonous work is avoided The ESAB range of light mechanization equipment for MIG MAG and FCAW consists of ESAB Miggytrac for horizontal welds ESAB Railtrac for horizontal and horizontal vertical welds ESAB Railtrac orbital for circumferential joints
7. centerline cracking To avoid centreline cracking the following guidelines must be observed Centerline crack See page 14 for a correct root pass welded on ceramic backing increase welding current reduce arc voltage increase travel speed avoid slag running ahead of weld pool use dragging technique use 70 90 torch angle keep slag behind arc increase arc voltage or apply some weaving Apply a joint angle of 50 60 and 1 16 to 3 16 in 4 5mm root opening Use ceramic backing with a rectangular groove The groove width must be around 5 8 in 15mm Use welding currents below 200A for 045 in 1 2mm and a low enough arc voltage in order to obtain a flat or slightly convex bead profile A bead depth to width ratio of 1 1 will help avoid centerline cracking af iret 31 Unrivaled service and support Every ESAB product is backed by our commitment to superior customer service and support Our skilled customer service department is prepared to quickly answer any questions address problems and help with maintenance and upgrading of your machines Our products are backed with tne most comprehensive warranty in the business With ESAB you can be sure that you purchased a machine that will meet your needs today and in the future Product and process training is also available Ask your ESAB sales representative or distributor for a complete ESAB solution NOTICE Test results described abov
8. e appearance but penetration is often poor There is also a chance of slag running ahead of the weld pool causing slag traps and lack of fusion The same is valid for backhand when the torch angle is too small Direction of travel gt Correct Backhand with torch angle at 70 80 Direction of travel gt Incorrect Forehand welding Direction of travel gt ay wii Incorrect Backhand with the torch angle too small Welding positions The following are typical situations where the correct torch position plays an important role in avoiding weld defects 2F PB horizontal vertical fillet The photo shows the ideal torch position using the recommended backhand technique Still undercut and sagging faults can occur in this position The possible causes of these faults are listed below Undercut Welding current too high Arc voltage too high Travel speed too fast Arc positioned too close to the vertical plate Torch angle a too small Stickout too long Sagging Welding current too high Arc voltage too high Torch angle a too large Layer too thick Travel speed too slow Stickout too short 2G PC horizontal vertical Always maintain the torch angle of The correct torch position will 70 80 relative to the weld bead depend on plate thickness and joint and direction of travel as advised on angle If the torch positions shown Pa
9. e diameter when access to the weld joint allows this so full gas protection can be assured 12 15 54 in O Correct Use a smaller diameter nozzle or a conical nozzle for the 1st layers in the root area N 2 o n n Incorrect Use of standard gas nozzle restricts access to narrow joints resulting in too long a stick out Correct Use of standard gas nozzle for completing the joint ensures good gas protection and correct stick out Polarity and inductance Always use DCEP DC electrode positive polarity for ESAB all positional rutile flux cored wires DC ELECTRODE POSITIVE ESAB all positional rutile flux cored wires operate in the spray arc mode at all welding currents so no inductance is needed Switch off the inductance or select minimum setting if the inductance can not be disconnected Correct Minimum inductance setting selected Welding parameter setting A given welding current requires a specific arc voltage for optimum weldability The welding current is set by adjusting the wire feed speed control The arc voltage is regulated by the voltage setting of the power source Pages 16 and 17 give average parameters for various wire diameters and welding positions Achieving the optimum setting For the following procedure it is vitally important to keep the stick out constant within the correct range for each welding position Fromtherange given in the table on pages 16 and 17 s
10. e were obtained under controlled laboratory conditions and are not guarantees for use in the field Actual use of the product may produce varying results due to conditions and welding techniques over which ESAB has no control including but not limited to plate chemistry weldment design fabrication methods wire size welding procedure service requirements ad the environment The user should confirm by qualification testing or other appropriate means the suitability of any welding consumable and procedure before use in the intended application CAUTION Users should be thoroughly familiar with the safety precautions referenced in the product label for the relevant product and the Safety Data sheet for the product Safety Data Sheets are available at esabna com or by calling 800 ESAB 123 STRENGTH THROUGH COOPERATION GEN 26802 2 11 ESAB Welding amp Cutting Products esabna com 1 800 ESAB 123 USA PO Box 100545 411 South Ebenezer Road Florence SC 29501 0545 Canada 6010 Tomken Road Mississauga Ontario L5T 1X9 Mexico Ave Diego Diaz de Berlanga No 130 Col Nogalar San Nicolas de Los Garza N L CP 66480 Monterrey Mexico E En The ESAB group is J certified a according to x ISO 14001 amp FIND US facebook com esabna 3 twitter com esabna You CTB youtube com esabweb HOHHH Em OHSAS 18001 HE
11. elect a welding current I which suits your application Start welding with the lowest voltage value from the given range This may result in stubbing however wire burnback will be avoided a Correct Correct arc length Stable and concentrated arc with a quiet spray droplet transfer Incorrect Arc length too short Wire dips into weld pool stubbing caused by too low an arc voltage too high a wire speed or too long a stick out Incorrect Arc length too long Arc becomes too wide giving insufficient penetration and a risk of slag traps Also a risk of burnback to the contact tip This may be caused by the arc voltage being too high the wire feed speed too low or the stick out being too short Increase the arc voltage in steps of 1 or 2V until the arc becomes stable smooth and spatter free with a slightly crackling sound Ensure the correct stick out length is maintained Ifa different current is required Le change of welding position the procedure described on the previous page needs to be repeated The table on pages 16 and 17 gives settings for 75 Ar 25 CO mixed gas The arc voltage needs to be increased by 1 2V when CO shielding gas is being used Note that the CO arc is not as smooth with a more globular droplet transfer and more spatter NOTE As mentioned stick out control is very important If the recommended stick out length is not maintained constant weldabilit
12. ge 18 Maintain a steady travel cannot be used it is recommended Speed to achieve a regular bead that the joint angle or root gap is thickness without sagging increased A Root pass welded on round B 2nd pass positioned towards ceramic Avoid beads that are too horizontal plate thick C 3rd pass completes 2nd layer D 4th pass creates a favorable platform for the following passes E 5th pass Note how layers are always built up from the bottom side as weld thickness increases 20 Avoid sagging Sagging rollover is typically caused by Travel speed too slow Incorrect torch angle Welding current too high Wrong weld bead sequence Sagging requires grinding to avoid defects when welding subsequent passes 3G1 3F1 PF vertical up ESAB all positional rutile flux cored wires can weld a 3 16 in 4mm throat fillet weld at welding speeds up to 7 ipm 18cm min without weaving For butt welding in the vertical up position root passes are deposited onto ceramic backing materials with a rectangular groove The joint angle must allow good access to the root area If access is restricted then use a narrower gas nozzle Avoid sagging but if it occurs then grind back to dotted line as shown above Root pass Fill pass es 21 22 4G PE 4F PD overhead Use a stick electrode for the root pass and fill with ESAB all positional rutile flux cored wires Photo right gives the ide
13. ic backing is recommended for single sided root pass welding see page 14 Lack of penetration root area of a joint Shown below This occurs when the weld metal are two typical cases fails to extend into the complete lack of root penetration AS Lack of penetration General welding current too low arc voltage too high travel speed too high travel speed too low increase wire feed speed and arc voltage reduce arc voltage reduce travel speed Increase travel speed avoid slag running ahead of weld pool stay on front edge of puddle use backhand technique use correct angle a relative to joint see page 21 aim the arc at the leading edge of the pool forehand technique torch angle too small Butt welds incorrect joint preparation root gap too small increase gap reduce face included joint angle too small increase angle 29 Troubleshooting Porosity Possible causes Remedies draft wind close doors or windows and check fans Use shielding tents if outside paint grease or dirt clean and dry plates in the weld area gas nozzle diffuser clogged clean replace gas nozzle diffuser distorted replace gas nozzle diffuser too small use larger gas nozzle gas flow too high adjust flow rate gas leaks in system check by blocking gas cup aspirate air continued gas flow indicates leaks water leaks in cooled guns check connections gas cup to workpiece
14. mm because of the risk of lack of fusion Single sided root pass welding All positional rutile flux cored wires are not suited for welding single sided open root passes In many applications however high quality single sided root passes in V joints can be produced very economically on ceramic backing materials Always use ceramic backing with a rectangular groove Suitability for a typical application Root Fill Root Fill Root Fill Root Fill Root Fill Root Fill 1F PA 2F PB SEPE 4F PD 1G PA 1G PA 2G PC 2G PC 3G PF 3G PF 4G PE 4G PE 5G PF 5G PF 6G PF 6G PF yes yes yes yes on backing yes on backing yes on backing yes no yes no yes no yes yes yes yes yes on backing yes on backing yes on backing yes no yes no yes no yes yes yes yes yes not recommended yes not recommended yes not recommended possible no not recommended no not recommended no not recommended 1 One sided root pass on ceramic backing V joint Centerline cracking may occur at welding currents over 200A see page 31 2 052 and 062 in 1 4 and 1 6mm sizes will improve productivity 3 045 in 1 2mm size is preferred 15 Recommended parameter settings Current A WFS ipm WFS m min Volts 16 1F 2F i 180 300 240 550 6 0 14 0 24 31 3F 4F T 180 250 240 400 6 0 10 0 23 28 1G Root 180 200 240 320 6 0 8 0 23 26 DA Fill 180 28
15. n This guide provides practical information on the use of the ESAB all positional rutile flux cored wires listed below When correctly applied these wires provide Excellent weldability with spray arc droplet transfer in all welding positions Good weld appearance with smooth weld metal wetting High productivity especially in vertical up position Defect free welds with good mechanical properties Low hydrogen weld metal Before you start welding In order to fully benefit from the excellent weldability of ESAB all positional rutile flux cored wires the welding equipment needs to be maintained in good condition The following checklist serves as a guide CHECKLIST Contact tips and gas nozzle v Remove spatter and replace worn or damaged contact tip Correct Incorrect v Grind the end of the liner conically for optimal fitting of the contact tip ESAB M8 Contact tip size liner size and wire diameter v Ensure that the contact tip isthe correct size and fits tightly v Ensure the gas nozzle is free from spatter Shown with gas diffuser Liner Spiral steel liners are recommended v Ensure that the liner has the correct inner diameter for the wire size being used v Check liners regularly for kinks and excessive wear and replace when needed v Clean liners regularly using compressed air Note Remove contact tip prior to cleaning Gas and water v Check gas and water connec
16. rect parameter settings wrong shielding gas incorrect gas flow erratic wire feed damaged or worn contact tip roll pressure too low causing wire slippage roll pressure too high deforming the wire worn drive rolls misalignment of rolls or guide tubes damaged or worn liner incorrect liner type diameter incorrect contact tip size damaged or worn contact tip spool brake too tight spool brake too loose tangled wire incorrect parameters erratic wire feeding incorrect gas flow magnetic arc blow due to poor work cable 27 28 Troubleshooting Weld defects Lack of fusion defects There are several types of lack of fusion defects but all share the same feature in that deposited weld metal has not fused with the parent metal or previously deposited weld metal Typical forms of lack cold lap lack of interrun fusion of fusion are shown in a V butt h weld They can also occur in other lack of root fusion types of butt joints Also shown is lack of side wall fusion a typical side wall defect in a fillet weld Lack of fusion defects General travel speed too high reduce travel speed allow more dwell time at edges wrong parameter setting adjust parameters forehand technique backhand technique 70 80 torch angle Lack of root fusion enlarge root gap Fillet lack of fusion at standing leg Torch directed too much towards horizontal leg change torch orientation use of ceram
17. tions for leaks v Check if water cooler is filled and pump operates properly Note If equipped with water cooled torch Wire feed unit v Position wire guide tubes as close as possible to the rollers to prevent kinking of the wire v A substantial amount of fine metallic shavings underneath the drive rolls indicates misalignment or excessive drive roll pressure re Incorrect Before you start welding v Use v groove drive rolls for solid Wires v Use knurled drive rolls for flux cored and most metal cored wires Knurled drive rolls typically increase wear on contact tip and liner assemblies and will likely need to be replaced more often v Check that the groove size is correct for the wire diameter Smooth Knurled v groove v groove v Apply the correct pressure on feed rolls Too much pressure flattens the wire resulting in feedings problems and higher liner and contact tip wear Insufficient pressure may cause wire to slip in the feed rolls resulting in irregular feeding and possible wire burnback v Check that the wire is feeding correctly from the contact tip Shielding gas v Check that the appropriate gas is used page 3 Adjust gas flow rate between 30 and 40 cfh 15 and 20 l min v Use 40 cfh 20 l min when welding outside v Check that the gas flow from the gas nozzle is at the recommended rate R 33 FM580 regulator flowmeter v Check the gas flow rate again if
18. y will fluctuate Shortening the stick out will result in an increasing current and a longer arc Lengthening the stick out will result in a lower current and the arc being too short 38 36 Ww 34 32 30 28 26 Good weld shape Voltage v h Excessive weld metal difficult to control Weld too narrow i i 1 16 in 1 6mm dia 3 4 t 1 in 20 25mm s o Weld voltage too ie 20 low small narrow weld 18 100 150 200 250 i 052 in 1 4mm dia 1 2 to 3 4 in 15 20mm s o e i S 045 in 1 2mm dia 1 2 to 3 4 in 15 20mm s o 5 300 350 400 450 500 Current amps stick out ASME and EN ISO positions 1G PA 3G PF amp PG 5G PF amp PG w DI 1F PA 3F PF amp PG 2G PC 4G PE 6G HL045 2F PB 4F PD Choice of wire size The diameter range of ESAB all positional rutile flux cored wires is 045 1 16 in 1 2 1 6mm allowing optimal productivity for various combinations of plate thicknesses and welding positions Diameter 052 in 1 4mm provides a useful compromise between productivity and the use of a single diameter wire for all welding positions The table on page 15 shows suitable recommendations for each diameter Vertical down welding is not recommended particularly on PF 3G butt weld in 3 4 in 18mm plate Root pass on ceramic backing thicker plate material gt 3 16 in 5
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