Electrode, Filler & Gas Selections
See below...
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Re: Electrode, Filler & Gas Selections
Aint seen ne1 post one so I figured I'd write one real quick. SMAW (Stick) Carbon Steels: * E6010, Run DCEP. Flat beads, deep penetration, common & cheap, good on poor preparation. Good for root passes, especially on pipe. * E7018, Run DCEP or AC. Low-hydrogen, great for fill / cap passes, low skill involved, high quality welds. Stainless Steels: * 301-305 to 301-305 Stainless steels use E308-XX * 301-305 Stainless to non-stainless steels use E309-XX * 316 Stainless steel use E316-XX * 321 & 347 Stainless steels use E347-XX XX denotes -15, or -18 (EX: E308-15) -15 runs DCEP & is easier out of position -18 runs DCEP and AC. Has less arc blow & good for thicker metals. Cast Iron: * #55 (EniFeCl), stronger, less ductil & cheaper. * #99 (ENiCl) high nickel, easier to weld Pre-heat to 350*F, maintain 350-600*F between weld passes. Post heat, and insulating (sand / blanket / dirt) is recommended. Once welded, do not disturb for 48 hours. I do not recommend welding turbo manifolds. Because the nickle will expand much more than the cast iron under excessive temperatures, it will eventually crack. (The best way I know to weld an exhaust manifold successfully is oxy-fuel / tig with a real cast iron filler.) Aluminum: E4043 I do not recommend. Requires too much experience, not enough common selection of rods. GMAW (mig), and GTAW (tig) wire / filler Carbon Steels: * ER70S-2, Easy to weld all positions, most common, least cost. use C25 gas. * ER70S-6, Most resilient to mill scale & rust, use C02 & higher currents. * ER70S-A1, Even more expensive. Addition of Moly increases weld strength & corrosion resistance at high temperature. Stainless Steels: * For 301-305 to 301-305 stainless steels use ER308, or ER308H. The higher carbon content of ER308H rods increass strength at high temperature. * For 301-305 stainless steels to carbon steel forgings use ER307. * For 301-305 stainless steels to carbon steel castings, and general mild carbon steel use ER307, or ER309. 307 is stronger at high temperature, 309 is more resistant to corrosion. * For 316 stainless steels use ER316, or ER316H. The higher carbon content of ER316H rods increass strength at high temperature. * For 321 stainless steels use ER321 or ER347 * For 347 stainless steels use ER347 Aluminum ER4043, ER4145, ER5356 are common. Please consult a chart for the correct choice. FCAW (flux-core, wire feed. sex welds) Carbon Steels: * ER71T-1M, DCEP. All position (no downhill), cheap, dual-shielded requiring C25 shielding gas, multi-pass is OK when flux is cleaned. * ER71T-7, DCEN. All position (no downhill), cheap, no shielding gas, multi-pass is OK when flux is cleaned. * ER71T-9, DCEN. ALl position (no downhill), cheap, dual-shielded requiring CO2 shielding gas. multi-pass is OK when flux is cleaned. * ER71T-13, DCEN. All position (no downhill), cheap, no shielding gas, single pass only. If you have a chinese welder, or are welding under atleast 180amps. This is the flux-core wire you want to buy. Note. All non-EXXX-13 FCAW welding is done in spray transfer. HF/chinese buzz-boxes can not achieve the current & voltage needed for spray transfer. They should be avoided at the gross amount of inclusions in the weld if weld quality is a concern. If you are using one... To get a quality weld you must use ERXXT-13 wire, and it can-not be multi-passed. GMAW (mig) gas selections! Short Circuit (low currents & voltage ranges). Primarily small boxes. Carbon Steels use C25. High speeds, minimum spatter & distortion. Good apperance. Good control out of position. And virtually eliminates undercut if you're remotely in the ballpark of correct welding angles. Stainless Steels use a tri-mix. 90% Helium, 7.5% Argon, 2.5% C02. No effect on corrosion resistance, minimal distortion. Good apperance, virtually no undercutting, small heat aaffected zone. Aluminum use pure argon on sheet metal and, 75-25 mix of argon & helium on 1/8" and greater. Spray transfer (high currents & voltage ranges) Carbon Steels use argon + 3-5% oxygen. Improves arc stability, easily controlled weld puddle, nice bead, minimizes undercutting. Higher speed welding than pure argon. Stainless steels use 99-98% argon, 1-2% oxygen. Use 9822 for thinner steels. Use 99-1 for thick steel. Aluminum use pure argon for the least spatter. Use 65-35 argon-helium, and 75-25 helium-argon when even higher heat input is required. Higher weld currents need more flow rates. For short circuit typically 10-15 CFH is good. For spray transfer 15-40CFH is typical, helium mixtures may require 40-50 CFH as it's lighter than air. GTAW (tig) gas & electrodes! Don't be a douche. Use 100% argon; or a helium mixture for DC & aluminum welding. Don't expect to get much penatration with DCEP, and there is no surface cleaning with DCEN. 15-20CFH with argon. 30-50CFH for helium mixes. If using a large cup (#8+), or a gas-lens the CFH requirement may be half of normal; all things depending. 10-15CFH. * 2% thoriated (red) for DCEN steels, grinding dust is radioactive, but longest useable life * 2% ceriated (orange) for DCEN steels and AC welding on inverter units, not radioative. * 1-1.5-2% lanthanated (black, gold, blue) for DCEN steels. not radioative. * Pure tungstens (green) for AC welding on transformer units. * Zirconiated (brown) for AC xray ---- you'll never do. Stickied. I love useful info. |
Re: Electrode, Filler & Gas Selections
thanks CSaddict :)
racin it welds the same to me, it just melts sooner so it doesn't last *quite* as long as thoriated. I like it alot better on AC tho. To me its a more stable arc. To someone like engloid it probably doesn't make a ---- LoL! |
Re: Electrode, Filler & Gas Selections
so what is the white tip tangsten then?
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Re: Electrode, Filler & Gas Selections
Above is all AWS code.
If, instead of AWS code yall use ISO 6848 in Africa; then white would be .7-.9% Zirconiated. If that's the case then some of them overlap & some of them don't. Or you could use some other code... IDK man. |
Re: Electrode, Filler & Gas Selections
Good info. I only use red, i have a few orange that came with my machine.
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Re: Electrode, Filler & Gas Selections
Originally Posted by Toysrme
GTAW (tig) gas & electrodes!
Don't be a douche. Use 100% argon, or a helium mixture for DCEP & aluminum welding. 15-20CFH with argon. 30-50CFH for helium mixes. |
Re: Electrode, Filler & Gas Selections
Originally Posted by Engloid
You're not going to get much aluminum welded on DCEP. Do you mean DCEN? If so, you won't get much done with 100% argon. You need helium, or at least a mix of argon and helium.
i dont know about you guys but i weld aluminum on AC. the only thing i uses DC for while welding aluminum is when i am using a tranformer machine and have to ball the tungsten. if there is a way to weld aluminum on DC- then spill the beans because AC is to damn noisy |
Re: Electrode, Filler & Gas Selections
You can weld it whatever you want.
In big industry doing big tig welds you'd work it DC- to get the maximum amount of heat input. You're just sacraficing the surface cleaning action that DC + provides during DC+ & the DC+ cycle of AC. E is right, I meant to write that with a semi-colon. As in USE 100% argon; unless you're welding DC. |
Re: Electrode, Filler & Gas Selections
Thx for the info Toys good post.
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