Low-carbon Steel Filler Metal Electrode Wire For GMAW, MCAW and SAW

Question 1

What is the white glove test?

Answer 1

You run the wire between your fingers and if it comes away dirty you need to place a felt scrubber ahead of your wire feeder drive rolls

Question 2

How much CO2 is lost when used as a shielding gas why and what’s used to compensate for this?

Answer 2

CO2 breaks down into carbon monoxide and oxygen because of the high temperatures. It loses 20 to 30% of the shielding gas to oxygen. To compensate for this oxidizing characteristic, the filler metal wire must contain deoxidizing agents.

Question 3

What is ER49S-1 (ER70S-1)

Answer 3

This class of filler metal wire is not widely used. It contains the lowest amount of silicon and provides little deoxidization. These filler metal wires are generally used for applications where weld quality is not critical and lower costs are important. If high-quality weld deposits are required, these filler metal wires run under an argon or argon-mix shielding. Otherwise CO2 is shielding gas used.

Question 4

What is ER49S-1 (ER70S-2) used for?

Answer 4

This class of filler metal wire contains considerable more deoxidizing agents, up to 2% of titanium, zirconium and aluminum combination as well as silicon and manganese. They are mainly designed to be used with an argon or argon-mix shield, but CO2 can also he used for short-circuit transfer. The powerful deoxidizing agents (aluminum, titanium and zirconium) make these filler metal wires a good choice for welding rusty or dirty surfaces. They are also often used for out-of-position welding using short-circuit metal transfer

Question 5

What is ER49S-3 (ER70S-3)?

Answer 5

This class of filler metal wire is for low-carbon and high strength, low alloy steels (HSLA). These filler metal wires are similar in composition to S-1 but they contain greater amounts of deoxidizing agents silicon and manganese. They can be used with an argon or argon mix or with CO2. They are good for out of position welding

Question 6

What is ER49S-4 (ER70S-4)

Answer 6

Has a slightly higher silicon and manganese content. Produces higher tensile strength then the first 3. The shielding gas used is CO2. This filler metal wire is designed to use a slightly longer arc length and is used most often for welds requiring more deoxidization than that provided by the S-3 filler metal wires.

Question 7

What is ER49S-5 (ER70S-5)

Answer 7

Like S-2 They contain powerful deoxidizer aluminum, titanium and zirconium. Used for tough welding conditions, such as rusty or dirty base metal or base metals containing higher carbon or sulphur content. CO2 is used in globular metal sections and in heavier sections where good penetration can be a problem. Not available in smaller diameters

Question 8

What is ER49S-6 (ER70S-6)

Answer 8

Highest combination of manganese and silicon. Good weld bead appearance and low spatter. Excellent impact resistance and high mechanical properties. One of the most often used filler metals. Recommended shielding gas is CO2 or Argon CO2 mixture. Welding in all positions is possible with short-circuit and pulse transfer

Question 9

What is ER49S-7 (ER70S-7)

Answer 9

Used with a CO2 shielding gas, has a high manganese content, which provides good wetting action and has a good weld bead appearance. The weld deposit also exhibit slightly higher mechanical properties.

Question 10

What is ER49S-G (ER70S-G)

Answer 10

General classification, newly developed GMAW wires that exceed standard specifications often fall under this.

Question 11

What is ER55S-D2 (ER80S-D2)

Answer 11

Low-alloy filler metal containing 0.40% and 0.60% molybdenum, recommended for welding low-alloy steels such as AISI 4130. Produces a tensile strength of 552 Mpa (80 000 psi)

Question 12

What is ER309LSi

Answer 12

Austenitic stainless steel filler metal designed to join stainless steels to carbon steels or low-alloy steels. An Argon-oxygen blend is recommended

Question 13

What is ER4043

Answer 13

An aluminum filler metal contains 5% silicon. First welding 1050, 1100, 3003, 6063, and 6061 aluminum alloy base metals. For GMAW and GMAW-P, argon or an argon-helium mixture shielding gas

Question 14

What does the letters M, C, H and J mean in an FCAW AWS classification.

Answer 14

M stands for mixed gas

C stands for 100% CO2

J indicates that the electrode meets the minimum impact requirements for the improved toughness test

H followed by 4, 8, or 16 indicates a low-hydrogen electrode with a maximum hydrogen limit of 4, 8 or 16 ml per 100 grams of deposited metal. Electrodes with low-hydrogen limits are designed for welding crack-sensitive steels.

Question 15

What flux are the 
T-1
T-2
T-3
T-4
T-5
T-6
T-7
T-8
T-9
T-10
T-11
T-G 
T-GS

Answer 15

T-1       Rutile
T-2        Rutile, extra metal powder 
T-3        Fluorspar, Rutile, aluminum 
T-4        Fluorspar, aluminum 
T-5       Lime, fluorides (basic)
T-6       Fluorspar, lime, rutile, aluminum 
T-7       Fluospar, aluminum 
T-8       Fluospar, aluminum 
T-9       Rutile 
T-10     Fluorspar, aluminum 
T-11     Fluorspar, iron powder, aluminum 
T-G       not defined 
T-GS    not defined

Question 16

What is a T-1 and a T-2 used for

Answer 16

T-1 has a high deposition rate, stable arc and relatively little splatter. Gas shielded with CO2 is required and us suitable to weld flat and horizontal positions

T-2 has a higher manganese content and can be used on steels that havent been carefully cleaned. Requires a CO2 shielding gas

Question 17

What is T-3 and T-4 used for?

Answer 17

T-3 is self shielded and designed for welding sheet and light plate in the flat and horizontal in a single pass

T-4 self shielded and used for both single and multi-task welding. More commonly used filler metal wires.

Question 18

What is T-5 and T-6 used for?

Answer 18

T-5 can be used with or without external gas shielding. Weld beads with CO2 are higher quality than those without external shielding gas. Characterized by globular metal transfer, relatively shallow penetration, a slightly convex weld bead profile and a thin, easily removed slag. Particularly good for high-impact applications, has the highest impact resistance of all the flux-cored filler metal wires

T-6 are very similar to T-5 but are designed exclusively for use without externally applied shielding gas. used for both single and multi-pass welding amd are specially designed to give good low-temperature impact values. In general, these filler metals use DCEP and are characterized by spray metal transfer

Question 19

What are T-7 and T-8 used for?

Answer 19

T-7 are used without external gas shielding and may use both single and multi-pass welding in all positions. Good resistance to cracking and the slag is designed to desulpherize the weld metal. Used with DCEN

T-8 are self-shielded designed for high-deposition, all position welding for structural fabrication. Uses DCEN and can be used for single or multi-pass welding and have good impact properties

Question 20

What are T-9 and T-10 used for?

Answer 20

T-9 shares similarities with T-5 and uses globular transfer. It requires an external shielding gas. Can be used for single and multi-pass welding. Characterized by low penetration, slightly convex bead profile and a thin, easily removable slag, These wires meet the requirements of a good impact resistance.

Question 21

What are T-11 and T-G used for?

Answer 21

T-11 are self-shielding can be used for single and self shielding in all positions. Used with DCEN and produce a spray metal transfer sim6to cellulose SMAW electrodes such as E6010

T-G us solid wire specifications, this classification includes electrodes that are not included in the previous classifications