Cigweld deposition data
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(2) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA Electrode Weld Metal Recovery (Process Efficiency) Electrode weld metal recovery to ISO 2401-1972 allows us to calculate the amount of welding consumable which will actually be deposited into the finished weld metal less any waste such as, stub ends, slag and spatter not adhered to the test plate. An example is when 100kgs of electrodes are used with a quoted efficiency of 60%, the net result is that only 60kg of the weight of that electrode will actually end up in the deposited weld metal. The remaining 40% (40kg) of the electrode is waste. To achieve weld metal recovery rates practical tests are carried out by weighing the test plate before and after welding, weighing the consumables before welding and then using the following formula allowing for 50mm stub ends. If the welder discards more than 50mm stub ends than the recovery rate (process efficiency) will be lower. Weld Metal Recovery % to ISO 2401 = Weight of test plate before welding - Weight of test plate after welding Weight of the Consumable. X 100. e.g. Satincraft 13 Ø4mm x 380mm. Plate before welding: 2kg - 2.15kg Plate after welding = 150grams, weight of five (5) electrodes, Ø4mm x 380mm long before welding = 261.20grams, 150grams ÷ 261.20grams x 100 = 57.43% Weld Metal Recovery (Process Efficiency). e.g. Ferrocraft 22 Ø3.2mm x 380mm. Plate before welding: 2kg - 2.167kg Plate after welding = 167grams, weight of five (5) electrodes, Ø3.2mm x 380mm long before welding = 281.50grams, 167grams ÷ 281.50grams x 100 = 59.33% Weld Metal Recovery (Process Efficiency).. General Process Efficiencies. Welding Process. Average Efficiency. Gas Tungsten Arc Welding (GTAW) & Oxy-Acetylene Welding (OAW) Manual Metal Arc Welding (MMAW) Gas Metal Arc Welding (GMAW) Short Arc, Ar + 25% CO2 Gas Metal Arc Welding (GMAW) Spray Arc, Ar + 25% CO2 Gas Metal Arc Welding (GMAW) Pulse Arc, Ar + 25% CO2 Flux Cored Arc Welding (FCAW) E70T-4 types, self shielded Flux Cored Arc Welding (FCAW) E71T-1 types, Ar + 25% CO2 Flux Cored Arc Welding (FCAW) E70T-5 types, Ar + 25% CO2 Flux Cored Arc Welding (FCAW) E70C-6M types, Ar + 25% CO2 Cobalarc Flux Cored Hardfacing Wires Gas shielded. 100% 60% 92% 95% 98% 82% 85% 88% 92% 80%. GMAW and FCAW average efficiencies can vary in result depending upon the shielding gases used, machine settings, stick out, spatter losses, wire sniped off before starts etc.. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. Generally process efficiencies can be stated as averages for costing purposes. The following table outlines CIGWELD’s suggested process efficiency percentages. If the welding application calls for the Oxy-Acetylene or GTAW welding processes to be employed, then it is prudent to use all of the consumable by joining stub ends to ensure that 100% of the filler metal is utilised.. 361.
(3) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA CIGWELD Electrodes, Deposition Rates, Electrode Efficiencies, and Electrode Weld Metal Recovery Rates The following Table lists some popular CIGWELD consumables and their Deposition Rates, Electrode Efficiencies and Weld Metal Recovery Rates: CIGWELD Product Ferrocraft 12XP Ferrocraft 12XP Satincraft 13 Satincraft 13 Ferrocraft 11 Ferrocraft 11 Ferrocraft 21 Ferrocraft 21 Ferrocraft 22 Ferrocraft 22 Ferrocraft 16TXP Ferrocraft 16TXP Ferrocraft 7016 Ferrocraft 7016 Ferrocraft 61 Ferrocraft 61 Alloycraft 90 Alloycraft 90 Satincrome 316L-17 Satincrome 316L-17 Castcraft 55 Castcraft 55 Cobalarc 750 Cobalarc 750 Cobalarc CR70 Cobalarc CR70 Cobalarc 9. Size (mm). Amps. Deposition Rate kg/hr. Electrode Efficiency. Weld Metal Recovery. 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 3.2 4.0 8.0. 110 150 115 160 110 145 120 170 150 210 120 165 120 170 125 180 125 180 95 130 100 125 115 145 115 165 180. 0.90 1.20 0.92 1.30 1.00 1.30 1.20 1.70 2.00 2.80 1.20 1.60 1.10 1.50 1.30 1.80 1.30 1.80 0.90 1.10 0.95 1.15 1.00 1.30 1.20 1.70 1.30. 109% 111% 91% 92% 90% 90% 113% 112% 155% 157% 95% 90% 101% 97% 110% 113% 111% 114% 105% 108% 116% 115% 109% 112% 191% 206% 85%. 66% 69% 56% 58% 64% 66% 63% 62% 59% 61% 58% 56% 63% 60% 57% 59% 60% 62% 55% 54% 69% 70% 62% 64% 69% 71% 77%. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. The information provided in this table is a guide only, actual on the job figures may vary. Results are influenced by many factors including, welding parameters, arc length, travel speed and machine characteristics.. 362.
(4) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA CIGWELD Solid and Flux Cored Wires, Deposition and Weld Metal Recovery Rates. CIGWELD Product Autocraft LW1-6 Autocraft LW1-6 Autocraft LW1-6 Autocraft LW1-6 Autocraft Silicon Bronze Autocraft 316LSi Autocraft 316LSi Autocraft AL5356 Autocraft AL5356 Satin-Cor XP Satin-Cor XP Satin-Cor XP Satin-Cor XP Satin-Cor XP Satin-Cor XP Verti-Cor 3XP Verti-Cor 3XP Verti-Cor 3XP Verti-Cor 3XP Verti-Cor 3XP Verti-Cor 3XP Metal-Cor XP Metal-Cor XP Supre-Cor 5 Supre-Cor 5 Tensi-Cor 110TXP Tensi-Cor 110TXP Shieldcrome 309LT Shield-Cor 4XP Shield-Cor 4XP Shield-Cor 15 Shield-Cor 11. Size (mm). Volts. Amps. WFS m/min. Deposition Rate kg/hr. Weld Metal Recovery. 0.8 0.9 1.0 1.2 0.9 0.9 1.2 1.0 1.2 1.6 1.6 1.6 2.4 2.4 2.4 1.2 1.2 1.2 1.6 1.6 1.6 1.2 1.6 1.2 1.6 1.6 2.4 1.2 2.4 3.0 0.9 1.2. 20 26 28 32 24 22 26 22 24 28 29 30 30 31 32 25 26 28 27 28 29 26 28 22 26 28 29 26 29 30 17 17. 150 180 240 300 180 180 250 180 220 300 350 400 400 450 500 200 250 320 300 350 400 250 350 170 320 280 400 190 375 500 120 150. 12.0 12.0 13.5 10.8 13.2 10.0 8.5 16.3 14.0 5.5 6.5 7.0 4.2 5.0 6.0 6.7 9.9 15.0 6.2 9.5 12.0 10.0 6.6 7.8 5.9 5.0 3.8 11.4 5.4 2.9 3.9 3.0. 2.5 3.1 4.8 5.6 3.2 2.8 4.4 1.5 2.5 4.3 5.4 6.0 5.7 6.8 8.2 2.7 3.8 5.9 4.1 6.4 8.1 5.0 5.6 2.3 3.3 3.0 5.8 3.7 7.0 6.7 0.7 1.0. 96% 96% 95% 97% 95% 97% 98% 90% 92% 86% 87% 89% 85% 86% 90% 86% 84% 88% 86% 81% 88% 92% 94% 86% 89% 88% 90% 84% 84% 86% 75% 80%. The information provided in this table is based on welding with constant voltage (C.V.) GMA Welding machines. Results may vary and are influenced on the job by shielding gases used, machine settings, stick out, spatter losses, wire sniped off before starts etc.. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. The following Table lists some popular CIGWELD consumables and their Deposition and Weld Metal Recovery Rates:. 363.
(5) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA Manual Arc Electrode Consumption Calculator Guide Instructions for Use of this Data The following tables provide data on the approximate mass in kilograms required of the different types of electrodes for welding the various weld joints used throughout industry today. This data will aid in estimating material requirements and costs. The basis for the following tabulations is given below. Where variations from the given conditions or joint preparations are encountered, adjustments in the tabulated values must be made to compensate for such differences. Basis of Calculations Electrode requirements have been calculated as follows: Where M = Mass of electrodes required D = Mass of weld metal to be deposited E = Proportion of electrode lost M = D 1-E To arrive at the mass of weld metal to be deposited it is necessary to calculate first the volume of metal to be added (area of the cross section of the weld multiplied by the length). This volumetric value is converted to mass by multiplying by the factor 0.0079 kilograms per cubic centimetre for steel.. Square Butt Joints, Welded both sides Joint Dimensions Root Gap (R). With Reinforcement**. With Reinforcement**. 3mm. 0 1mm 1mm 1.6mm 1.6mm 2.5mm. 0.23 0.26 0.38 0.41 0.48 0.56. 0.14 0.16 0.23 0.25 0.29 0.34. 6mm. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. kg of weldmetal deposited per liner metre of weld (Approx.). Plate Thickness. 5mm. 364. kg of electrodes per linear metre of weld* (Approx.). * Includes spatter losses and 50mm stub end loss. ** Height of Reinforcement = 2mm..
(6) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA Horizontal-Vertical (HV) Fillet welds Fillet Weld leg length Dimensions. kg of electrodes per linear metre of weld* (Approx.). kg of weldmetal deposited per liner metre of weld (Approx.). 3mm 5mm 6mm 8mm 10mm 12mm 16mm 20mm 25mm. 0.06 0.16 0.24 0.42 0.65 0.95 1.68 2.62 4.10. 0.04 0.10 0.14 0.25 0.39 0.57 1.01 1.57 2.46. * Fillet weld figures are calculated based on true mitre fillets. Convex or overwelded fillets can increase these figures by 33% or more.. Single Vee Butt Joints, (single groove butts) Joint Dimensions. kg of electrodes per linear metre of weld* (Approx.). kg of weldmetal deposited per liner metre of weld (Approx.). Plate Root Thickness Face (F). Root Gap (R). With Reinforcement**. With Reinforcement**. 6mm 8mm 10mm 12mm 16mm 20mm 25mm. 1.6mm 1.6mm 1.6mm 3mm 3mm 3mm 3mm. 0.39 0.63 0.87 1.33 2.22 3.37 5.14. 0.23 0.38 0.52 0.80 1.33 2.02 3.08. 1.6mm 1.6mm 1.6mm 3mm 3mm 3mm 3mm. * Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm.. Joint Dimensions. kg of electrodes per linear metre of weld* (Approx.). kg of weldmetal deposited per liner metre of weld (Approx.). Plate Root Thickness Face (F). Root Gap (R). With Reinforcement**. With Reinforcement**. 12mm 16mm 20mm 25mm. 1.6mm 1.6mm 1.6mm 3mm. 0.92 1.46 2.12 3.33. 0.55 0.88 1.27 2.00. 1.6mm 1.6mm 1.6mm 3mm. * Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm.. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. Double Vee Butt Joints, Welded both sides (double groove butts). 365.
(7) T E C H N I C A L A N D I N F O R M AT I O N. T R A D E. DEPOSITION DATA Consumable Weights & Lengths Tables:. 1. Gas Metal Arc Welding (GMAW - MIG) Wires for Mild and Low Alloy Steels WIRE SIZE (mm). 0.6. 0.8. 0.9. 1.2. 1.6. gms of wire per metre. 2.2. 4. 4.85. 8.5. 15.7. metres of wire per kg. 450. 254. 200. 113. 63. 2. Flux Cored Arc Welding (FCAW) Wires for Mild and Low Alloy Steels WIRE SIZE (mm). 1.2. 1.6. 2.0. 2.4. gms of wire per metre. 7.5. 13. 21. 28.5. metres of wire per kg. 132. 77. 50. 36. 3. Submerged Arc Welding (SAW) Wires for Mild and Low Alloy Steels WIRE SIZE (mm). 2.0. 2.4. 3.2. 4.0. 4.8. gms of wire per metre. 24.6. 35.5. 63. 99. 142. metres of wire per kg. 40.5. 28. 16. 10. 7. 4. Stainless Steel Gas Metal Arc Welding (GMAW - MIG) Wires WIRE SIZE (mm). 0.9. 1.2. gms of wire per metre. 5.1. 9. 1.6 16. metres of wire per kg. 198. 111. 63. © 2000 Comweld Group Pty Ltd. A.B.N. 56 007 226 815. 5. Aluminium Gas Metal Arc Welding (GMAW - MIG) Wires. 366. WIRE SIZE (mm). 0.9. 1.2. 1.6. gms of wire per metre. 1.7. 3.1. 5.4. metres of wire per kg. 582. 327.5. 184. 6. Autopak Gas Metal Arc Welding (GMAW - MIG) Wires WIRE SIZE (mm). 0.9. 1.0. 1.2. 1.6. gms of wire per metre. 4.85. 6.1. 8.5. 15.7. km of wire / 300kg Pack. 62. 49. 35. 16 (250kg Pack).
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