Consumables Articles

The devil is in the details, especially when it comes to welding processes. This technology area has information on consumables, including cutting tips, electrodes and wire, spatter prevention compounds, temporary purge dams, and welding torch components.

Filter Content

Consumables Corner: Examining weld cracking, Part I—Hot cracking

July 15, 2014

By: ,

Editor’s Note: This is the first article of a two-part series. Q: I work in a midsized job shop, and we weld with the FCAW, GMAW, and SMAW processes. Occasionally we encounter weld cracking issues. What causes weld cracking, and what can I do to prevent it? A: To ensure that the measures you...

Continue Reading

Consumables Corner: Selecting the correct diameter for flux-cored wire

July 9, 2014

By: ,

I work in a large manufacturing fabrication shop where we weld subassemblies and then fit and weld them together to complete the machines we manufacture. Currently we use gas-shielded, flux-cored wires from 0.045 to 0.09375 in. in diameter. At what point is a small-diameter wire too inefficient,...

Continue Reading

Consumables Corner: Combating overheating in work clamps

July 8, 2014

By: ,

Q: I weld in a large pressure vessel shop and use many welding processes, including SMAW, GMAW, FCAW, and SAW. Regardless of the process, our work clamps always get very hot. We’ve even had some arcing from the ground clamp. We have welded several grounds to the workpiece to remedy this problem,...

Continue Reading

Consumables Corner: Combating dull weld appearance with metal-cored stainless steel wire

July 7, 2014

By: ,

Q: We fabricate 401 stainless steel components and have considered using metal-cored stainless steel consumables. One of the issues with metal-cored consumables is the dull appearance of the weld compared to the appearance achieved with a solid wire. What can we do to maintain a clean or shiny...

Continue Reading

Consumables Corner: Nixing porosity during weld start

July 3, 2014

By: ,

Q: I work for a job shop that fabricates and welds process piping for various applications. The pipes, made from A106-88a carbon steel and 304 and 316 stainless steel, are welded using GMAW, FCAW, and GTAW. We have been experiencing porosity, primarily on the weld starts. Our shielding gas is a...

Continue Reading

Consumables Corner: Welding heat treatable steels

July 2, 2014

By: ,

Q: Our shop won a contract that requires welding 4130 steel. I’ve been told this is a heat-treatable steel. Can you tell me which different welding procedures have to be used to weld this material? A: The most commonly welded heat-treatable steels are 4130, 4340, and 8630. However, any steel...

Continue Reading

Consumables Corner: Horizontal fillet test troubles

July 1, 2014

By: ,

Q: For a recently acquired large structural job, we have had to qualify a single-pass 5/16-in. fillet using 0.045-in. E71T-9M flux-cored wire. We are having trouble passing the horizontal fillet test. When performing the weld break test on the horizontal fillet weld, there is incomplete penetration...

Continue Reading

Consumables Corner: Welding weathering-grade material with a nickel-containing filler

June 27, 2014

By: ,

Q: I work for a structural steel fabricator and we are getting ready to start work on a bridge job that specifies A588 material. We have worked on this material in the past using a weathering-grade filler metal. Our engineer has recommended we use a 1 percent nickel electrode. Is this right? A:...

Continue Reading

Consumables Corner: Issues with incomplete fusion

June 27, 2014

By: ,

Q: Recently our shop started using metal-cored wire. On one side we perform full-penetration welds to D1.1 structural code on 3/4- to 1-1/2-in.-thick plate. On the second side we carbon-arc-gouge to clean the metal and then we do a magnetic particle inspection before welding. We encounter two...

Continue Reading

Consumables Corner: Figuring out FCAW Charpy V-notch failure

June 26, 2014

By: ,

Q: We performed an AWS D1.1 procedure qualification test using gas-shielded FCAW. We used a 0.052-in. E71T-9C electrode with 100 percent CO2 shielding at 200 amps and 26 V on 1-in. thick plate. We used a preheat and interpass temperature of 70 degrees F. Our pass layer sequence was three full...

Continue Reading

Consumables Corner: Simple steps to avoid cracking

June 25, 2014

By:

Q: When welding a thick section of a forged 4130 ring to a thinner A36 plate in a T-joint configuration, we experience longitudinal cracking issues that originate from the ends of the welds. The required fillet size is ½ inch. It is skip-welded 12 in. on 18-in. center-to-center spacing. The...

Continue Reading

Consumables Corner: Before choosing filler, know your 4140

June 24, 2014

By:

Q: We need to weld 4140 steel to AR 360 plate and are thinking of using an E120 electrode to try and match the strength. Is this the right electrode for our welding application? A: Before you choose a filler metal, there are a few things you should consider for this application. First, 4140...

Continue Reading

Consumables Corner: Pinning down the cause of porosity in SAW

June 23, 2014

By:

Q: Our company produces large structures fabricated from mild steel plate with a small amount of HSLA forgings ranging from 0.5 in. to 4 in. thick. Our main process is submerged arc welding (SAW) using a mild steel electrode and a neutral-bonded flux. We have been experiencing some issues with...

Continue Reading

Consumables Corner: Reducing weld cleanup in pulsed GMAW

June 20, 2014

By: , ,

Q: Our company manufactures the main structures used to build fitness equipment. These structures are mild steel tubing of various shapes and sizes and in relatively thin material, typically 10 to 16 gauge. We are using 90 percent argon/10 percent CO2 shielding gas with a 0.035-in.-dia. ER70S-3...

Continue Reading

Consumables Corner: Eliminating porosity in submerged-arc welding

June 19, 2014

By: , ,

Q: Our shop manufactures bridge and structural steel components. Most of the material is A36 or A572 and welded with E70X-X class electrodes using FCAW with 75 percent Ar/25 percent CO2 shielding gas (bottle-supplied) and SAW. We're having issues with porosity in our SAW process. We find that once...

Continue Reading