Consumables

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.

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Consumables Corner: Combating overheating in work clamps

July 8, 2014

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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,...

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

July 7, 2014

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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...

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Consumables Corner: Nixing porosity during weld start

July 3, 2014

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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...

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Consumables Corner: Welding heat treatable steels

July 2, 2014

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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...

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Consumables Corner: Horizontal fillet test troubles

July 1, 2014

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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...

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Seamless wires resist moisture pickup

June 30, 2014

Hobart Brothers Co. has introduced new seamless flux-cored and metal-cored wires designed to offer extreme resistance to moisture pickup and minimize cracking. The new Hobart® MEGAFIL® wires also have less than 4 ml of diffusible hydrogen per 100 g of weldment, which further mitigates cracking...

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

June 27, 2014

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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:...

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Consumables Corner: Issues with incomplete fusion

June 27, 2014

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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...

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Consumables Corner: Figuring out FCAW Charpy V-notch failure

June 26, 2014

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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...

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Consumables Corner: Simple steps to avoid cracking

June 25, 2014

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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...

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Consumables cover plasma cutting from 50 to 200 amps

June 24, 2014

Thermacut, The Cutting Company, offers a line of replacement consumables suitable for use with the HyPro 2000 ® upgrade for MAX200® and HT2000® plasma cutting systems from Hypertherm®. The product line covers cutting applications from 50 to 200 amps and material that includes mild steel,...

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Consumables Corner: Before choosing filler, know your 4140

June 24, 2014

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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...

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Consumables Corner: Pinning down the cause of porosity in SAW

June 23, 2014

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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...

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Consumables Corner: Reducing weld cleanup in pulsed GMAW

June 20, 2014

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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...

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Brochure highlights long hand torches, accessories

June 19, 2014

Uniweld has published a brochure of its U.S.-made long torches, featuring V-, H-, and A-style torches and equipment. Also included are hand and machine cutting torches in a variety of lengths and styles and flashback...

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