Volume 06 - Welding, Brazing and Soldering Part 13 pps

1989 ANNUAL BOOK OF STANDARDS, CAST METALS; ALUMINUM AND MAGNESIUM ALLOYS,DIE-TABLE 3 COMPOSITIONS OF ELECTRODES AND FILLER METALS USED IN GAS SHIELDED ARC WELDING OF MAGNESIUM ALLOYS PE

MODERN WELDING TECHNOLOGY,

METALS HANDBOOK,

WELDING HANDBOOK,

TABLE 1 RELATIVE ARC WELDABILITY OF MAGNESIUM ALLOYS

ALLOY RATING

CASTING ALLOYS

WROUGHT ALLOYS

TABLE 2 COMPOSITION OF SELECTED MAGNESIUM ALLOYS

DESIGNATION COMPOSITION, WT% OTHER ELEMENTS

ASTM UNS

NO.

Mg

1989 ANNUAL BOOK OF STANDARDS, CAST METALS; ALUMINUM AND MAGNESIUM ALLOYS,

DIE-TABLE 3 COMPOSITIONS OF ELECTRODES AND FILLER METALS USED IN GAS SHIELDED ARC WELDING OF MAGNESIUM ALLOYS PER AWS A5.19

TABLE 4 SELECTION GUIDE FOR USING FILLER METAL TO JOIN TWO MAGNESIUM-BASE ALLOYS

FILLER METAL FOR USE WITH INDICATED BASE ALLOYS

AZ3

1, AZ3 1C

AZ6 1A

AZ6 3A

AZ8 0A

AZ8 1A

AZ9 1C

AZ9 2A

EK4 1A

EZ3 3A

HK3 1A

HM2 1A

HM3 1A

HZ3 2A

K1A LA14 1A

M1A , MG1

QE2 2A

ZE1 0A

ZE4 1A

ZX2 1A

ZH6 2A, ZK5 1A, ZK6 0A, ZK6 1A

TABLE 5 TYPICAL JOINT DESIGNS USED FOR GAS SHIELDED ARC WELDING OF SELECTED THICKNESSES OF MAGNESIUM ALLOY SHEET AND PLATE

APPLICABLE RANGE OF WORK-METAL THICKNESS (A)

CIRCUITING

PULSED ARC

TABLE 6 TYPICAL DEPTH OF GROOVES IN BACKING BARS OR PLATES USED IN ARC WELDING OF MAGNESIUM ALLOYS

DEPTH OF GROOVE

GMAW

BASE-METAL THICKNESS

GTAW

NO ROOT OPENING(A) ROOT OPENING

TABLE 7 PREHEAT TEMPERATURES AND POSTWELD HEAT TREATMENTS FOR MAGNESIUM ALLOY CASTINGS

TEMPER OF ALLOY(A) MAXIMUM

PREHEAT TEMPERATURE(B)ALLOY

BEFORE

WELDING

AFTER TREATMENT

POSTWELD HEAT TREATMENT(C)

TABLE 8 TYPICAL OPERATING CONDITIONS FOR GAS-METAL ARC BUTT WELDING OF MAGNESIUM ALLOYS AT WELDING SPEED OF 610 TO 915 MM/MIN (24 TO 36 IN./MIN)

ELECTRODE BASE-

mm in.

TYPE OF GROOVE

NO

OF PASSE

n

in./mi n

ft 3 / h

SHORT CIRCUITING MODE OF METAL TRANSFER

PULSED ARE MODE OF METAL TRANSFER(C)

SPRAY ARC MODE OF METAL TRANSFER(E)

TABLE 9 TYPICAL PARAMETERS FOR MANUAL GTAW OF BUTT JOINTS WITH MAGNESIUM ALLOYS

FILLER METAL BASE-METAL

THICKNESS

ELECTRODE DIAMETER

ARGON FLOW RATE DIAMETER CONSUMPTION

mm in.

JOINT DESIGN (A)

NO OF PASSES

mm in.

AC CURRENT (B) ,

/h ft 3 /h mm in kg/m lb/ft

CONDITIONS FOR MANUAL GTAW

TABLE 10 MANUAL GTAW OF ALLOY AZ31B

TABLE 11 OPERATING PARAMETERS FOR AUTOMATIC GTAW OF AZ31B MAGNESIUM ALLOY BUTT JOINTS

ER AZ61A OR ER AZ92A FILLER METAL,

1.60 MM (0.063 IN.) DIAM

DIAMETER OF TUNGSTEN ELECTRODE

ARC LENGTH

FEED RATE CONSUMPTION

OF WELD

TRAVEL SPEED

TYPE OF

CURRENT

CURRENT A

mm in mm in m/min in./min kg/m lb/ft mm/min in./min

AZ31B, 1.60 MM (0.063 IN.) THICK

AZ31B, 4.83 MM (0.190 IN.) THICK

AUTOMATIC GTAW

MANUAL GTAW

MANUAL GTAW

WELDING CONDITION EXAMPLE 8 EXAMPLE 9 EXAMPLE 10 CONDITIONS FOR MANUAL GTAW(A)

TABLE 12 POSTWELD TREATMENTS TO OBTAIN 80 TO 95% STRESS RELIEF IN MAGNESIUM ALLOYS

TEMPERATURE ALLOY

TIME SHEET

EXTRUSIONS

CASTINGS(C)

1989 ANNUAL BOOK OF STANDARDS, CAST METALS; ALUMINUM AND MAGNESIUM ALLOYS,

DIE-MODERN WELDING TECHNOLOGY,

TABLE 1 CHEMICAL COMPOSITION REQUIREMENTS FOR TITANIUM AND TITANIUM ALLOY ELECTRODES AND RODS

Notes:

TABLE 2 DIMENSIONS OF TYPICAL JOINTS FOR WELDING TITANIUM AND TITANIUM ALLOYS

BASE-METAL THICKNESS

ROOT OPENING (A) GROOVE ANGLE, DEGREES WELD-BEAD

WIDTH (A)SQUARE-GROOVE BUTT JOINT

TABLE 3 STRESS-RELIEVING TIMES AND TEMPERATURES FOR SELECTED TITANIUM ALLOYS

TEMPERATURE GRADE

TIME, H

TABLE 1 CHEMICAL COMPOSITIONS OF COMMERCIAL ZIRCONIUM AND ZIRCONIUM ALLOYS PER ASTM SPECIFICATION B 550-92

R60804 (ZIRCALOY-4)

R60901 (ZR-2.5NB)

TABLE 3 CHEMICAL COMPOSITIONS OF ZIRCONIUM AND ZIRCONIUM-ALLOY ELECTRODES

COMPOSITION, WT%

ELEMENT

ERZR2 (R60702)

ERZR3 (R60704)

ERZR4 (R60705)

TABLE 1 COMPOSITIONS, HARDNESS, AND ABRASION DATA FOR A PEARLITIC LOW-ALLOY STEEL (EFE1) AND AUSTENITIC MANGANESE STEELS (EFEMN-C AND EFEMN-CR) USED FOR BUILDUP OVERLAYS AND AIR-HARDENING OF MARTENSITIC STEELS USED FOR METAL-TO-METAL WEAR APPLICATIONS

ABRASION, VOLUME LOSS COMPOSITION, WT%

LOW-STRESS (C) HIGH-STRESS (D) ALLOY

Fe Cr C Si Mn Mo Ni

HARDNESS, HRC

MM 3 IN 3 × 10 -3 MM 3 IN 3 × 10 -3BUILDUP WELD OVERLAY

METAL-TO-METAL WELD OVERLAY

TABLE 2 COMPOSITIONS OF HIGH-CHROMIUM WHITE IRONS USED FOR METAL-TO-EARTH ABRASION APPLICATIONS

COMPOSITION, WT%

ALLOY

Cr C Si Mn Mo Ni B Fe

•

•

AWS DESIGNATION MESH SIZE RANGE

TABLE 3 ABRASION DATA FOR TUNGSTEN CARBIDE HARDFACING MATERIALS

ABRASION, VOLUME LOSS MATERIAL

LOW-STRESS(A) HIGH-STRESS(B)CARBIDE, WT% MESH SIZE mm3 in.3 × 10-3 mm3 in.3 × 10-3

TABLE 4 COMPOSITIONS OF SELECTED COBALT-BASE HARDFACING ALLOYS

COMPOSITION, WT%

ALLOY

CR MO W SI C CO CARBIDE-CONTAINING ALLOYS

LAVES PHASE ALLOYS

TABLE 5 PROPERTIES OF SELECTED COBALT-BASE HARDFACING ALLOYS

21 (A)

RCOCRA RCOCRB RCOCRC TRIBALOY

T-800

WEAR

TABLE 6 COMPOSITION OF NICKEL-BASE AND HIGH-NICKEL-CONTENT HARDFACING ALLOYS

COMPOSITION, WT%

ALLOY

Fe Cr Mo W Si C B Co Ni BORIDE-CONTAINING ALLOYS

CARBIDE-CONTAINING ALLOYS

LAVES PHASE ALLOYS

TABLE 7 PROPERTIES OF SELECTED NICKEL-BASE HARDFACING ALLOYS

0.12C)

(NI-17CR-17MO-TRIBALOY T-700

TABLE 8 PHASES FORMED IN BORIDE-CONTAINING NICKEL-BASE HARDFACING ALLOYS

SECONDARY PHASES CHROMIUM

CONTENT COMPOUND

FORMED

REQUIRED CONDITIONS

DOMINANT HARD PHASE

ELEMENT COMPOSITION, WT%

HARDFACING PROCESS CONSUMABLE FORM

TABLE 9 SELECTION GUIDE FOR HARDFACING ALLOYS

HIGH HARDNESS

in situ

in situ

TABLE 10 CHARACTERISTICS OF WELDING PROCESSES USED IN HARDFACING

METAL DILUTION,

DEPOSIT EFFICIENCY,

%

MATH OMITTED

PR PN CA

X,

μ

TABLE 11 TYPICAL APPLICATIONS FOR LASER HARDFACING

ALLOY

HARDFACING TECHNIQUE

COMPANY

ET AL., WELDING, BRAZING, AND SOLDERING, METALS HANDBOOK,

FRICTION,

LUBRICATION, AND WEAR TECHNOLOGY, ASM HANDBOOK,

PROPERTIES AND SELECTION: IRONS, STEELS, AND HIGH-PERFORMANCE ALLOYS, ASM HANDBOOK,

WELD J.,

WELD DES FABR.,

POWDER

FRICTION, LUBRICATION, AND WEAR TECHNOLOGY, ASM HANDBOOK,

ET AL.,

WELDING, BRAZING, AND SOLDERING, ASM HANDBOOK,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

SOURCEBOOK ON APPLICATIONS OF THE LASER IN METALWORKING,

J MET., PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT

OF METALS,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

TABLE 12 COMPARISON OF THERMAL SPRAY PROCESSES

GAS FLOW FLAME OR

EXIT PLASMA TEMPERATURE

PARTICLE IMPACT VELOCITY

MAXIMUM SPRAY RATE

POWER ENERGY

REQUIRED

TO MELT PROCESS

M 3 /H FT 3 /H °C °F M/S FT/S

RELATIVE ADHESIVE STRENGTH (A)

COHESIVE STRENGTH

OXIDE CONTENT,

%

RELATIVE PROCESS COST (A)

KG/H LB/H KW HP KW/KG KW/LB

FLAME POWDER:

FLAME WIRE:

WIRE ARC:

CONVENTIONAL PLASMA:

DETONATION GUN:

HIGH-VELOCITY OXYFUEL:

HIGH-ENERGY PLASMA:

VACUUM PLASMA:

ADVANCED MATERIALS

& PROCESSES

μ μ

μ μ R

μ

ADV MATER PROCESS.,

THERMAL SPRAY TECHNOLOGY,

TABLE 13 THERMAL SPRAY COATINGS USED FOR HARDFACING APPLICATIONS

TYPE OF WEAR COATING

MATERIAL

COATING PROCESS(A)

APPLICATIONS

TABLE 14 THERMAL SPRAY COATINGS USED FOR ELEVATED-TEMPERATURE SERVICE

COATING THICKNESS SERVICE TEMPERATURE COATING METAL OR ALLOY

μm mils

CORROSION ASM HANDBOOK,

MACH DES.,

ADV MATER PROCESS.,

TABLE 15 STAINLESS STEEL FILLER METALS FOR WELD CLADDING APPLICATIONS

WELD

OVERLAY

TYPE

COVERED ELECTRODE(A)

BARE ROD OR ELECTRODE(B)

COVERED ELECTRODE(A)

BARE ROD OR ELECTRODE(B)

TABLE 16 BASE METAL AND WELD METAL COMPOSITIONS PRODUCED WHEN AISI 1050 CARBON STEEL WAS WELD CLAD USING E312-16 STAINLESS STEEL FILLER METAL

MATERIAL AISI

1050

E312-16 ALL-WELD-METAL

30% DILUTION CLADDING

(EQ 3)

(EQ 4)

• AMPERAGE:

• POLARITY:

TABLE 17 TYPICAL WELDING PARAMETERS FOR STAINLESS STEEL WELD CLADDING BY SAW

SIZE OF ELECTRODE

TRAVEL SPEED

OSCILLATION PRODUCTIVITY FORM OF

ELECTRODE

mm in.

POWER SOURCE

CURRENT, A

VOLTAGE, V

mm/min in./min mm in kg/h lb/h

DILUTION(A),

%

SERIES ARC

SIX WIRE

TABLE 18 CHEMICAL COMPOSITION VARIATIONS IN SERIES-ARC WELD CLADDING DEPOSITS USING AN AGGLOMERATED FLUX AND TYPE 308 OR 309 WIRE

WELDING CONDITIONS

mm in.

ANGLE BETWEEN WIRES, DEGREES

CURRENT (AC), A

VOLTAGE,

V mm/min in./min

CHEMICAL ANALYSIS

9.83 9.57 9.02 8.16 13.36 13.14 11.08 11.43 CARBON STEEL BASE 0.07 0.51 0.013 0.016

TABLE 19 TYPICAL WELDING PARAMETERS FOR STAINLESS STEEL WELD CLADDING USING SELF-SHIELDED FLUX-CORED WIRES

TRAVEL SPEED

CAPACITY (A)

CURRENT, A

VOLTAGE, V

MM/MIN IN./MIN

OSCILLATION, CYCLES/MIN

TRAVEL SPEED

PRODUCTIVIT Y

NO

OF WIRE S

m m in.

CURRENT ,

n

in./mi n

kg/h lb/h

8-12 8-12 8-15

500 39 1.4 85 2 2.4 240 255 10 27-32 60-70 8-15

TABLE 21 NONFERROUS FILLER METALS USED FOR WELD CLADDING OF STEELS

WELD OVERLAY TYPE

AWS SPECIFICATION NO.

CLASSIFICATION NO.

AWS SPECIFICATION NO.

ERCUAL-AL ERCUSI ERCUNI (A) ERNI-1 ENICU-7 ERNICR-3 ERNICRMO-3 ERNIMO-7

HASTELLOY C A5.11 ENICRMO-4 A5.14 ERNICRMO-4

ET AL., WELDING, BRAZING, AND SOLDERING, METALS HANDBOOK,

POWDER

ET AL., WELDING, BRAZING, AND SOLDERING METALS HANDBOOK

WELD J.,

MET PROG.,

WELD J.,

WELD J.,

WELD J.,

•

•

•

X D X D X D X (EQ 5)

D D

ALLOY

CR NI MO

95.5 63.0 ERNICR-3 20.0 72.0 3.0

(EQ 6) (EQ 7) (EQ 8)

•

TABLE 22 BASE METAL AND WELD METAL COMPOSITIONS PRODUCED WHEN ASTM A 36 STRUCTURAL STEEL AND TYPE 304 STAINLESS STEEL WERE JOINED BY SMAW USING E309L-16 FILLER METAL

10.38 0.15 0.049 20.04 13.39 WRC-1988 FN 3.2 17.4 4.3

(EQ 9) (EQ 10)

(EQ 11)

(EQ 12)

•

•

LOW-ALLOY STEEL

ENI-1, ENICRFE-2, ENICRFE-3 ERNI-1, ERNICR-3, ERNICRFE-6 ENICRFE-2, ENICRFE-3 ERNICR-3, ERNICRFE-6 ENICRFE-2, ENICRFE-3 ERNICR-3, ERNICRFE-6 ENICRMO-3

ERNICRMO-3

ENIMO-7 ERNIMO-7 ENICRMO-4 ERNICRMO-4 ENICRMO-4 ERNICRMO-7 ENICRMO-9 BARE WIRE ERNICRMO-1 ERNICRMO-1

TABLE 24 FILLER METALS AND PREHEAT AND INTERPASS TEMPERATURES USED IN

GAS-TUNGSTEN ARC WELDING OF COPPERS AND COPPER-BASE ALLOYS TO STEELS

SILICON

ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) STAINLESS

STEEL

ERCUAL-A2 OR ERCU OR ERNI-3 (540 °C, OR 1000 °F)

ERCUSN-A (205

°C, OR 400 °F)

ERCUAL-A2 (65

°C, OR 150 °F MAX)

ERCUAL-A2 (65 °C, OR 150

°F MAX)

ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX)

TABLE 25 FILLER METALS AND PREHEAT AND INTERPASS TEMPERATURES USED IN GAS-METAL ARC WELDING OF COPPERS AND COPPER-BASE ALLOYS TO STEELS

PHOSPHOR BRONZES

ALUMINUM BRONZES

SILICON

ERCUAL-A2OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX) ERCUAL-A2, OR ERNI-3 (65 °C, OR

150 °F MAX) STAINLESS

STEEL

ERCUAL-A2 OR ERCU OR ERNI-3 (540 °C, OR 1000 °F)

ERCUAL-A2 OR ERCUSN-A (315 °C,

OR 600 °F)

ERCUAL-A2 (315 °C, OR 600

ERCUAL-A2 (65

°C, OR 150 °F MAX)

ERCUAL-A2 OR ERNI-3 (65 °C, OR

150 °F MAX)

WELD J., WELDING HANDBOOK,

ET AL., WELDING, BRAZING, AND SOLDERING, METALS HANDBOOK,

FRICTION, LUBRICATION, AND WEAR TECHNOLOGY, ASM HANDBOOK,

PROPERTIES AND SELECTION: IRONS, STEELS, AND HIGH-PERFORMANCE ALLOYS, ASM HANDBOOK,

WELD J.,

WELD DES FABR.,

POWDER

FRICTION, LUBRICATION, AND WEAR TECHNOLOGY, ASM HANDBOOK,

ET AL.,

WELDING, BRAZING, AND SOLDERING, ASM HANDBOOK,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

SOURCEBOOK ON APPLICATIONS OF THE LASER IN METALWORKING,

J MET., PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT

OF METALS,

PROC NATO ADVANCED STUDY INSTITUTE ON LASER SURFACE TREATMENT OF METALS,

FRICTION, LUBRICATION, AND WEAR TECHNOLOGY, ASM HANDBOOK,

ADV MATER PROCESS.,

THERMAL SPRAY TECHNOLOGY,

MACH DES.,

ADV MATER PROCESS.,

ET AL., WELDING, BRAZING, AND SOLDERING METALS HANDBOOK

WELD J.,

MET PROG.,

WELD J.,

WELD J.,

WELD J., WELDING HANDBOOK,

TABLE 1 RELATIVE WELDABILITY RATINGS OF SELECTED METAL AND ALLOY COMBINATIONS USED FOR RESISTANCE SPOT WELDING OPERATIONS

METALS ALUMIN

UM

STAINL ESS STEEL

NICK

EL SILV

ER

TERNEPL ATE

TABLE 2 MINIMUM DIMENSIONS FOR SINGLE-IMPULSE SPOT WELDS IN LOW-CARBON STEEL

STOCK THICKNESS MINIMUM WELD

0.375 0.433 0.433 0.500 0.551 0.625

0.669 0.750 0.827 3.2 0.125 51 2.000 22 0.875

T

TABLE 3 RECOMMENDED PARAMETERS FOR RESISTANCE SPOT WELDING OF UNCOATED LOW-CARBON STEEL SHEET PRODUCED FOR AUTOMOTIVE APPLICATIONS

SPACING (D)

SHEET

THICKNESS

FACE DIAMETER

CONTACT OVERLAP TWO

STACK

THREE STACK

MINIMUM SHEAR STRENGTH

WELDING CURRENT,

A

MM IN MM IN MM IN KN LBF MM

0.10 0.12 0.14 0.16 0.18 0.19 0.20 0.21 0.23 0.25 0.26 0.27 0.28 3.05 0.120 9.53 0.375 E,A,B 30° 9.4 2100 26 21,000 22.4 0.88 46.0 1.81 63.5 2.50 22.4 5000 7.6 0.30

MATERIALS AND PROCESSES, PART B: PROCESSES, HANDBOOK OF PRODUCT DESIGN FOR MANUFACTURING,

MATERIALS AND PROCESSES, PART B: PROCESSES,

HANDBOOK OF PRODUCT DESIGN FOR MANUFACTURING, WELDING HANDBOOK,

• CIRCULAR:

• LONGITUDINAL:

• UNIVERSAL:

• PORTABLE:

TABLE 4 COMMON SIZES OF ELECTRODE WHEELS USED FOR RESISTANCE SEAM WELDING APPLICATIONS

WHEEL DIAMETER MACHINE SIZE

- LARGE 25-30 10-12 9.5-19

-

•

•

TABLE 5 RECOMMENDED PRACTICE FOR SEAM WELDING OF 1010 LOW-CARBON STEEL

ELECTRODE DIMENSIONS

(W)(B)

FACE WIDTH

(W)(B)

NET ELECTRODE FORCE

WELDING SPEED

mm in mm in mm in kn lbf

HEAT TIME, CYCLES (60 HZ)

COOL TIME (PRESSURE TIGHT), CYCLES (60 HZ)

mm/min in./min

WELDS PER

MM

WELDS PER IN

APPROXIMATE WELDING CURRENT,

A

MM

3.18 0.125 19 13 9.8 2200 10 7 115 45 0.20 5 22,000 22

T.

HANDBOOK OF PRODUCT DESIGN FOR MANUFACTURING,