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site under construction 2004

The following data is intended as a quick reference guide. No guarantee of accuracy is
provided. Clarify consumable selection and heat treat with consumable or
metal manufacturer. Qualify before welding.

MISCELLANEOUS METALS IN ALPHABETICAL ORDER

 

Aluminizing. An aluminum alloy coating formed on a steel by hot sprray, dip or diffusion.

Common Aluminum Filler Metals:
5356 - 4043 - 1100 - 5556 - 4047
5XXX = Al - Mg
4XXX = Al - Si
1XXX = Al
2XXX = Al - Cu
3XXX = Al - Mn

Metric Conversion of Filler Strength. KSI x 6.894 = MPa

Alumumum Filler Metal Information:
filler	International Specs	Chemistry	Melt	Yield	Tensile
1050A	ISO / Germany A199.5 France A5 Italy P-AP5
1100		Al 99% - Mn0.05 Cu 0.05 - 0.2 Si - Fe0.95 Zn 0.10	1190 to 1215F 643 to 657C	5 ksi 34MPA	13 ksi 90 MPa
1100 - H12				15 ksi	16 ksi
1100 - H14				17 ksi	18 ksi
ER filler 1100 used to weld all 1XXX alloys plus 3003 and 5005 alloys
1188	UNS A91188	Al 99.8% Si 0,06, Fe 0.06 Cu 0.005, Mn 0.01, Zn 0.03. Ti0.01	1215F 657C
2319	UNS A 92319 used for Al lithium aircraft alloy 2090 2319 is heat treatable good strength ductility on Al Cu Casts dont use 2319 on 5XXX	Cu 5.8 - 6.8 Si 0.2 / Fe0.3 Mn0.2-0.4 Mg 0.02 Zn 0.1 Ti 0.1 - 0.2	1010 to 1190F 543 to 643C
2319 used on 2219 2014 and aluminum Copper Cast Alloys
4043	Germany ISO S - ALSi5 Italy S-AlSi5 France A- S5 "dont" use to weld high Mg 5XXX 5083 - 5086- 5456	Si 4.5 - 6 Fe 0.8, Cu 0.3 Mn 0.05 Mg 0,05, Zn 0.1 Ti 0.2	1155F 623 C	10 ksi 69 Mpa	21 ksi 145 Mpa
4043 - 18				39 ksi 270 MPa	41 ksi 285 MPa
4047	Germany ISO S- AlSi12 Italy S-AlSi12 France A-S12	Si 11 - 13 Fe 0.8, Cu 0.3 Mn 0.15, Mg 0.1 Zn 0.2	1050F 565C
ER 4043 - 4047 Moderate strength good corrosion resistance. ER 4043 - 4047 Low sensistivity to cracking while welding ER 4043 - 4047 Lower weld ductility than 1XXX - 2XXX - 5XXX fillers ER 4043 - 4047 Can weld 1XXX - 3XXX - 6XXX 2014 / 2219 / 5005 /5052 / 7005 / 7039 Al - Si and Al - Si - Mg casts
4145		Si 9.3 - 10.7 Fe 0.8 Cu 3.3 -4.7 Mg/Mn/Cr 0.15 Zn 0.2	970F
ER 4145 Low sensitivity to weld cracking on 2XXX alloys ER 4145 Good for Al - Cu Al Si Cu Cast Alloys Reponds to heat treat. ER 4145 Can replace ER 4043 4047 will however have lower ductility.
4643		Si 3.6 - 4.6 Fe 0.8, Cu 1.1 Mg 0.1 - 0.3 Zn 0.1, Mn 0.05 Ti 0.15	1065 to 1175F 573 to 635C
ER 5XXX Higher strength than other aluminum filler metals ER 5XXX used to weld 5XXX - 6XXX - 7005 alloys Dont use ER5XXX filler on 2XXX alloys ER 5XXX Higher Mg Higher strength and crack sensitivity decreases ER 5XXX Pre heat and interpass max temp 150F 65C
5056	ISO/Germany AlMg5 France A-G5MC Italy P-AG5
5083	ISO /Germany AlMg4.5Mn France A-G4,5MC
5154	ISO AlMg3.5 Germany AlMg3 France A-G3C
5183	Germany S-AlMg4.5Mn France AlMg4.5Mn	Mg 4.3 - 5.2 Si/Fe 0.4 Cu 0.1 Mn 0.5 -1 Cr 0.05 -0.25 Zn 0.25 Ti 0.15	1075 to 1180F 579 TO 637 C
5356	Germany France S - AlMg5 Italy S-ALMG5	Mg 4.5 - 5.5 Cu 0.1 Ti 0.06 - 0.2 Cr/Mn 0.05-0.2 Zn 0.1 Si 0.25 / Fe 0.4	1180F 637C
5454	ISO AlMg3Mn Germany AlMg2.7Mn France A-G2.5MC
5554	Italy S-AlMg3Mn	Cu 0.1, Mn0.05-1 Mg 2.4 - 3 Cr/Ti 0.05-0.2 Zn 0.25	1115F 601C

Annealing. Provide heatto a metal and holf at a specific temperature and then cool at at a controled rate. To improve machining, to reduce hardness, produce a specific microstructure, obtain certain mechanical properties.

SMAW and GMAW Mechanical Strength
E6010 Minimum Yield 50,000 psi Minimum Tensile 62,000 psi.
E6011 Minimum Yield 50,000 psi Minimum Tensile 62,000 psi.
E7010 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.
E7018 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.

MIG E70S-3-6 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.

The "yield strength", the stress that can be applied to a base metal or weld without permanent deformation of the metal.

The "tensile strength", "the ultimate tensile strength" is the maximum tensile strength that the metal or weld can with stand before failure occurs.

Mechanical Strength of Gas Shielded Flux Cored Electrodes from the
ANSI/AWS A5.29. 1198 Specification
Low Alloy Steel Electrodes for Flux Cored Arc Welding

Anode. The point at which electrons depart and current arrives. In MIG welding the anode in reverse polarity is the tip of the MIG wire.

Aging. The slow change of metal properties that occur at room temperature. Artificial aging is the change of properties at above room temp.

ustenite. A solid solution of one or more elements in a face centered cube.

Austenitic Steel. A steel alloy which should be austenitic at room temperature.

Austenizing. The creatingof autenite by heat treatment of an iron alloy.

Bainite. A decomposition of austenite (ferrrite and carbide).

Basic steel. The forming, melting of steel under a slag, in a furnace with a basic base and lining.

Bessemer. A method for making steel in which air is forced through the molten pig iron to remove by oxidation reaction specificamoounts of carbon silicon and manganese

Blow hole. A hole in a weld or casting caused by gas during the metal soolidification.

 

 

Brittleness:The ease at which the weld or metal will break or crack without appreciable deformation. The ease at which the weld or metal will break or crack without appreciable deformation. The ease at which the weld or metal will break or crack without appreciable deformation. When a metal gets harder it becomes more brittle. Preheat, inter-pass temp controls and post heat all are designed to reduce the potential for brittleness.

Many manufactures of parts and equipment containing ASTM steels do not use the recommended pre or post-heat treatments.   The requirements for weld heat treatment is greatly influenced by many factors, the application, the governing specifications or codes, the plate condition, plate thickness, the weld consumables the weld procedures, the weld size and amount of welds required. In many cases the manufacturer that uses ASTM steels will find that its not necessary for the weld to match the mechanical properties of the steel, and will therefore typically utilize low hydrogen, highly ductile E7018 /E70S-3-6 / E71T-1 electrodes. When using the low hydrogen electrodes, the pre and post heat treatment recommendations are frequently eliminated, however from a weld quality perspective always ensure that the weld locations are dry, the metal is over 60F, and that rust and mill scale is removed from the weld area. Also even when heat treatment is not used its frequently beneficial to not allow the multi-pass inter-pass weld temperatures to exceed 200F If you ignore the heat treat requirements as recommended by the metal specifications ensure you use low hydrogen electrodes then, (a) Establish the welding procedure. (b) Qualify the weld and HAZ properties. Ensure the after weld and HAZ properties are compatible with the steel specifications, ref grain size, hardness and strength. PRE HEAT IN THESE CHARTS ALSO APPLIES TO MINIMUM INTER-PASS TEMPERATURE

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Alloy steels always require your weld consideration. Compare the low alloy steels chemistry and mechanicals with a standard A36 steel. Remember this is only a guide, weld responsibility starts with the weld decisiopn maker verifying the consumables and heat treat recommendations.

STRESS RELIEVING (SR) BASIC GUIDELINES:

• STRESS RELIEF - CONTROLLED HEATING & COOLING TO REDUCE STRESS.
• STRESS RELIEF MACHINED PARTS FOR DIMENSIONAL STABILITY.
• STRESS RELIEF SLOW HEATING AND COOLING REQUIRED
• CONFIRM WITH CODE SPECIFICAIONS FOR STRESS RELIEF REQUIREMENTS.
  
  
  
  

Metric Conversion 1000 psi = ksi x 6.894 = MPa

Many steel types and their grades go back for 30 to 50 years.
Today many grades are obsolete. Its helpful to include these grades as many rebuilds and repairs deal with the older grades. By the way if you don't see a chemistry range you are typically seeing the maximum alloy content.

Fatigue:The ability of a metal or weld to withstand repeated loads. Fatigue failures occur at stress levels less than the metal or weld yield strength.

Some things that can influence fatigue failure:

• Excess weld profiles.
• Welds which cause undercut.
• FCAW or SMAW slag inclusions.
• Lack of weld penetration.
• Excess weld heat, typically from multi-pass welds without inter-pass temp controls.
• Items to a part that adds restraint while welding.
• Items added to a part that can concentrate stresses in a specific location.
• Incorrect selection of filler metal, weld too weak or weld too strong.
  
  
  
  
  

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Weld Question: When you see an electrode recommendation such as E8018-C1, who is the best reference source to convert that electrode to a flux cored or MIG wire?
Answer: I believe both Alloy rods and Tri Mark, flux cored manufacturers have the best reference source for this subject

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Weld Question: Which should be the greater concern rust or mill scale.
Answer: Mill scale causes much more weld issues than m rust. Mill scale can effect [1] the weld fusion potential, [2] the weld travel rates attained, [3] the weld appearance, [4] the weld mode and arc stability and [5] weld spatter formation.

Ductility: The amount that a metal or weld will deform without breaking. The amount that a metal or weld will deform without breaking. Measured on welds by the % of elongation in 2 inch 51 mm test piece. An E71T-1 flux cored electrode should result in a minimum of 20% elongation. An E70S--6 MIG weld should produce 22%.

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Weld Question: I have welded parts at Caterpillar plants. They weld many of the ASTM steels listed here. They rarely use pre heat even on the very thick steels, why do they not comply with the ASTM specs heat treat requirements?

Answer: "A spec is a spec" no code or specification body takes responsibility for what is written in there codes or specifications. Specifications are set of guidelines. In the case of the ASTM specs the heat treat recommendations are to make the weld properties conform with the base metal properties, many times its not practical or logical to do this. If an organization produces multi-pass welds, the multi pass heat input has an extensive influence on the mechanical properties of the welds and the base metals. Qualification of the multi-pass welds and HAZ with the specific weld procedures utilized always will have far more relevance than a specification which was typically written for a single pass weld.

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Hardness:
The resistance of the metal or the weld to penetration. The resistance of the metal or the weld to penetration. Hardness is related to the strength of the metal. A good way to test a weld after the weld and heat treatment are complete is to test the hardness of weld and the base metal surrounding the weld.

Toughness:
The ability of the metal or weld sample at a predetermined temperature to withstand a shock.
The test for toughness measures the impact of a pendulum on a notched specimen. You may see that the required impact properties for the metal or weld are 20ft-lbf @ -20 F (27 j @ -29C)

Dual - Ten manufactured by US Steel

Dual TEN are dual phase steels with a mix of ferrite matrix and martensite islands decorating grain boundaries with possible addition of bainite. These steels contain approx. 5 - 15% martensite. These steels therefore offer that unique combination of Ferrite = soft phase (ductility) and martensite = hard phase offering high strength.

Grades Dual Ten 590 / 600

Grades Dual Ten 780 / 800

Dual Ten Strength UTS 72 - 175 ksi 500 - 1200 Mpa

Dual Ten high rate of work hardening

Dual Ten offer weigh reduction even in comparison to high strength steels, this means the auto industry will embrace them and you will be welding parts less than 1.2 mm thick For more information on the unique mechanical properties of this steel vist the US Steel site.

The only information on welding i found at US STEEL on welding, is that these steels meet auto application weld needs. From my perspectice, Its logical with these steels to minimize weld heat input, so short circuit or high weld speeds with the open arc modes of weld transfer would be logical.. No pre-heat on gage and definately look to interpass temp controls, at a guess i would state 200 f.