Welding Information
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WELD WIRE SELECTOR
When dealing with specialty alloys, there can be unique welding combinations where guidance is not easily found. The Rolled Alloys Weld Wire Selector helps to take guesswork out of the equation by allowing you to select any two alloys and see which weld wire is preferred. This tool was created with welders and fabricators in mind to determine the best wire options for their specific alloys or applications.
FABRICATION MANUALS
TYPES OF WELDING
GMAW [Gas Metal Arc Welding]
Metal Inert Gas (MIG) welding, now referred to as Gas Metal Arc Welding (GMAW), is an arc welding process that involves automatically feeding a consumable wire from a spool through a gun. The weld is protected by external shielding gas that is also delivered through the gun. The machine allows for adjustments to parameters such as wire feed rate, travel speed, and amperage. These welding wires come in various diameters, ranging from 0.015 inches to 0.200 inches, with 0.035 inches and 0.045 inches being the most common sizes.
GTAW [Gas Tungsten Arc Welding]
Tungsten Inert Gas (TIG) welding, now known as Gas Tungsten Arc Welding (GTAW), is an arc welding process that utilizes a non-consumable tungsten electrode to create an arc with the workpiece. In this method, a consumable wire is manually fed into the weld pool while the welding gun supplies shielding gas. TIG welding is generally more challenging than Gas Metal Arc Welding (GMAW) because the wire is fed by hand rather than being automatically controlled by a machine. The consumable wires used in this process typically come in 36-inch straight lengths.
SMAW [Shielded Metal Arc Welding]
SMAW is commonly called “stick welding,” manual arc welding, or welding with covered electrodes. This is because the welding is done with a stick of metal that is covered in flux, which provides the shielding for the weld pool. The flux will float to the top of the weld pool and must be removed afterward. Electrodes will commonly come in 10-pound containers and must be kept completely dry to ensure they are not ruined. This is usually done by keeping electrode containers in a heated box to prevent unwanted moisture.
FCAW [Flux Cored Arc Welding]
FCAW, like GMAW, is a thin-diameter wire that comes in a spool. However, flux-cored wire is a hollow metal tube with powdered flux and alloying elements within the tube. FCAW can be used in all welding positions and is extremely welder-friendly. The flux-filled wire is automatically fed through the center of the gun using the same equipment as GMAW. The shielding gas is supplied through the gun and protects the weld pool from oxidation during welding. The flux inside the wire will protect the weld from the atmosphere since it forms a slag that covers the weld. It is available in stainless and nickel-grade alloys. Delong Calculator Under the Image Verbiage:
WELDING POSITIONS
SCHAEFFLER DELONG DIAGRAM
300 series stainless steels, such as 304/304L and 316/316L, are austenitic and non-magnetic in their annealed state, typically free of ferrite. However, cast products and cold-worked versions may contain ferrite, which can introduce magnetic properties and, in some environments, reduce corrosion resistance. Ferrite is controlled through alloy composition, with elements like carbon, nitrogen, nickel, and manganese promoting the formation of austenite and reducing ferrite. In cast 304 stainless (CF8), ferrite content typically ranges from 8-20% to prevent solidification cracking. Predictive tools like the DeLong diagram are commonly used to balance ferrite content, particularly in wrought 304/304L alloys, which generally maintain 1-6% ferrite to prevent cracking during hot working.
Calculate the nickel and chromium equivalents from the weld metal chemistry. If nitrogen analysis of the weld is not available, assume 0.06% for GTA and covered electrode or 0.08% for GMA weld metals. If the chemistry is accurate, the diagram predicts the WRC Ferrite Number within plus or minus 3 in approximately 90% of the tests for 308, 309, 316, and 317 families.
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