Weld Deposition Data

DEPOSITION DATA DEPOSITION DATA DEPOSITION RATES, RATES, ELECTRODE ELEC TRODE EFFICIENCY, EFFICIENCY, AND ELECTRODE WELD MET ME TAL RECOVERY! WHAT ARE THE DIFFERENCES? Deposition Rates The deposition rate o a welding consumable (electrode, wire or rod) is the rate at which weld metal is deposited (melted) onto a metal surace. Deposition rate is expressed in kilograms per hour (kg/hr). Deposition rate is based on continuous operation, not allowing or stops and starts such as, electrode change overs, chipping slag, cleaning spatter, machine adjustments or other reasons. When welding current is increased so to does the deposition rate. When electrical stick out is increased in the case o GMAW and FCAW the deposition rate will also increase. Deposition rates are calculated by doing actual welding tests, and the ollowing shows the ormula or measuring deposition rates. Deposition Rate = Weight o test plate beore welding - Weight o test plate ater welding ÷ Measured period o time (normally 60 seconds). e.g. Plate beore welding: 2kg - 2.95kg Plate ater welding = 95grams, welded in 60 seconds. 95grams x 60/1000 = 5.7kg/hr.

6

ELECTRODE EFFICIENCY (DEPOSITION EFFICIENCY) Technically to ISO 2401-1972 electrode eciency (AS/NZS 1553.1: 1995 deposition eciency) is the dierence between the weight o the weld metal deposited and the weight o the ller metal consumed (not including including fux and stub ends) in making the weld. The eciency o an electrode is calculated by using the ollowing ormula; Electrode Eciency % to ISO 2401and AS/NZS 1553.1 = Weight o test plate including weld metal - Weight o test plate beore welding X 100 Mass o the Core Wire o 5 electrodes - Weight o core wire o the 5 stub ends

e.g. Satincrat 13 Ø4mm x 380mm.

e.g. Ferrocrat Ferrocrat 22 Ø3.2mm x 380mm.

Plate beore welding: 2kg - 2.15kg Plate ater welding = 150grams,


weight o ve (5) electrode core wires, Ø4mm x 3 80mm long beore welding = 188grams,

weight o ve (5) electrode core wires, Ø3.2mm x 380mm long beore welding = 124grams,

weight o ve (5) electrode stub ends, Ø4mm x 50mm long ater welding = 24.7grams,

weight o ve (5) electrode stub ends, Ø3.2mm x 50mm long ater welding = 16.3grams,

150grams ÷ 163.3grams x 100 = 91.85% Electrode Eciency (Deposition Eciency).

167grams ÷ 107.7grams x 100 = 155.06% Electrode Eciency (Deposition Eciency).

ELECTRODE WELD METAL RECOVERY RECOVERY (PROCESS EFFICIENCY) EFFICIENCY ) Electrode weld metal recovery to ISO 2401-1972 allows us to calculate the amount o welding consumable which will actually be deposited into the nished weld metal less any waste such as, stub ends, slag and spatter not adhered to the test plate. An example is when 100kgs o electrodes are used with a quoted eciency o 60%, the net result is that only 60kg o the weight o that electrode will actually end up in the deposited weld metal. metal. The remaining 40% (40kg) o the electrode is waste. To achieve weld metal recovery rates practical tests are carried out by weighing the test plate beore and ater welding, weighing the consumables beore welding and then using the ollowing ormula allowing or 50mm stub ends. I the welder discards more than 50mm stub ends than the recovery rate (process eciency) will be lower. Weld Metal Recovery % to ISO 2401 = Weight o test plate beore welding - Weight Weight o test plate ater welding X 100 Weight o the Consumable e.g. Satincrat 13 Ø4mm x 380mm.

e.g. Ferrocrat Ferrocrat 22 Ø3.2mm x 380mm.



weight o ve (5) electrodes, Ø4mm x 380mm long beore welding = 261.20grams,

weight o ve (5) electrodes, Ø3.2mm x 380mm long beore welding = 281.50grams,

150grams ÷ 261.20grams x 100 = 57.43% Weld Metal Recovery (Process Eciency).

167grams ÷ 281.50grams x 100 = 59.33% Weld Metal Recovery (Process Eciency).

L A C I N H C E T

DEPOSITION DATA GENERAL PROCESS EFFICIENCIES Welding Process Average Eciency Gas Tungsten Arc Welding (GTA (GTAW) W) & Oxy-Acetylene Welding (OAW) 100% Manual Metal Arc Welding (MMAW) 60% Gas Metal Arc Welding (GMAW) Short Arc, Ar + 25% CO2 92% Gas Metal Arc Welding (GMAW) Spray Arc, Ar + 25% CO2 95% Gas Metal Arc Welding (GMAW) Pulse Arc, Ar + 25% CO2 98% Flux Cored Arc Welding (FCAW) E70T-4 types, sel shielded 82% Flux Cored Arc Welding (FCAW) E71T-1 types, Ar + 25% CO2 85% Flux Cored Arc Welding (FCAW) E70T-5 types, Ar + 25% CO2 88% Flux Cored Arc Welding (FCAW) E70C-6M types, Ar + 25% CO2 92% Cobalarc Flux Cored Hardacing Wires Gas shielded 80% GMAWandFCAW FCAWaverageecienciescanvaryinresultdependingupon theshieldinggasesused,machinesettings,s tickout,spatter losses,wiresnipedofbeorest artsetc.

CONSUMABLE WEIGHT CALCULATION Required Welding Consumable In KG =

6

(Area x 1 in M x 7900 KG) See detail below (Deposition eciency as a percentage / 100) See detail above

X

Length In M

The Above ormula will calculate your required weld metal using a particular welding consumable process in KG per Metre o weld. (Area x 1 in M x 7900 KG) Areacanbecalculatedusingtheequationsonpage560.Bymultiplyingtheareaby1 willgiveusavolumeoweldmetalrequiredorevery1 metreoweld.Wethen multiply the volume by the weight o steel at 7900 KG per Cubic Metre to give us a weight in KG per Metre o weld. For ease o calculation we have included a series o tables on page 556 & 557. This can be used in the equation above in place o (Area x 1 in M x 7900 KG). The tables can be used as ollows. Simply select the shapes rom the above samples and read the relevant tables on the ollowing page to determine the weight o weld metal in KG or every M o weld. Add each o the shapes together that make up your weld and insert in the equation above in place o (Area x 1 in M x 7900 KG). You can add 2 x Triangles Triangles together to get your total weld weight or a butt weld with 2 preps. In the Triangle table table we have included the legth o the top o the weld so you can calculate the width o the Cap. (Deposition eciency as a percentage / 100) See detail above Deposition eciency is expressed as a percentage on this page above. Divide this percentage by 100 to convert to a decimal.

W

TRIANGLE

T

F

X Where T = Plate Thickness

X = Bevel angle

W = Width or Cap

RECTANGLE

T E C H N I C A L

T

W

Where T = Plate Thickness

W = Width

TRIANGLE Weight o Weld Metal in KG/M o weld For Filet calculations use 45 degrees and F being the Fillet length X (Angle in degrees) 15 20 30 45 KG/M W KG/M W KG/M W KG/M KG/M 3.15 0.01 0.8 0.01 1.1 0.02 1.8 0.04 4.2 0.02 1.1 0.03 1.5 0.04 2.4 0.07 5.25 0.03 1.4 0.04 1.9 0.06 3.0 0.11 6 0.04 1.6 0.05 2.2 0.08 3.5 0.14 8 0.07 2.1 0.09 2.9 0.15 4.6 0.25 ) 0.11 2.7 0.14 3.6 0.23 5.8 0.40 m 10 m 12 0.15 3.2 0.21 4.4 0.33 6.9 0.57 n i 14 0.21 3.8 0.28 5.1 0.45 8.1 0.77 s s e 16 0.27 4.3 0.37 5.8 0.58 9.2 1.01 n k 18 0.34 4.8 0.47 6.6 0.74 10.4 1.28 c i h 20 0.42 5.4 0.58 7.3 0.91 11.5 1.58 T e t 22 0.51 5.9 0.70 8.0 1.10 12.7 1.91 a l 24 0.61 6.4 0.83 8.7 1.31 13.9 2.28 P ( 25 0.66 6.7 0.90 9.1 1.43 14.4 2.47 A 26 0.72 7.0 0.97 9.5 1.54 15.0 2.67 28 0.83 7.5 1.13 10.2 1.79 16.2 3.10 30 0.95 8.0 1.29 10.9 2.05 17.3 3.56 32 1.08 8.6 1.47 11.6 2.34 18.5 4.04 34 1.22 9.1 1.66 12.4 2.64 19.6 4.57 36 1.37 9.6 1.86 13.1 2.96 20.8 5.12 38 1.53 10.2 2.08 13.8 3.29 21.9 5.70 40 1.69 10.7 2.30 14.6 3.65 23.1 6.32 RECTANGLE Weight o Weld Metal in KG/M o weld W (Width in mm) 1 2 3 4 5 6 7 6 0.05 0.09 0.14 0.19 0.24 0.28 0.33 8 0.06 0.13 0.19 0.25 0.32 0.38 0.44 ) 0.08 0.16 0.24 0.32 0.40 0.47 0.55 m 10 m 12 0.09 0.19 0.28 0.38 0.47 0.57 0.66 n i 14 0.11 0.22 0.33 0.44 0.55 0.66 0.77 s s e 16 0.13 0.25 0.38 0.51 0.63 0.76 0.88 n k 18 0.14 0.28 0.43 0.57 0.71 0.85 1.00 c i h 20 0.16 0.32 0.47 0.63 0.79 0.95 1.11 T e 22 0.17 0.35 0.52 0.70 0.87 1.04 1.22 t a l 24 0.19 0.38 0.57 0.76 0.95 1.14 1.33 P ( 25 0.20 0.40 0.59 0.79 0.99 1.19 1.38 T 26 0.21 0.41 0.62 0.82 1.03 1.23 1.44 28 0.22 0.44 0.66 0.88 1.11 1.33 1.55

W 3.2 4.2 5.3 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 25.0 26.0 28.0 30.0 32.0 34.0 36.0 38.0 40.0

60 F KG/M 6.0 0.07 8.0 0.12 10.0 0.19 11.4 0.25 15.2 0.44 19.0 0.68 22.8 0.99 26.7 1.34 30.5 1.75 34.3 2.22 38.1 2.74 41.9 3.31 45.7 3.94 47.6 4.28 49.5 4.62 53.3 5.36 57.1 6.16 60.9 7.01 64.7 7.91 68.5 8.87 72.3 9.88 76.1 10.9

W 5.5 7.3 9.1 10.4 13.9 17.3 20.8 24.2 27.7 31.2 34.6 38.1 41.6 43.3 45.0 48.5 52.0 55.4 58.9 62.4 65.8 69.3

70 KG/M K G/M 0.11 0.19 0.30 0.39 0.69 1.09 1.56 2.13 2.78 3.52 4.34 5.25 6.25 6.78 7.34 8.51 9.77 11.1 12.5 14.1 15.7 17.4

W 8.7 11.5 14.4 16.5 22.0 27.5 33.0 38.5 44.0 49.5 54.9 60.4 65.9 68.7 71.4 76.9 82.4 87.9 93.4 98.9 104 110

8 0.38 0.51 0.63 0.76 0.88 1.01 1.14 1.26 1.39 1.52 1.58 1.64 1.77

9 0.43 0.57 0.71 0.85 1.00 1.14 1.28 1.42 1.56 1.71 1.78 1.85 1.99

12 0.57 0.76 0.95 1.14 1.33 1.52 1.71 1.90 2.09 2.28 2.37 2.46 2.65

15 0.71 0.95 1.19 1.42 1.66 1.90 2.13 2.37 2.61 2.84 2.96 3.08 3.32

20 0.95 1.26 1.58 1.90 2.21 2.53 2.84 3.16 3.48 3.79 3.95 4.11 4.42

10 0.47 0.63 0.79 0.95 1.11 1.26 1.42 1.58 1.74 1.90 1.98 2.05 2.21

DEPOSITION DATA

CAP CA P CH

CW Where CH = Cap Height

CW = Cap Width

CAP Weight o Weld Metal in KG/M o weld CH (Cap Height in mm) 1 1.5 2 2.5 3 5 0.03 0.04 0.06 0.07 0.09 6 0.04 0.05 0.07 0.09 0.11 7 0.04 0.06 0.08 0.10 0.12 8 0.05 0.07 0.09 0.12 0.14 10 0.06 0.09 0.12 0.15 0.18 12 0.07 0.11 0.14 0.18 0.21 14 0.08 0.12 0.17 0.21 0.25 15 0.09 0.13 0.18 0.22 0.27 16 0.09 0.14 0.19 0.24 0.28 ) 18 0.11 0.16 0.21 0.27 0.32 m 0.12 0.18 0.24 0.30 0.36 m 20 n 22 0.13 0.20 0.26 0.33 0.39 i h 24 0.14 0.21 0.28 0.36 0.43 t d i 25 0.15 0.22 0.30 0.37 0.44 W 0.15 0.23 0.31 0.39 0.46 p 26 a C 28 0.17 0.25 0.33 0.41 0.50 ( 0.18 0.27 0.36 0.44 0.53 W 30 C 35 0.21 0.31 0.41 0.52 0.62 40 0.24 0.36 0.47 0.59 0.71

4 0.12 0.14 0.17 0.19 0.24 0.28 0.33 0.36 0.38 0.43 0.47 0.52 0.57 0.59 0.62 0.66 0.71 0.83 0.95

5 0.15 0.18 0.21 0.24 0.30 0.36 0.41 0.44 0.47 0.53 0.59 0.65 0.71 0.74 0.77 0.83 0.89 1.04 1.19

6 0.18 0.21 0.25 0.28 0.36 0.43 0.50 0.53 0.57 0.64 0.71 0.78 0.85 0.89 0.92 1.00 1.07 1.24 1.42

6 CIGWELD SOLID AND FLUX CORED WIRES, DEPOSITION AND WELD METAL RECOVERY RATES The ollowing Table Table lists some popular CIGWELD consumables and their Deposition and Weld Metal Recovery Rates: CIGWELD Product Size (mm) Volts Amps WFS m/min Deposition Rate kg/hr kg/hrWeld Weld Metal Recovery Autocrat LW1-6 0.8 20 150 12.0 2.5 96% Autocrat LW1-6 0.9 26 180 12.0 3.1 96% Autocrat LW1-6 1.0 28 240 13.5 4.8 95% Autocrat LW1-6 1.2 32 300 10.8 5.6 97% Autocrat Silicon Bronze 0.9 24 180 13.2 3.2 95% Autocrat 316LSi 0.9 22 180 10.0 2.8 97% Autocrat 316LSi 1.2 26 250 8.5 4.4 98% Autocrat AL5356 1.0 22 180 16.3 1.5 90% Autocrat AL5356 1.2 24 220 14.0 2.5 92% Satin-Cor XP 1.6 28 300 5.5 4.3 86% Satin-Cor XP 1.6 29 350 6.5 5.4 87% Satin-Cor XP 1.6 30 400 7.0 6.0 89% Satin-Cor XP 2.4 30 400 4.2 5.7 85% Satin-Cor XP 2.4 31 450 5.0 6.8 86% Satin-Cor XP 2.4 32 500 6.0 8.2 90% Verti-Cor 3XP 1.2 25 200 6.7 2.7 86% Verti-Cor 3XP 1.2 26 250 9.9 3.8 84% Verti-Cor 3XP 1.2 28 320 15.0 5.9 88% Verti-Cor 3XP 1.6 27 300 6.2 4.1 86% Verti-Cor 3XP 1.6 28 350 9.5 6.4 81% Verti-Cor 3XP 1.6 29 400 12.0 8.1 88% Metal-Cor XP 1.2 26 250 10.0 5.0 92% Metal-Cor XP 1.6 28 350 6.6 5.6 94% Supre-or 5 1.2 22 170 7.8 2.3 86% Supre-Cor 5 1.6 26 320 5.9 3.3 89% Tensi-Cor 110TXP 1.6 28 280 5.0 3.0 88% Tensi-Cor 110TXP 2.4 29 400 3.8 5.8 90% Shieldcrome 309LT 1.2 26 190 11.4 3.7 84% Shield-Cor 4XP 2.4 29 375 5.4 7.0 84% Shield-Cor 4XP 3.0 30 500 2.9 6.7 86% Shield-Cor 15 0.9 17 120 3.9 0.7 75% Shield-Cor 11 1.2 17 150 3.0 1.0 80% Theinormationprovidedinthis tableisbasedon weldingwithconstantvoltage(C.V.)GMAWeldingmachines.Resultsmayvaryandareinfuencedonthe jobby shielding gases used, machine settings, stick out, spatter losses, wire sniped o beore starts etc.

MANUAL ARC ELECTRODE CONSUMPTION CALCULATOR GUIDE Instructions or Use o this Data The ollowing tables provide data on the approximate mass in kilograms required o the dierent types o electrodes or welding the various weld jointsusedthroughoutindustrytoday.Thisdatawill aidinestimatingmaterial requirements and costs. The basis or the ollowing tabulations is given below. Where variations rom the given conditions or joint preparations are encountered,adjustmentsinthetabulatedvaluesmustbemadetocompensate or such dierences.

Basis o Calculations Electrode requirements have been calculated as ollows: Where M = Mass o electrodes required D = Mass o weld metal to be deposited E = Proportion o electrode lost M = D 1-E To arrive at the mass o weld metal to be deposited it is necessary to calculate rst the volume o metal to be added (area o the cross section o the weld multiplied by the length). This volumetric value is converted to mass by

L A C I N H C E T

DEPOSITION DATA SQUARE BUTT JOINTS, WELDED BOTH SIDES Joint Dimensions

kg o electrodes per linear metre o weld* (Approx.)

kg o weldmetal deposited per liner metre o weld (Approx.)

Plate Thickness

Root Gap (R)

With Reinorcemen Reinorcement** t**


3mm

0

0.23

0.14

1mm

0.26

0.16

1mm

0.38

0.23

1.6mm

0.41

0.25

1.6mm

0.48

0.29

2.5mm

0.56

0.34

5mm 6mm

* Includes spatter losses and 50mm stub end loss. ** Height o Reinorcement = 2mm.

HORIZONTAL-VE HORIZONT AL-VERTICAL RTICAL (HV) FILLET WELDS

6

Fillet Weld leg length length Dimensions

kg o electrodes per linear linear metre metre o weld* (Approx.)

kg o weldmetal deposited per per iner metre o weld (Approx.)

3mm

0.06

0.04

5mm

0.16

0.10

6mm

0.24

0.14

8mm

0.42

0.25

10mm

0.65

0.39

12mm

0.95

0.57

16mm

1.68

1.01

20mm

2.62

1.57

25mm

4.10

2.46

* Fillet weld gures are calculated calculated based on true mitre llets. Convex or overwelded llets can increase increase these gures by 33% or more.

SINGLE VEE BUTT JOINTS, (SINGLE GROOVE BUTTS) BUT TS) Fillet Weld leg length length Dimensions



Plate Root Thickness Face (F)

Root Gap (R)


With Reinorceme Reinorcement** nt**

6mm

1.6mm

1.6mm

0.39

0.23

8mm

1.6mm

1.6mm

0.63

0.38

10mm

1.6mm

1.6mm

0.87

0.52

12mm

3mm

3mm

1.33

0.80

16mm

3mm

3mm

2.22

1.33

20mm

3mm

3mm

3.37

2.02

25mm

3mm

3mm

5.14

3.08

* Includes spatter, 50mm stub ends and back gouging losses. ** Height o Reinorcement = 2mm.

DOUBLE VEE BUTT JOINTS, WELDED BOTH SIDES (DOUBLE GROOVE BUTTS)

T E C H N I C A L

Fillet Weld leg length length Dimensions



Plate Root Thickness Face (F)

Root Gap (R)


With Reinorceme Reinorcement** nt**

12mm

1.6mm

1.6mm

0.92

0.55

16mm

1.6mm

1.6mm

1.46

0.88

20mm

1.6mm

1.6mm

2.12

1.27

25mm

3mm

3mm

3.33

2.00

* Includes spatter, 50mm stub ends and back gouging losses. ** Height o Reinorcement = 2mm.

DEPOSITION DATA 1. GAS METAL ARC WELDING (GMAW - MIG) WIRES FOR MILD AND LOW ALLOY STEELS WIRE SIZE (mm)

0.6

0.8

0.9

1.2

1.6

gms o wire per metre

2.2

4

4.85

8.5

15.7

metres o wire per kg

450

254

200

113

63

2. FLUX CORED ARC WELDING (FCAW) WIRES FOR MILD AND LOW ALLOY ALLOY STEELS WIRE SIZE (mm)

1.2

1.6

2.0

2.4


7.5

13

21

28.5


132

77

50

36

3. SUBMERGED ARC WELDING (SAW) WIRES FOR MILD AND LOW ALLOY ALLOY STEELS WIRE SIZE (mm)

2.4


35.5

63


28

16

6

3.2

4. STAINLESS STEEL GAS METAL ARC WELDING (GMAW - MIG) WIRES WIRE SIZE (mm)

0.9

1.2

1.6


5.1

9

16


198

111

63

5. ALUMINIUM GAS METAL ARC WELDING (GMAW - MIG) WIRES WIRE SIZE (mm)

0.9

1.2

1.6


1.7

3.1

5.4


582

327.5

184

6. AUTOPAK GAS METAL ARC WELDING (GMAW - MIG) WIRES WIRE SIZE (mm)

0.9

1.0

1.2

1.6


4.85

6.1

8.5

15.7

km o wire / 300kg Pack

62

49

35

16 (250kg Pack)

L A C I N H C E T

Weld Deposition Data

Recommend Documents