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WELDING REFERENCE GUIDE
Star Alloys welding reference guide
TABLE OF CONTENTS FIVE ESSENTIALS FOR GOOD WELDING. . . . . . . . . . . . . . . . . . . . . .
5
WELDING ELECTRODE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
ARC WELDING BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
WELDING METALS AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .
3
BASIC WELDING SAFETY AND WELDING TIPS. . . . . . . . . . . . . . . .
3
WELDING PRODUCTS AND ACCESSORIES. . . . . . . . . . . . . . . . . . .
DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
LENS CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2
8 BRAZING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MIG WIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TIG WIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Star Alloys welding reference guide
BASIC SAFETY AND WELDING TIPS If you are new or relatively inexperienced in selling welding products, here are some basic safety tips and precautions to follow whenever you are in a customer’s facility where welding is in operation.
GENERAL PRECAUTIONS • DO NOT allow anyone to strike an arc on a compressed gas cylinder • DO NOT weld near flammables or combustible materials • DO NOT weld on containers which were used to hold combustible or flammable materials without first exercising the proper precautions recommended by the American Welding Society • DO NOTweld in either confined spaces or without adequate ventilation • DO NOT pick up objects marked “hot” without testing • DO NOT chip or grind without wearing safety goggles • DO NOT move individual cylinders that do not have a cap over the cylinder valve • DO NOT drop or abuse cylinders in any way • Make sure the cylinders are well secured in their stations so they will not tip or fall • DO NOT use a hammer or pipe wrench to force open a cylinder valve. If the valve cannot be opened by hand, do not attempt to open it without the assistance or supervision of an authorized person • DO NOT use white lead, oil or grease, or other pipe fitting compounds to make joints, fittings or unions • Never force connections which do not fit easily • Never tamper with fuse plugs (they melt off at 212° F) • Always protect hoses from being stepped on or run over. Avoid tangles and kinks. Never leave the hose where it can be tripped over, as a connection may be ripped off, or the equipment and cylinders may be pulled over • Keep flying sparks, hot slag, hot objects and open flames away from hoses • DO NOT allow hose to come in contact with oil or grease; these corrode the rubber and constitute a hazard with oxygen • Keep connections tight between the regulators, adapters and cylinder valves. Escaping acetylene can usually be detected by an odor. Test for leaks with soapy water, never with an open flame. • DO NOT use matches for lighting torches. Use suitable friction lighters, stationary pilot flames or some other appropriate source of ignition. Do not light torches from hot work when in a small or confined space. Do not try to relight a torch that has “blown out” without first closing both torch valves. Relight in the usual manner. • DO NOT use regulators or cylinder valves as hooks for hanging torches and hoses. When flame cutting, direct torch so that sparks, hot metal, or the severed section will not fall on the cylinder hose or your own legs or feet. Direct flame away from cylinders. • When welding or cutting is to be discontinued for some time (lunch hour or overnight), close the cylinder valves first, then release gas pressures from the regulators by opening the torch valves until flow stops. Next, release the pressure adjusting screw, then close the torch valves. If the equipment is to be dismantled or a cylinder is to be replaced, follow the procedure.
WELDING METALS AND SPECIFICATIONS Almost every metal known can be welded by one process or another. The arc welding processes used primarily for steels include: Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW). Welding electrodes should be selected based on the composition of the steel to be welded. Steels are manufactured and specified in many different ways. In general, steels are classified according to the carbon content. That is; low carbon, medium carbon or high carbon steels. In addition, they are also classified according to the type of alloy employed, such as chrome moly, nickel, manganese, etc. Steels are also sold under many trade names and specifications. The following is a brief listing of some of the specifications in use:
ASTM
The American Society for Testing Materials (ASTM) sponsors specifications covering many different types of steels. Their specification is always prefixed by ASTM.
API
The American Petro Institute (API) specifies steels usually employed in pipe.
ASME The American Society of Mechanical Engineers (ASMF) specifies steels, but in general utilizes the same numbers as the ASTM specifications.
MILITARY AND FEDERAL SPECIFICATION The government specifications are usually indicated by the letters MIL or QQ.
SAE AND AISI
The Society of Automotive Engineers (SAE) and the American Iron and Steel Institute (AISI) have a complete listing of steels using code numbers that indicate the steel composition. Stainless steels are covered by the AISI numbers.
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Star Alloys welding reference guide
LENS CHART PROCESS: MANUAL METAL ARC Type of Welding
Lens No.
Type of Welding
Lens No.
1/16", 3/32", 1/8", 5/32" Electrodes
10
Soldering
3/16", 7/32", 1/4" Electrodes
12
Torch Blazing
3-4
5/16", 3/8" Electrodes
14
Light Cutting up to 1"
3-4
MIG Welding (nonferrous)
11
Medium Cutting up to 6"
4-5
Atomic Hydrogen Welding
10-14
Heavy Cutting 6" and thicker
5-6
12
Gas Welding (Light) up to 1/8"
4-5
Gas Welding (Medium) 1/8" to 1/2"
5-6
Gas Welding (Heavy) 1/2" and thicker
6-8
TIG Welding Open Arc (semi-auto hardface with 7/64" core wire)
10-14
Plasma Cutting
14
Carbon Arc
14
2
ARC WELDING BASICS This page is intended to provide some general information on the basics of two of the most common types of arc welding processes: Electrode and MIG welding.
ELECTRIC ARC
• Always wear a full face coverage welding helmet with approved welding lens (No. 10 or darker) to protect eyes and face • Never strike an arc in the presence of other persons whose eyes are not shielded • Wear heavy gloves and protective clothing, shielding the entire body from hot metal spatter and intense ultraviolet rays • Provide adequate ventilation when welding in confined areas • Assure that electrode holder is fully insulated and welding cables are free of worn or frayed insulation • See that the ground terminal lug is connected through the input cable or by separate conductor to the power system ground • An underground machine can cause death by electrocution to personnel coming in contact with it • Do not reposition the voltage bars while power source is connected to the machine; doing so could cause a serious electrical shock and possible death
ELECTRODE (STICK) WELDING
Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or flux covered electrode welding. Stick welding is one of the most widely used and versatile welding processes. The flux covering the electrode melts during welding. This forms the gas and slag to shield the arc and molten weld pool. The slag must be chipped off the weld bead after welding. A welding chip hammer is the recommended tool for chipping off slag. The flux also provides a method of adding deoxidizers and alloying elements to the weld metal. Star Alloys electrodes are smooth running, have very low spatter and produce professional quality welds. Most competitors’ electrodes do not produce the quality of results that Star Alloy products do.
ELECTRODE (STICK) WELDING BENEFITS
• Equipment is simple to use. It’s inexpensive, and can be portable • Electrode provides and regulates its own flux • Lower sensitivity to wind and drafts than gas shielded welding processes such as MIG, making electrodes ideal for welding outdoors • Easy to get into tight areas – most Star Alloys sticks will weld in all positions
MIG WELDING
Metal Inert Gas welding (MIG) is also referred to as Gas Metal Arc Welding (GMAW). MIG welding is a commonly used high deposition rate welding process where wire is continuously fed from a spool through a MIG gun. We stock two types of MIG welding wire – solid and flux cored. Both types require a shielding gas, usually Argon or a mixture of Argon and Carbon Dioxide. There are suppliers that handle and sell the gas as a separate commodity. Flux cored MIG welding is generally more forgiving than solid wire MIG welding, as less cleaning may be necessary to obtain a good weld appearance. However, flux cored welding produces a coating that must be removed. With solid wire MIG welding, post weld cleaning is typically very minimal. Application and often just the welder’s preference will determine which one is used. Star Alloys MIG wire is made of premium alloys, has very low spatter and produces professional quality welds.
MIG WELDING BENEFITS
• Less operator skill is required • Long welds can be made without starts and stops • Most will weld in all positions • Higher continuous deposition rate than stick welding
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Star Alloys welding reference guide
FIVE ESSENTIALS FOR GOOD WELDING Besides the steady sizzling sound a correct arc produces, the shape of the molten pool and the movement of the metal at the rear of the pool serve as a guide in checking weld quality. In a correctly made deposit, the ripples produced on the bead will be uniform and the bead will be smooth, with no overlap or undercut. Here are Five essentials for producing a good weld:
1. CORRECT ELECTRODE SIZE
The correct choice of electrode size involves consideration of a variety of factors, such as: • Type • Position • Preparation of the joint • Ability of the electrode to carry high current values without injury to the weld metal or loss of deposition efficiency • Mass of work metal and its ability to maintain its original properties after welding • Characteristics of the assembly with reference to effect of stresses set up by heat application • Practicability of heat treatment before and/or after welding • Specific requirements as to welding quality and the cost of achieving the desired results
2. CORRECT CURRENT
If current on equipment is either too high or too low, you are certain to be disappointed in your weld. If the current is too high, the electrode will melt too fast and the molten pool will be large and irregular. If the current is too low, there will not be enough heat to melt the base metal and the molten pool will be too small, will pile up and will look irregular.
3. CORRECT ARC LENGTH
If the arc is too long or the voltage too high, the metal will melt off the electrode in large globules which wobble from side to side as the arc wavers, giving a wide, spattered and irregular bead, causing poor fusion between the original metal and deposited metal. If the arc is too short or the voltage is too low, there will not be enough heat to melt the base metal properly and the electrode will quite often stick to the work, resulting in a high, uneven bead having irregular ripples with poor fusion.
4. CORRECT TRAVEL SPEED
When the speed is too fast and the pool does not last long enough, impurities and gas are locked in it. The bead will be narrow and have pointed ripples. When the speed is too slow, the metal piles up, the bead is high and wide with a straight ripple.
5. CORRECT ELECTRODE ANGLE
The electrode angle is of particular importance in fillet welding and deep groove welding. Generally speaking, when making a fillet weld, the electrode should be held so that it bisects the angle between the plates and is perpendicular to the line of weld. If undercut occurs in the vertical member, the angle of the arc should be lowered and directed toward the vertical member.
WELDING ELECTRODE SELECTION Here are Five basic factors to consider when selecting or recommending electrodes.
BASE METAL STRENGTH PROPERTIES
Know and match mechanical properties: Mild Steel – generally standard E-60XX and/or E-70XX electrodes match base metal. Star Alloys 220MS (Mild Steel) replaces any E-60 series electrode and have a higher tensile strength and elongation percentage. Star Alloys 1116LH (Low Hydrogen) replaces any E-70 series electrode and has a higher tensile strength and elongation percentage. Star Alloys low hydrogen electrodes also work well on low alloy carbon steels.
BASE METAL COMPOSITION
Know and match mechanical composition: Select the electrode type that most closely matches your base metal composition. If you are unsure of your base metal composition, Star Alloys 2200DS (Dissimilar Steels) is an excellent choice when dealing with “mystery metals”.
BASE METAL CONDITION
The condition of your base material is also an important consideration. Is it rusty, dirty or greasy? Many standard electrodes on the market require some sort of prep work and cleaning before you can weld. Our Star Alloys electrodes are specially formulated to weld right through rust, dirt and even grease and oil. This saves the end user time and money.
WELDING POSITION
Know and match electrode to welding position encountered: Star Alloys electrodes are all position, which means you can weld horizontal, vertical and overhead.
WELDING CURRENT
Match power supply available: Some electrodes are designed for direct current (DC) and/or alternating current (AC). Always observe correct polarity. The proper welding current and recommended amperages are shown on all packages of Star Alloys electrodes.
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Star Alloys welding reference guide
TROUBLESHOOTING
CAUSES AND CURES FOR SEMIAUTOMATIC WELDING EQUIPMENT PROBLEM
PROBABLE CAUSE
REMEDY
Wire feed motor does not operate and pilot light is NOT lit
• No power to wire feeder
• Check position of power switch • Check 115V input power cable for good connections at both wire feeder and source • Check source of 115V power to ensure correct voltage
Wire feeder motor does NOT operate and pilot light is lit
• Fuse blown
• Replace Fuse
• Control relay not operating
• Check control cable connection from gun to wire feeder or check gun switch (see gun manual)
• Control relay operates but contacts not closing circuit
• Clean relay contacts with file or 00 sandpaper
• Auxiliary contacts in welding power source • Check auxiliary contactor in welding not operating power source. They must close when gun switch is closed • Check the control cable connections between wire feeder and welding power source Wire feed operates but wire does NOT feed
Wire wraps around the wire drive rolls (“Bird Nest”)
No speed control
Wire feeds but no gas flows
• Too little pressure on wire feed rolls
• Increase the pressure adjustments on the wire feed roll pressure plate
• Incorrect wire feed rolls
• Check size stamped on wire feed rolls per table. Match to wire spool
• Wire spool or reel brake pressure too great
• Decrease the drag on the wire spool
• Restriction in the gun and assembly
• Examine cable, gun and current contact tip for damage and correct size contact tip and cable liner if used
• Incorrect gear reduction case
• Check gear box and data for recommended gear ratio – gear ratio is indicated on casing
• Too much feed roll pressure
• Decrease the pressure adjustment on the wire roll pressure plate
• Incorrect cable liner or current tip
• See the table in gun manual. Match liner and tip to electrode
• Knob loose on variable transformer
• Tighten knob
• Broken or loose wires in the wire feed control circuit
• Correct by checking all connections
• Variable transformer winding is broken
• Replace the variable transformer
• Failure of gas valve solenoid
• Replace gas valve solenoid
• Loose or broken wires to gas valve solenoid • Check all connections
Welding current NOT stable and rolls
• Gas cylinder valve not open or flow meter not adjusted
• Open gas valve at cylinder and adjust the flow meter
• Gas cylinder empty
• Replace gas cylinder
• Restriction in gas line
• Check gas hose between flow meter and wire feeder • Check between gas hose in gun and cable assembly
• Gun nozzle plugged
• Clean gun nozzle
• Wire slipping in drive wire feed roll
• Readjust pressure on wire feed roll
• Restriction in gun cable or gun
• See gun manual
• Wrong size liner or current contact tip
• See table in gun manual – match liner and tip to electrode wire size
• Incorrect voltage adjustment for selected wire feed speed on welding power source
• Readjust. See procedure information
• Loose connections on welding or work cable • Check and tighten all connections
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Star Alloys welding reference guide
TROUBLESHOOTING CAUSES AND CURES OF COMMON WELDING PROBLEMS PROBLEM
PROBABLE CAUSE
REMEDY
Porous welds
• Excessively long or short arc length
• Maintain proper arc length
• Welding current too high
• Use proper welding current
• Insufficient or damp shielding gas
• Increase gas flowrate and check gas purity
• Travel speed too fast
• Reduce travel speed
• Base metal surface covered with oil, grease, moisture, rust, mill scale, etc
• Properly clean base metal prior to welding
• Wet, unclean or damaged electrode • Insufficient weld size
• Properly maintain and store electrode • Maintain proper arc length
• Excessive joint restraint
• Use proper welding current
• Poor joint design and/or preparation
• Increase gas flowrate & check gas purity
• Filler metal does not match base metal
• Reduce travel speed
• Rapid cooling rate
• Properly clean base metal prior to welding
• Base metal surface covered with oil, grease, moisture, rust, dirt or mill scale • Faulty electrode manipulation
• Properly maintain and store electrode
Cracked welds
Undercutting
Distortion
Inclusion
Lack of fusion
Poor penetration
Magnetic arc blow
Spatter
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• Welding current too high • Too long an arc length • Travel speed too fast • Arc blow • Improper tack welding and/or fault with joint preparation • Improper bead sequence • Improper set-up and fixturing • Tungsten spitting or sticking • Incomplete slag removal between passes • Too large an electrode
• Pause at each side of the weld bead when using a weaving technique • Use proper electrode angles • Use proper welding current for electrode • Reduce arc length • Reduce travel speed • Reduce effects of arc blow • Tack weld parts with allowance for distortion
• Use proper bead sequencing • Tack or clamp parts securely • Make welds to specified size • Completely remove slag between passes • Use a smaller electrode size for better access to the joint • Letting slag run ahead of arc • Increase travel speed, change electrode angle or reduce arc length • Wet, unclean or damaged electrode • Prepare tungsten and use proper current • Improper travel speed • Reduce travel speed • Welding current too low • Increase welding current • Faulty joint preparation • Weld design should allow electrode accessibility to all surfaces within the joint • Electrode diameter too large • Reduce electrode diameter • Magnetic arc blow • Reduce effects of magnetic arc blow • Wrong electrode angle • Use proper electrode angles • Travel speed too fast • Decrease travel speed • Welding current too low • Increase welding current • Poor joint design and/or preparation • Increase root opening or decrease rootface • Electrode diameter too large • Use smaller electrode • Wrong type of electrode • Use electrode with deeper penetration characteristics • Excessively long arc length • Reduce arc length • Unbalanced magnetic field during welding • Change the location of the work connection on workpiece or use A/C • Excessive magnetism in parts or fixture • Reduce welding current and arc length • Arc blow • Attempt to reduce the effect of arc blow • Welding current too high • Reduce welding current • Too long an arc length • Reduce arc length • Wet, unclean or damaged electrode • Properly maintain and store electrodes
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Star Alloys welding reference guide
BRAZING, ELECTRODES, MIG WIRE & ACCESSORIES • Premium alloys for all types of Automotive & MRO welding, joining, and brazing repairs • The best welding electrodes in the industry, in the highest quality packaging available • For repairing all types of metals and alloys, and all types of vehicles, equipment and structures • Products for welding and joining many materials, including mild steel, low & medium carbon steels, low alloy steels, stainless steels, cast iron, aluminum, aluminum alloys, manganese, zinc alloys, dissimilar steel combinations, sheet metal, galvanized metals, copper and brass. • High quality MIG Alloys in spools of solid wire or flux-coated wire • High performance cutting/chamfering electrodes Brazing technology for brazing repairs made easy, clean and strong
• Fewer products to accomplish all of your repair needs, with no sacrifice in performance • Accessories that make your job safer, easier and more efficient
BRAZING ROD 67FC SILVER BRAZING
80FC BRONZE BRAZING
Diameter
Length
Part No.
Diameter
Length
3/64"
18"
Flux Color Pack Size Pink
5 lbs
F41820
3/32"
18"
Flux Color Pack Size Blue
5 lbs
Part No. F41821
1/16"
18"
Orange
5 lbs
F41976
1/8"
18"
Blue
5 lbs
F41979
31AZ BRAZING ROD Diameter
Length
5/32"
18"
Flux Color Pack Size Silver
1 lb
Part No. F41854
ELECTRODES 513MN (MANGANESE)
51CI (CAST IRON)
Diameter
Length
Part No.
Diameter
Length
1/8"
14"
Flux Color Pack Size Dark Gray
10 lbs
F42047
3/32"
14"
Flux Color Pack Size Black
5 lbs
Part No. F42044
5/32"
14"
Dark Gray
10 lbs
F41848
1/8"
14"
Black
5 lbs
F41847
3/16"
14"
Dark Gray
10 lbs
F42048
5/32"
14"
Black
5 lbs
F42045
38SS (STAINLESS STEEL) Diameter
Length
5/64"
12"
White
5 lbs
F42032
3/32"
12"
White
5 lbs
F41845
1/8"
12"
White
5 lbs
F41844
8
Flux Color Pack Size
Part No.
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Star Alloys welding reference guide
ELECTRODES 220MS (MILD STEEL) Diameter
Length
1/16"
12"
Flux Color Pack Size Tan
5 lbs
Part No. F41835
50 lb Bulk Pack
3/32"
14"
Gold
10 lbs
F42010
1/8"
14"
Gold
10 lbs
F41836
F42008
5/32"
14"
Gold
10 lbs
F41838
F42011
3/16"
14"
Gold
10 lbs
F41837
F42009
Part No.
50 lb Bluk Pack
1116LH (LOW HYDROGEN) Diameter
Length
3/32"
14"
Flux Color Pack Size Gray
10 lbs
F41992
1/8"
14"
Gray
10 lbs
F41826
5/32"
14"
Gray
10 lbs
F41828
F41990 F41994
3/16"
14"
Gray
10 lbs
F41827
F41991
Part No.
50 lb Bluk Pack
2200DS (DISSIMILAR STEELS) Diameter
Length
Flux Color Pack Size
3/32"
12"
Light Gray
5 lbs
F41840
1/8"
12"
Light Gray
5 lbs
F41839
5/32"
12"
Light Gray
5 lbs
F41841
F42016
1120HF (HARDFACING) Diameter
Length
1/8"
14"
Flux Color Pack Size Gray
10 lbs
Part No. F41849
5/32"
14"
Gray
10 lbs
F42055
3/16"
14"
Gray
10 lbs
F42053
50 lb Bluk Pack F42056
111C (CHAMFERING) Diameter
Length
Part No.
50 lb Bluk Pack
1/8"
14"
Flux Color Pack Size Black
10 lbs
F41846
F42035
5/32"
14"
Black
10 lbs
F42036
521AL (ALUMINUM) Diameter
Length
5/64"
10"
Flux Color Pack Size White
2.5 lbs
F42068
5/64"
10"
White
5 lbs
F41853
F42069
1/8"
14"
White
5 lbs
F41852
F42065
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Part No.
50 lb Bluk Pack
9
Star Alloys welding reference guide
MIG WIRE 220MS (MILD STEEL)
220MS (MILD STEEL) FLUX CORED WIRE
Wire Diameter
Spool Size
Part No.
Wire Diameter
Spool Size
Part No.
.023
2 lbs
F41997
.030
2 lbs
F42000
.023
11 lbs
F41829
.030
10 lbs
F41999
.030
2 lbs
F41831
.035
2 lbs
F42003
.030
11 lbs
F41830
.035
11 lbs
F42002
.030
33 lbs
F41998
.045
33 lbs
F42005
.035
2 lbs
F41833
.035
11 lbs
F41832
.035
33 lbs
F41834
.045
33 lbs
F42004
38SS (STAINLESS STEEL) SOLID WIRE
38SS (STAINLESS STEEL) FLUX CORED WIRE
Wire Diameter
Spool Size
Part No.
Wire Diameter
Spool Size
Part No.
.023
2 lbs
F42024
.035
2 lbs
F42030
.023
10 lbs
F42023
.035
10 lbs
F42029
.030
2 lbs
F41842
.030
10 lbs
F42025
.035
2 lbs
F41843
.035
12.5 lbs
F42028
1116LH (LOW HYDROGEN) SOLID WIRE
1116LH (LOW HYDROGEN) FLUX CORED WIRE
Wire Diameter
Spool Size
Part No.
Wire Diameter
Spool Size
Part No.
.023
11 lbs
F41822
.030
2 lbs
F41983
.030
11 lbs
F41982
.030
10 lbs
F41984
.035
2 lbs
F41824
.035
2 lbs
F41985
.035
11 lbs
F41823
.045
33 lbs
F41987
.035
33 lbs
F41925
1/16"
33 lbs
F41988
.035
10 lbs
F41984
.035
33 lbs
F41985
1/16"
33 lbs
F41981
521AL (ALUMINUM) SOLID WIRE
513MN (MANGANESE) FLUX CORED WIRE
Wire Diameter
Spool Size
Part No.
Wire Diameter
Spool Size
Part No.
.023
1 lb
F42059
.045
25 lbs
F42046
.030
1 lb
F42060
.030
3 lbs
F42061
.035
1 lb
F41850
10
.035
3 lbs
F42063
.045
1 lb
F42449
.045
16 lbs
F41851
1120HF (HARDFACING) FLUX CORED WIRE Wire Diameter
Spool Size
Part No.
.045
10 lbs
F42050
.045
25 lbs
F42051
1/16"
25 lbs
F42052
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Star Alloys welding reference guide
TIG Wire 220MS (MILD STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F41995
3/32"
5 lbs
36"
F42001
1/8"
5 lbs
36"
F41996
2200DS (DISSIMILAR STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42012
3/32"
5 lbs
36"
F42014
1/8"
5 lbs
36"
F41013
2200HT (HEAT-TREATABLE DISSIMILAR STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42017
3/32"
5 lbs
36"
F42019
1/8"
5 lbs
36"
F41018
38SS (STAINLESS STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42022
3/32"
5 lbs
36"
F42447
51CI (CAST IRON) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42041
3/32"
1 lb
36"
F42039
521AL (ALUMINUM) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42057
3/32"
5 lbs
36"
F42062
1/8"
5 lbs
36"
F42058
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Star Alloys welding reference guide
TIG Wire A2 (AIR HARDENING STEEL) Wire Diameter
Pack Size
Length
1/16"
5 lbs
36"
Part No. F42071
3/32"
5 lbs
36"
F42072
D2 (AIR HARDENING STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42073
3/32"
5 lbs
36"
F42074
H13 (HEAT-TREATABLE STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42075
3/32"
5 lbs
36"
F42076
P20 (HIGH TEMPERATURE STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42077
3/32"
5 lbs
36"
F42078
S7 (SHOCK–RESISTANT TOOL STEEL) Wire Diameter
Pack Size
Length
Part No.
1/16"
5 lbs
36"
F42079
3/32"
5 lbs
36"
F42080
FLUX SS (STAINLESS STEEL) Wire Diameter
Pack Size
Length
Part No.
3/32"
5 lbs
18"
F43276
12
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Star Alloys welding reference guide
WELDING ACCESSORIES STAR SHIELD HEAT-RESISTANT COMPOUND
COOL GEL HEAT BARRIER SPRAY
Net Weight
Part No.
Net Weight
Part No.
2 lbs
F41818
16 fl oz
F41164
ELECTRODE HOLDER
GROUND CLAMP
Length
Electrode Size
Amps
Part No.
Length
Electrode Size
Amps
Part No.
9-1/4"
3/16"
250-300
F41490
8"
1-1/2"
300
F41553
SELF-IGNITING TORCH
SHURLITE® THREE–FLINT SPARK LIGHTER
Fuel
Part No.
Description
Packaging
Part No.
MAPP or Propane
F43280
Three Flint Renewal
1 per card
F41050
Three Flint Spark Lighter
1 per card
F4797
F4797
1/4" OXY-ACETYLENE TWIN HOSES
CYLINDER TANK WRENCH
Length
Part No.
Part No.
25 ft
F4521
F41340
50 ft
F4919
WELDING TIP CLEANER SET
NOZZLE GEL
Part No.
Net Weight
Part No.
F4459
6 oz
F4677
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F41050
13
Star Alloys welding reference guide
WELDING ACCESSORIES MIG CONTACT TIPS Description
Wire Size
Part No.
Tweco Style 11
.023
F41572
Tweco Style 11
.030
F4189
Tweco Style 11
.035
F4168
Tweco Style 11
.045
F4893
Tweco Style 14
.023
F41594
Tweco Style 14
.030
F41232
Tweco Style 14
.035
F41593
Tweco Style 14
.045
F4394
Miller Style
.023
F41023
Miller Style
.030
F41248
Miller Style
.035
F41315
Miller Style
.045
F4917
Tweco Style 11
Tweco Style 14
Miller Style
MIG NOZZLES AND ADAPTERS Description
Part No.
Tweco Style Nozzle
F4158
Tweco Style Adapter
F41408
Miller Style Nozzle
F4814
Miller Style Adapter
F41113
F4158
F4814
F41408
F41113
WELDING WALL CHARTS Description
Part No.
Electrodes
F012132
MIG Wire
F012133
TIG Wire
F012134
WELDING TOOL STEEL PREHEAT CHART
F0
12
13
4
Part No. F102136
F012135
14
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Star Alloys welding reference guide
DEFINITIONS
COMMON WELDING TERMS AND DEFINITIONS
Acceptable weld: A weld that meets all the requirements and the acceptable criteria prescribed by the welding specifications.
Base metal (Material): The metal or material that is welded, brazed, soldered or cut.
Arc blow: The deflection of an electric arc from it’s normal path due to magnetic forces.
Bevel: An angular edge preparation.
Arc gouging: Thermal gouging process that uses an arc cutting process variation, used to form a bevel or groove. Arc length: The distance from the tip of the welding electrode to the adjacent surface of the weld pool. Arc strike: A discontinuity consisting of any localized re-melted metal, heat-affected metal or change in the surface profile of any part of a weld or base metal resulting from an arc. Arc time: The time during which an arc is maintained in making an arc weld. Arc voltage: The voltage across the welding arc. Arc welding (AW): A group of welding processes which produces coalescence of metals by heating them with an arc. The processes are used with or without the application of pressure and with or without the use of filler metal. Arc welding electrode: A component of the welding circuit through which current is conducted and which terminates the arc. Arc welding gun: A device used to transfer current to a continuously fed consumable electrode, guide the electrode and direct the shielding gas. As-welded: Pertaining to the condition of weld metal, welded joints and weldment after welding, but prior to any subsequent thermal, mechanical or chemical treatment. Autogenous weld: A fusion weld made without the addition of filler metal. Automatic welding: Welding with equipment that requires only occasional or no observation of the welding and no manual adjustment of the equipment controls. Back gouging: The removal of weld metal and base metal from the weld root of a welded joint, to facilitate complete fusion and complete joint penetration upon subsequent welding from that side. Backing: A material or device placed against the back side of the joint, or at both sides of a weld in electroslag and electrogas welding, to support and retain molten weld metal. The material may be partially fused or remain unfused during welding and may be either metal or nonmetal. Backing bead: A weld bead resulting from a backing pass. Backing ring: Backing in the form of a ring, generally used in the welding of piping. Backing weld: Backing in the form of a weld. Backstep sequence: A longitudinal sequence in which weld passes are made in the direction opposite to the progress of welding. Bare electrode: A filler metal electrode that has been produced as a wire, strip or bar with no coating, flux or covering.
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Bevel angle: The angle formed between the prepared edge of a member and a plane perpendicular to the surface of a member. Boxing: The continuation of a fillet weld around a corner of a member as an extension of the principal weld. Braze: A weld produced by heating an assembly to the brazing temperature using a filler metal having a liquidus above 450 degrees Celsius (840 degrees Fahrenheit) and below the solidus of the base metal. The filler metal is distributed between the closely fitted faying surfaces of the joint by capillary action. Brazing operator: One who operates automatic, furnace or mechanized brazing equipment. Brazing temperature: The temperature to which the base metal is heated to enable the filler metal to wet the base metal and form a brazed joint. Buttering: A surfacing variation that deposits surfacing on one or more surfaces to provide metallurgically compatible weld metal for the subsequent completion of the weld. Butt joint: A joint between two members aligned approximately in the same plane. Capillary action: The force by which liquid, in contact with a solid, is distributed between closely fitted fraying surfaces of the joint to be brazed or soldered. Carbon electrode: A non-filler material electrode used in arc welding or cutting, consisting of a carbon or graphite rod, which may be coated with copper or materials. Cascade sequence: A combined longitudinal and cross sectional sequence in which weld passes are made in overlapping layers. Chain intermittent weld: An intermittent weld on both sides of a joint in which the weld increments on one side are approximately opposite those on the other side. Coalescence: The growing together or growth into one body of the materials being welded. Complete fusion: Fusion over the entire fusion faces and between adjoining weld beads. Complete joint penetration: Penetration of weld metal through the thickness of a joint with a groove weld. Concave fillet weld: A fillet weld having a concave face. Concavity: The maximum distance from the face of a concave fillet weld perpendicular to a line joining the weld toes. Consumable electrode: An electrode that provides filler metal. Consumable insert: Preplaced filler metal that is completely fused into the joint root and becomes part of the weld. Contact tube: A device which provides electric current to a continuous electrode.
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Star Alloys welding reference guide
DEFINITIONS
COMMON WELDING TERMS AND DEFINITIONS
Continuous weld: A weld which extends continuously from one end of a joint to the other. Where the joint is essentially circular, it extends completely around the joint.
Electrode: A component of the welding circuit that terminates at the arc, molten conductive slag or base metal.
Convex fillet weld: A fillet weld having a convex face.
Electrode extension: The length of electrode extending beyond the end of the contact tube.
Convexity: The maximum distance from the face of a convex fillet weld, perpendicular to a line joining the weld toes.
Electrode holder: A device used for mechanically holding and conducting current to an electrode during welding.
Corner joint: A joint between two members located approximately at right angles to each other.
Electrode lead: The electrical conductor between the source of the arc welding current and the electrode holder.
Covered electrode: A composite filler metal electrode consisting of a core of a bare electrode or metal cored electrode, to which a covering (flux) sufficient to provide a slag layer on the weld metal has been applied. The covering may contain materials providing such functions as shielding from the atmosphere, deoxidation, arc stabilization and can serve as a source of metallic additions to the weld.
Electrogas welding (EGW): An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool, employing vertical position welding with backing to confine the molten weld metal. The process is used with or without an externally supplied shielding gas and without the application of pressure.
Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of length and width to opening displacement. Crater: A depression in the weld face at the end of a weld bead. Crater crack: A crack in the crater of a weld bead. Cutting tip: The part of an oxygen cutting torch from which the gases issue. Cutting torch: Also know as Oxyfuel gas; a device used for directing the preheating flame produced by the controlled combustion of fuel gases and to direct and control the cutting oxygen. Defect: A discontinuity or discontinuities which by nature or accumulated effect (for example, total crack length) render a part or product unable to meet minimum applicable acceptance standards or specifications. This term designates rejectability. Defective weld: A weld containing one or more defects. Deposit metal: Filler metal that has been added during a welding operation. Deposition rate: The weight of material deposited in a unit of time. Dilution: The change in chemical composition of welding filler metal caused by the admixture of the base metal or previous weld metal in the weld bead. It is measured by the percentage of base metal or previous weld metal in the weld bead. Direct current electrode negative (DCEN): The arrangement of direct current arc welding leads, in which the electrode is the negative pole and the workpiece is the positive pole of the welding arc. Direct current electrode positive (DCEP): The arrangement of direct current arc welding leads in which the electrode is the positive pole and the workpiece is the negative pole of the welding arc. Discontinuity: An interruption of the typical structure of a material, such as lack of homogeneity in its mechanical, metallurgical or physical characteristics. A discontinuity is not necessarily a defect. Effective throat: The minimum distance minus any convexity between the root weld and the face of a fillet weld.
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Electron beam welding (EBW): A welding process that produces coalescence with a concentrated beam, composed primarily of high velocity electrons, impinging on the joint. The process is used without shielding gas and without the application of pressure. Electroslag welding (ESW): A welding process that produces coalescence of metals with molten slag that melts the filler metal and the surface of the workpieces. The weld pool is shielded by this slag, which moves along the full cross section of the joint as welding progresses. The process is initiated by an arc that heats the slag. The arc is then extinguished by the conductive slag, which is kept molten by its resistance to electric current passing between the electrode and the workpieces. Erosion brazing: A condition caused by dissolution of the base metal by molten filler metal, resulting in a reduction in the thickness of the base metal. Expulsion: The forceful ejection of molten metal from a resistance spot, seam or projection weld usually at the faying surface. Face shield: A device positioned in front of the eyes, over all or a portion of the face, for protection. Faying surface: The mating surface of a member that is in contact with or in close proximity to another member to which it is joined. Ferrite number: An arbitrary, standardized value designating the ferrite content of an austenitic stainless steel weld metal. It should be used in place of percent ferrite or volume percent ferrite on a direct replacement basis. Filler metal: The metal or alloy to be added in making a welded, brazed or soldered joint. Fillet weld: A triangle cross weld, joining two surfaces approximately at right angles to each other in a lap joint, T-joint or corner joint. Fillet weld leg: The distance from the joint root to the toe of the fillet weld. Fixture: A device designed to hold parts to be joined in proper relation to each other. Flaw: An undesirable discontinuity.
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Star Alloys welding reference guide
Flux: A material used to hinder or prevent the formation of oxides and other undesirable substances in molten metal or solid metal surfaces used to dissolve or otherwise facilitate the removal of such substances. Flux cored arc welding (FCAW): An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. The process is used with shielding gas from a flux contained within the tubular electrode, with or without additional shielding from an externally supplied gas, without the application of pressure. Flux cored electrode: A composite tubular filler metal electrode consisting of a metal sheath and a core of various powdered materials, producing an extensive slag cover on the face of a weld bead. External shielding may be required. Friction welding (FRW): A solid-state welding process that produces a weld under compressive force contact of workpieces rotating or moving, relative to one another to produce heat and plastically displace material from the faying surfaces. Fusion welding: The melting together of filler metal and base metal, or base metal only, to produce a weld. Gas lens: One or more fine mesh screens located in the torch nozzle to produce a stable stream of shielding gas. Primarily used for gas tungsten arc welding. Gas metal arc welding (GMAW): An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. The process is used with shielding from an externally supplied gas and without the application of pressure. Gas nozzle: A device at the exit end of the torch or gun that directs shielding gas. Gas regulator: A device for controlling the delivery of gas at a substantially constant pressure. Gas tungsten arc welding (GTAW): An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. The process is used with shielding gas and without the application of pressure. Globular transfer arc welding: The transfer of molten metal in large drops from a consumable electrode across the arc. Groove angle: The total angle of the groove between workpieces. Groove face: The surface of a joint member included in the groove. Groove weld: A weld made in a groove between the workpieces. Ground connection: An electrical connection of the welding machine frame to the earth for safety. Hardfacing: A surfacing variation in which surfacing material is deposited to reduce wear. Heat-affected zone: The portion of the base metal whose mechanical properties or microstructure have been altered by the heat of welding, brazing, soldering or thermal cutting.
by the controlled combustion of fuel gases. Inclusion: Entrapped foreign solid material, such as slag, flux, tungsten or oxide. Incomplete fusion: A weld discontinuity in which fusion did not occur between weld metal and fusion faces or adjoining weld beads. Incomplete joint penetration: Joint penetration that is unintentionally less than the thickness of the weld joints. Inert gas: A gas that does not combine chemically with materials. Intermittent weld: A weld in which the continuity is broken by recurring unwelded spaces. Joint: The junction of members or the edges of members that are to be joined or have been joined. Joint type: The weld joint classification based on the five basic arrangements of the component parts, such as a butt joint, corner joint, edge joint, lap joint and T-joint. Kerf: The width of a cut produced during the cutting process. Keyhole welding: A technique in which a concentrated heat source penetrates completely through a workpiece, forming a hole at the leading edge of the weld pool. As the heat source progresses, the molten metal fills in behind the hole to form the weld bead. Laser beam welding (LBW): A welding process that produces coalescence with the heat from a laser beam impinging on the joint. The process is used without a shielding gas and without the application of pressure. Linear discontinuity: A discontinuity with a length that is substantially greater than its width. Liquidus: The lowest temperature at which a metal or an alloy is completely liquid. Longitudinal crack: A crack with its major axis orientation approximately parallel to the weld axis. Neutral flame: An oxyfuel gas flame that has characteristics neither oxidizing nor reducing. Neutral flux submerged arc welding: A flux that will not cause a significant change in the weld metal composition when there is a large change in the arc voltage. Nozzle arc spraying: A device at the exit end of the gun that directs the atomizing air or other gas. Open root joint: An unwelded joint without backing or consumable insert. Overhead position: The position in which welding is performed from the underside of the joint. Overlap fusion welding: The protrusion of weld metal beyond the weld toe or weld root.
Heating torch: A device for directing the heating flame produced
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17
Star Alloys welding reference guide
DEFINITIONS
COMMON WELDING TERMS AND DEFINITIONS
Oxidizing flame: An oxyfuel gas flame in which there is an excess of oxygen, resulting in an oxygen-rich zone extending around and beyond the cone. Peel test: A destructive method of testing that mechanically separates a lap joint by peeling. Plasma arc welding (PAW): An arc welding process that uses a constricted arc between a nonconsumable electrode and the weld pool (transferred arc), or between the electrode and the constricting nozzle (nontransferred arc). Shielding is obtained from the ionized gas issuing from the torch, which may be supplemented by an auxiliary source of shielding gas. The process is used without the application of pressure. Plug weld: A weld made in a circular hole in one member of a joint fusing that member to another member. A fillet-welded hole is not to be construed as conforming to this definition. Porosity: Cavity-type discontinuities formed by gas entrapment during solidification of molten metal. Also called “pin holes�. Postflow time: The time interval from current shut off to either shielding gas or cooling water shut off. Postheating: The application of heat to an assembly after welding, brazing, soldering, thermal spraying or thermal cutting. Power source: An apparatus for supplying current and voltage suitable for welding, thermal cutting or thermal spraying. Preflow time: The time interval between start of shielding gas flow and arc starting. Preheat: The heat applied to the base metal or substrate to attain and maintain preheat temperature. Pulsed gas tungsten arc welding (GTAW-P): A gas tungsten arc welding process variation in which the current is pulsed. Pulse start delay time: The time interval from current initiation to the beginning of current pulsation. Pulse time resistance welding: The duration of a pulse.
Slag: A nonmetallic product resulting from the dissolution of flux and nonmetallic impurities in some welding and brazing processes. Shielded metal arc welding (SMAW): An arc welding process with an arc between a covered electrode and the weld pool. The process is used with shielding from the decomposition of the electrode covering, without the application of pressure and with filler metal from the electrode. Solidus: The highest temperature at which a metal or an alloy is completely solid. Spatter: The metal particles expelled during fusion welding that do not form a part of the weld. Spray transfer arc welding: Metal transfer in which molten metal from consumable electrode is propelled axially across the arc in small droplets. Stickout: The length of unmelted electrode extending beyond the end of the gas nozzle. Straight Polarity: A nonstandard term for direct current (DC) electrode positive. Stringer bead: A type of weld bead made without appreciable weaving motion. Submerged arc welding (SAW): An arc welding process that uses an arc or arcs between a bare metal electrode or electrodes and the weld pool. The arc and molten metal are shielded by a blanket of granular flux on the workpieces. The process is used without pressure and with filler metal from the electrode, sometimes from a supplemental source (welding rod, flux or metal granules). Surfacing: The application by welding, brazing or thermal spraying of a layer of material to a surface to obtain desired properties or dimensions as opposed to making a joint. Tack weld: A weld made to hold the parts of a weldment in proper alignment until the final welds are made.
Reducing flame: An oxyfuel gas flame with an excess of fuel gas.
Thermit welding (TW): A welding process that produces coalescence of metals by heating them with superheated liquid metal from a chemical reaction between a metal oxide and aluminum, with or without the application of pressure. Filler metal is obtained from the liquid metal.
Residual stress: A stress that cannot exist in a member if the member is isolated as a free body without connection to other parts of the structure.
TIG welding: A nonstandard term for gas tungsten arc welding. Tungsten electrode: A nonfiller metal electrode used in arc welding, arc cutting and plasma spraying, made principally of tungsten.
Reverse polarity: Also known as electrode positive; a nonstandard term for direct current (DC) which results in the deepest penetration.
Underbead crack: A crack in the heat-affected zone, generally not extending to the surface of the base metal.
Root bead: A weld bead that extends into, or includes part or all of the joint root.
Undercut: A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal.
Seal weld: Any weld designed primarily to provide a specific degree of tightness against leakage.
Underfill: A depression on the weld face or root surface extending below the adjacent surface of the base metal.
Reaction stress: A stress that cannot exist in a member if the member is isolated as a free body without connection to other parts of the structure.
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Star Alloys welding reference guide
Vertical position: The position of welding in which the weld axis is approximately vertical. Weave bead: A type of weld bead made with transverse oscillation. Weld: A localized coalescence of metals or nonmetals produced either by heating the materials to the welding temperature with or without the application of pressure, or by the application of pressure alone and with or without the use of filler metal. Weld bead: A weld resulting from a pass. Weld crack: A crack located in the weld or heat affected zone. Weld face: The exposed surface of a weld on the side from which welding was done. Weld gage: A device designed for measuring the shape and size of the welds. Weld pool: The localized volume of molten metal in a weld prior to it’s solidification as weld metal. Weld toe: The junction of the weld face and the base metal. Weldability: The capacity of material to be welded under the imposed fabrication conditions into a specific, suitably designed structure and to perform satisfactorily in the intended service. Welding arc: A controlled electrical discharge between the electrode and the workpiece that is formed and sustained by the establishment of a gaseous conductive medium, called arc plasma. Welding head: The part of a welding machine in which a welding gun or torch is incorporated. Welding leads: The workpiece lead and electrode lead of an arc welding circuit. Welding power source: An apparatus for supplying current and voltage suitable for welding. Welding procedure specification (WPS): A document providing in detail the required variables for specific application to assure repeatability by properly trained welders and welding operators. Welding rod: A form of welding filler metal, normally packaged in straight lengths that do not conduct the welding current. Weldment: Assembly whose component parts are joined by welding. Wetting: The phenomenon where a liquid filler metal or flux spreads and adheres in a thin continuous layer on a solid base metal. Wire feed speed: The rate at which wire is consumed in arc cutting, thermal spraying or welding. Wire straightener: Device used for controlling the cast and helix of coiled wire to enable it to easily feed through the wire feed system. Workpiece: The part that is welded, brazed, soldered, thermal cut or thermal sprayed.
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