Quality is is Priority

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1 Quality is is our our Priority. Priority You get reliability. You get knowledge and service. You get the right solution for each joint. Our quality gets you results.

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3 ALUNOX provides optimum connections with guaranteed quality. You need reliability Our programme on this. You need know-how and service. You need the appropriate solution for every connection. Our current programme is there to support you in the first stage of your work And if you have any questions, just call. Our quality guarantees your results ALUNOX Schweißtechnik GmbH Gießerallee 7a D-7877 Willich Tel + (15) 5-0 Fax + (15) A

4 You will achieve the greatest benefits with our products. The best performance with our know-how. ALUNOX has the experience you need. For more than 0 years over 750 customers in Germany and abroad have considered ALUNOX to be a provider of products that deliver what they promise. Only by working continuously with wellknown producers can we ensure that you are always working with state of the art welding technology even with future developments. Our service and our product performance have been certified.

5 Your success is built on three pillars at ALUNOX:. Advice. Service. Sales We take it very personally. By for example being available hours a day for you. With a team of 18 office-based and field service staff we are also available to offer you on-site support. In-house materials testing and quality assurance ensure consistently good products. We are happy to assist you with our reliable services:. High levels of product availability. Fast delivery. Technical advice ALUNOX provides the products and answers you need. 0 The latest product information is available for you at all times in digital and printed form. We want you to know that we want to be the best. Every day A

6 ALUNOX Schweißtechnik GmbH Gießerallee 7a D-7877 Willich Tel + (15) 5-0 Fax + (15) 5-0

7 Aluminium Gruppe Group Hochlegiert High alloyed Gruppe Group Medium Mittellegiert alloyed Gruppe Group Hartauftrag Hardfacing Gruppe Group Kupfer Copper Gruppe Group Bar Elektroden electrodes Gruppe Group Nickel Gruppe Group Flux-cored Fülldraht wire Gruppe Group Sonderwerkstoffe Special materials Gruppe Group Accessories Zubehör Gruppe Group Appendix Anhang Gruppe Group A ALUNOX Manual 5

8 Aluminium Welding Consumables Aluminium Solid wires/tig rods AX-100 AX-150 AX-0 AX-07 AX-5087 AX-518 AX-55 AX-575 AX-0 AX-07 AX-Al,5 AX-Al,5Ti AX-AlSi5 AX-AlSi1 AX-AlMg.5MnZr AX-AlMg.5Mn AX-AlMg5 AX-AlMg Spray wire Spray wire Aluminium After oxygen and silicon aluminium is the third most common element in the earth s crust and thus the most common metal. Aluminium is a relatively soft and tough metal, the tensile strength of pure aluminium is MPa, that of its alloys up to 700 MPa. The pure light metal aluminium very quickly forms a thin oxide layer in air. With ph values of to, it makes pure aluminium very corrosion resistant. This oxide layer protects from further oxidation but is a hindrance for electrical contacting and welding. Compared with steel, aluminium displays large differences in the following physical properties: Density.7 g/ cm - steel 7.85 Melting point 0 C/Al-oxide 050 C - steel approx C, Thermal conductivity. W/cm x K-steel Electrical conductivity: 5 S x m/min -steel 10 Solubility of hydrogen in solidified state: 0.05 cm -steel 8 ALUNOX Manual

9 Above all, because of low density (weight), the good corrosion resistance and good conductivity, aluminium and its alloys are mainly used in the following sectors: automotive technology shipbuilding/ rail vehicle construction aerospace tank construction construction industry packaging industry electrotechnology There are the following alloys: Al wrought alloys non-age-hardenable, such as: AW-1050A (Al.5) AW-5005 (AlMg1) AW-501 (AlMg5) AW-508 (AlMg,5Mn0.7) age-hardenable, such as: AW-005A (AlSiMg (A)) AW-00 (AlMgSi) AW-08 (AlSi1MgMn) AW-700 (AlZn.5Mg1) Al casting alloys AlSi- and AlSiMg alloys with 5 to max. 0% Si Welding aluminium Aluminium is mainly welded in the TIG and MIG processes. Welding with the bar electrode has rather a subordinate importance. When welding aluminium certain rules must be observed. This starts right with the seam preparation. The oxide layer present in the weld seam area must be completely removed, in addition the welding seam edges must be broken above all in the root area to avoid oxide inclusions there. Because of the high solubility of aluminium for hydrogen in the molten and the very low solubility in the solid state the susceptibility to pores is very high. It can be reduced by taking appropriate measures such as increased cleanliness, e.g. also new gloves and brushes. In addition, because of the great thermal conductivity of aluminium, preheating is necessary above all with larger wall thicknesses to reduce pores and binding faults and lack of penetration. This is supported with MIG welding by the use of argonhelium mixtures with 0-70% helium, in many cases preheating can be avoided. With increasing helium content the number of pores decreases because of the improved gas release, at the same time the penetration improves and the welding seam becomes wider and flatter. The electric arc does, however, become somewhat more unsteady. The spray arc section is reached at low current intensities. Thin sheet and constrained welding position welds are therefore carried out in the MIG pulsed arc process. Non-age- hardenable aluminium wrought alloys are welded with metals of identical or similar composition with Al.5 and AlMg. Agehardenable alloys are welded with AlMg.5Mn or AlMg.5MnZr. It must however be considered that the strength in the area of the welding seam and the heataffected zone is lower, it can also no longer be increased by subsequent ageing. Aluminium casting alloys are again welded with metals of identical or similar composition with AlSi A ALUNOX Manual 7

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11 Standard EN ISO 187 Material number AWS A.5.10 S Al 100 (Al.5).08 ER1100 Area of application Filler rod/wire electrode of aluminium for TIG or MIG welding of pure aluminium. AX-100 AX-Al.5 Special hints Weld seam area must be metallic bright. With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C. Typical analysis in % Al Other min Important base materials Pure aluminium e.g. EN AW-1050A (Al.5), EN AW-1070A (Al.7), EN AW-1080A (Al.8), EN AW-108 (Al.8), EN AW-100 (Al.0), EN AW-150 (Al.5A) 0 1 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength R m Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm²] [W/(m*K)] [1/K] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Mechanical properties of the weld metal as per DIN EN * Product forms (as per EN ISO 5) (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm A ALUNOX Manual

12 AX-150 AX-Al.5Ti Standard EN ISO 187 Material number AWS A.10 S Al 150 (Al.5 Ti) Area of application Filler rod/wire electrode of aluminium for TIG or MIG welding of pure aluminium. Special hints Weld seam area must be metallic bright. With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C. Typical analysis in % Al Ti min Important base materials Pure aluminium e.g. EN AW-1050A (Al.5), EN AW-1070A (Al.7), EN AW-1080A (Al.8), EN AW-108 (Al.8), EN AW-100 (Al.0), EN AW-150 (Al.5A) Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Mechanical properties of the weld metal as per DIN EN ,5*10 - Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm ALUNOX Manual

13 Standard DIN EN ISO 187 Material number AWS A 5.10 S Al 0 (AlSi5 (A)).5 ER0 Area of application Filler rod/wire electrode of aluminium-silicon alloy for TIG or MIG welding of aluminium-silicon-alloys. AX-0 AX-AlSi5 Special hints Weld seam area must be metallic bright. With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C-00 C. Typical analysis in % Al Si Basis 5 Important base materials Aluminium-silicon-alloys, such as: EN AW-01 (AlMgSi1), EN AW-0 (AlMgSi0.7), EN AW-08 (AlMgMnSi1), AlSi and AlSiMg cast with max. 7% Si Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm Mechanical properties of the weld metal as per DIN EN * A ALUNOX Manual 11

14 AX-07 AX-AlSi1 Standard DIN EN ISO 187 Material number AWS A.5.10 S Al 07 (AlSi1 (A)).585 ER07 Area of application Filler rod/wire electrode of an aluminium-silicon alloy for TIG or MIG welding of aluminium-siliconalloys. Special hints With large workpieces and wall thicknesses above15mm, preheat the area of the welding groove to 150 C. Typical analysis in % Al Si Mn Basis 1 0. Important base materials Aluminium cast alloys up to 1%Si. e.g.: EN AC-000 (G-AlSi10Mg), EN AC-00 (G-AlSi1), EN AC-000 (G-AlSi11), EN AC-00 (G-AlSi8Cu) Material properties Welding process Shielding gas Test temperature 0.%-yield strength (Rp ) 0. Tensile strength R m Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Mechanical properties of the weld metal as per DIN EN *10 - Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm ALUNOX Manual

15 Standard EN ISO 187 Material number AWS A 5.10 S Al 5087 (AlMg.5MnZr).5 - AX-5087 AX-AlMg.5MnZr Area of application Filler rod/wire electrode of aluminium-magnesium alloy for TIG or MIG welding of aluminium alloys. Increased protection from hot-cracking. Special hints Weld seam area must be metallic bright. With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C-00 C. When welding age-hardenable alloys, do not place the welding seam in the mechanically highly loaded areas. Typical analysis in % Al Mg Mn Basis Cr 0.15 Ti 0.1 Zr 0. Important base materials EN AW-508 (AlMg.5Mn0.7), EN AW-501 (AlMg5), EN AW-005A (AlSiMg(A)), EN AW-01 (AlMg1SiCu), EN AW-08 (AlSi1MgMn), EN AW-700 (AlZn,5Mg1), EN AC-5100 (G-AlMg5), EN AC-5100 (G-AlMg5Si) Material properties Welding process Shielding gas Test temperature 0.%-yield strength (Rp ) 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm Mechanical properties of the weld metal as per DIN EN * ALUNOX Manual 1 A

16 AX-518 AX-AlMg.5Mn Standard EN ISO 187 Material number AWS A 5.10 S Al 518 (AlMg.5Mn).58 ER518 Area of application Filler rod/wire electrode of aluminium-magnesium alloy for TIG or MIG welding of aluminium alloys. Special hints Weld seam area must be metallic bright. With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C-00 C. When welding age-hardenable alloys, do not place the welding seam in the mechanically highly loaded areas. Typical analysis in % Al Mg Mn Basis. 0.8 Cr 0.15 Ti 0.15 Important base materials EN AW-508 (AlMg.5Mn0.7), EN AW-501 (AlMg5), EN AW-005A (AlSiMg(A)), EN AW-01 (AlMg1SiCu), EN AW-08 (AlSi1MgMn), EN AW-700 (AlZn,5Mg1), EN AC 5100 (G-AlMg5), EN AC-5100 (G-AlMg5Si) Material properties Welding process Shielding gas Test temperature 0.%-yield strength (Rp ) 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Mechanical properties of the weld metal as per DIN EN *10- Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm ALUNOX Manual

17 Standard EN ISO 187 Material number AWS A.5.10 S Al 55 (AlMg5).55 ER55 AX-55 AX-AlMg5 Area of application Filler rod/wire electrode of aluminium-magnesium alloys for TIG or MIG welding of aluminium alloys. Special hints With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C. Typical analysis in % Al Mg Mn Basis Cr 0.1 Ti 0.15 Important base materials EN AW-5005 (AlMg1), EN AW-575 (AlMg), EN AW-501 (AlMg5), EN AW-508 (AlMg), EN AW- 55 (AlMgMn), EN AW-01 (AlMg1SiCu), EN AW-08 (AlSi1MgMn), EN AC (G-AlMg), EN AC-5100 (G-AlMg5), EN AC-5100 (G-AlMg5Si) Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm] [W/(m*K)] [1/K] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm Mechanical properties of the weld metal as per DIN EN * A ALUNOX Manual 15

18 AX-575 AX-AlMg Standard EN ISO 187 Material number AWS A 5.10 S Al 575 (AlMg).5 - Area of application Filler rod/wire electrode of aluminium-magnesium alloy for TIG or MIG welding of aluminium alloys. Special hints With large workpieces and wall thicknesses above 15mm, preheat the area of the welding groove to 150 C. Typical analysis in % Al Mg Mn Basis 0. Cr 0.1 Ti 0.1 Important base materials EN AW-5005 (AlMg1), EN AW-575 (AlMg), EN AW-55 (AlMgMn), EN AW-01 (AlMg1SiCu), EN AW-08 (AlSi1MgMn), EN AW-07 (AlMn0.), EN AW-551 (AlMg), EN AC (G-AlMg) Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Electrical conductivity Thermal conductivity Thermal expansion coefficient TIG/MIG argon I1 at 0 C [%] [S*m/mm ] [W/(m*K)] [1/K] Mechanical properties of the weld metal as per DIN EN *10- Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1 and argon-helium mixtures I Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spools Ø mm Rods Ø mm x mm 1 ALUNOX Manual

19 Standard Material number AWS A (AlSi5) similar to ER 0 Area of application Al-wire for overlays of aluminium-silicon-alloys for electric arc wire spraying. Special hints Spray wire AX-0 AlSi5 0 1 Typical analysis in % Al Si Mn Basis Cr 0.1 Fe 0.1 Important base materials Material properties Tensile strength R 170 Applicable shielding gases (EN ISO 1175) Argon I1 Approval Product forms (as per EN ISO 5) (other dimensions available on request) Spools Ø mm kg A ALUNOX Manual 17

20 Spray wire AX-07 AlSi1 Standard Material number AWS A similar to ER 07 Area of application Al-wire for overlays of aluminium-silicon-alloys for electric arc wire spraying. Special hints Typical analysis in % Al Si Mn Basis 1 0. Important base materials Cr 0.1 Fe 0. Material properties Tensile strength R m m 180 Applicable shielding gases (EN ISO 1175) Argon I1 Approval (Request current scope if required) Product forms (as per EN ISO 5) (other dimensions available on request) Spools Ø mm kg Other dimensions ensions request. on request. 18 ALUNOX Manual

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22 High alloyed Welding Consumables High Alloyed Solid wires/tig rods AX-07 AX-08L AX-0L AX-0LMo AX-0 AX-10 AX-1 AX-1L AX-17L AX-18L AX-7L AX-10 AX-0L AX- AX-5 AX-551 AX-70 AX-1 AX- AX-5 AX-8 AX-8 AX-7 AX-0 AX-8 AX-57 AX-551 AX-00 AX-51 AX- AX-501 AX-80 Stainless steel Stainless steels are by definition iron alloys containing a minimum of 10.5% chromium and a maximum of 1.% carbon. The essential property of the stainless steels is their corrosion resistance caused by the formation of a protective passive layer. The effectiveness of the passive layer rises with the chromium content. By increasing the chromium content to approx. 18% the corrosion resistance rises and the passive layer becomes more stable. By the subsequent addition of molybdenum the resistance to pitting and crevice corrosion is increased, an addition of nickel extends the austenite range and improves ductility and forming capacity as well as weldability. Further alloying constituents that increase corrosion resistance and strength are e.g. copper and nitrogen. Carbon has a negative influence on corrosion resistance through the formation of chromium carbide. With austenitic CrNi steels the C-content is restricted to 0.08%, often Nb and/or Ti is added to stabilise the chromium. Ferritic and martensitic Cr steels may also show higher C contents. 0 ALUNOX Manual

23 Depending on alloy content and the resulting structure a distinction is made according to EN between: ferritic steels with mainly % C and % Cr. In addition up to 1% Nb or 0.7% Ti can be alloyed to it. martensitic steels with mainly % C and % Cr. In addition up to 10.% Ni,.8% Mo and 5.0% Cu can be alloyed to it. austenitic-ferritic (duplex) steels with mainly % C, 18-0% Cr,.5-8.0% Ni, % Mo and % N. In addition up to % Cu can be alloyed to it. austenitic steels with mainly %C, 1-8% Cr,.0-5% Ni, and % Mn. In addition up to 8% Mo, 0.55% N, 1.0% Nb and 0.7%Ti can be alloyed to it. Welding stainless steels In the heat-affected zone (HAZ) ferritic steels tend to grain growth during welding which cannot be removed by subsequent heat treatment. In addition, depending on C- content, carbides may be precipitated that further reduce toughness. Similar effects are to be expected in the weld metal of fillers of similar composition. For this reason, whenever possible austenitic welding fillers are used for welding. Except when identical colouring is required or in the case of attack by sulphureous gases. To avoid internal welding stresses, preheating to C should take place. Subsequent heat treatment at C can likewise contribute to the improvement of toughness. Martensitic steels are essentially only suitable for welding to a limited extent. With C-contents of >0.15% joint welding is inadvisable. Martensitic steels must always be preheated and heat treated. Because of the risk of hydrogen-induced cracks in the martensitic weld metal basic bar electrodes and fluxcored wires as well as basic SAW powder must be used. Soft martensitic steels have a very low C-content of <0.05% and a Ni-content of 1- %. This enables the formation of a soft martensite with good toughness which is even more improved by subsequent heat treatment. They are welded with welding fillers of similar composition that must display a low hydrogen content of 5 ml/100 g in the weld deposit. Because of the stresses arising with the martensite conversion the preheating should be max. 100 C, the interpass temperature C. Austenitic steels and duplex steels are welded with materials of similar composition. Preheating is not normally required, because of the susceptibility to hot cracking the interpass temperature should, primarily for fully austenitic steels, be limited to max C A ALUNOX Manual 1

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25 Standard ISO 1-A ISO 1-B Material number AWS A5. W 18 8 Mn/G 18 8 Mn SSZ ER07 mod. AX-07 AX-70 0 Area of application Filler rod/filler wire for joints between differently alloyed steels and those hard to weld and 1%-Mn steels. Tough intermediate layers with hardfacings. Wear- and corrosion resistant overlays on rail and points parts, valve seats and cavitation protection shielding on hydraulic power machinery. Capable of work hardening, very good cavitation resistance, crack-proof, thermal shock resistant, scale-resistant up to 850 C, insensitive to sigma-phase embrittlement above 500 C. Tough at subzero down to -110 C. Heat treatment is no problem. With operating temperatures of above 50 C consultation with the manufacturer is advisable. Excellent sliding and conveying properties. Very good weld and flow behaviour. Special hints The structure is created fully austenitically without delta ferrite. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Important base materials High strength, unalloyed and alloyed structural and tempering steels with and among each other; unalloyed and alloyed steels with high-alloyed Cr and Cr-Ni steels; heat-resistant steels up to 850 C; Austenitic manganese steels with each other and with other steels; sheet and tubular steels tough at sub-zero in combination with tough at sub-zero austenitic materials. 1 5 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength R m Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual

26 AX-08L AX-1 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 1 L Si/G 1 L Si SS08LSi 1.1 ER08L Si Area of application Filler rod/filler wire for use in all branches of industry where steels of similar composition and ferritic 1% chromium steels are welded together, e.g. chemical apparatus and tank construction, textile and cellulose industry, dyeworks and many more. Excellent sliding and conveying properties. Very good weld and flow behaviour. Resistant to intercrystalline corrosion up to 50 C operating temperature. Tough at sub-zero down to -1 C Special hints The structure is created austenitically with delta ferrite. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Important base materials Stainless austenitic Cr-Ni steel/cast steel e.g. 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10, 1.1 GX10CrNi18-8 ASTM A 1 Gr. TP0L, TP7; A 0 Gr. 0L, 7; A 1 Gr. TP1, TP7i; A 0 Gr. WP0L, WP0, WP1, WP7; A 51 Gr. CPF, CPF8; A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods 1..0 Ø mm Ø mm x 1000 mm ALUNOX Manual

27 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 1 L Si/G 1 L Si SS0LSi 1. ER0 L (Si) AX-0L AX- 0 Area of application Filler rod/filler wire of austenitic chrome-nickel steel with low carbon content and increased ferrite content for TIG or MAG welding of stainless claddings, steels of different characteristics (dissimilar joints) and buffer layers. Special hints Coatings and buffer layers are already corrosion resistant in the first layer. Even at higher melting grades with unalloyed materials there is no risk of martensite formation (root welding). Operating temperatures for dissimilar joints maximum 00 C. With operating temperatures above 00 C and annealing procedures use nickel based welding fillers. Composition of the filler rod/filler wire (typical data in %) C 0.05 Si 0.8 Mn 1.7 Cr.5 Ni 1.5 Important base materials Joints of stainless ferritic Cr steels and austenitic CrNi(Mo) steels with each other and with unalloyed steels (dissimilar joints), hard to weld, unalloyed and alloyed tempering steels, Mn hard steels and for the first layer of chemically resistant CrNi weld coatings. 1 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 5

28 AX-0LMo AX-5 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 1 L/G 1 L (SS0LMo) 1.5 ER0LMo Area of application Filler rod/filler wire of austenitic chrome-nickel-molybdenum steel with low carbon content and increased ferrite content for TIG or MAG welding of stainless claddings, steels of different characteristics (dissimilar joints) and buffer layers and for overlays of Mo-alloyed steels. Special hints Coatings and buffer layers are already corrosion resistant in the first layer. Even at higher melting grades with unalloyed materials there is no risk of martensite formation (root welding). Operating temperatures for dissimilar joints maximum 00 C. With operating temperatures above 00 C and annealing procedures use nickel based welding fillers. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Mo Ni Important base materials Joints of stainless ferritic Cr steels and austenitic CrNi(Mo) steels with each other and with unalloyed steels (dissimilar joints), hard to weld, unalloyed and alloyed tempering steels, Mn hard steels and for the first layer of chemically resistant CrNiMo weld coatings. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm 1.0 Ø mm x mm ALUNOX Manual

29 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 1 H/G 1 H (SS0) 1.8 ER0 mod. AX-0 AX-8 0 Area of application Filler rod/filler wire for heat-resistant rolled, forged and cast steels of similar composition as well as for heat-resistant, ferritic CrSiAl steels, e.g. annealing shops, hardening shops, steam boiler construction, oil industry, ceramics industry. Austenitic weld metal with approx. 8% ferrite content. Preferred in the case of attack by oxidising gases. For joints on Cr-Si-Al steels exposed to reducing, sulphureous gases, the final layer must be welded with AX 551. Scale-resistant to 1000 C. Special hints Preheating and interpass temperature for ferritic Cr steels C. Composition of the filler rod/filler wire (typical data in %) C 0.1 Si 1.1 Mn 1. Cr Ni 1.5 Important base materials Ferritic 1.71 X10CrAlSi7, 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, GX0CrSi7, 1.70 GX0CrSi17 Austenitic 1.88 X15CrNiSi0-1, 1.8 X1CrNi-1, 1.8 GX0CrNiSi-10 ASTM A 17 Gr. 0; A 7 Gr. 0; A 1 Gr. 0; A 0 Gr. WP0; A 7 Gr. 0; A 580 Gr. 0 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) STIG: argon I1, MAG: mixed gas e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods 1..0 Ø mm Ø mm x 1000 mm A ALUNOX Manual 7

30 AX-10 AX-8 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 5 0/G 5 0 (SS10) 1.8 ER 10 mod. Area of application Filler rod/filler wire for heat-resistant rolled, forged and cast steels of similar composition, e.g. annealing shops, hardening shops, steam boiler construction, oil industry, ceramics industry. Fully austenitic weld metal. Preferred in the case of attacks by oxidising, nitrogenous and gases with low oxygen content. For joints on Cr-Si-Al steels exposed to reducing, sulphureous gases, the final layer must be welded with AX 551. Scale-resistant to 100 C. Tough at sub-zero down to -1 C Because of the risk of embrittlement, the temperature range between 50 C- 00 C should be avoided. Special hints The structure is created fully austenitically. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Important base materials Austenitic heat-resistant materials 1.81 X15CrNiSi5-0, 1.85 X8CrNi5-1, 1.81 X15CrNiSi5-, 1.8 GX5CrNiSi0-1, 1.87 GX0CrNiSi5-1, 1.80 GX15CrNi5-0, 1.8 X0CrNi5-1, 1.88 GX0CrNiSi5-0 ASTM A 17 Gr. 10; A 18 Gr. F10; A 7 Gr. 10, 10S, 1; A 1 Gr. 10, 10S, 1; A 0 Gr. TP10S; A 580 Gr. 10, 10S, 1; Ferritic heat-resistant materials 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, 1.7 X10CrAlSi5, GX0CrSi7, 1.70 GX0CrSi17 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Weld argon untreated 0 C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Mechanical properties of the weld metal according to EN ISO Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm ALUNOX Manual

31 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W /G SS1 1.7 ER1 AX-1 AX-7 0 Area of application Filler rod/filler wire of ferritic-austenitic chrome-nickel steel for TIG or MAG welding steels of different characteristics and for cladding Special hints Because of high ferrite content and high crack resistance particularly suitable for hard to weld materials. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Important base materials For joint welding on hard to weld materials with high strength, also on weldable tools. Joints of differently alloyed steels, tough intermediate layers for hardfacings. Because of its high strength and work hardening capability, also suitable for wear-resistant overlays to clutches, wheel rims and shafts and tools. 1 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods 1..0 Ø mm Ø mm x 1000 mm A ALUNOX Manual

32 AX-1L AX-0 Standard EN ISO 1-A EN IOS 1-B Material number AWS A5. W 1 1 L Si/G 1 1 L Si SS1LSi 1.0 ER1LSi Area of application Filler rod/filler wire of austenitic chromium-nickel-molybdenum steel with low carbon content for TIG or MAG welding of stainless cold tough, austenitic clad steels. The weld metal is tough at sub-zero down to -1 C and resistant to intercrystalline corrosion up to 00 C Special hints The structure is created austenitically with delta ferrite. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Mo Important base materials 1.01 X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNiMo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 18 Gr. F1, F1L, F1LN, F1Ti; A1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFMN; A 0 Gr. WP1, WP1L, WP1LN; A 580 Gr. 1, 1L; A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: mixed gases argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods 1..0 Ø mm Ø mm x 1000 mm ALUNOX Manual

33 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W N L/G N L SSZ17L 1.0 ER 17L mod. AX-17L AX-8 0 Area of application Filler rod/filler wire for joint welding to chromium-nickel-molybdenum steels of identical or similar composition as well as to austenite-ferrite steels. Stainless filler metal resistant to intercrystalline corrosion that, because of the high Mo content, displays good resistance in chloride-containing media. It is specially employed for joints and overlays on steels of identical or similar composition. The material is not magnetizable. Special hints The structure is created fully austenitically without ferrite. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Mo Important base materials 1. XCrNiMo17-1-, 1. XCrNiMoN17-1-5, 1. XCrNiMo17-1-, 1.5 XCrNi- Mo18-1-, 1.8 XCrNiMo18-15-, 1. XCrNiMo18-1-, 1.58 X10CrNiMoNb18-1 ASTM A 18 Gr. F1, F17, F17L, TP1LN; A 1 Gr. TP1, TP17, TP17L, TP1LN; A 1 Gr. 1, TP17, TP17L; A 0 Gr. TP1, WP17, WP17L; A 88 Gr. UNS 100, UNS 1700, UNS 170 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength R m Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm 1.0 Ø mm x mm 1... Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 1

34 AX-18L AX-57 Standard ISO 1-A ISO 1-B material number AWS A5. W 1 1 Nb Si/G 1 1 Nb Si SSZ18Si 1.57 ER18 mod. Area of application Filler rod/filler wire for use in all branches of industry where steels of similar composition also higher carburized and ferritic 1-17% chromium steels are welded together, e.g. chemical apparatus and tank construction, chemical, pharmaceutical and artificial silk, textile and cellulose industries and many more. Excellent sliding and conveying properties. Very good weld and flow behaviour. Resistant to intercrystalline corrosion up to 00 C operating temperature. Tough at sub-zero down to -10 C Special hints The structure is created austenitically with delta ferrite. Composition of the filler rod/filler wire (typical data in %) C 0.0 Si 0.8 Mn 1. Cr 1.0 Mo.7 Ni 11,5 Nb+Ta <1.1 Important base materials Stainless austenitic Cr-Ni-Mo steel/cast steel e.g X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNiMo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 18 Gr. F1, F1L, F1LN, F1Ti; A1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFM, CFMN; A 0 Gr. WP1, WP1L, WP1LN; A 580 Gr. 1, 1L; A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Mechanical properties of the weld metal according to EN ISO Approval (Request current scope if required) Product form (other dimensions available on request) Spool Rod Ø mm Ø mm x1000 mm ALUNOX Manual

35 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W 1 Nb Si/G 1 Nb Si SS7Si ER7 Si AX-7L AX Area of application Filler rod/filler wire for use in all branches of industry where steels of similar composition also higher carburized and ferritic 1-17% chromium steels are welded together, e.g. chemical apparatus and tank construction, chemical, pharmaceutical and artificial silk, textile and cellulose industries and many more. Excellent sliding and conveying properties. Very good weld and flow behaviour. Resistant to intercrystalline corrosion up to 00 C operating temperature. Tough at sub-zero down to - 1 C Special hints The structure is created austenitically with delta ferrite. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Nb+Ta <1.1 Important base materials Stainless austenitic Cr-Ni steel/cast steel e.g. 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.1 GX10CrNi18-8, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10 ASTM A 18 Gr. F0, F0L, F1, F7; ASTM A 1 Gr. TP0, TP0L, TP1, TP7; A 0 Gr. 0, 0L, 1, 7; A 1 Gr. 0, TP0L, TP1, TP7; A 0 Gr. WP0, WP0L, WP1, WP7; A 51 Gr. CPF8, CPF, A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7, A 88 UNS 000, UNS Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1 Approval (Request current scope if required) Product form (other dimensions available on request) (Other dimensions available on request) Spools Ø mm Rods Ø mm x mm 8 A ALUNOX Manual

36 AX-10 AX-00 Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. G Z1 SSZ ER 10 Area of application Wire electrodes of ferritic chromium steel for MAG welding of stainless chromium steels. Special hints Wire electrode for welding stainless steels with 1 1% Cr. Also contact surface armouring on fittings of unalloyed and low-alloyed steels for operating temperatures up to 50 C. Rustproof and heat resistant weld metal. The chip removing machinability of the weld metal is largely dependent on the degreed of dilution. Excellent sliding and conveying properties. Very good weld and flow behaviour. Colour similarity for joint welding 1% Cr steels of similar composition, with very good polishability. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Important base materials Ferritic chromium steel XCr1, 1.00 X1Cr1, GX1Cr1, 1.01 X0Cr1, 1.0 X15Cr1 Corrosion-proof overlays: all un- and low-alloyed base materials suitable for welding ASTM A 17 Gr. 0, 0; A 0 Gr. 10, 10S; A 1 Gr. 0, 10, 0; A 511 MT 0, MT10; A 580 Gr. 0, 10, 0; A 88 UNS 1000 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Hardness Mixed gas M0 heat-treated h/70 C 0 C [%] [HB] Mechanical properties of the weld metal as per DIN EN (untreated 0) Applicable shielding gases (EN ISO 1175) MAG: Mixed gases M0, M1, M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Ø mm ALUNOX Manual

37 Standard EN ISO 1-A EN ISO 1-B Material number AWS A 5. W Cu L /G Cu L SS ER0L AX-0L AX-51 0 Area of application Filler rod/filler wire for highly corrosion-resistant joints and overlays on austenitic CrNiMoCu steels/types of cast steel of similar composition as well as for clad steels of similar composition, also in combination with each other. The weld metal is fully austenitic and possesses a pronounced resistance to pitting and crevice corrosion in media containing chloride. High resistance to sulphuric, phosphoric, acetic and formic acid, sea and brackish water. The high Ni content gives good resistance to flake crack corrosion. Special hints The cleanliness of the workpiece in the weld seam area is a requirement for a crack-free joint. Interpass temperature max.150 C. Wire electrode preferably weld in pulsed arc. Composition of the filler rod/filler wire (typical data in %) C 0.0 Si 0. Mn 1.8 Cr 0.0 Ni 5.0 Mo.5 Cu 1.5 Important base materials 1.5 X1NiCrMoCu5-0-5, 1.57 X1CrNiMoCuN5-5-5, 1. XCrNiMoN17-1-5, 1.8 XCrNiMo ASTM A 18 Gr. F17L, F0L; A 1 Gr. TP17L; A 1 Gr. TP17L, UNS N08; A 0 Gr. WP17L; A 81 Gr. TP17L; A 88 Gr. UNS Material characteristics Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases M1 e.g. argon-helium mixture with 0-0% He and 0.5-% CO Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm Ø mm x 1000 mm A ALUNOX Manual 5

38 AX- AX- Standard EN ISO 1-A EN ISO 1-B Material number AWS A5. W N L/G N L SS0 similar to 1. (duplex) ER0 Area of application Filler rod/filler wire of nitrogenous ferrite-austenitic chromium-nickel-molybdenum steel for TIG or MAG welding of stainless ferrite-austenitic duplex steels for operating temperatures up to 50 C. Also for joining duplex with unalloyed steels (dissimilar joints) and to standard austenites. Special hints The delta ferrite content in the untreated weld metal is around 5 5%. The weld metal has a particularly good resistance to pitting, crevice corrosion and flake crack corrosion in chloride aqueous media. The structure is created ferritic-austenitically. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Mo Ni N 0.15 Important base materials Stainless ferritic-austenitic steel/cast steel, e.g. 1. XCrNiMo-5-, 1. XCrNiN- and joints with unalloyed, low-alloyed and stainless steel/cast steel. ASTM A 88 Gr. UNS 180 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases M1 e.g. argon-helium mixture with 0-0% He and 0.5-% CO Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm Ø mm x1000mm ALUNOX Manual

39 Standard EN ISO 1-A EN ISO 1-B Material number AWS A 5. W 5 N L/G 5 N L SSZ ER5 mod. AX-5 AX Area of application Filler rod/filler wire of nitrogenous ferrite-austenitic chromium-nickel-molybdenum steel for TIG or MAG welding of stainless ferrite-austenitic super duplex steels especially in the offshore area for operating temperatures up to 50 C. Very good resistance to pitting and flake crack corrosion. Special hints The structure is created ferritic-austenitically. 1 Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Mo Ni Cu 0. W N Important base materials 5% Cr super duplex joints such as XCrNiMoCuWN5-7-, XCrNiMoCuN5--, 1.10 XCrNiMoN5-7- ASTM A 18 Gr. F55, F5; A 0 Gr. 55, UNS S70; A 1 Gr. UNS S70; A 7 Gr. UNS S550, UNS S70; A 815 Gr. WPS550, WPS70 Material characteristics Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases M1 e.g. argon-helium mixture with 0-0% He and 0.5-% CO Approval (Request current scope if required) Product form (other dimensions available on request) Spools Rods Ø mm 1. Ø mm.0.. x1000mm A ALUNOX Manual 7

40 AX-551 AX-80 Standard EN ISO 1-A Material number G Area of application Wire electrode of ferritic-austenitic chrome-nickel steel for MAG welding of heat-resistant steels; weld metal scale-resistant up to 1100 C. Special hints The weld metal is heat and scale-resistant up to 1100 C and resistant to reducing sulphureous furnace gases. Joint welding to steels of similar composition up to the upper layers preferably carried out with austenitic additions such as AX-0 or AX-10. Only the upper layers are welded with AX- 80 because of the chemical resistance. In this way better toughness of the weld metal is achieved. The structure is ferritic-austenitic. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Ni Important base materials Heat and scale-resistant ferritic and ferritic-austenitic steels e.g X10CrAlSi7, 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, 1.7 X10CrAlSi5, GX0CrSi7, 1.70 GX0CrSi17, 1.81 X15CrNiSi5-, 1.8 GX0CrNiSi7- ASTM A 7 Gr. HC, HD; AISI 7 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av M1 untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: mixed gases e.g. M1, M1 Approval (Request current scope if required) Product form (other dimensions available on request) Spools Ø mm ALUNOX Manual

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42 Construction and fine grain structural steels Structural steels have a carbon content (C) of % and a specified carbon equivalent value (CEV). They are supplied either in hotformed (AR=As Rolled), normalized (N) or cold-formed (C) state. Medium alloyed Welding Consumables Unalloyed/Medium Alloyed Solid wire/ TIG rods unalloyed AX-SG AX-SGZinc AX-SG AX-WSG Solid wire/ TIG rods low-alloyed AX-Mo AX-CrMo1 AX-CrMo AX-Ni,5 AX-NiCu AX-NiMo AX-NiMoCr AX-NiMoCr0 Gas welding rods AX-G I AX-G II AX-G III AX-G IV Structural steels such as S5JR, S75J0 or S55J are used in steel construction. These steels are weldable and can be stress relieved annealed. Structural steels such as E5, E5 or E0 are used in mechanical engineering. Because of the high carbon content they are only weldable to a certain degree and must not be used in steel structures subject to acceptance. This also applies to the steel S185 because of the non-specified carbon content. Structural steels are standardized in EN Fine grain structural steels have a fine-grained structure with a ferrite grain structure <, a max. C-content of 0.0%, a restricted carbon equivalent value and thus very good welding characteristics. They are microalloyed, non-ageing and have better toughness properties in the tough at subzero area than structural steels. There are normalized (N), thermomechanically treated (M) and quenched and tempered (Q) fine grain structural steels. 0 ALUNOX Manual

43 Normalized (N) fine grain structural steels are subjected to normalizing heat treatment. They have 0.% yield strengths of 75-0 MPa and are standardized in EN Thermomechanically treated (M) fine grain structural steels achieve their strength and toughness through a rolling process with targeted temperature control. This achieves 0. yield strengths up to 0 MPa. They are standardized in EN Quenched and tempered fine grain structural steels are in addition alloyed with Cr, Mo and Ni. A subsequent tempering treatment enables 0. yield strengths up to 100 MPa to be achieved. They are standardized in EN Weather resistant structural steels are alloyed with chromium and copper and in the atmosphere form a tight and bonded layer which prevents further corrosion. They are standardized in EN They are welded with metals of similar composition. Welding structural and fine grain structural steels Filler metals are to be selected in accordance with the minimum requirements for the mechanical properties of the base material. From wall thicknesses of 0 mm (up to 55 MPa yield strength) or from 0 mm (>55 MPa yield strength), structural and fine grain structural steels suitable for welding are to be preheated to C. In the case of higher strength fine grain structural steels with a 0. yield strength of MPa, preheat from approx. 1 mm, from a 0. yield strength of 550 MPa from 8 mm. Because of the risk of cold cracking, with higher strength fine grain steels only hydrogencontrolled weld fillers must be used, e.g. basic bar electrodes. In addition, the regulations of EN are to be followed. Creep resistant steels Structural steels can only be used up to temperatures of approx. 50 C. Beyond that a significant strength reduction takes place because of creep and flow processes. Creepresistant steels are alloyed with Cr, Mo, V, W, Co, Ti and Nb. An increase of the creep resistance is achieved by mixed crystal and formation of special carbides. A distinction is made between: Ferritic pearlitic steels P5GH, P55GH and 1Mo Bainitic steels 1CrMo-5, 10CrMo-10 and P/P Martensitic -1% Cr steels P1, P, E11 and X0CrMoV1-1 Welding creep resistant steels Creep resistant steels are in principle welded with metals of similar composition. Ferritic pearlitic steels are preheated only from wall thicknesses of 5 mm (P5GH) and 15 mm (1Mo) to approx. 150 C. Bainitic and martensitic steels are air-hardening steels and must therefore always be preheated ( C) and tempered. For martensitic steels correct observation of the preheating and interpass temperature is even more important. Depending on wall thickness, martensitic steels must be directly heat treated in a cycle from the welding heat via intermediate cooling-off. The prescribed heat treatment temperature and time is to be observed precisely A ALUNOX Manual 1

44 ALUNOX Manual

45 Standard EN ISO 11-A EN ISO 11-A EN ISO 11-B Material number AWS A5.18 G Si1 (Wire) G M1 Si1/G C1 Si1 G A U M1 S/G U C1 S ER70S- AX-SG Area of application Wire electrode for joints on unalloyed and low-alloyed steels in boiler, tank, machinery and vehicle construction. Special hints Composition of the wire electrode (typical data in %) C Si Mn Important base materials S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P75NL1-P55NL1, P15NL, P5NL, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L15MB, GE00-GE0, shipbuilding steels: A, B, D, E, A -E ASTM A Gr. 101, 101; A 10 Gr. C; A, B; A 8 Gr. B, C, D; A 50 Gr. LF1; A 501 Gr. B; A 510 Gr. 101; A 51 Gr. 101, 10; A 51 Gr. 101, 10; A 51 Gr. 0, 70; A 57 Gr. ; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; A 70 Gr., 50; A 711 Gr. 101; API 5 L B, X, X5, X0 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: mixed gases M1-M and CO Approvals (Request current scope if required) Product forms Spool Ø mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual

46 AX-SGZinc Standard EN ISO 11-A EN ISO 11-A EN ISO 11-B Material number: AWS A5.18 G Ti (Wire) G M Ti G A M S ER70S-G Area of application Wire electrode of low-alloyed steel for MAG welding of unalloyed and low-alloyed steels. Particularly suitable for overwelding prefabrication primers and protective zinc coatings. Non-ageing weld metal for operating temperatures of 10 C to 50 C. Special hints The wire electrode is matched to mixed gases M and M. Particularly suitable for welding galvanized, primed or slightly rusty components. The weld metal is non-ageing under mixed gases M 1 and M. Composition of the wire electrode (typical data in %) C 0.07 Si 0.8 Mn 1. Al 0.1 Zr <0.1 Ti 0.1 Important base materials S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P55N, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L15MB, shipbuilding steels: A, B, D, E, A -E ASTM A Gr. 101, 101; A 10 Gr. C; A, B; A 8 Gr. B, C, D; A 501 Gr. B; A 510 Gr. 101; A 51 Gr. 101, 10; A 51 Gr. 101, 10; A 51 Gr. 70; A Gr. C; A Gr. A, B; A 70 Gr., 50; A 711 Gr. 101; API 5 L B, X, X5, X0 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: CO or mixed gases e.g. M, M, M1, M Approvals (Request current scope if required) Product forms Spool Ø mm ALUNOX Manual

47 Standard EN ISO 11-A EN ISO 11-A EN ISO 11-B Material number AWS A5.18 G Si1 (wire) G M1 Si1/G C1 Si1 G 55A U M1 S/G 55A U C1 S ER70S- AX-SG Area of application Wire electrode with joint welding on general structural and tubular steels, as well as on fine grain steels. Special hints Composition of the wire electrode (typical data in %) C Si Mn Important base materials S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P75NL1-P0NL1, P15NL, P5NL, P55N, P85NH-P0NH, P15TR1- P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, GE00-GE0, shipbuilding steels: A, B, D, E, A -E ASTM A Gr. 101, 101; A 10 Gr. C; A, B; A 8 Gr. B, C, D; A 50 Gr. LF1; A 501 Gr. B; A 510 Gr. 101; A 51 Gr. 101, 10; A 51 Gr. 101, 10; A 51 Gr. 0, 70; A 57 Gr., 5; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; A 70 Gr., 50; A 711 Gr. 101; API 5 L B, X, X5, X0, Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: Mixed gases M1, M, M, CO Approvals (Request current scope if required) Product forms Spool Ø mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 5

48 AX-WSG Standard EN ISO -A EN ISO -A EN ISO -B Material number AWS A5.18 W Si1 (Wire) W 5 WSi1 WSi1 WA 5U W ER70S- Area of application Filler rod for joints on unalloyed and low-alloyed steels in boiler, tank, machinery and vehicle construction. Special hints Composition of the filler rod (typical data in %) C Si Mn Important base materials S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S0N, S75M-S0M, S75NL-S0NL, S75ML-S0ML, P5GH-P55GH, P75NL1-P55NL1, P75NL-P55NL, P15NL, P5NL, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L15MB, GE00-GE0 ASTM A Gr. 101, 101; A 10 Gr. C; A, B; A 8 Gr. B, C, D; A 50 Gr. LF1; A 501 Gr. B; A 510 Gr. 101; A 51 Gr. 101, 10; A 51 Gr. 101, 10; A 51 Gr. 0, 5, 70; A 57 Gr. ; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; A 707 Gr. L1, L; A 70 Gr., 50; A 711 Gr. 101; A 81 Gr. A, B, C; API 5 L B, X, X5, X0 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av TIG argon I1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon l1 Approvals (Request current scope if required) Product forms Rod Ø mm x 1000 mm ALUNOX Manual

49 Standard EN ISO 15-A EN ISO 15-B Material number AWS A5.8 W CrMoSi/G CrMoSi W C1M/G C1M 1.78 ER0S-B (mod.) AX-CrMo Area of application Filler rod/filler wire of low-alloyed chromium-molybdenum steel for TIG or MAG welding of creep resistant and high-pressure hydrogen resistant steels of identical or similar composition for operating temperatures up to 00 C. Special hints Preheat temperature 00 to 50 C: interpass temperature maximum 50 C; heat treatment after welding: minimum 1/ h at 700 to 750 C. Cooling-off in still air. Composition of the wire electrode (typical data in %) C Si Mn Cr Mo Important base materials CrMo-10, CrMo11, CrMo-, CrMo-10, 1.75 CrMo7, 1.77 G17CrMo-10, 1.78 G1CrMo-10, similarly alloyed case hardening, tempering and nitriding steels ASTM A 18 Gr. F; A 1 Gr. T; A Gr. WP; A 5 Gr. P; A Gr. F; A CP 1 Material properties (after heat treatment h/70 C) Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M 1, M, M Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms Spool Ø mm Rod Ø mm x 1000 mm A ALUNOX Manual 7

50 AX-CrMo1 1.7 Standard EN ISO 15-A EN ISO 15-B Material number AWS A5.8 W CrMo1Si/G CrMo1Si W 1CM/G 1CM 1.7 ER80S-B (mod.) Area of application Filler rod/filler wire of low-alloyed chromium-molybdenum steel for TIG or MAG welding of creep resistant and high-pressure hydrogen-resistant steels of similar composition for operating temperatures up to 570 C. Special hints Preheat temperature 00 to 50 C: interpass temperature maximum 50 C; heat treatment after welding: minimum 1/ h at 0 to 700 C cooling-off in still air. Composition of the wire electrode (typical data in %) C Si Mn Cr Mo Important base materials CrMo-5, CrMo5, CrMo, CrMo5, CrMoV, CrMo CrMo-, 1.75 GCrMo5- and similarly alloyed case hardening, tempering and nitriding steels ASTM A 18 Gr. F1; A 1 Gr. T1; A Gr. WP11; A 5 Gr. P11, P1; A Gr. F11, F1; A Gr. CP1 Material properties (after heat treatment h/80 C) Welding process MAG Shielding gas M1 Test temperature 0C 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M 1, M, M Approvals (Request current scope if required) Product forms Spool Rod Ø mm Ø mm x 1000 mm ALUNOX Manual

51 Standard EN ISO 15-A EN ISO 15-B Material number AWS A5.8 W CrMoSi/G CrMoSi W C1M/G C1M 1.78 ER0S-B (mod.) AX-CrMo Area of application Filler rod/filler wire of low-alloyed chromium-molybdenum steel for TIG or MAG welding of creep resistant and high-pressure hydrogen resistant steels of identical or similar composition for operating temperatures up to 00 C. Special hints Preheat temperature 00 to 50 C: interpass temperature maximum 50 C; heat treatment after welding: minimum 1/ h at 700 to 750 C. Cooling-off in still air. Composition of the wire electrode (typical data in %) C Si Mn Cr Mo Important base materials CrMo-10, CrMo11, CrMo-, CrMo-10, 1.75 CrMo7, 1.77 G17CrMo-10, 1.78 G1CrMo-10, similarly alloyed case hardening, tempering and nitriding steels ASTM A 18 Gr. F; A 1 Gr. T; A Gr. WP; A 5 Gr. P; A Gr. F; A CP 1 Material properties (after heat treatment h/70 C) Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0C [%] [J] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M 1, M, M Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms Spool Ø mm Rod Ø mm x 1000 mm A ALUNOX Manual

52 AX-Ni.5 Standard EN ISO -A EN ISO 11-A EN ISO -A/EN ISO -B EN ISO 11-A/EN ISO 11-B AWS A5.8 WNi (TIG rod) G Ni (MAG wire) W WNi/W 55A WN5 G M1 Ni/G 55A M1 SN5 ER80S-Ni Area of application Low alloyed steels and fine grain structural steels tough at sub-zero Special hints Nickel alloyed filler rod/filler wire for gas-shielded welding of fine grain structural steels tough at sub-zero to an operating temperature of -0 C. Composition of the wire electrode (typical data in %) C Si Mn Ni Important base materials Special structural steels such as 10Ni1, 1Ni1, 1MnNi-, 15NiMn, P75NL1- P0NL1, P75NL-P0NL, S55NL-S0NL ASTM A 0 Gr. D, E; A Gr. ; A Gr. ; A 50 Gr. LF1, LF, LF; A 0 Gr. WPL, WPL; A 51 Gr. 0, 5; Gr. A 5 Gr. 50; A 57 Gr., 5; A Gr. A, D, E; A Gr. A, B, C; A 707 Gr. L1, L, L; A 78 Gr. A; A 81 Gr. A, B, C Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength ISO-V KV MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1; MAG: Mixed gases M1, M, M, CO Approvals (Request current scope if required) Product forms Spool Rod Ø mm Ø x 1000 mm ALUNOX Manual

53 AX-NiCu Standard EN ISO 11-A EN ISO 11-A EN ISO 11-B AWS A5.8 G ZNi1Cu (wire) G M1 ZNi1Cu G 55A M1 SZNCu ER80S-G 0 Area of application Wire electrode with copper-nickel filler for MAG welding of weather resistant steels. Weld metal for operating temperatures of -0 to 50 C. Special hints Composition of the wire electrode (typical data in %) C Si Mn Cu Ni Important base materials Weather resistant structural steels such as S5JRGCu, S5JGCu, S5J0Cu, S5JRW, S55J0Cu, S55JGCu, S55J0W, 5JW-S55JW, S55KW, Cor-ten A, Patinax 7 ASTM A 588 Gr. A, B, C, K; A 18 Gr. II; 70 Gr. C Material properties Welding process/shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1, M, M, CO Approvals (Request current scope if required) Product forms Spool Ø mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 51

54 AX-NiMo Standard EN ISO 18-A EN ISO 18-A EN ISO 18-B AWS A5.8 G MnNi1Mo (wire) G 55 M1 MnNi1Mo G A M1 NN1T ER0S-G Area of application Wire electrode of low-alloyed steel for MAG welding of tempered fine grain structural steels up to a yield strength of approx. 550 MPa. Weld metal for operating temperatures of 0 C to 50 C. Special hints The mechanical properties are dependent on the shielding gas; optimum welding characteristics are achieved under mixed gas M 1. Weldable in short arc or spray arc section. Preheating temperature dependent on base material. Interpass temperature must not exceed 00 C. Composition of the wire electrode (typical data in %) C 0.08 Si 0. Mn 1. Ni 1.0 Important base materials S0Q-S550Q, S0QL-S550QL, S0N, S0M, L15NB, L15QB-L555QB, L15MB-L555MB, N-A-XTRA 550 M, PAS 0-550, alform 550 M, 0MnMoNi5-5 (1.10), Welmonil (1.1), 15NiCuMoNb5-- (1.8), GMn ASTM A 57 Gr. 5; A Gr. E; API 5 L X0, X0Q, X70, X70Q, X80, X80Q Mo 0. Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1, M, M, CO Approvals (Request current scope if required) Product forms Spool Ø mm ALUNOX Manual

55 AX-NiMoCr Standard EN ISO 18-A EN ISO 18-A EN ISO 18-B AWS A5.8 G MnNi1CrMo (wire) G 5 M1 MnNi1CrMo G 7A 5 M1 NCMT ER110S-G 0 Area of application Wire electrode of low-alloyed steel for MAG welding of tempered fine grain structural steels up to a yield strength of approx. 700 MPa. Weld metal for operating temperatures of 50 C to 50 C. Special hints The mechanical properties are dependent on the shielding gas; optimum weld metal is achieved under mixed gas M 1 with corresponding welding conditions. Weldable in short arc or spray arc section. Preheating temperature dependent on base material. Pay attention to controlled heat input, interpass temperature should not exceed 180 C. Composition of the wire electrode (typical data in %) C Si Mn Ni V Cr Important base materials S550Q-S0Q, S550QL-S0QL, N-A-XTRA M 550-M 700, PAS , alform 550 M-700 M ASTM A 51 Gr. F, H, Q; A 70 Gr. 100 Type B, E, F, H, Q, HPS 100W Mo 0. 1 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M0, M1, M, M Approvals (Request current scope if required) Product forms Spool Ø mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 5

56 AX-NiMoCr0 Standard EN ISO 18-A EN ISO 18-A EN ISO 18-B AWS A5.8 G MnNiCrMo (wire) G 8 5 M1 MnNiCrMo G 8A 5 M1 N5M ER10S-G Area of application Wire electrode of low-alloyed steel for MAG welding of high strength, tempered fine grain structural steels. Weld metal for operating temperatures of -50 C to 50 C. Special hints The mechanical properties are dependent on the shielding gas; optimum weld metal is achieved under mixed gas M 1 with corresponding welding conditions. Weldable in short arc or spray arc section. Preheating temperature dependent on base material. Pay attention to controlled heat input, interpass temperature should not exceed 180 C. Composition of the wire electrode (typical data in %) C 0.1 Si 0. Mn 1.7 Ni.1 Cr 0. Mo 0.5 Important base materials S0Q-S80Q, S0QL-S80QL, S0Q, S0QL, N-A-XTRA M 700, PAS 700, XABO 80, XABO 0, alform 700 M, alform 00 x-treme, alform 0 x-treme ASTM A 70 Gr. 100 Type B, E, F, H, Q, HPS 100W Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M0, M1, M, M Approvals (Request current scope if required) Product forms Spool Ø mm ALUNOX Manual

57 Standard EN 15 Material number AWS A5. O I 1.0 R5-G Area of application Filler rod of low-alloyed steel for gas welding of unalloyed steels. Weld metal for operating temperatures up to 50 C. Low viscosity weld metal. Special hints AX-G I Composition of the filler rod (typical data in %) C Si Mn Important base materials S5JR, P15TR1-P5TR1 ASTM A Gr. 101; A 510 Gr. 101, A 711 Gr. 101 Material properties Heat treatment Test temperature 0.%-yield strength Rp eh eh Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av untreated 0 C [%] [J] Applicable shielding gases Acetylene-oxygen mixture, neutral flame Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms Rod Pack contents Ø mm x 1000 mm 5kg each A ALUNOX Manual 55

58 AX-G II 1.0 Standard EN15 Material number AWS A5. O II 1.0 R0-G Area of application The weld metal has higher mechanical properties and higher viscosity and is thus more suitable for welding in constrained welding positions than AX-G I. It can be welded almost spatterfree. Special hints Composition of the filler rod (typical data in %) C Si Mn Important base materials S5JR-S75JR, P15TR1-P5TR1 ASTM A Gr. 101; A 510 Gr. 101, A 711 Gr. 101, A 501 Gr. B; A 51 Gr. 101; A 51 Gr. 101; A57 Gr. 5; A Gr. A: A 70 Gr. 50 Material properties Heat treatment Test temperature Yield strength R eh Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) Acetylene-oxygen mixture, neutral flame Approvals (Request current scope if required) Product forms Rod Ø mm x1000mm Pack 5kg each ALUNOX Manual

59 Standard EN 15 Material number AWS A5. O III 1.15 R0-G AX-G III 1.15 Area of application Filler rod of nickel-containing steel for gas welding of unalloyed and low-alloyed steels Weld metal for operating temperatures of 0 C to 50 C. Because of its tough flow, this spatterfree, weldable gas welding filler rod is particularly suitable for welding in constrained positions in pipeline construction. Ideal filler rod for gas and heating installation, for vent construction, boiler and container construction. Special hints Composition of the filler rod (typical data in %) C Si Mn Ni Important base materials S5JR-S75JR, S5J0-S75J0, P15TR1-P5TR1, L5NB, L5MB ASTM A Gr. 101, 101; A 8 Gr. C, D; A 510 Gr. 101, A 711 Gr. 101, A 501 Gr. B; A 51 Gr. 101; A 51 Gr. 101, 101; A 57 Gr., 5; A Gr. A, C: A 5 Gr. 101; A 70 Gr., Material properties Heat treatment Test temperature Yield strength R eh Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) Acetylene-oxygen mixture, neutral flame Approvals (Request current scope if required) Product forms Rod Ø mm x1000mm Pack 5kg each 7 8 A ALUNOX Manual 57

60 AX-G IV 1.55 Standard EN 15 Material number AWS A5. O IV 1.5 R5-G Area of application Filler rod of low-alloyed molybdenum-containing steel for gas welding of creep resistant steels. Weld metal for operating temperatures up to 500 C. Viscous, smoothly and evenly melting off filler rod with low slag formation. Because of its clear weld pool the weld filler is particularly suitable for difficult welding work in pipeline and boiler construction. Special hints Composition of the wire electrode (typical data in %) C 0.1 Si 0.15 Mn 1.0 Mo 0.5 Important base materials S5JR-S75JR, S5J0-S75J0, P15TR1-P5TR1, L5NB, L5MB, 1Mo, Mo ASTM A Gr. 101, 101; A 18 Gr. F1; A 0 Gr. T1; A Gr. WP1; A 8 Gr. C, D; A 5 Gr. P1; A 510 Gr. 101, A 711 Gr. 101, A 501 Gr. B; A 51 Gr. 101; A 51 Gr. 101, 101; A 57 Gr., 5; A Gr. A, C: A 5 Gr. 101; A 70 Gr., 50 Material properties Heat treatment Test temperature Yield strength R eh eh Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength ISO-V RT untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases Acetylene-oxygen mixture, neutral flame Approvals (Request current scope if required) Product forms Rod Ø mm x1000mm Pack 5kg each ALUNOX Manual

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62 Wear mechanisms and Hardfacing Wear causes an annual loss of several billion euros worldwide. By the term wear is meant both the material loss itself and the process that leads to the material loss. The material loss from the surface of a workpiece is caused by mechanical causes as a consequence of tribological stress. Hardfacing Welding Consumables Hardfacing Solid wires/tig rods Fe-base AX AX AX-50W 1.57 AX AX AX AX-50W 1.8 Flux-cored wires Fe-base AX-FD-DW AX-FD-CrMn AX-FD-50 AX-FD-00 AX-FD-00 AX-FD-00TIC/O AX-FD-HC AX-FD- UP&OA AX-FD-5 UP&OA AX-FD-WZ50 AX-FD-NiFe Tribological stress is caused by contact and relative movement of a solid, liquid or gaseous opposing body and thus leads to friction and wear. The various wear mechanisms lead to characteristic manifestations as shown in the table on the following page. To achieve as high a service life as possible, it is necessary to identify exactly the tribological system present and then to select the weld filler. A weld filler that achieves a good service life with a sliding stress, may completely fail with a colliding or butting stress. Often several mechanisms are responsible for the wear. Flux-cored wires cobalt-base AX-FD-Co1 Stellite 1 AX-FD-Co Stellite AX-FD-Co1 Stellite 1 AX-FD-Co1 Stellite 1 0 ALUNOX Manual

63 By welding a hardfacing a wear resistant cladding layer is created that is particularly good at resisting attack. Decisive for a successful hardfacing is the knowledge of the type of wear and the right choice and correct implementation of the hardfacing welding. Carrying out the hardfacing welding If the surface of the workpiece is very badly worn, it is often sensible to fill up so-called additional layers with a weld filler of similar composition or low-alloyed (softer) to reestablish the original form before actual hardfacing. Wear mechanism Adhesion Abrasion Surface breakdown Tribochemical reaction Manifestation seizures, holes, bumps, scales scratches, striae, ruts, recesses, undulations cracks, dimples scales Reaction products such as oxide layers and particulates Buffer layers between workpiece and facing are always sensible if the base material is susceptible to cracking, e.g. with highly carburized or alloyed steels sensitive to cracks. As a rule, for the buffer layer a weld filler of type 1.70, such as AX- 07, EI 07 R, EI 07 B or AX-FD-DW07 is used. Before hardfacing and also before welding the additional and/or buffer layer, the workpiece must be cleaned on the facing surface of all contaminations such as grease, oil, paint, scale and other residues. Likewise badly deformed or other affected areas must be removed by grinding or milling. Areas gouged out with an electrode such as AX-EFug are likewise to be ground over. The surface to be coated must be clean, dry and metallic plain. Effect and consequenc es Material removal through formation and separation of surface adhesions Material removal through microcutting or scratching stress Material removal through material fatigue in the surface Material removal through chemical reactions on the contact area Cracks or other blemishes must likewise be completely removed. The preheating and interpass temperature depends both on the base material and on the facing alloy. The information given by the base material manufacturer is likewise to be observed. If you have any questions the ALUNOX team will be happy to support you with advice and assistance A ALUNOX Manual 1

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65 Standard EN 1700 DIN 8555 AWS A 5.1 Material number S Fe1 MSG 1-GZ 50 ERFe AX Application areas Filler wire of low-alloyed manganese-chromium steel for MAG welding of machinable, wear resistant facings, preferably for rolling wear. Special hints Preheat base materials sensitive to cracks to around 50 C. Welding with other shielding gases may alter the hardness values. 1 Composition of the filler wire (typical data in %) C Si Mn Cr Al Ti 0. Important areas of application Overlays on machinery parts of structural steel or cast steel, areas of application e.g. slideways, track wheels, bearing surface, wheel rims, rails, rollers, guide ways, conveyor rollers, clutches. Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Brinell hardness Vickers hardness MAG M1 0 C [HRC] [HB] [HV] Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1, M, M Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA, PB, PC, PF 1, mm only PA; PB - Mechanical properties of the weld metal as per DIN EN A ALUNOX Manual

66 AX Standard EN 1700 DIN 8555 AWS A 5.1 Material number S Fe MSG -GZ 50 ERFe-1A Application areas Filler wire of low-alloyed manganese-chromium steel for MAG welding of machinable, wear resistant facings exposed to pressure, shock and abrasion. The weld metal can be hardened and close annealed. Special hints Welding with other shielding gases may alter the hardness values. Untreated weld metal is still machinable. Preheat base materials susceptible to cracking to 00 to 50 C. Composition of the filler wire (typical data in %) C Si Mn Cr Ti Al 0.1 Important areas of application Facings on machinery parts of structural steel or cast steel, e.g. slideways, track wheels, bearing surfaces, wheel rims, rails, rollers, guide ways, conveyor rollers, clutches and push rods. Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal MAG M1 0 C [HRC] [HRC] [HB] Mechanical properties of the weld metal as per DIN EN 55-0 (untreated/as welded) 0 (hardened C/oil) 00 (close annealed C) Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1, M, M Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA, PB, PC, PF 1, mm only PA; PB - ALUNOX Manual

67 Standard EN 1700 DIN 8555 Material number S Fe W / MSG GZ-5-T 1.57 AX-50W 1.57 Area of application Wire electrode / filler rod for cladding highly stressed hot working tools. Weld metal of chromiumtungsten-vanadium hard alloy Special hints Weld metal can be machine cut after soft-annealing; otherwise only machinable by grinding. Preheat tool depending on base material, form and size to 00 to 00 C and keep to this temperature during welding. Then allow to cool down slowly. Harden and/or anneal corresponding to the intended use. Composition of the wire electrode (typical data in %) C Si Mn Cr V W Important areas of application Welding new or tools to be repaired of hot work steel, e.g. die casting moulds, plastic moulds, press boxes, pressing discs, impact molding dies, bottom dies, push rods, upsetting tools. 0 1 Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal TIG argon 0 C [HRC] [HRC] [HB] [HRC] Mechanical properties of the weld metal as per DIN EN 55- (untreated/as welded) 5 (hardened 1080 C/oil) 0 (close annealed 780 C) 8 (tempered at 00 C) 5 Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1, M Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x Welding position/ polarity MAG PA, PB, PC, PF 1, mm only PA; PB - TIG - _ 7 8 A ALUNOX Manual 5

68 AX Standard EN 1700 DIN 8555 Material number S Fe MSG -GZ Application Wire electrode of chromium-silicon steel for MAG welding of tough abrasion resistant overlays. Special hints Welding with other shielding gases may alter the hardness values. Untreated weld metal only workable by grinding. Preheat base materials susceptible to cracking to 00 to 00 C. With base materials very susceptible to cracking weld intermediate layer (buffer), e.g. with the wire electrode AX- 07 or the bar electrode El07B or El07R. Composition of the wire electrode (typical data in %) C Si Mn Cr Important areas of application Facings on machinery parts of structural steel or cast steel or manganese steel. E.g. contact surfaces, caterpillar tracks, running wheels, chaser mills, dredger parts, rolling mill guidance, clamping jaws. Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Vickers hardness MAG M1 0 C [HRC] [HV] Mechanical properties of the weld metal as per DIN EN Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M, M Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA, PB, PC, PF 1. mm only PA; PB ALUNOX Manual

69 Standard EN 1700 DIN 8555 Material number S Fe8 MSG -GZ-0-S AX Properties Filler rod/filler wire of chromium-silicon steel for TIG or MAG welding of tough abrasion resistant coatings. Application areas For tough, crack, cut and abrasion resistant overlay on wearing parts that are exposed to strong striking and moderate abrasion stress, e.g. sand processing plants, mining industry, steelworks, cement works, cutting and forming tools for the automotive industry and plants in quarries. The weld metal is only workable by grinding. With base materials very susceptible to cracking weld intermediate layer (buffer), e.g. with the wire electrode AX-07 or the bar electrode El07B or El07R. Composition of the wire electrode (typical data in %) C 0.5 Si.0 Mn 0.5 Cr. Important areas of application Overlays on machinery parts of structural steel or cast steel or manganese steel, e.g. rollers, contact surfaces, caterpillar tracks, running wheels, chaser mills, dredger parts, screw conveyors, rolling crushers, paving breakers, rolling mill guides, cams, clamping jaws, impact jaws, mixing arms, anvils, upper layers of Mn steels and for regenerating cutting edges and working surfaces of cold work tools. Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal MAG M1 0 C [HRC] [HV] [HRC] [HB] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1, M, M, CO Approvals (Request current scope if required) Mechanical properties of the weld metal as per DIN EN 55-5 (untreated/as welded) 80 (untreated/as welded) (hardened 1080 C/oil) 0 (close annealed 780 C) Product forms (others available on request) Spool Ø mm Rod Ø mm x Welding position/ polarity MAG PA, PB, PC, PF 1, mm only PA; PB TIG A ALUNOX Manual 7

70 AX Standard EN 1700 DIN 8555 AWS A 5.1 Material number S Fe8 MSG GZ-0 ERFe-8 mod. 1.0 Area of application Filler rod / filler wire of chromium-silicon steel for MAG welding of tough abrasion resistant overlays on components exposed to strong abrasion, impact and shock load. Can be used up to 500 C. The weld metal is then only workable by grinding. Special hints The hardness of the weld metal is dependent on the dilution with the base material. With the increasing number of layers the influence is reduced. The weld area must be ground and depending on wall thickness and base material preheated to C. If there are more than two layers, a buffer layer should be welded, e.g. with the wire electrode AX-07 or the bar electrode El07B or El07R. Composition of the wire electrode (typical data in %) C 0.5 Si 1.1 Mn 0. Cr 5.5 Mo 1. V 0.5 W 1. Important areas of application For overlays of components from sand processing plants, dies for abrasives, final passes of Mn steels, rail tamper picks, hammer boring tools, shredder hammers, bottom dies, guillotine shears, crusher jaws, cold and hot working tools. Material properties Welding process Shielding gas Test temperature Hardness of the weld metal MAG M1 0 C [HRC] Mechanical properties of the weld metal as per DIN EN 55-5 Applicable shielding gases (EN ISO 1175) TIG: argon, MAG: mixed gases e.g. M, M, CO Approvals (Request current scope if required) ² Product forms (others available on request) Spool Ø mm Rod Ø mm x Welding position/ polarity MAG PA, PB, PC, PF 1. mm only PA; PB _ TIG 8 ALUNOX Manual

71 Standard EN 1700 DIN 8555 AWS A 5.1 Material number S Fe W / MSG -0-S ERFe- mod. 1.8 AX-50W Application Filler wire / filler rod for overlay of high-speed steel tools. Weld metal of tungsten-molybdenumchromium hard alloy. Special hints Weld metal can be machine cut after soft-annealing; otherwise only workable by grinding. Preheat tool slowly and evenly to 00 to 500 C and keep to temperature during welding. Slow cool down is essential (furnace, hot sand). Then carry out heat treatment (hardening, tempering). With small repairs and newly manufactured tools, local preheating to 50 to 50 C is sufficient without subsequent heat treatment with likewise slow cool down covered or in the furnace down to about 100 C. With base materials very susceptible to cracking weld intermediate layer (buffer), e.g. with the wire electrode AX-07 or the bar electrode El07B or El07R. 1 Composition of the wire electrode (typical data in %) C 0. Si 0. Mn 0. Cr.0 Mo 8.5 V.0 W 1.8 Important areas of application Repair and new manufacture of high speed steel tools with high cutting performance and good toughness also with impact-type load. For turning and planing tools, milling cutters, broaching tools, reamers, spiral drills, wood working tools, cold working and cutting tools Material properties Welding process Shielding gas Test temperature Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal Hardness of the weld metal MAG M1 0 C [HRC] [HV] [HRC] [HB] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M1, M1 Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x Welding position/ polarity MAG PA, PB, PC, PF TIG Mechanical properties of the weld metal as per DIN EN (untreated/as welded) 80 (untreated/as welded) - (hardened C/oil) tempered at 50 C/h 0 (close annealed C) A ALUNOX Manual

72 AX-FD-DW07 Standard EN ISO 17-A EN ISO 17-B AWS A5. T 18 8 Mn R M1 TS Z07-F M1 0 E07T0-G Application Flux-cored electrode with filling containing rutile primarily for vertical and horizontal welding positions. The flux-cored electrode represents excellent welding characteristics, self-releasing slag, extremely low spattering and seam oxidation, finely rippled weld bead with good flank wetting and evenly secure penetration. Welding characteristics Characteristics of the weld metal: capable of work hardening, very good cavitation resistance, crackproof, thermal shock resistant, scale-resistant up to 850 C, insensitive to brittling above 500 C, tough at sub-zero down to -100 C. Operating temperatures up to 50 C. Typical weld metal composition in % C 0.07 Si 0. Mn. Cr 1. Ni 8.1 P 0.0 S Important base materials The AX-FD-DW07 is suitable for high strength, unalloyed and alloyed structural, tempering and armour steels with and to each other; unalloyed and alloyed boiler or structural steels with highalloyed Cr and Cr-Ni steels; heat-resistant steels up to 850 C; austenitic manganese steels with each other and with other steels; sheet and tubular steels tough at sub-zero in combination with tough at subzero austenitic materials. Material properties Shielding gas Heat treatment Test temperature MAG M1 0 C Mechanical properties of the weld metal according to EN ISO %-yield strength Tensile strength Rm Elongation A (L = 5d0) % 0 Impact strength Av [%] [J] >50 >500 >0 0 Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100%CO ) Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm kg Welding position/ polarity MAG PA; PB; PC 70 ALUNOX Manual

73 AX-FD-CrMn Standard DIN EN 1700 DIN 8555 AWS A 5.1 T Fe MF 7-GF-50-KNP ERCFeMnCr 0 Properties Austenitic high manganese and high chromium alloyed flux-cored electrode for welding manganese steels. The weld metal is rustproof, anti-magnetic and has high toughness. This electrode is to be preferred for use on parts exposed to very high pressures and high impact load. Likewise for applying to unalloyed and low-alloyed steels exposed to high impacts and pressures. Strain hardenable up to approx. 8 HRC. Because of the risk of brittling, manganese steels must be welded as cold as possible, the interpass temperature should not exceed 50 C, if necessary the welding is to be cooled. Application areas Wear resistant overlays to rails, crushing hammers, crusher jaws, beating arms, baffles, bucket teeth, rotary furnace collars, rollers, blast furnace bells as well as overlays on Mn steels and interpass layers before hardfacings.] Composition of the weld metal (typical data in %) Fe C Si Mn Cr Basis Material properties Shielding gas Heat treatment Test temperature Hardness Hardness after work hardening MAG M1 0 C [HB] [HRC] Applicable shielding gases (EN ISO 1175) MAG: M1, M1 Approvals (Request current scope if required) Ni 1. Mo 0.5 Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG PA; PB V 0. Mechanical properties of the weld metal as per DIN EN A ALUNOX Manual 71

74 AX-FD-50 Standard EN 1700 DIN 8555 AWS A 5.1 T Fe1 MF 1-GF-00-P ERCFe-1 Area of application The AX-FD-50 quality is suitable for hardfacing welding on components that are primarily exposed to rolling and sliding wear and are stressed by impact and shock such as running wheels, rope pulleys, wheel rims, slideways and crane wheels. The martensitic weld metal can be easily worked with tungsten carbide tools Special hints Smooth, stable arc, does not tend to spray, low smoke development, finely rippled, non-porous seam aspect. Metal recovery is approx. 8 % Preheating min. 150 C depending on thickness of component and base material. Composition of the weld metal (typical data in %) Fe C Si Mn Cr Basis Mo 0. Material properties Shielding gas Heat treatment Test temperature Hardness MAG M1 0 C [HB] Mechanical properties of the weld metal as per DIN EN Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1 Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA; PB 7 ALUNOX Manual

75 AX-FD-00 Standard EN 1700 DIN 8555 AWS A 5.1 T Fe1 MF1-GF-0-P ERCFe- 0 Area of application The AX-FD-00 quality is suitable for overlay on components subject to high pressure load in combination with rolling wear and impact and shock, such as running wheels, bucket chains, rope pulleys, wheel rims, slideways, chain and crane wheels. With increased C-content in the base material a buffer layer with AX-FD-DW07 is recommended. Special hints Smooth, stable arc, does not tend to spray. Preheating C depending on thickness of component and base material. The weld metal can still be machined with tungsten carbide tools. 1 Composition of the weld metal (typical data in %) Fe Basis C 0. Si 0. Mn.0 Cr.0 Mo 0. Material properties Shielding gas Heat treatment Test temperature Hardness MAG M1 0 C [HRC] Applicable shielding gases (EN ISO 1175) MAG: Mixed gases e.g. M1 Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA; PB Mechanical properties of the weld metal as per DIN EN A ALUNOX Manual 7

76 AX-FD-00 Standard EN 1700 DIN 8555 T Fe 8 MF -GF-0-GP Properties This C-, Mn-, Cr-, Mo-, V-alloyed flux-cored wire is suitable for tough and abrasion resistant overlays on wearing parts exposed to strong impact and moderate abrasion stress. The weld metal is heat resistant up to approx. 500 C. An increase in hardness is possible by hardening with subsequent tempering. Preheating is required depending on wall thickness and base material. With a hard to weld base a buffer layer should be applied with AX-FD-DW07. Application areas Shredder plants, carrying rollers, impact jaws, screw conveyors, roll crushers, paving breakers, crusher mills, bucket teeth and cold cutting tools. Composition of the weld metal (typical data in %) C Si Mn V Cr Mo 0. Mechanical properties Hardness weld metal: 5-57HRC Applicable shielding gases (EN ISO 1175) e.g. ArCO², mixed gas M1 Welding conditions and versions Dimensions (in mm) Voltage Amperage V 1-8V 50-0A 0-0A Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA; PB 7 ALUNOX Manual

77 AX-FD-00-TIC/O Standard EN 1700 DIN 8555 T Fe8 MF -GF-0-GP Properties C-, Cr-, Ti- and Mo-alloyed flux-cored electrode for hardfacings not susceptible to cracking on parts exposed to highly abrasive wear in combination with impact and shock load. The structure consists of a martensitic matrix with embedded extremely highly wear resistant chromium and titanium carbides. With a hard to weld base a buffer layer should be applied with AX-FD- DW07. Application areas Cement rollers, crushing rollers and crushing hammers, gravel pumps, screw conveyors, mixers, earth moving equipment. 0 1 Composition of the weld metal (typical data in %) C 1.8 Si 1. Mn 1. Cr 7.0 Mo 1. Ti 5.0 Mechanical properties Hardness weld metal: 5-58HRC Welding conditions and versions Dimensions (in mm) Voltage V -V OA = Open Arc (self-shielding/without shielding gas). Approvals (Request current scope if required) Amperage 150-0A 180-0A 5 Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG PA; PB 7 8 A ALUNOX Manual 75

78 AX-FD-HC Standard EN 1700 DIN 8555 AWS A 5.1 T ZFe1 MF 10-GF-0-GR ERCFeCr-A Properties AX-FD-HC-OA is a self-shielding flux-cored wire which is highly C-, Cr-alloyed. It is suitable for overlay on parts exposed to heavy wear from mineral materials and heavy corrosion attacks. The weld metal is rustproof. Overlay should be carried out in - layers with maximum 8 mm thickness. The best results are obtained with two-layer welding. The weld metal should be stressed less for impact and shock. With sensitive base materials a ductile intermediate layer with e.g. AX-FD- DW07 or AX-FD-CrMn is recommended. Application areas Pumps, mixer blades, screw conveyors, stirring arms, concrete pump bushing blocks Composition of the weld metal (typical data in %) C Si Mn Cr Mechanical properties Hardness weld metal: 55-5HRC Welding conditions and versions Dimensions (in mm) Voltage Amperage V -7V -8V -0V 7-0V 10-80A 180-0A 0-50A 0-0A 0-0A AX-FD-HC-OA = Open Arc (self-shielding/without shielding gas) AX-FD-FC-UP = (under powder (SAW = submerged arc welding) Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA; PB 7 ALUNOX Manual

79 AX-FD- Standard DIN EN 1700 DIN 8555 T ZFe15 MF 10-GF-0-GR Properties AX-FD-OA is a high C-, Cr-, Nb-alloyed flux-cored electrode for overlays to parts exposed to very strong sanding wear at temperatures up to 80 C. The weld metal consists of ledeburitic structure with embedded very hard Cr and Nb carbides. The impact and shock load should be as low as possible. With sensitive base materials a ductile intermediate layer with e.g. AX-FD-DW07 or AX-FD-CrMn is recommended. Application areas Mixer blades, cement- and concrete pumps, grinding rolls and wear plates, screw conveyors, chutes, coke- and coal crushers, worm presses and dredger parts. Composition of the weld metal (typical data in %) C 5. Si 1.1 Mn 0. Cr.0 Nb Mechanical properties Hardness weld metal: 1-HRC Welding conditions and versions Dimensions (in mm) Voltage V 0-V AX-FD--OA = Open Arc (self-shielding/without shielding gas) AX-FD--UP = (under powder (SAW = submerged arc welding) Approvals (Request current scope if required) Amperage 10-0A 10-0A 5 Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG PA; PB _ 7 8 A ALUNOX Manual 77

80 AX-FD-5 Standard DIN EN 1700 DIN 8555 T Fe1 MF 10-GF-5-GRTZ Properties AX-FD-5-OA is a high C-, Cr-, Mo-,Nb-, W-, V-alloyed flux-core electrode for overlay on parts exposed to very strong sanding wear at temperatures up to 00 C. The weld metal consists of ledeburitic structure with embedded extremely hard Cr and Nb carbides. With sensitive base materials a ductile intermediate layer with e.g. AX-FD- DW07 or AX-FD-CrMn is recommended. Application areas Blast furnace bells in the impact area, furnace grates, spike crushers, sinter crushers, grate bars, coking plant sinter, hammer mills for cement and clinker crushing. Composition of the weld metal (typical data in %) C 5. Si 1.0 Mn 0. Cr 1.0 Mo 7.0 Nb 7.0 V 1.0 W.0 Mechanical properties Hardness of weld metal: -5HRC at +0 C Hardness of weld metal: approx. 5 HRC at 00 C Welding conditions and versions Dimensions (in mm) Voltage Amperage 1. 0-V 10-0A AX-FD-5-OA = Open Arc (self-shielding/without shielding gas) AX-FD-5-UP = (under powder (SAW = submerged arc welding) Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG PA; PB 78 ALUNOX Manual

81 AX-FD-WZ50 Standard EN 1700 DIN 8555 T Fe MF -GF-50-ST Properties The AX-FD-WZ50 is a C-, Cr-, V- and W-alloyed flux-cored wire for overlay of hot working tools or for cladding the work surfaces of hot working tools of low-alloyed steels. Likewise suitable for components that at high temperature are subject to pressure, impact and abrasion. The weld metal can only be cut by machine to a limited extent otherwise must be worked by grinding. Application areas Hot cutting equipment, bottom dies, push rods, impact dies, forging dies, die casting dies, mandrels 0 1 Composition of the weld metal (typical data in %) C Si Mn Cr V W.5 Mechanical properties Hardness of weld metal: 8 50 HRC Welding conditions and versions Dimensions (in mm) Voltage V 5 V 5 8 V 0 V AX-FD-WZ50- OA = Open Arc (self-shielding/without shielding gas) AX-FD-WZ50-UP = (under powder (SAW = submerged arc welding) Amperage 10 0 A 0 0 A 0 00 A A 5 Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG PA; PB _ 7 8 A ALUNOX Manual 7

82 AX-FD-NiFe Standard EN ISO 1071 DIN 8555 AWS A 5.15 TC NiFe-M MF-NiFe- ENiFeT-Cl mod. Properties This Ni-Fe-alloyed flux-cored electrode (0% Ni) is suitable for joining and cladding cast iron with nodular graphite, malleable cast iron and lamellar grey cast iron and for joining cast iron with steel. Application areas Welding filler wire for GJL (grey cast iron), GJS (cast iron with nodular graphite) joint and process welding. Composition of the weld metal (typical data in %) C Si Mn Ni Fe 0.5 <1.0.0 Rest 0 Mechanical properties Hardness of weld metal: 10-0 HB Applicable shielding gases (EN ISO 1175) MAG: e.g. mixed gases M11, M1, M1 Welding conditions and versions Dimensions (in mm) Voltage Amperage V -V 150-0A A Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity MAG Ø 1.mm Ø mm PA, PB, PC, PF PA; PB _ 80 ALUNOX Manual

83 AX-FD-Co1 Standard EN 1700 DIN 8555 AWS A 5.1 T Co MF 0-GF-55-CGTZ ERCCoCr-C Properties Hardest of the generally used cobalt base alloys. The weld metal is very abrasion, creep and heat resistant. The high hardness only allows machining by grinding. The alloy is corrosion resistant, especially against reducing acids and scale resistant to approx C. Very well suited to metal on metal sliding stress. Depending on base material, a buffer layer with AX- FD-DW07 is recommended. Application areas The AX-FD-Co1 is used in grinding and chaser mills, wear rings, wear elements in the chemical industry as well as salt and lye pumps, bearing surfaces, hot shears, valves for running and sealing surfaces on fittings, valve seats and plugs as well as for heavily stressed hot working tools without thermal shock load. Composition of the weld metal (typical data in %) C Si Mn Cr W Mechanical properties Hardness of weld metal: 5 HRC Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: mixed gas M1 Fe.0 Co Rest Welding conditions and versions Dimensions Amperage [A] Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity TIG/MAG PA; PB Voltage [V] A ALUNOX Manual 81

84 AX-FD-Co Standard EN 1700 DIN 8555 AWS A 5.1 T Co MF 0-GF-5-CTZ ERCCoCr-A Properties The Co-base alloy Co is the mainly used stellite alloy. It is used where wear stress is accompanied by corrosion and light impact stress. Very well suited to workpieces that have to withstand pressure and abrasion under high temperatures. Scale resistant up to approx. 00 C. Excellent sliding properties and good toughness and polishing properties. Still easily machinable with tungsten carbide tools. Depending on base material, a buffer layer with AX-FD-DW07 is recommended. Application areas Sealing surfaces on fittings, valve seats and plugs in combustion engines, highly stressed hot working tools without thermal shock load, hot press dies, shafts and spindles, high temperature liquid pumps as well as for metal on metal sliding surfaces. Composition of the weld metal (typical data in %) C Si Mn Cr W Fe.0 Co Rest Mechanical properties Hardness of weld metal: HRC Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: mixed gas M1 Welding conditions and versions Dimensions Amperage [A] Voltage [V] Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity TIG/MAG PA; PB 8 ALUNOX Manual

85 AX-FD-Co1 Standard EN 1700 DIN 8555 AWS A 5.1 T Co MF 0-GF-50-CTZ ERCCoCr-B Properties The Co-base alloy Co1 is somewhat more wear resistant compared with Co. The toughness and the hardness can be placed between AX-FD-Co1 and AX-FD- Co. Particularly suitable for wear stress in combination with corrosion and heat, scale resistant up to approx. 00 C. Depending on base material, a buffer layer with AX-FD-DW07 is recommended. Application areas The alloy is particularly suitable for machining tools for the hardwood, paper and plastics industry, extruder worms, valve spindles, earth borers. For running and sealing surfaces of fittings, hot press dies, high temperature liquid pumps, valve seats and plugs of combustion engines and billet shears, as well as for highly stressed hot working tools. Composition of the weld metal (typical data in %) C Si Mn Cr W Mechanical properties Hardness of weld metal: HRC Fe.0 Co Rest 0 1 Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: mixed gas M1 Welding conditions and versions Dimensions Amperage [A] Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity TIG/MAG PA; PB Voltage [V] A ALUNOX Manual 8

86 AX-FD-Co1 Standard EN 1700 DIN 8555 AWS A 5.1 T Co1 MF 0-GF-50-CKTZ ERCCoCr-E Properties The Co-base alloy Co1 is high-temperature resistant and resistant to corrosion and cavitation. This alloy is considered as the most creep and corrosion resistant Co-base alloy and can be workhardened by cold forming up to 5HRC. Excellent sliding and polishing properties. Very good toughness and thermal shock resistance. Very suitable also against impact load. Application areas Particularly suitable for hot working tools with thermocycling, for contact surfaces on steam, water, gas and acid fittings, for high temperature liquid pumps, valve seats of combustion engines, hot stamping dies. Composition of the weld metal (typical data in %) C 0.5 Si 1.0 Mn 1.0 Cr 8.5 Mo 5.5 Ni.0 Fe.0 Co Rest Mechanical properties Hardness of weld metal: HRC Work hardened: approx. 5 HRC Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: mixed gas M1 Welding conditions and versions Dimensions Amperage [A] Voltage [V] Approvals (Request current scope if required) Product forms (others available on request) Spools / Ø mm drum Welding position/ polarity TIG/MAG PA; PB 8 ALUNOX Manual

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88 Welding Consumables Copper Solid wires/tig rods AX-CuAg.111 AX-CuAl8.01 AX-CuAlFe.07 AX-CuAl8Ni.0 AX-CuAl8Ni.0 AX-CuMn1Al7.17 AX-CuSi.11 AX-CuSiA.11 AX-CuSn.100 AX-CuSn.10 AX-CuSn1.105 AX-CuNi10Fe.087 AX-CuNi0Fe.087 Copper Copper Copper Copper has long been known as a basic material and, because of its good formability, became the first metal used. Copper can form alloys with many metals, through this, technical mechanical properties such as tensile strength, yield strength, hardness, wear resistance and others can be influenced in a targeted way. Copper has a density of 8. g/ cm and belongs to the nonferrous metals. Because of its cubic face-centred lattice structure (like austenitic steel) good low temperature toughness and cold workability is present. Copper has high electrical and thermal conductivity and good corrosion resistance to many media. Copper materials are divided by their handling state into: precipitation-hardening and non-precipitation-hardening materials Precipitation-hardening copper alloys are practically not used for welded constructions because of precipitations disadvantageous for welding. 8 ALUNOX Manual

89 Depending on production, copper alloys are available as forging or casting alloys. They are divided into pure copper, low alloyed up to max. 5% and high alloyed of more than 5% alloying constituents. The low alloyed are alloyed with Ag, Mg, Zn, Pb or Si, the most important high alloyed with Zn (brass), Sn (bronze), Sn+ Zn (red bronze), Ni+Zn (nickel silver), Ni or with Al. The oxygen content in the copper has a decisive influence from a technical welding aspect. It is added to improve the electrical conductivity but also has the effect of increasing the absorption of hydrogen. This leads to the formation of cracks and loosening of the structures (hydrogen brittleness). These copper materials are therefore not weldable. Types of copper used in apparatus and tank construction are for this reason either molten oxygenfree or deoxidized with P. Welding of copper and copper alloys During welding copper also tends to absorb oxygen and hydrogen from the ambient air. Care must therefore be taken to ensure adequate gas shielding. Because of the high thermal conductivity particularly of the unalloyed and low alloyed copper materials, either the base material must be preheated or a high energy density welding method must be chosen. The level of the preheat temperature depends on the conductivity of the base material and the wall thickness. With unalloyed copper from mm preheating must be approx. 00 C, with a wall thickness of 15 mm approx. 500 C. For clean and defect-free weld seams and as protection for the root side, in many cases the use of fluxes is of benefit. They are applied before welding onto the surface of the workpiece, release the oxide layers present during heating and prevent them reforming. Fluxes are mainly used in gas and electric arc welding. Because of the high energy density in many cases it is possible to do without them in shielded gas welding processes. In TIG welding fluxes are only still used in exceptional cases, in MIG welding not at all now. In manual metal arc welding the flux is often already present in the coating. With high preheat temperatures, from approx. 00 C; flux should be used as edge protection for the weld zone. Because of the high heat expansion and the high shrinkage of copper materials caused by it, sufficient tack welds or clamp fastenings must be used. The TIG and MIG processes are the main welding processes used for copper materials. Gas welding is limited to unalloyed copper, manual arc welding only to repair and restoration work A ALUNOX Manual 87

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91 Standard EN ISO 7 Material number AWS A 5.7 S-Cu 187 (CuAg1).111 ERCu AX-CuAg.111 Area of application Filler rod/filler wire of copper-silver alloy for welding pure copper, also suitable for gas welding. Low viscosity weld metal. Special hints Weld zone must be metallic bright. Composition of the filler rod/filler wire (typical data in %) Cu P Mn Ag Bal. <0.05 < Important base materials Joint welds and overlays to copper e.g.:.000 (E-Cu 57),.0070(SE-Cu) electrical industry, heating engineering, profiles and installations Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1, I, GAS: autogenous gas flame neutral to slightly oxidizing Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Rods Ø mm Ø mm x 1000 mm A ALUNOX Manual 8

92 AX-CuAl8.01 Standard EN ISO 7 Material number AWS A-5.7 S-Cu 100 (CuAl8).01 ERCuAl-A1 Area of application Filler rod/filler wire of copper-aluminium alloy for TIG or MIG welding. Corrosion and saltwater-proof, good sliding properties. Special hints Preheating only necessary for large workpieces. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. When TIG welding use flux to avoid oxide formation. Composition of the filler rod/filler wire (typical data in %) Cu Al Fe Bal Important base materials Copper-aluminium-alloys, e.g. Al-bronze with 7-% Al, copper- and copper-zinc alloys (brass) and overlays on unalloyed and low alloyed steels and on cast iron. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C [%] [HB] [J] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG/MIG argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm Rod Ø mm x mm ALUNOX ALUNOX Manual Manual

93 Standard EN ISO 7 Material number AWS A-5.7 S-Cu 180 (CuAi IOFe).07 ER CuAl-A Area of application Filler wire of copper-aluminium alloy with increased iron content for MIG welding. AX-CuAlFe.07 Special hints Preheating only necessary for large workpieces. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler rod/filler wire (typical data in %) Cu Al Ni Fe Mn Bal. 10 < < 1 Important base materials Copper-aluminium alloys with increased wear resistance, copper and copper-zinc alloys and overlays on unalloyed and low alloyed steels and on cast iron. This alloy is also used as metal spray wire. 0 1 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C MPa MPa [%] [HB] [J] [W/(m*K)] Applicable shielding gases (EN ISO 1175) MIG: argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm 1. Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 1

94 AX-CuAl8Ni.0 Standard EN ISO 7 Material number S-Cu 7 (CuAl8Ni).0 Area of application Filler rod/filler wire of multi-alloy aluminium bronze for TIG or MIG welding of copper-aluminium alloys. Corrosion and saltwater-proof. Special hints TIG preheating of the base material is not required as a rule. MIG preheating only necessary for large workpieces. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. When TIG welding use flux to avoid oxide formation. Composition of the filler rod/filler wire (typical data in %) Cu Al Ni Fe Mn Bal Important base materials Copper-aluminium-alloys with increased wear resistance, e.g. Al-bronze with 7-% Al. Also for overlays on unalloyed and low alloyed steels and on cast iron. This alloy is also used as metal spray wire. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C [%] [HB] [J] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG/MIG argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm Rod Ø mm x mm 1..0 ALUNOX Manual

95 Standard EN ISO 7 Material number AWS A.5-7 Area of application S-Cu 8 (CuAlNi5).0 ERCuNiAl AX-CuAl8Ni.0 Filler wire of multi-alloy aluminium bronze with Ni and Fe additive for TIG or MIG welding of copperaluminium alloys. Corrosion and saltwater-proof. Special hints TIG preheating of the base material is not required as a rule. Preheating only necessary for large workpieces. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler rod/filler wire (typical data in %) Cu Bal. Al Ni.5 Important base materials Fe.5 Copper-aluminium-nickel alloys, saltwater-proof overlays on unalloyed and low alloyed steels and on cast iron as well as for dissimilar joints on aluminium bronzes and steel. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity 0. Mn 1. Argon untreated 0 C [%] [HB] [W/(m*K)] Applicable shielding gases (EN ISO 1175) MIG: argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual

96 AX-CuMn1Al7.17 Standard EN ISO 7 Material number AWS A.5-7 S-Cu 8 (CuMn1Al7).17 ERCuMnNiAl Area of application Filler wire of manganese-containing multi-alloy aluminium bronze for MIG welding. Corrosion and saltwater-proof, good sliding properties. Special hints Preheat base materials to max. 10 C if required. Because of the risk of brittling interpass temperature must not exceed 150 C. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler wire (typical data in %) Cu Al Ni Fe Mn Bal Important base materials Copper-aluminium-nickel alloys, saltwater-proof overlays on unalloyed and low alloyed steels and on cast iron. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) Argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm ALUNOX Manual

97 Standard EN ISO 7 Material number AWS A.5-7 S-Cu 50 (CuSiMn1).11 ERCuSi-A AX-CuSi.11 Area of application Filler rod/filler wire of copper-silicon-alloy with low melting point for TIG or MIG welding (soldering) of galvanized steel panels in car body construction. The corrosion proofing of galvanized surfaces remains very largely maintained. Special hints Preheating of the base material is not required as a rule. Do not keep weld pool too wide. Take care to introduce little heat, when MIG welding in short electric arc/ pulsed arc process, when TIG welding introduce as much weld metal as possible. Composition of the filler rod/filler wire (typical data in %) Cu Si Sn Fe Mn Bal Important base materials Galvanized steel sheets and copper-silicon and copper-manganese-alloys of similar composition, such as CuSiMn, CuSiMn. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C [%] [HB] [J] [W/(m*K)] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1, I Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool/drum Ø mm Rods Ø mm x mm A ALUNOX Manual 5

98 AX-CuSiA.11 Standard EN ISO 7 Material number AWS A-5.7 S-Cu 50 (CuSiMn1).11 ERCuSi-A Area of application Filler wire of copper-silicon alloy for the automotive industry and here especially for laser or MIG soldering. Special hints Preheating of the base material is not required as a rule. Do not keep weld pool too wide. Take care to introduce little heat, when MIG welding in short electric arc/ pulsed arc process, when TIG welding introduce as much weld metal as possible. For the 1st layer of overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler rod/filler wire (typical data in %) Cu Si Sn Fe Mn Bal Important base materials Copper, low alloyed copper and copper-zinc alloys and overlays on unalloyed and low alloyed steels and on cast iron. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C [%] [HB] [J] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MIG: argon I1, I Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool/drum Rods Ø mm Ø mm x 1000 mm ALUNOX Manual

99 Standard EN ISO 7 Material number AWS A.5-7 S-Cu 188 (CuSn1).100 ERCu Area of application Filler rod/filler wire of copper for TIG or MIG welding of pure copper. Viscous weld metal. AX-CuSn.100 Special hints With wall thicknesses above mm preheating is necessary (approx. 100 C per mm thickness of the metal sheet but not more than 00 C). With preheat temperatures above 00 C flux must be used. Composition of the filler rod/filler wire (typical data in %) Cu Bal. Si 0. Sn 0.8 Al 0.01 Mn 0. Important base materials Weldable copper types, e.g. SE - Cu (.0070), SW - Cu (.007), SF - Cu (.000), OF - Cu (.000) Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Impact strength Av Thermal conductivity Argon untreated 0 C [%] [HB] [J] [W/(m*K)] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1, I Flux F-SH Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO Product forms (other dimensions available on request) Spool/drum Ø mm Rods Ø mm x mm A ALUNOX Manual 7

100 AX-CuSn.10 Standard EN ISO 7 Material number AWS A.5-7 S-Cu 5180 (CuSnP).10 ERCuSn-A Area of application Filler rod/filler wire of copper-tin alloy for TIG or MIG welding. Good sliding properties. Special hints With wall thicknesses above mm preheating to 50 C is necessary. With TIG overlays on ferrous materials introduce as much filler material into the electric arc as possible. With MIG overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler rod/filler wire (typical data in %) Cu Sn P Bal. 0.5 Important base materials Copper-tin-alloys, e.g. bronze with -8% Sn, copper-zinc alloys (brass), copper-tin-zinc-lead-casting alloys, overlays on cast iron. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1, I Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool/drum Rods Ø mm Ø mm x 1000 mm ALUNOX Manual

101 Standard EN ISO 7 Material number S-Cu 510 (CuSn1P).105 Area of application Filler rod/filler wire for welding tin bronzes, multi-alloy tin bronzes and red bronze. Weld metal of 1% tin bronze. Saltwater-proof. AX-CuSn1.105 Special hints With wall thicknesses above mm preheating to 50 C is necessary. With TIG overlays on ferrous materials introduce as much filler material into the electric arc as possible. With MIG overlays on ferrous materials pulsed arc welding is recommended. Composition of the filler rod/filler wire (typical data in %) Cu Bal. Sn 1 P <0.5 Fe <0.1 Important base materials Copper-tin-alloys, e.g. bronze with 10-1% Sn, copper-zinc alloys (brass), coppertin-zinc-lead cast alloys (red bronze: Rg 5, Rg7), overlays on cast iron and steel. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MIG: argon I1, I Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO Product forms (other dimensions available on request) Spool/drum Ø mm Rods Ø mm x mm A ALUNOX Manual

102 AX-CuNi10Fe.087 Standard EN ISO 7 Material number S-Cu 701 (CuNi10).087 Area of application Filler rod/filler wire for highly stressed corrosion resistant joint welding and overlay in chemical apparatus construction, in shipbuilding and in the offshore area as well as in desalination plants. Highly corrosion and saltwater-proof. Special hints Composition of the filler rod/filler wire (typical data in %) Cu Ni Mn Fe Ti Bal Important base materials Copper-nickel-alloys with 5-10% nickel, e.g. CuNi5Fe (.08), CuNi10Fe1Mn (.087) Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG/MIG argon I1 Approvals (Request current scope if required) Product forms (other dimensions available on request) Spool/drum Rods Ø mm 1. Ø mm x mm 100 ALUNOX Manual

103 Standard EN ISO Material number AWS A.5.7 S-Cu 7158 (CuNi0).087 ErCuNi AX-CuNi0Fe Area of application Filler rod/filler wire for highly stressed corrosion resistant joint welding and overlay in chemical apparatus construction, in shipbuilding and in the offshore area as well as in desalination plants. Highly corrosion and saltwater-proof. Special hints Composition of the filler rod/filler wire (typical data in %) Cu Ni Mn Fe Ti Bal Important base materials Copper-nickel-alloys with up to 0% nickel e.g. CuNi0Fe (.0878), CuNi0Fe (.088) Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Thermal conductivity Argon untreated 0 C [%] [HB] [W/(m*K)] Applicable shielding gases (EN ISO 1175) TIG/MIG argon I1 Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO Product forms (other dimensions available on request) Spool/drum Ø mm 1. Rods Ø mm x mm A ALUNOX Manual 101

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106 Welding Consumables Bar electrodes unalloyed ESR 11 ESR 1 ESR 1M ESR 5 ESB ESB 8 ESB 5 ESC 0 ESC 70 low alloyed EM 10 EM 170 EM 171 EM 180 EM 01 EM 0 EM 11 EM 1 EM EM 5 EM 1 Bar electrodes high alloyed EI 07B EI 07R EI 08L EI 0L EI 0MoL EIS 0 EI 10 EI 1 EI 1L EI 18 EI 7 EIS 10 EI 0 10 ALUNOX Manual Nickel AX-ENi AX-ENiFe1 AX-ENiFe0/0 AX-E8 AX-E5 Cobalt AX-ES1 AX-ES AX-ES1 AX-ES1 Hardfacing EH 5 EH 0 EH 0 EH 0B EH 0R EH 515 EH 5 EH 58 EH 51 EH 50 Gouging electrode AX-EFug Aluminium AX-EAlSi5 AX-EAlSi1 Manual Metal Arc Welding with bar electrodes Coated electrodes can be used on all base materials suitable for welding. The cost effectiveness is rather low, MAG welding with solid wire or flux-cored wire has almost completely replaced the bar electrode. Because of universal use in the craft trade sector and on building sites and the low equipment expenditure, the bar electrode will continue to play an important role in the future. The bar electrode consists of a live core bar and a coating. During welding, through the coating components both shielding gas is generated and simultaneously slag formed to protect the weld area from the ambient air. Apart from that, because of the coating the welding and technological mechanical properties of the weld metal are affected, above all also at low temperatures. In addition the positional weldability and the metal recovery are influenced and the melting loss of alloying constituents is compensated.

107 There are three types of coatings: rutile coated (R) basic coated (B) cellulosic coated (C) and their mixed types such as: rutile-cellulosic (RC) rutile-basic (RB) bar electrodes. Rutile bar electrodes are used most often in practice. They have a very stable electric arc and this provides easy handling for the welder. They have very good striking and restriking properties. They are weldable with direct and alternating current and suitable for all welding positions except in the vertical down position (PG). High alloyed bar electrodes and thick coated (RR) can only be used to a limited extent in vertical up (PF) and overhead (PD, PE) positions. They have compact and easily removable slag, the seam is finely rippled and smooth; except with high alloyed they do not need to be rebaked. The disadvantages are insufficient toughness at low temperatures and a limit in the wall thickness. They cannot be used for energized components and for higher carburized steels. The hydrogen content can reach up to 0 ml/100 g weld metal. Basic coated bar electrodes have excellent toughness properties, above all in the low temperature area, they can be welded with no limit to the wall thickness. They can be welded in all welding positions except vertical down (also high alloyed). They can also be used for higher carburized steels and after rebaking have a very low hydrogen content of <5 ml/100 g weld metal. The disadvantages are an unstable electric arc, a somewhat worse slag detachability and a somewhat roughly rippled and cambered welding seam. Apart from a few exceptions they can only be welded with direct current plus pole and, except for high alloyed, must be rebaked before welding. A special variant is the double-clad electrode with an inner rutile and an outer basic coat. Essentially they unite the advantages of both coating types. Cellulose bar electrodes are specially Cellulose developed bar electrodes for are the vertical specially down developed welding for the of large-diameter vertical down welding pipes. of Because large-diameter of the high cellulose pipes. content Because and of the a high high hydrogen cellulose content in and the a coating high hydrogen a sharp and content intensive the coating electric a arc sharp is created and intensive which electric enables arc rapid is and created economic which welding enables in rapid the vertical and economic down position. welding Use in the is limited vertical by down the position. wall thickness Use is and the temperature. For higher requirements basic vertical down electrodes must be used. Mixed types always have a rutile coating with either a cellulosic (RC) or basic proportion (RB). Because of the cellulose content the bar electrode can also be used in the vertical down position, because of the basic content both the weldability in the root and in the constrained position at the pipe improves and also the impact strength at minus temperatures. ALUNOX Manual A

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109 Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 8 0 RC 11 E1 A E01 ESR 11 Rutile-cellulosic coated electrode for welding unalloyed and low alloyed steels Application Universal electrode for installation, shop and repair welding with good suitability for vertical down welding positions. Good gap bridging. Especially suitable for spot welding. Suitable for galvanized, primered and slightly rusty parts. Smooth, slightly concave seams with notchless transition to the base material. Slag partially self releasing. Easy striking and restriking. Chemical composition (typical values in %) C 0.08 Si 0.0 Mn 0.50 Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, P15TR1-P5TR1, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB, shipbuilding steels: A, B, A, A ASTM A 10 Gr. A, B; A 8 Gr. A, C; A 85 Gr. A, B, C; A 501, Gr. B; A 57, Gr. 58, 5; A, Gr. A, C; A 711 Gr. 101; API 5 L Gr. B, X, X5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF, PG Amperage [A].0 mm.5 mm mm mm Rebaking not necessary, in exceptional cases 1h/110 C Approvals TÜV, DB, BV, TSE, CE 5.0 mm Impact strength ISO-V(J) 0 C Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual 107 A

110 ESR 1 Thick rutile-coated bar electrode for welding unalloyed and low alloyed steels. Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 0 RR 1 E1 A E01 Application Versatile bar electrode with outstanding welding characteristics for all positions except vertical down. Extremely easy handling so also suitable for inexperienced welders. Especially suitable for spot welding jobs. Easy striking and restriking. Smooth and stable arc. Regular drop transfer. Very smooth and clean seams with notchless transfer to the base material. Self releasing slag. Chemical composition (typical values in %) C Si Mn Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, P15TR1-P5TR1, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB, L15NB, L15MB, shipbuilding steels: A, B, A, A ASTM A 10 Gr. A, B; A 8 Gr. A, C; A 85 Gr. A, B, C; A 501, Gr. B; A 57, Gr. 58, 5, 70; A, Gr. A, C; A 711 Gr. 101; API 5 L Gr. B, X, X5, X0 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Impact strength ISO-V(J) 0 C 55 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm.5 mm mm mm mm Rebaking not necessary, in exceptional cases 1h/110 C Approvals TÜV, DB, ABS, BV, CWB, TL, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

111 Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 5 0 R 1 E1 A E01 ESR 1M Rutile-coated electrode for welding unalloyed and low alloyed steels Application Versatile bar electrode with outstanding welding characteristics for all positions except vertical down. To be preferred for welding thin sheets in light steel construction. Excellent seam aspect. Easy striking and restriking. Easily removable slag. Smooth and stable arc. Chemical composition (typical values in %) C 0.08 Si 0.5 Mn 0.50 Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, P15TR1-P5TR1, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB ASTM A 10 Gr. A, B; A 8 Gr. A, C; A 85 Gr. A, B, C; A 501, Gr. B; A 57, Gr. 58, 5; A, Gr. A, C; A 711 Gr. 101; API 5 L Gr. B, X, X5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm.5 mm mm mm Rebaking not necessary, in exceptional cases 1h/110 C Approvals TÜV, TSE 5.0 mm Impact strength ISO-V(J) 0 C Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 10

112 ESR 5 Rutile-coated bar electrode for welding unalloyed and low alloyed steels Standard EN ISO 50-A EN ISO 50-B AWS / ASME / SFA 5.1 E 8 RB 1 E0 A E01 Application Bar electrode with particular suitability for pipe root welding and in constrained positions in pipeline, boiler and container construction. Especially suitable as weld pool backing during submerged-arc welding. Because of its low Si content especially suitable for subsequent galvanizing or enamelling. Chemical composition (typical values in %) C 0.0 Si 0.0 Mn 0.0 Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, S75N-S55N, S75M-S55M, P5GH-P55GH, P15TR1- P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB ASTM A 10 Gr. A, B; A 8 Gr. A, C; A 85 Gr. A, B, C; A 1 Gr. A, B, D, G; A 501 Gr. B; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C, D; A Gr. A, B, C; A 711, Gr. 101; API 5 L Gr. B, X, X5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength aw/u (as welded/ untreated) Elongation at rupture A5(%) 5 Impact strength ISO-V(J) +0 C -0 C Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm mm mm mm mm Rebaking not necessary Approvals TÜV, DB, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual

113 Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 8 B 1 H10 E1 E701H8 ESB Basic-coated double-clad electrode for welding unalloyed and low alloyed steels Application Versatile bar electrode for installation, shop and repair welding. Smooth and clean seams with notchless transfer to the base material. Very good gap bridging. The double cladding gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions and in the root. Weld seams are X-ray proof. Chemical composition (typical values in %) C 0.0 Si 0.50 Mn 1.00 Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S55N, S75M-S55M, P5GH- P55GH, P55N, P85NH-P55NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB, GE00-GE0, shipbuilding steels: A, B, D, A -D ASTM A 10 Gr. A, B, C; A 181 Gr. 0, 70; A 8 Gr. A, C; A 85 Gr. A, B, C; A 1 Gr. A, B, C, D, E, F, G; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C; A Gr. A, B, C; A 78 Gr. A, B; API 5 L Gr. B, X, X5 Please note the permissible operating temperatures for the weld filler and the base material 0 1 Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Impact strength ISO-V(J) -0 C 50 5 Amperage [A].5 mm. mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, DNV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 111

114 ESB 8 Basic-coated bar electrode for welding unalloyed and low alloyed steels Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E B H10 E18 A H10 E7018H8 Application Bar electrode for crack-free and tough weld joints. Particularly suitable for welding dynamically loaded components. Can be used in ship-, tank- and boiler construction. Approx. 115% metal recovery. Smooth and clean seams with notchless transfer to the base material. Good gap bridging. Good for welding in constrained positions and in the root. Weld seams are X-ray proof. Suitable for buffer layers on higher carburized steels. Chemical composition (typical values in %) C Si Mn Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH- P55GH, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L15MB, GE00-GE00, shipbuilding steels: A, B, D, A -D ASTM A 10 Gr. A, B, C; A 181 Gr. 0, 70; A 8 Gr. A, C; A 85 Gr. A, B, C; A 1 Gr. A, B, C, D, E, F, G; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. A, B; API 5 L Gr. B, X, X5, X5, X0 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Impact strength ISO-V(J) -0 C -0 C Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, ABS, BV, CWB, DNV, GL, LR, RINA, TL, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual

115 Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E B H5 E18 A H5 E7018 1H ESB 5 Basic-coated bar electrode for welding unalloyed and low alloyed steels Application Bar electrode for crack-free and tough weld joints, also suitable for C-steels up to 0.% C. Weld metal with very low hydrogen content; non-ageing. Approved for track joint welding. Very good gap bridging. The double cladding (up to Ø.mm) gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. Weld seams are X-ray proof. Chemical composition (typical values in %) C Si Mn Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH- P55GH, P55N, P15NL, P75NL1-P55NL1, P5NL, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L15MB, GE00-GE00, shipbuilding steels: A, B, D, E, A -E ASTM A 10 Gr. A, B, C; A 181 Gr. 0, 70; A 8 Gr. A, C; A 85 Gr. A, B, C; A 50 Gr. LF1; A 1 Gr. A, B, C, D, E, F, G; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. A, B; API 5 L Gr. B, X, X5, X5, X0 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment aw/u (as welded/ untreated) Yield strength 500 Tensile strength 580 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, ABS, BV, CWB, DNV, GL, LR, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton Elongation at rupture A5(%) kg/carton Impact strength ISO-V(J) - C -0 C A ALUNOX ALUNOX Manual Manual 11

116 ESC 0 Bar electrode for welding unalloyed and low alloyed steels cellulosic coated Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 5 C 1 E10 A E010 Application Medium thick coated cellulosic electrode for vertical down welding in pipeline construction and general piping construction. Root welding in vertical down and vertical up position with direct current negative pole. In addition to be used for all welding jobs where high economic efficiency caused by high welding velocity is to be combined with great penetration. Chemical composition (typical values in %) C 0.10 Si 0.0 Mn 0.50 Important base materials /most important areas of application L10GA-L0GA, L5NB-L0NB, L5MB-L0MB API 5 L Gr. A, B, X, X5, for root welds up to API 5 L Gr. X80 (L555) Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength aw/u (as welded/ untreated) Elongation at rupture A5(%) Impact strength ISO-V(J) -0 C -0 C 0 50 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF, PG Amperage [A].0 mm Rebaking not permitted. mm mm mm Approvals TÜV, DB, ABS, BV, CWB, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

117 Standard EN ISO 50-A EN ISO 50-B AWS A5.5 E Mo C 1 E10-1M A E7010 A1 ESC 70 Bar electrodes for welding unalloyed and low alloyed high strength steels cellulosic coated Application Medium thick coated cellulosic electrode for the vertical down welding of unalloyed and low alloyed higher tensile steels in pipeline construction and general piping construction. Particularly suitable for hot pass, filling and upper layers. Over and above that to be used for all welding jobs where high economic efficiency caused by high welding velocity is to be combined with great penetration. 0 1 Chemical composition (typical values in %) C Si Mn Mo Important base materials /most important areas of application L10GA-L0GA, L5NB-L15NB, L5MB-L15MB API 5 L Gr. A, B, X, X5, X0 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF, PG Amperage [A].5 mm Rebaking not permitted. mm mm mm Impact strength ISO-V(J) -0 C -0 C Approvals 8 Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 115

118 11 ALUNOX Manual

119 Standard EN ISO 50-A EN ISO 50-B AWS A5.1 E 8 0 RC 11 E1 A E01 ESR 11 Rutile-cellulosic coated electrode for welding unalloyed and low alloyed steels Application Universal electrode for installation, shop and repair welding with good suitability for vertical down welding positions. Good gap bridging. Especially suitable for spot welding. Suitable for galvanized, primered and slightly rusty parts. Smooth, slightly concave seams with notchless transition to the base material. Slag partially self releasing. Easy striking and restriking. Chemical composition (typical values in %) C 0.08 Si 0.0 Mn 0.50 Important base materials /most important areas of application S5JR-S55JR, S5JO-S55JO, P15TR1-P5TR1, P15GH-P5GH, L5NB-L0NB, L5MB-L0MB, shipbuilding steels: A, B, A, A ASTM A 10 Gr. A, B; A 8 Gr. A, C; A 85 Gr. A, B, C; A 501, Gr. B; A 57, Gr. 58, 5; A, Gr. A, C; A 711 Gr. 101; API 5 L Gr. B, X, X5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Yield strength Tensile strength Elongation at rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF, PG Amperage [A].0 mm.5 mm mm mm Rebaking not necessary, in exceptional cases 1h/110 C Approvals TÜV, DB, BV, TSE, CE 5.0 mm Impact strength ISO-V(J) 0 C Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 117

120 EM 170 Basic coated bar electrode for crack-free and tough weld joints on steels up to 500 MPa yield strength Standard EN ISO 50-A EN ISO 50-B AWS A5.5 E 50 Mn1Ni B H5 E5518-N A H5 E018-GH Application Bar electrode for crack-free and tough weld joints on low alloyed high strength steels and fine grain structural steels. Weld metal is of particular metallurgical purity and with very low hydrogen content. The double cladding with dimensions.5 and. gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. The weld seams are X-ray proof. Chemical composition (typical values in %) C Si Mn Ni Important base materials /most important areas of application S50J0, S75N-S0N, S75NL-S0NL, S75M-S0M, S75ML-S0ML, P75N-P0N, P75NL1-P0NL1, P75NL-P0NL, P75M-P0M, P75ML1-P0ML1, P75ML-P0ML, S0Q-S500Q, S0QL-S500QL, S0QL1-S500QL1, L5NB-L15NB, L5MB-L85MB, L0QB-L85QB ASTM A 10 Gr. A, B, C; A 181 Gr. 0, 70; A 8 Gr. A, C; A 85 Gr. A, B, C; A 50 Gr. LF1; A 1 Gr. A, B, C, D, E, F, G; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C, D, E; A Gr. A, B, C; A 78 Gr. A, B; API 5 L Gr. B, X, X5, X5, X0, X5, X70 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength Elongation at treatment rupture aw/u A5(%) (as welded/ untreated) Impact strength ISO-V(J) -0 C 0 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm 0-0. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

121 Standard EN ISO 50-A EN ISO 50-B AWS A5.5 E Ni B H5 E18-N5A H5 E8018 C1H EM 171 Basic coated bar electrode for weld joints on nickel alloyed steels tough at sub-zero Application Bar electrode for crack-free and tough weld joints on fine grain structural steels and especially on steels tough at sub-zero. The weld metal is of particular metallurgical purity and with very low hydrogen content. Because of its cracking resistance can also be used under difficult operating conditions such as dynamic loads and low ambient temperatures. Suitable for welding storage tanks and pipelines with operating temperatures down to -80 C. The double cladding with dimensions.5 and. mm gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. The weld seams are X-ray proof. Chemical composition (typical values in %) C Si Mn Ni Important base materials /most important areas of application S75N-S0N, S75NL-S0NL, S75M-S0M, S75ML-S0ML, P75N-P0N, P75NL1- P0NL1, P75NL-P0NL, P75M-P0M, P75ML1-P0ML1, P75ML-P0ML, L5NB- L15NB, L5MB-L50MB, L0QB-L50QB, 10Ni1, 1Ni1, 1MnNi ASTM A 10 Gr. A, B, C; A 181 Gr. 0, 70; A 85 Gr. A, B, C; A 50 Gr. LF1; A 1 Gr. A, B, C, D, E, F, G; A 51 Gr. 55, 0, 5, 70; A 57 Gr. 58, 5, 70; A 588 Gr. A, B; A Gr. A, C, D, E; A Gr. A, B, C; A 78 Gr. A, B; API 5 L Gr. B, X, X5, X5, X0, X5 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength Elongation at treatment rupture aw/u A5(%) (as welded/ untreated) Impact strength ISO-V(J) -0 C Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm Rebaking h/50 C, if necessary Approvals.0 mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual A

122 EM 180 Basic coated bar electrode for crack-free and tough weld joints on steels up to 700 MPa yield strength Standard EN ISO 1875-A EN ISO 1875-B AWS A5.5 E MnNiCrMo B H5 E718-G A H5 E11018 GH Application Bar electrode for crack-free and tough weld joints on low alloyed high strength steels and fine grain structural steels. Weld metal is of particular metallurgical purity and with very low hydrogen content. Because of its cracking resistance suitable even under difficult operating conditions such as dynamic loads, high and low ambient temperatures for steel structures, pressure vessels, tanks, boilers and special applications. The double cladding with dimensions.5 and. gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. The weld seams are X- ray proof. Chemical composition (typical values in %) C 0.0 Si 0.0 Mn 1.50 Ni.00 Cr 0.50 Mo 0.0 Important base materials /most important areas of application S550Q-S0Q, S550QL-S0QL, N-A-XTRA M550-M700, PAS , alform 550M-700M ASTM A 51 Gr. F, H, Q; A 70 Gr. 100 Type B, E, F, H, Q, HPS 100W; A 85 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength Elongation at treatment rupture aw/u A5(%) (as welded/ >18 untreated) Impact strength ISO-V(J) -0 C 50 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual

123 Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E Mo R 1 E1-1M E801-G EM 01 Rutile-coated electrode for welding creep resistant 0.5% Mo-steels Application Bar electrode for welding creep resistant steels in pressure vessel, boiler and pipeline construction with operating temperatures up to 500 C. Easy striking and restriking. Very smooth and clean seams with notchless transfer to the base material. Preheat, interpass temperature and heat treatment after welding corresponding to the base material. 0 1 Chemical composition (typical values in %) C Si Mn Mo Important base materials /most important areas of application 1Mo, S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M- S0M, P5GH-P55GH, P15NL, P5NL, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L50MB ASTM A 18 Gr. F1; A 5 Gr. P1; A 5 Gr. B, C; A 10 Gr. B, C; A 8 Gr. B, C, D; A 501 Gr. B; A 51 Gr. 1018; A 51 Gr. 0, 5, 70; A 57 Gr. ; A Gr. A, D; A Gr. A, B, C; A 78 Gr. A, B; API 5 L B, X, X5, X0, X5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength Elongation at treatment rupture aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Impact strength ISO-V(J) 0 C 80 5 Amperage [A].5 mm. mm mm Rebaking not necessary, in exceptional cases 1h/110 C Approvals 8 Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 11

124 EM 0 Basic-coated bar electrode for welding creep resistant 0.5% Mo-steels Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E Mo B H10 E18-1M H10 E7018 A1H8 Application Bar electrode for welding creep resistant steels in pressure vessel, boiler and pipeline construction with operating temperatures up to 500 C. The double cladding with dimensions.5 and. mm gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. Weld seams are X-ray proof. Preheat, interpass temperature and heat treatment after welding corresponding to the base material. Chemical composition (typical values in %) C Si Mn Mo Important base materials /most important areas of application 1Mo, 0MnMoNi-5, S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N- S0N, S75M-S0M, P5GH-P55GH, P15NL, P5NL, P55N, P85NH-P0NH, P15TR1- P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L5MB-L50MB, GE00- GE0 ASTM A 18 Gr. F1; A 5 Gr. P1; A 5 Gr. B, C; A 10 Gr. B, C; A 8 Gr. B, C, D; A 501 Gr. B; A 51 Gr. 1018; A 51 Gr. 0, 5, 70; A 57 Gr. ; A Gr. A, D; A Gr. A, B, C; A 78 Gr. A, B; API 5 L B, X, X5, X0, X5 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength Elongation at treatment rupture aw/u A5(%) (as welded/ untreated) Impact strength ISO-V(J) 0 C 15 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

125 Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E CrMo1 R 1 E551-1CM E801-G EM 11 Rutile-coated electrode for welding similarly alloyed creep resistant steels Application Bar electrode for welding creep resistant steels in pressure vessel, boiler and pipeline construction with operating temperatures up to 550 C. Easy striking and restriking. Very smooth seams with notchless transfer to the base material. For greater wall thicknesses the basic coated EM 1 is recommended. Preheat, interpass temperature and heat treatment after welding corresponding to the base material. 0 1 Chemical composition (typical values in %) C Si Mn Cr Mo Important base materials /most important areas of application CrMo-5, CrMo5, CrMo, CrMo5, CrMoV, CrMo-, CrMo-, 1.75 GCrMo5- ASTM A 18 Gr. F1; A 1 Gr. T1; A Gr. WP11; A 5 Gr. P11, P1; A Gr. F11, F1 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength treatment h/80 C Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm Rebaking not necessary, in exceptional cases 1h/110 C Elongation at rupture A5(%) Impact strength ISO-V(J) 0 C Approvals 8 Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 1

126 EM 1 Basic-coated bar electrode for welding similarly alloyed creep resistant steels such as 1CrMo-5 Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E CrMo1 B H10 E5518-1CM H10 E8018 BH8 Application Bar electrode for welding creep resistant steels in pressure vessel, boiler and pipeline construction with operating temperatures up to 570 C. The double cladding with dimensions.5 and. mm gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. Weld seams are X-ray proof. Preheat, interpass temperature and heat treatment after welding corresponding to the base material. Chemical composition (typical values in %) C Si Mn Cr Mo Important base materials /most important areas of application CrMo-5, CrMo5, CrMo, CrMo5, CrMoV, CrMo-, CrMo-, 1.75 GCrMo5-, similarly alloyed case hardening, tempering and nitriding steels ASTM A 18 Gr. F1; A 1 Gr. T1; A Gr. WP11; A 5 Gr. P11, P1; A Gr. F11, F1 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength treatment h/80 C Elongation at rupture A5(%) Impact strength ISO-V(J) 0 C 100 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

127 Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E CrMo B H10 E18-C1M H10 E018 BH8 EM Basic-coated bar electrode for welding creep resistant and high-pressure hydrogen resistant steels Application Bar electrode for welding creep resistant and high-pressure hydrogen resistant steels in pressure vessel, boiler and pipeline construction with operating temperatures up to 00 C. The double cladding with dimensions.5 and. mm gives the electrode a stable, directed electric arc; it is therefore good for welding in constrained positions. Weld seams are X-ray proof. Preheat, interpass temperature and heat treatment after welding in accordance with the base material. Chemical composition (typical values in %) C 0.08 Si 0.0 Mn 0.0 Cr.0 Mo 1.00 Important base materials /most important areas of application CrMo-10, CrMo11, CrMo-, CrMo-10, 1.75 CrMo7, 1.77 G17CrMo-10, 1.78 G1CrMo-10, similarly alloyed case hardening, tempering and nitriding steels ASTM A 18 Gr. F; A 1 Gr. T; A Gr. WP; A 5 Gr. P; A Gr. F Please note the permissible operating temperatures for the weld filler and the base material. 0 1 Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength treatment h/70 C 50 0 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm mm Rebaking h/50 C, if necessary Approvals.0 mm Elongation at rupture A5(%) 0 Impact strength ISO-V(J) 0 C Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 15

128 EM 5 Basic-coated bar electrode for welding creep resistant steels of type 5% Cr 0.5% Mo Standard EN ISO 580-A EN ISO 580-B AWS A5.5 E CrMo5 B H10 E5515-5CM H10 E8015 BH8 Application Bar electrode for welding creep resistant steels. The weld metal is adapted to X1CrMo5 steel and possesses corresponding high-pressure hydrogen and heat resistance and long-term creep rupture strength. Typical areas of use: petrochemicals and hydrogenation plants in the chemical industry. Suitable for pressure vessel and boiler construction with operating temperatures up to 00 C. Preheat, interpass temperature and heat treatment after welding in accordance with the base material. Chemical composition (typical values in %) C 0.07 Si 0.70 Mn 0.80 Cr 5.50 Mo 0.0 Important base materials /most important areas of application 1.7 X1CrMo5, 1.7 GX1CrMo5 ASTM A 1 Gr. T5; A 5 Gr. P5 Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength treatment h/70 C Elongation at rupture A5(%) 5 Impact strength ISO-V(J) 0 C 100 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm 0-0. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX ALUNOX Manual Manual

129 Standard EN ISO 580-A EN ISO 580-B AWS A5.5 EM 1 Basic-coated bar electrode for high-temperature resistant steels of type % Cr-1% Mo-V-Nb-N E CrMo1 B H 5 E15-C1MV H5 E018 BH Application Bar electrode for welding high-temperature resistant, quenched and tempered % Cr-steels in power plant and turbine construction as well as in the chemical industry for operating temperatures up to 50 C. The bar electrode is easy to weld in all positions except vertical down. Preheat and interpass temperature C. 0 1 Chemical composition (typical values in %) C Si Mn Cr Mo Ni 0.0 V 0.0 N Nb Important base materials /most important areas of application 1.0 X10CrMoVNb-1, 1.0 X1CrMoVNbN10-1 ASTM A 18 Gr. F1; A 1 Gr. T1; A Gr. WP1; A 5 Gr. P1; A Gr. FP1; A 87 Gr. 1 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat 0. yield strength Tensile strength treatment h/70 C > Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A]. mm.0 mm Rebaking h/50 C, if necessary Approvals Elongation at rupture A5(%) Impact strength ISO-V(J) 0 C -0 C Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 17

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131 Standard EN ISO 581-A EN ISO 581-B AWS A5. EI 07B Basic-coated bar electrode for welding steels of different characteristics and for cladding on ferritic steels. E 18 8 Mn B E07-15 mod. Application Basic-coated bar electrode for difficult to weld steels, austenite-ferrite dissimilar joints, hardfacings and buffer layers. Can also be used for joint welding of manganese steel (e.g. X10Mn1). Stainless, fully austenitic chromium-nickel-manganese weld metal, low delta ferrite content possible. High crack resistance. Scale resistant up to 850 C. The hardness of the weld metal is approx. 180 HB; after work hardening by shock up to 50 HB. Maximum operating temperature for dissimilar joints 00 C, at higher temperatures or heat treatments use electrode AX-8. Chemical composition (typical values in %) C 0.1 Si 0.50 Mn 5.00 Cr 1.00 Ni.00 Important base materials /most important areas of application Hard to weld steels, austenitic manganese steels such as X10Mn1 (1.01), high strength unalloyed and alloyed tempering and armouring steels with and to each other, heat-resistant steels up to 850 C, ferrite-austenite joints (dissimilar joints) Please note the permissible operating temperatures for the weld filler and the base material. 0 1 Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ 00 5 untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Impact strength ISO-V(J) 0 C 70 5 Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 1

132 EI 07R Rutile-coated bar electrode for welding steels of different characteristics and for cladding on ferritic steels. Standard EN ISO 581-A EN ISO 581-B Workpiece no. AWS A5. E 18 8 Mn R E07-1 mod. Application Rutile-coated bar electrode for difficult to weld steels, austenite-ferrite dissimilar joints, hardfacings and buffer layers. Can also be used for joint welding of manganese steel (e.g. X10Mn1). Stainless, fully austenitic chromium-nickel-manganese weld metal, low delta ferrite content possible. High crack resistance. Scale resistant up to 850 C. The hardness of the weld metal is approx. 180 HB; after work hardening by shock up to50 HB. Maximum operating temperature for dissimilar joints 00 C, at higher temperatures or heat treatments use electrode AX-8. Chemical composition (typical values in %) C Si Mn Cr Ni Important base materials /most important areas of application Hard to weld steels, austenitic manganese steels such as X10Mn1 (1.01), high strength unalloyed and alloyed tempering and armouring steels with and to each other, heat-resistant steels up to 850 C, ferrite-austenite joints (dissimilar joints) Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ 50 0 untreated) Impact strength ISO-V(J) 0 C 80 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm.5 mm Rebaking h/50 C, if necessary Approvals. mm mm Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

133 Standard EN ISO 581-A EN ISO 581-B AWS A5. E 1 L R 1 ES08L-1 E08L-1 EI 08L Rutile-coated bar electrode for austenitic Cr-Ni steels/cast steel types of similar characteristics Application Bar electrode for welding stainless austenitic Cr-Ni steel or cast steel with very low carbon content and stainless or heat resistant Cr-steel / cast steel. Suitable for welding stainless steel tanks, valves, pipes and linings in the chemical and food industries. For operating temperatures up to 50 C. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, finely rippled weld surface, easily removable slag. Chemical composition (typical values in %) C Si Mn Cr Ni Important base materials /most important areas of application 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10, 1.1 GX10CrNi18-8 ASTM A 1 Gr. TP0L, TP7; A 0 Gr. 0L, 7; A 1 Gr. TP1, TP7; A 0 Gr. WP0L, WP0, WP1, WP7; A 51 Gr. CPF, CPF8; A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment aw/u (as welded/ untreated) Tensile strength 00 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Elongation A5(%) 8 Impact strength ISO-V(J) 0 C Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 11

134 EI 0L Rutile-coated bar electrode for welding ferrite-austenite joints (dissimilar joints) and stainless claddings. Standard EN ISO 581-A EN ISO 581-B AWS A5. E 1 L R 1 ES0L-1 E0L-1 Application Bar electrode for welding steels of different characteristics (dissimilar joints) and stainless claddings. The weld metal consists of austenite with approx. 15% delta ferrite. Overlays on unalloyed and low alloyed steels are already corrosion resistant in the first layer. Highest operating temperature with dissimilar joints 00 C. At higher temperatures the AX-8 electrode must be used. Regular drop transfer, good coverage of the weld zones, finely rippled weld surface, easily removable slag, easy striking and restriking. Chemical composition (typical values in %) C 0.0 Si 0.0 Mn 1.00 Cr.00 Ni 1.00 Important base materials /most important areas of application Stainless ferritic Cr steels and austenitic CrNi steels with each other and with unalloyed steels (dissimilar joints), hard to weld and unalloyed and alloyed tempering steels, Mn steels and for the first layer of chemically resistant CrNi weld coatings. Please note the permissible operating temperatures for the weld filler and the base material Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u (as welded/ untreated) 00 A5(%) 5 Impact strength ISO-V(J) 0 C 0 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, BV, TSE, CE. mm mm Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

135 Standard EN ISO 581-A EN ISO 581-B AWS A5. EI 0Mo L Rutile-coated bar electrode for welding ferrite-austenite joints (dissimilar joints) and stainless claddings. E 1 L R 1 ES0LMo-1 E0MoL-1 Application Bar electrode for welding steels of different characteristics (dissimilar joints) and stainless claddings. The weld metal consists of austenite with approx. 15% delta ferrite. Overlays on unalloyed and low alloyed steels are already corrosion resistant in the first layer. Highest operating temperature with dissimilar joints 00 C. At higher temperatures the AX-8 electrode must be used. Regular drop transfer, good coverage of the weld zones, finely rippled weld surface, easily removable slag, easy striking and restriking. Chemical composition (typical values in %) C 0.0 Si 0.0 Mn 0.70 Cr.50 Ni 1.50 Mo.50 Important base materials /most important areas of application Stainless ferritic Cr steels and austenitic CrNi steels with each other and with unalloyed steels (dissimilar joints), hard to weld and unalloyed and alloyed tempering steels, Mn steels and for the first layer of chemically resistant CrNiMo weld coatings. Please note the permissible operating temperatures for the weld filler and the base material 0 1 Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ 00 0 untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Impact strength ISO-V(J) 0 C 50 5 Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, DB, BV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 1

136 EIS 0 Rutile-coated bar electrode for heat resistant steels and cast steel types of identical/similar characteristics Standard EN ISO 581-A EN ISO 581-B AWS A5. E 1 R 5 ES0- E0-1 Application Bar electrode with 10% metal recovery for welding heat resistant chromium- and chromium- nickel steels / cast steel. The weld metal consists of austenitic steel with approx. 8% delta ferrite. Suitable for operating temperatures up to 1000 C, scale-resistant to 1050 C. Preferred in the case of attacks by oxidising and nitrogenous gases and those with low oxygen content. The weld metal is not resistant in sulphureous acids. Also suitable for joints with unalloyed and low alloyed steels and claddings on unalloyed and low alloyed steels. Higher current load possible because of unalloyed core rod. Chemical composition (typical values in %) C 0.10 Si 0.0 Mn 0.80 Cr.00 Ni 1.00 Important base materials /most important areas of application 1.88 X15CrNiSi0-1, 1.8 X1CrNi-1, 1.8 GX0CrNiSi-10, 1.71 X10CrAlSi7, 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, GX0CrSi7, 1.70 GX0CrSi17 ASTM A 17 Gr. 0; A 7 Gr. 0; A 1 Gr. 0; A 0 Gr. WP0; A 7 Gr. 0; A 580 Gr. 0 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ 00 0 untreated) Impact strength ISO-V(J) 0 C 70 Type of current/polarity/welding positions PA; PB; PC Amperage [A].0 mm mm Rebaking h/50 C, if necessary Approvals. mm mm Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX ALUNOX Manual Manual Packet/ carton kg/carton

137 Standard EN ISO 581-A EN ISO 581-B AWS A5. E 5 0 R 1 ES10-1 E10-1 EI 10 Rutile-coated bar electrode for heat resistant steels and cast steel types of identical/similar characteristics Application Bar electrode for welding heat resistant chromium- and chromium- nickel steels / cast steel. The weld metal consists of fully austenitic steel. Suitable for operating temperatures up to 100 C, scaleresistant to 150 C. Preferred in the case of attacks by oxidising and nitrogenous gases and those with low oxygen content. The weld metal is not resistant in sulphureous acids. Because of the risk of brittling, the temperature range between 50 C- 00 C should be avoided. Ensure low heat input when welding. Chemical composition (typical values in %) C 0.10 Si 0.50 Mn 1.50 Cr 5.00 Ni 0.00 Important base materials /most important areas of application 1.81 X15CrNiSi5-0, 1.85 X8CrNi5-1, 1.81 X15CrNiSi5-, 1.8 GX5CrNiSi0-1, 1.87 GX0CrNiSi5-1, 1.80 GX15CrNi5-0, 1.8 X0CrNi5-1, 1.88 GX0CrNiSi5-0, 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, 1.7 X10CrAlSi5, GX0CrSi7, 1.70 GX0CrSi17 ASTM A 18 Gr. F10; A 1 Gr. 10, 10S, 1; A 0 Gr. TP10S; A 580 Gr. 10, 10S, 1; Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment aw/u (as welded/ untreated) Tensile strength 00 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Elongation A5(%) 0 Impact strength ISO-V(J) 0 C Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals 8 Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX ALUNOX Manual Manual 15

138 EI 1 Rutile-coated bar electrode for difficult to weld steels, dissimilar joints, wear resistant overlays and buffer layers. Standard EN ISO 581-A EN ISO 581-B AWS A5. E R 1 ES1-1 E1-1 Application Bar electrode for welding steels of different characteristics and for cladding. The weld metal consists of ferritic-austenitic Cr-Ni steel with high ferrite content. The weld metal possesses high crack resistance, so also suitable for hard to weld steels and tension-equalizing buffer layers on materials susceptible to cracks. Joint welding with thin stringer beads, fillet weld if possible only single layer. Can also be used for welding galvanized sheets. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, finely rippled weld surface, easily removable slag. Work hardenable. Chemical composition (typical values in %) C 0.10 Si 1.00 Mn 1.00 Cr.00 Ni Important base materials /most important areas of application Hard to weld base materials such as high carbon content steel, tool steel, spring steel, manganese steel, case hardening steel, armour steel to each other or with other steels. For overlays and repairs to tracks, shafts, clutches, wheels, hot working tools, press, trimming and punching dies. Hardness after work hardening: approx. 0 HB Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u (as welded/ untreated) 750 A5(%) 5 Impact strength ISO-V(J) 0 C 50 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm mm 0-80 Rebaking h/50 C, if necessary. mm mm Approvals TÜV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet ALUNOX Manual Packet/ carton kg/carton

139 Standard EN ISO 581-A EN ISO 581-B AWS A5. E 1 1 L R 1 ES1L-1 E1L-1 EI 1l Rutile-coated bar electrode for austenitic Cr-Ni-Mo steels / cast steel types of similar characteristics Application Bar electrode for welding austenitic, stainless Cr-Ni-Mo steel / cast steel with low carbon content. For operating temperatures up to 00 C. Particularly suitable for welding stainless chemical tanks and pipes in the chemical, textile, paint and paper industries. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, finely rippled weld surface, easily removable slag. Chemical composition (typical values in %) C Si Mn Cr Ni Mo.50 Important base materials /most important areas of application 1.01 X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNi Mo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFMN; A 0 Gr. WP1, WP1L, WP1LN. A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment aw/u (as welded/ untreated) Tensile strength 00 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, BV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton Elongation A5(%) 5 kg/carton Impact strength ISO-V(J) 0 C A ALUNOX ALUNOX Manual Manual 17

140 EI 18 Rutile-coated bar electrode for stabilized austenitic Cr-Ni-Mo steels/cast steel types of similar characteristics Standard EN ISO 581-A EN ISO 581-B AWS A5. E 1 1 Nb R 1 ES18-1 E18-1 Application Bar electrode for welding stabilized austenitic, stainless Cr-Ni-Mo-steel / cast steel. For operating temperatures up to 00 C. Suitable for welding stainless tanks, valves and pipes in the chemical, textile, paint and paper industries. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, easily removable slag. Chemical composition (typical values in %) C Si Mn Cr Ni Mo.50 Nb 0.5 Important base materials /most important areas of application 1.01 X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNi Mo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFMN; A 0 Gr. WP1, WP1L, WP1LN. A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment aw/u (as welded/ untreated) Tensile strength 00 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Elongation A5(%) Impact strength ISO-V(J) 0 C 70 Amperage [A].0 mm.5 mm mm mm Rebaking h/50 C, if necessary Approvals TÜV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

141 Standard EN ISO 581-A EN ISO 581-B AWS A5. EI 7 Rutile-coated bar electrode for stabilized austenitic Cr-Ni steels/cast steel types of similar characteristics E 1 Nb R 1 ES7-1 E7-1 0 Application Bar electrode for welding stabilized stainless austenitic, chromium-nickel steel / cast steel and stainless and heat resistant chromium steel / cast steel. For operating temperatures up to 00 C. Particularly suitable for welding stainless tanks, valves and pipes in the dairy, beverage, food and chemical industries. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, finely rippled weld surface, easily removable slag. Chemical composition (typical values in %) C 0.0 Si 0.80 Mn 0.80 Cr 1.00 Ni Nb 0.5 Important base materials /most important areas of application 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10, 1.1 GX10CrNi18-8 ASTM A 1 Gr. TP0L, TP7; A 0 Gr. 0L, 7; A 1 Gr. TP1, TP7; A 0 Gr. WP0L, WP0, WP1, WP7; A 51 Gr. CPF, CPF8; A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7 Please note the permissible operating temperatures for the weld filler and the base material. 1 Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ 00 5 untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].0 mm mm Rebaking h/50 C, if necessary. mm mm Impact strength ISO-V(J) 0 C Approvals TÜV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 1

142 EIS 10 Basic-coated bar electrode for stainless steels and cast steel types of identical/similar characteristics Standard EN ISO 581-A EN ISO 581-B AWS A5. E (1) B ES10-15 E10-15 Application Bar electrode with approx. 10% metal recovery for welding ferritic and martensitic chromium steels /cast steel. Also for corrosion and abrasion resistant claddings on gas and water fittings up to an operating temperature of 50 C, scale resistant to 850 C. Preheating and interpass temperature depending on base material from C. After welding, heat treat at approx. 750 C. Chemical composition (typical values in %) C Si Mn Cr Ni Important base materials /most important areas of application XCr1, 1.00 X1Cr 1, GX1Cr1, 1.01 X0Cr1, 1.0 X15Cr1 ASTM A 17 Gr. 0, 0; A 0 Gr. 10, 10S; A 1 Gr. 0, 10, 0; A 580 Gr. 0, 10, 0; A 88 UNS 1000 Corrosion-proof overlays: all un- and low-alloyed base materials suitable for welding. Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation 1h/750 C 70 A5(%) 0 Impact strength ISO-V(J) 0 C 50 Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Amperage [A].5 mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

143 Standard EN ISO 581-A EN ISO 581-B AWS A5. E N L R 1 ES0-1 E0-1 EI 0 Rutile-coated bar electrode for duplex steels/cast steel types of similar characteristics Application Bar electrode for welding ferritic-austenitic, duplex steels / cast steel. For operating temperatures up to 50 C. Areas of use above all in offshore technology or in the chemical industry. High strength and toughness from the high delta ferrite content (approx. 5-5%), excellent resistance to tension crack corrosion. Easy striking and restriking. Regular drop transfer, good coverage of the weld zone, finely rippled weld surface, easily removable slag. Chemical composition (typical values in %) C Si Mn Cr Ni Mo.80 N 0.1 Important base materials /most important areas of application 1. XCrNiMo-5-, 1. XCrNiN- ASTM A 88 Gr. UNS 180 Also for dissimilar joints with unalloyed and low alloyed stainless steel/cast steel. Please note the permissible operating temperatures for the weld filler and the base material. Mechanical properties of the pure weld metal (typical values) Heat treatment Tensile strength Elongation aw/u A5(%) (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF Impact strength ISO-V(J) 0 C -0 C Amperage [A].5 mm. mm mm Rebaking h/50 C, if necessary Approvals TÜV, BV, TSE, CE Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 11

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145 AX-ENi Standard EN ISO 1071 E C Ni-Cl 1 AWS A5.15 ENi-CI Application AX-ENi is an electrode with basic-graphitic special covering cold welding grey, malleable cast iron and cast steel as well as for welds on fatigued casting parts. It has excellent welding characteristics even at low amperages and a smooth, intensive flow with low spatter losses and easy slag removal. The welding seam is soft and easy to file and machinable including the transition zones to the base material. Rebaking temperature 10 C/ 1h Composition of the weld metal (typical data in %) C Si Mn Cu Ni Basis Welding hints The welding area must be thoroughly cleaned, the weld zones cleared of the cast skin of the base material over a sufficiently wide area. When welding cast iron, ensure as little heat input as possible. So chose low amperages. The width of the beads may be a maximum of twice, the length of the beads a maximum of ten times the core rod diameter. After welding, the weld beads are to be immediately thoroughly hammered to reduce stresses. Welding with direct current - pole gives a smooth seam aspect through cleanly flowing weld metal. With direct current + the result is a cambered seam aspect with a smoother flow as the low heat effect causes high overlay on the base material. With alternating current the seam aspect and welding characteristics lie between the two welding currents mentioned above. Material properties Welding process Test temperature m Manual metal arc welding +0 C Hardness [HB] 10 Tensile strength R 00 Elongation A (L = 5d %) [%] 8 Approvals 0 0 (Request current scope if required) Product forms (others available on request) Mechanical properties of the weld metal according to EN ISO x x x x Welding position/ polarity PA; PB; PC; PD; PE; PF (open ( circuit voltage >50V) A ALUNOX Manual 1

146 AX-ENiFe1 Standard EN ISO 1071 E C NiFe-1 AWS A5.15 ENiFe-CI Application AX-ENiFe1 is an electrode with basic-graphitic special covering and a bimetal core wire for cold welding all grey cast iron types, also in combination with steel. In particular however for welding spheroid cast iron. The alloy possesses excellent crack resistance and high strength. The welding seam is still machinable even at the transition zones. Rebaking temperature 10 C/ 1h Composition of the weld metal (typical data in %) C Si Mn Fe Ni Basis Welding hints The welding area must be thoroughly cleaned, the weld zones cleared of the cast skin of the base material over a sufficiently wide area. When welding cast iron ensure as little heat input as possible and choose low amperages. The beads must be no wider than twice and no longer than ten times the core rod diameter. Welding with alternating current achieves the highest crack resistance. The constant change of polarity promotes the connection to critical cast parts by a flat flowing weld bead. Special hint: the bimetal core wire provides excellent resistance to overheating and deposition rate. This enables melt off of the electrode over the whole length without the annealing during melt off of the nd half of the rod typical with this material. Material properties Welding process Test temperature 0.% yield strength Rp Tensile strength R m Manual metal arc welding 0 C Elongation A (L = 5d0) %) 0 [%] 10 Hardness [HB] 10 Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC; PD; PE; PF (open circuit voltage >50V) 1 ALUNOX Manual

147 AX-ENiFe0/0 Standard EN ISO 1071 E C NiFe-1 AWS A5.15 ENiFe-CI Application AX-ENiFe0/0 is an electrode with basic-graphitic special covering for cold welding all grey cast iron types, also in combination with steel. In particular however for welding spheroid cast iron. The alloy possesses excellent crack resistance and high strength. The welding seam is still machinable even at the transition zones. Rebaking temperature 10 C/ 1h Composition of the weld metal (typical data in %) C Si Mn Fe Ni Basis Welding hints The welding area must be thoroughly cleaned, the weld zones cleared of the cast skin of the base material over a sufficiently wide area. When welding cast iron ensure as little heat input as possible and choose low amperages. The beads must be no wider than twice and no longer than ten times the core rod diameter. After welding, the weld beads must be immediately hammered to reduce stresses. In principle welding should be with direct current positive polarity particularly with sensitive cast pieces to keep the heat input as low as possible. Welds on the minus pole or with alternating current are possible but only recommended with reservations. Material properties Welding process Test temperature 0.% yield strength Rp Tensile strength R m Manual metal arc welding 0 C Elongation A (L = 5d0%) 0 [%] 10 Hardness [HB] 10 Approvals (Request current scope if required) Product forms (others available on request) Mechanical properties of the weld metal according to EN ISO x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC; PD; PE; PF (open circuit voltage >50V) A ALUNOX Manual 15

148 AX-E8 Standard EN ISO 117 E Ni 08 (NiCr0MnNb) Material no..8 AWS A5.11 ENiCrFe- mod Application AX-ENi8B is a basic coated Ni base electrode with an alloyed core for tough joints of identical and similar characteristics and materials of different characteristics. When joining creep resistant ferritic and high-temperature resistant austenitic materials no formation of brittling Cr carbide layers occurs. The weld metal is stainless, high-temperature resistant, scale resistant to 1000 C and tough at subzero down to -1 C. There is no tendency to hot crack formation. Construction of high-quality equipment in the chemical and petrochemical industries for operating temperatures above 00 C. Rebaking temperature 50 C / 1h Composition of the weld metal (typical data in %) C Mn Mo Cr Ni Fe Nb < Basis < Welding hints Dissimilar joints: Ni base with austenite / Ni base with ferrite / austenite with ferrite up to 550 C NiCrFe alloys such as NiCr15Fe (.81), NiCrFe (.851), creep-resistant austenitic steels such as X10NiCrAlTi-0 (1.87) and X5NiCrAlTi1-0 (1.58), cryogenic steels such as X8Ni (1.5) and dissimilar joints with operating temperatures >00 C and / or subsequent heat finishing. Incoloy 800, Incoloy 800H, Incoloy 800HT, UNS N000, UNS N001, UNS N 0075, UNS N07080, UNS N105, UNS N08800 Material properties Welding process Test temperature Rp 0, Manual metal arc welding 0 C 0.% yield strength 0. 0 Tensile strength R m 700 Elongation A (L = 5d0%) [%] 0 0 Impact strength Av [J] 80 (at -1 C) Mechanical properties of the weld metal according to EN ISO Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC; PD; PE; PF (open circuit voltage >50V) 1 ALUNOX Manual

149 AX-E5 Standard EN ISO 117 E Ni 5 (NiCrMoNb) Material no..1 AWS A5.11 ENiCrMo- Application AX-E5 is a bar electrode suitable for alternating current with approx. 10% metal recovery for joint welding of CrMo alloyed Ni base materials with each other and in combination with high-temperature resistant, high-temperature resistant, cold tough, heat treatable low alloyed or corrosion resistant steels with nickel-based alloys. Also suitable for cold tough %-Ni steels with each other. The fully austenitic weld metal displays high resistance to many corrosive media e.g. pitting, tension crack and crevice corrosion. The weld metal is scale resistant to 1100 C and creep resistant up to 1000 C. Because of risk of brittling between 00 and 850 C, this temperature range is to be avoided. Rebaking temperature 00 C /1h Composition of the weld metal (typical data in %) C Si Mn Mo Cr Ni Fe Nb < Basis <.5 Welding hints Nickel chromium molybdenum alloys, e.g. NiCr Mo Nb (.85), NiCr1Mo (.858), NiCrMoCu (.18), NiCrMo7Cu (.17), X1NiCrMoCuN5-0-7 and their joints with unalloyed, low and high alloyed steel/cast steel as well as for corrosion-resistant claddings. Nickel steels tough at sub-zero, e.g. X8Ni (1.5) and dissimilar joints for operating temperatures exceeding 00 C. Inconel 5, NiCrofer 1hMo, Hastelloy G, Hastelloy G, Incoloy 800, UNS N05, UNS N0885, UNS N08, UNS N080 Material properties Welding process Test temperature Manual metal arc welding 0 C Mechanical properties of the weld metal according to EN ISO % yield strength Rp , Tensile strength R m m 750 Elongation A (L = 5d0%) 0 [%] 5 Impact strength Av [J] 0 (at -1 C) Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC; PD; PE; PF (open circuit voltage >50V) A ALUNOX Manual 17

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151 AX-ES1 Standard EN 1700 DIN 8555 AWS A5.1 E Co E0-UM-55-CSTZ ECrCo-C Application AX-ES1 is a high recovery electrode suitable for alternating current with approx. 10 % metal recovery. The weld metal forms the hardest, most abrasion resistant of the common cobalt base alloys. The alloy is of the highest corrosion resistance, is creep and heat resistant, and is scale resistant to approx C and corrosion resistant especially to reducing acids. Particularly suitable for wearing parts in the chemical industry, cutting and crushing tools, heavily stressed hot working tools without thermal shock, grinding, stirring and boring tools as well as for running and contact surfaces on fittings and valve seats or cones in combustion engines. Excellent sliding properties and good polishing properties. Because of its great hardness the alloy is only machinable by grinding. Rebaking temperature 50 C / 1h Composition of the weld metal (typical data in %) C Si Mn Cr W Fe Co Residue Processing hint The working temperature is dependent on the base material. Preheating and interpass temperature of 00 C to 00 C and very slow cool down, if necessary furnace cooling. Short arc and steep electrode guide. Subsequent heat treatment according to requirements of the base material. Material properties Welding process Manual metal arc Mechanical properties of the weld metal as per DIN 55- Hardness at 0 C [HRC] approx. 55 Hardness at 00 C [HRC] approx. Hardness at 800 C [HRC] approx. Approvals (Request current scope if required) Product forms (others available on request). x A 5.0 x x A Welding position/ polarity PA; PB; PC (open circuit voltage >V) A ALUNOX Manual 1

152 AX-ES Standard EN 1700 DIN 8555 AWS A5.1 E Co E0-UM-0-CTZ ECrCo-A Application AX-ES is a high recovery electrode suitable for alternating current with approx. 10 % metal recovery. For armouring on components exposed to multiple stresses from abrasion and cavitation, corrosion and also pressure, shock and high temperatures up to approx. 00 C. Particularly suitable for contact surfaces on fittings and valve seats or cones in combustion engines, sliding surfaces metal on metal, heavily stressed hot working tools without thermal shock, grinding, stirring and boring tools. Excellent sliding properties and good polishing properties, good toughness. The weld metal is still easily machinable by cutting with tungsten carbide tools. Rebaking temperature 50 C / 1h Composition of the weld metal (typical data in %) C Si Mn Cr W Fe Co Residue Processing hint Preheating and interpass temperature to be used in accordance with the steelmaker s instructions, a preheating and interpass temperature of 00 C to 00 C is recommended and slow cool down, if necessary furnace cooling is to be observed. Subsequent heat treatment according to requirements of the base material. Material properties Welding process Manual metal arc Mechanical properties of the weld metal as per DIN 55- Hardness at 0 C [HRC] approx. Hardness at 00 C [HRC] approx. 5 Hardness at 00 C [HRC] approx. Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC (open circuit voltage >V) 150 ALUNOX Manual

153 AX-ES1 Standard EN 1700 DIN 8555 AWS A5.1 E Co E0-UM-50-CTZ ECrCo-B Application AX-ES1 is a high recovery electrode suitable for alternating current with approx. 10 % metal recovery. For armouring on components exposed to multiple stresses from abrasion and cavitation, corrosion and also pressure, shock and high temperatures up to approx. 00 C. The hardness and toughness of this alloy lies between AX-ES1 and AX-ES. It is more wear resistant than AX-ES and tougher than AX-ES1. For armouring on running, seal and slip surfaces of fittings and pumps, machining tools in the hardwood, paper and plastics industries, as well as for crushing hammers, valve spindles and earth augers and also for heavily stressed hot working tools without thermal shock. The weld metal is still machinable by cutting with tungsten carbide tools, otherwise by grinding. Rebaking temperature 50 C / 1h Composition of the weld metal (typical data in %) C Si Mn Cr W Fe Co Residue Processing hint Preheating and interpass temperature to be used in accordance with the steelmaker s instructions; a preheating and interpass temperature of 00 C to 00 C is recommended with following slow cool down, if necessary furnace cooling. Subsequent heat treatment according to requirements of the base material. Material properties Welding process Manual metal arc Mechanical properties of the weld metal as per DIN 55- Hardness at 0 C [HRC] approx. 8 Hardness at 00 C [HRC] approx. 7 Hardness at 00 C [HRC] approx. Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC (open circuit voltage >V) A ALUNOX Manual 151

154 AX-ES1 Standard EN 1700 DIN 8555 AWS A5.1 E Co1 E0-UM-00-CKTZ ECrCo-E Application AX-ES1 is a high recovery electrode suitable for alternating current with approx. 10 % metal recovery. It has the toughest, most corrosion resistant and creep resistant weld metal of the common cobalt hard alloys. It is suitable for tough and crack-proof armourings exposed to a combined load of pressure, shock, abrasion, corrosion and high temperatures up to around 00 C. For contact surfaces on gas, water, steam and acid fittings and pumps, valve seats and cones of combustion engines as well as for hot working tools with thermocycling. The alloy has excellent sliding properties and is work hardening up to approx. 5 HRC. Gas weld metal is very easily machinable by cutting. Rebaking temperature 50 C /1h Composition of the weld metal (typical data in %) C Si Mn Cr Mo Ni Fe Co Residue Processing hint Preheating and interpass temperature to be used in accordance with the steelmaker s instructions, a preheating and interpass temperature of 150 C to 00 C is recommended. After welding slow cool down is to be observed, if necessary furnace cooling. Subsequent heat treatment to be guided by the requirements of the base material. Material properties Welding process Manual metal arc welding Mechanical properties of the weld metal as per DIN 55- Hardness at 0 C [HRC] approx. 0 Hardness at 00 C [HB] approx. 80 Work-hardened [HRC] approx. 5 Approvals (Request current scope if required) Product forms (others available on request).5 x A.0 x A. x A 5.0 x A Welding position/ polarity PA; PB; PC (open circuit voltage >V) 15 ALUNOX Manual

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157 Standard EN 1700 DIN 8555 AWS A 5.1 E Fe E 7 UM 00 KP E FeMn - A EH 5 Basic coated manganese hard steel electrode for hardfacings Application Basic coated manganese hard steel electrode for wear resistant overlays. The weld metal obtains its high hardness by work hardening. It is therefore particularly suitable for parts exposed mainly to high shock and impact stress. The workpieces should not become too hot during welding, if necessary stop for them to cool down. With large workpieces of austenitic manganese steel such as crusher jaws it is advisable to weld them in a water bath. High amperages and wide oscillation should be avoided. With several layers an intermediate layer with the EI 07 is recommended. When joint welding austenitic manganese steels the EI 07 is likewise to be used. Suitable for overlay and repair welding of wearing parts of austenitic manganese steel such as crusher jaws, crusher cones, rollers and similar. Chemical composition (typical values in %) C Mn Ni Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HB) treatment aw/u 00 (as welded/untre ated) workhardened Type of current/polarity/welding positions _ PA; PB; PC Amperage [A].5 mm. mm Rebaking h/50 C, if necessary.0 mm mm Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 155

158 EH 0 Thickly basic coated electrode for overlays of medium hardness Standard EN 1700 DIN 8555 E Fe1 E 1 UM 00 Application Thickly basic coated bar electrode for overlays with medium hardness. Particularly suitable for components with fretting, high shock and impact stress. The weld metal is crack-proof and free from pores and can be machined by cutting. Suitable for reconditioning tracks, switches, sprockets and wearing parts such as rope pulleys, bucket rollers, rollers, rollers of caterpillar vehicles, bolts, studs etc. Chemical composition (typical values in %) C Si Mn Cr Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HB) treatment aw/u 00 (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF = Amperage [A].5 mm mm Rebaking h/50 C, if necessary Approvals.0 mm mm 10-0 Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

159 Standard EN 1700 DIN 8555 E Fe E 1 UM 00 EH 0 Thickly basic coated electrode for overlays of high wear resistance Application Thickly basic coated bar electrode for overlays of high wear resistance. Particularly suitable for components with fretting, high shock and impact stress. The weld metal can only be machine cut with sintered hard metals. A tough buffer layer with the ESB 8 or EI 07 is only necessary with base materials very susceptible to cracks. Multiple layer welding gives a crack-proof weld metal even without intermediate layers. Suitable for the rehabilitation of tracks, point rails and switches, wearing parts such as dredger parts, polygon corners, tapping tools, wheel rims, bottom dies, stamps etc. Chemical composition (typical values in %) C 0.0 Si 0.0 Mn 0.0 Cr.70 Ni 0.10 Mo 0.0 Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF = Amperage [A]. mm.0 mm Rebaking h/50 C, if necessary 5.0 mm Fe Residue Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 157

160 EH 0B Thickly basic coated electrode for tough and abrasion resistant overlays on components that are subject to heavy wear Standard EN 1700 DIN 8555 E Fe8 E UM 0 (5W) T Application Thickly basic coated bar electrode for tough and abrasion resistant overlays on components with high stress. The weld metal is resistant to shock and impact stress, crack-proof and free from pores and can only be machined by grinding. With base materials very susceptible to cracks a tough buffer layer with ESB 8 or EI 07 is necessary. Multiple layer welding gives a crack-free weld metal even without buffer layers. Suitable for the rehabilitation of dredger parts, front edges of the dredger scoop, bucket teeth, drill inserts, coal planes, screw conveyors, polygon corners, crusher jaws, crusher cones etc. Chemical composition (typical values in %) C Si Mn Cr V Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u 5 (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF _ Amperage [A].5 mm mm Rebaking h/50 C, if necessary Approvals.0 mm mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

161 Standard EN 1700 DIN 8555 E Fe8 E UM 0 (5W) T EH 0R Thickly rutile-coated electrode for abrasion resistant and tough hardfacings. Application Thickly rutile-coated bar electrode for tough and abrasion resistant overlays. The weld metal has sufficient heat hardness up to 00 C. It is only machinable by grinding. With base materials very susceptible to cracks a tough buffer layer with ESB 8 or EI 07 is necessary, after every layers EH 0 R a further one. The hardness as welded of 5 HRC can be increased by tempering once or twice to 0-5 HRC. Suitable for hardfacings that have to be wear resistant at higher temperatures, e.g. tools for hot working such as shear blades, dies, die-casting moulds, rollers, crushers. Chemical composition (typical values in %) C 0.0 Si 0.50 Mn 0.0 Cr 7.00 V 0.50 Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u 5 (as welded/ untreated) Type of current/polarity/welding positions PA, PB, PC, PD, PE, PF _ Amperage [A].5 mm. mm Rebaking h/50 C, if necessary.0 mm mm Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 15

162 EH 515 Thickly rutile-coated high recovery electrode for extremely wear resistant stainless hard armourings. Standard EN 1700 DIN 8555 E Fe1 E 10 UM 0 GR Application Thickly rutile-coated bar electrode with approx. 10% metal recovery for extremely wear resistant stainless overlays in the abrasive area without impact stress. The weld metal has a ledeburitic structure and is only machinable by grinding. The transverse cracks occurring with this hard weld metal are not a disadvantage with friction wear. With base materials very susceptible to cracks a tough buffer layer with EI 07 is necessary. Smooth and finely rippled weld beads. Suitable for hardfacings on components subject to heavy mineral wear such as screw conveyors, mixer blades, sludge pumps, stirrers, crusher parts, front edges of dredger scoops and components in coking plants exposed to corrosion and increased temperature. Chemical composition (typical values in %) C Si Cr Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u 0 (as welded/ untreated) Type of current/polarity/welding positions _ PA; PB; PC Amperage [A].5 mm. mm mm Rebaking h/50 C, if necessary Approvals Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

163 Standard EN 1700 DIN 8555 E Fe15 E 10 UM 55 GR EH 5 Thickly basic-coated high recovery electrode for extremely wear resistant stainless hard armourings. Application Thickly basic-coated bar electrode with approx. 180% metal recovery for extremely wear resistant stainless overlays in the highly abrasive area with light impact stress. The weld metal has a ledeburitic structure with Cr and Nb carbides and is only machinable by grinding. The transverse cracks occurring with this hard weld metal are not a disadvantage with friction wear. The wear factor of a -layer overlay against SiO is 1%. With base materials very susceptible to cracks a tough buffer layer with EI 07 is necessary. Suitable for hardfacings of wear plates in crusher plants, cone crushers, crushers in the cement and ore industries, oil mills, bucket teeth and front edges of dredger scoops. Chemical composition (typical values in %) C Si Nb Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u 55 (as welded/ untreated) Type of current/polarity/welding positions _ PA, PB Amperage [A].5 mm. mm Rebaking h/50 C, if necessary Approvals.0 mm mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 11

164 EH 58 Thickly basic-coated high recovery electrode for extremely wear resistant stainless hard armourings. Standard EN 1700 DIN 8555 E Fe1 E 10 UM 5 GR Application Thickly basic-coated bar electrode with approx. 180% metal recovery for extremely wear resistant stainless overlays in the highly abrasive area with light impact stress. The weld metal has a ledeburitic structure with Cr and Nb carbides and is only machinable by grinding. The transverse cracks occurring with this hard weld metal are not a disadvantage with friction wear. The wear factor of a -layer overlay against SiO is 0.5%. With base materials very susceptible to cracks a tough buffer layer with EI 07 is necessary. Suitable for cement crushers, cement presses and stone screw conveyors, mixer blades, bucket teeth and front edges of dredger scoops. Can be used for operating temperatures up to 50 C. Chemical composition (typical values in %) C 7.00 Si.00 Nb 7.00 Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u (1st layer) (as welded/ (nd layer) untreated) (rd layer) Type of current/polarity/welding positions _ PA, PB Amperage [A].5 mm. mm Rebaking h/50 C, if necessary Approvals.0 mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

165 Standard EN 1700 DIN 8555 E ZFe1 E 10 UM 5 GR EH 51 Thickly coated high recovery electrode for extremely wear resistant stainless hard armourings. Application Thickly basic-coated bar electrode with approx. 5% metal recovery for extremely wear resistant stainless overlays in the highly abrasive area without impact stress. The weld metal has a ledeburitic structure with Cr and B carbides and is only machinable by grinding. The transverse cracks occurring with this hard weld metal are not a disadvantage with friction wear. With base materials very susceptible to cracks a tough buffer layer with EI 07 is necessary. Smooth and finely rippled weld beads. The required hardness and wear resistance can already be achieved in the 1st layer on a low alloyed steel. Suitable for bucket teeth, and front edges of dredger scoops, mixer blades, pumps, screw conveyors and transport belts in the gravel industry. Chemical composition (typical values in %) C Si Mn Cr B Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u (as welded/ untreated) 0 1 Type of current/polarity/welding positions _ PA, PB Amperage [A]. mm.0 mm Rebaking h/100 C, if necessary Approvals 5.0 mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton A ALUNOX Manual 1

166 EH 50 Thickly basic-coated high recovery electrode for maximum wear resistant stainless hard armourings. Standard EN 1700 DIN 8555 E ZFe1 E 10 UM 5 GR Application Thickly basic-coated bar electrode with approx. 0% metal recovery for maximum wear resistant stainless overlays in the highly abrasive area without impact stress. Operating temperature up to max. 00 C. The weld metal has a ledeburitic structure with Cr, Nb-,Mo-, W- und V carbides and is only workable by grinding. The transverse cracks occurring with this hard weld metal are not a disadvantage with friction wear. With base materials very susceptible to cracks a tough buffer layer with EI 07 is necessary. The wear factor of a -layer overlay against SiO is 0.%. Suitable for hardfacings on crushing and screening plants, sintering plants, cement kilns, feed systems for furnaces, front edges of dredger scoops, and bucket teeth. Chemical composition (typical values in %) C Si Cr Mo V W.00 Nb.00 Fe Residue Mechanical properties of the pure weld metal (typical values) Heat Hardness (HRc) treatment aw/u (as welded/ untreated) (1st layer) (nd layer) 5 (rd layer) (th layer) Type of current/polarity/welding positions _ PA, PB Amperage [A].5 mm mm Rebaking h/50 C, if necessary Approvals.0 mm Packaging units Ø mm Length (mm) Items/packet kg/packet Packet/ carton kg/carton ALUNOX Manual

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168 AX-EFug Standard Groove electrode Application AX-Fug is a bar electrode with a special covering for joining and separating all steel qualities with a ferritic and austenitic structure as well as nonferrous metals, cast steel and grey cast iron except pure copper. It is used for seam preparation, for gouging grooves, for chamfering edges, for cutting steels, for punching holes and for removing defective welding and for opening cracks before welding. Can be used in all welding positions. Hints for use AX-Fug requires higher amperages than other bar electrodes of the same core rod dimensions and coating thicknesses. The best results are achieved if the workpiece is tilted in a slight inclined position so that the fused material can run down slightly. The electrode should be pushed forward if possible at an acute angle (approx. 15 ) to the workpiece in a step by step process. At the same time constant contact with the base material should be maintained. As a rule the AX-Fug produces a clean and smooth groove. Any remaining residue of the base material on the groove flank can be easily removed with the pick hammer. Before welding over the groove must be ground down to metallic plain. Approvals - Product forms (others available on request).5 x A. x A.0 x x A 0 00 A Welding position/ polarity PA; PB; PC; PD; PE; PG _ (open circuit voltage >50V) 1 ALUNOX Manual

169 AX-EAlSi5 Standard DIN 17 Material no. AWS A5. EL-AlSi5.5 E0 Application AX-EAlSi5 is a bar electrode for welds on aluminium forging alloys and casting alloys with silicon. The welding area is to be thoroughly cleaned, the weld zones must be metallic plain. The weldability and slag removal of the electrode is good. To obtain a tight non-porous seam the electrode must be welded in horizontal position (PA) with short electric arc. For larger workpieces (> mm) preheat to approx C. Special hints As the coating of aluminium electrodes is hygroscopic, it is essential to ensure dry, cool storage. Electrodes that have become damp must be rebaked before welding. The rebaking temperature is 10 C / 1h. Typical analysis in % Al Si Mn Basis 5 0. Fe 0. Important base materials /most important areas of application Aluminium-silicon alloys such as: EN AW-01 (AlMgSi1), EN AW-0 (AlMgSi0.7), EN AW-08 (AlMgMnSi1), AlSi und AlSiMg casting with max. 7% Si Material properties Welding process Test temperature 0.% yield strength Rp 0. Tensile strength R m m Elongation A (L = 5d %) 0 0 Thermal conductivity Approvals (Request current scope if required) Zn 0.1 Manual metal arc welding 0 C [%] [W/(m*K)] Mechanical properties of the weld metal as per DIN EN Product forms (others available on request).5 x A.0 x A. x A Welding position/ polarity PA; PB; PC; PF _ A ALUNOX Manual 17

170 AX-EAlSi1 Standard DIN 17 Material no. AWS A5. EL-AlSi1.585 E07 Application AX-EAlSi1 is a bar electrode with coating for welds on aluminium-silicon casting alloys. The welding area is to be thoroughly cleaned, the weld zones must be metallic plain. The weldability and slag removal of the electrode is good. To obtain a tight non-porous seam the electrode must be welded in horizontal position (PA) with short electric arc. For larger workpieces (> mm) preheat to approx C. Special hints As the coating of aluminium electrodes is hygroscopic, it is essential to ensure dry, cool storage. Electrodes that have become damp must be rebaked before welding. The rebaking temperature is 10 C /1h. Typical analysis in % Al Si Mn Basis Fe 0.5 Important base materials /most important areas of application Aluminium casting alloys up to 1%Si e.g.: EN AC-000 (G-AlSi10Mg), EN AC-00 (G-AlSi1), EN AC-000 (G- AlSi11), EN AC-00 (G-AlSi8Cu) Material properties Welding process Test temperature Yield strength Rp 0. Tensile strength R m Elongation A (L = 5d %) 0 0 Thermal conductivity Manual metal arc welding 0 C [%] [W/(m*K)] Mechanical properties of the weld metal as per DIN EN Approvals (Request current scope if required) Product forms (others available on request).5 x 00. x A A.0 x A Welding position/ polarity PA; PB; PC; PF = 18 ALUNOX ALUNOX Manual Manual

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172 Welding Consumables nickel Solid wires/tig rods AX-8 AX-.80 AX-5 AX-.81 AX-NiTi AX-.155 AX-NiCu0 AX-.77 AX-FeNi AX-.50 AX-.07 AX-.88 AX-.11 Flux-cored wires AX-FD-8 AX-FD-5 AX-FD-FeNi Nickel and Ni-alloys are used everywhere where particularly high demands are made regarding corrosion resistance, thermal and creep rupture strength, heat and high temperature corrosion resistance that can no longer be achieved with the classical austenitic materials. These alloys are mainly used in the chemical and petrochemical industries, in industrial furnace construction, in gas and coalfired power stations, in desulphurisation and in waste incineration plants, in wastewater treatment, in offshore technology, in desalination plants, in the automotive industry and in the aerospace industry. Nickel 170 ALUNOX Manual

173 Depending on application there are the following alloys: pure nickel with 1-.5% Ti nickel-copper with approx. 0% Cu e.g. Monel 00 nickel-chromium with approx. 0-5% Cr, Nb, Ti, Al nickel-chromium-iron with approx. 15-0% Cr, Fe, Nb, Mo, Al, Ti e.g. Incoloy 800, 800H nickel-molybdenum with approx. 15-0% Mo, Cr, W, Al, Ti e.g. Hastelloy B- nickel-chromiummolybdenum with approx. 15-5% Cr, 7,-1% Mo, Nb, W, Co, Al e.g. Inconel 5, alloy 5 nickel-chromium-cobalt with approx. 10-0% Co, Cr, Mo, Al, Ti, W nickel-chromium-tungsten with approx.1-15% W, Cr, Co, Al, Mo Welding of nickel-based alloys Nickel-based alloys have a fully austenitic structure and are susceptible to hot cracking. You will find some hints below: Ensure absolute cleanliness The weld seam area must be free from all residues such as grease, oil, dust etc. The seam opening angle must be larger than for unalloyed steels Tack at shorter intervals, root gap - mm, web height approx. mm. Redry bar electrodes and weld together with short electric arc. Strike in the welding groove, weld over arc strikes. Always pay attention to the heat input, with MAG welding use pulse technique. Do not preheat, the interpass temperature must not exceed 150 (10) C, energy input 8-1 KJ/cm, if possible use stringer bead technique, with bar electrodes weave max..5 x core bar diameter. Grind out end craters, use end crater- filling programme. Clean each welding layer with a rust-proof brush, remove slag residues and oxide skin. After welding in addition grind and pickle surface A ALUNOX Manual 171

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175 Standard EN ISO 187 Material number AWS A5.1 S Ni 01 (NiTi).155 ERNi-1 AX-NiTi AX Area of application Filler rod/filler wire of pure nickel with particularly low carbon content for TIG or MAG welding of pure nickel for operating temperatures up to +50 C; tough at sub-zero down to 1 C. Special hints The cleanliness of the workpiece in the weld seam area is a requirement for a crack-free joint. For thin sheets and root welds, lower seam protection: for V and X seams, opening angle minimum 70 ; filler wire preferably weld with pulsed arc. Composition of the filler rod/filler wire (typical data in %) Ni Bal. C 0.0 Fe <0. Mn 0. Important base materials Pure nickel also LC nickel such as Ni, (.01), low-alloyed Ni alloys such as NiMn1 (.10) and NiMn5 (.11), G-Ni5 (.170) as well as joints with steel, cast steel, copper and copper with high-alloyed steel, coatings and buffer layers. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av Argon untreated 0 C [%] [J] Si 0. Ti.0 Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm A ALUNOX Manual 17

176 AX-5 AX-.81 Standard EN ISO 187 Material number AWS A5.1 S Ni 5 (NiCrMoNb).81 ERNiCrMo- Area of application Filler rod/filler wire of nickel-chromium-molybdenum alloy for TIG or MAG welding of Ni alloys of identical or similar characteristics, nickel steels tough at sub-zero temperatures and joints of different characteristics for operating temperatures up to 1000 C; tough at sub-zero temperatures down to - 1 C. Special hints The cleanliness of the workpiece in the weld seam area is a requirement for a crack-free joint. With thin sheets and root welds, lower seam protection is required. With V and X seams the opening angle must be 70 minimum. MIG filler wire preferably weld in pulsed arc. Because of risk of brittling between 00 and 850 C, this temperature range is to be avoided. Composition of the filler rod/filler wire (typical data in %) Ni C Cr Mo Mn Si Bal Nb+Ta. Fe 1.5 Important base materials Nickel chromium molybdenum alloys, e.g. NiCr Mo Nb (.85), NiCr1Mo (.858), NiCrMoCu (.18), NiCrMo7Cu (.17), X1NiCrMoCuN5-0-7 and their joints with unalloyed, low and high alloyed steel/cast steel as well as for corrosion-resistant claddings. Nickel steels tough at sub-zero, e.g. X8Ni (1.5) and dissimilar joints for operating temperatures exceeding 00 C. Inconel 5, NiCrofer 1hMo, Hastelloy G, Hastelloy G, Incoloy 800, UNS N05, UNS N0885, UNS N08, UNS N080 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm ALUNOX Manual

177 Standard EN ISO 187 Material number AWS A5.1 S Ni 01 (NiTi).155 ERNi-1 AX-NiTi AX Area of application Filler rod/filler wire of pure nickel with particularly low carbon content for TIG or MAG welding of pure nickel for operating temperatures up to +50 C; tough at sub-zero down to 1 C. Special hints The cleanliness of the workpiece in the weld seam area is a requirement for a crack-free joint. For thin sheets and root welds, lower seam protection: for V and X seams, opening angle minimum 70 ; filler wire preferably weld with pulsed arc. Composition of the filler rod/filler wire (typical data in %) Ni Bal. C 0.0 Fe <0. Mn 0. Important base materials Pure nickel also LC nickel such as Ni, (.01), low-alloyed Ni alloys such as NiMn1 (.10) and NiMn5 (.11), G-Ni5 (.170) as well as joints with steel, cast steel, copper and copper with high-alloyed steel, coatings and buffer layers. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av Argon untreated 0 C [%] [J] Si 0. Ti.0 Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm A ALUNOX Manual 175

178 AX-NiCu0 AX-.77 Standard EN ISO 187 Material number AWS A5.1 S Ni 00 (NiCu0MnTi).77 ER NiCu 7 Area of application Filler rod/filler wire of nickel-copper-alloy for joint welding and overlay of nickel-copper alloys and claddings of similar composition for operating temperatures up to +5 C; tough at sub-zero down to -1 C. Special hints The cleanliness of the workpiece in the weld seam area is a requirement for a crack-free joint. For thin sheets and root welds, lower seam protection is required. With V and X seams, the opening angle must be 70 minimum. Always guide TIG filler rod in shielding gas area. MAG filler wire preferably weld in pulsed arc. At high welding velocities work with gas protection following the torch shroud (argonspray). Composition of the filler rod/filler wire (typical data in %) Ni Bal. C 0.0 Fe 1 Mn. Si 0. Ti.0 Cu 0 Important base materials Nickel copper alloys, e.g. NiCu0Fe (.0), NiCu0Al (.75) and joints of steel with nickel-copper- and copper alloys, coatings and buffer layers. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av Argon untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm ALUNOX Manual

179 Standard EN ISO 1071 Material number S C NiFe-.50 AX-FeNi AX-.50 Area of application The nickel-iron filler rod/filler wire for the joint welding and overlay on grey cast iron types with lamellar and nodular graphite such as shrinkage removal on cast iron parts, repair welding of engine blocks, tool machine frames, gearboxes, reducing pieces, pump blocks, cast parts and valve bodies. The weld metal (55 % Ni) is homogeneous and highly crack resistant. Likewise for dissimilar joints with unalloyed and high-alloyed steel, copper and Ni-alloys. Special hints The welding area must be metallic bright. Keep the dilution as low as possible. Good bonding of the weld metal with the base material, even flow. Composition of the filler rod/filler wire (typical data in %) Ni C Fe Mn Si Bal. 0.1 <1.0 <0. Important base materials Ferritic and austenitic nodular cast iron as well as dissimilar joints with steel, copper and Nialloys. 0 1 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Brinell hardness Argon untreated 0 C [%] [HB] Mechanical properties of the weld metal according to EN ISO > 00 > 500 > Applicable shielding gases (EN ISO 1175) TIG: Argon I1, MAG: mixed gas M1 Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x 1000 mm A ALUNOX Manual 177

180 AX-.07 Standard EN ISO 187 Material number AWS A5.1 S Ni 05 (NiCrMo1).07 ERNiCrMo-1 Area of application Filler wire with high corrosion resistance in reducing but primarily oxidising media. For joints and overlays on alloys of identical or similar characteristics and cast alloys. Welding the cladding side of sheets with identical or similar overlay. Structure The structure is created austenitically and is ferrite-free. Special hints Good corrosion resistance to acetic acid and acetic acid anhydride, hot contaminated sulphur and phosphoric acid and other contaminated mineral acids. Precipitation of intermetallic phases is largely prevented. Composition of the filler rod/filler wire (typical data in %) Ni C Cr Fe Mn Si Bal <1.5 < Mo 1 Important base materials NiCrMo1Al (.05), NiCr1Mo1W (.0), NiMo1Cr1Ti (.10), NiMo1Cr15W (.81) and materials of identical/similar characteristics. UNS N005 (alloy 5), UNS N00 (alloy C), UNS N 055 (alloy C), UNS N107 (alloy C7) Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av M1 untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) Weld argon; mixed gases e.g. M 11. Approvals TIG: Argon I1, MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Product forms (others available on request) Spool Ø mm Rod Ø mm x mm ALUNOX ALUNOX Manual Manual

181 AX-.88 Standard EN ISO 187 AWS A5.1 S Ni 7 (NiCr15Mo1FeW) Material number.88 ER NiCrMo- 0 Area of application Filler wire for joint welding and overlay of components in installations for chemical processes with highly corrosive media but also suitable for applying to press tools, mandrel plugs etc. working at high temperatures. Excellent resistance to sulphurous acids with high chloride concentrations. Special hints To avoid intermetallic precipitations, weld with the lowest possible heat input and low interpass temperature. Composition of the filler rod/filler wire (typical data in %) Ni C Cr Fe W Si Mo Bal Important base materials AX-.88 is suitable for joint welding of base materials of identical or similar characteristics, such as NiMo1Cr15 W (.81), UNS N107 (alloy C7) and for overlays to low-alloyed and hot working steels. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp Tensile strength R m 0. M1 untreated 0 C >50 >750 Elongation A (L = 5d %) [%] >0 Impact strength Av [J] >0 Applicable shielding gases (EN ISO 1175) MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 17

182 AX-.11 Standard EN ISO 187 Material number AWS A5.1 S Ni ERNiCrMo-7 Area of application Filler wire for joint weldings and overlays of highly corrosive materials of identical and similar characteristics in reducing and oxidising media in the chemical industry. Also suitable for dissimilar joints with high and low-alloyed materials. Special hints The heat input must be kept as low as possible. Composition of the filler rod/filler wire (typical data in %) Ni C Cr Fe Si Mo Bal < Important base materials AX-.11 is suitable for joint welding base materials of similar composition such as NiMo1Cr1Ti (.10), NiMo1Cr15W (.81) UNS N055 (alloy C), UNS N107 (alloy C7) Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av M1 untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO >00 >700 >0 >0 Applicable shielding gases (EN ISO 1175) MAG: M1 (Ar+0%He+0.5%CO ), Ar+8%He+%H +0.05%CO Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Rod Ø mm x mm ALUNOX Manual

183 AX-FD-8 Standard EN ISO 115 AWS A5. AWS A5.M T Ni 18 B M1 ENiCrFeT0- TNi 18-0 NiCr15FeMn 0 Area of application Flux-cored electrode for joint welding and plating nickel-based alloys but also for joints of dissimilar composition such as high-alloyed and unalloyed steels with nickelbased materials. In addition the AX-FD8 is used for repairs on steels that are difficult to weld. The material is the first choice where joints in the high temperature range between ferritic and austenitic steels are concerned. Special hints A special nickel based flux-cored wire with basic slag system ensures a good seam aspect and an optimum weld metal. The advantages of the AX-FD8 compared with solid wires are particularly clear in the PA and PB positions. Composition of the weld metal (typical data in %) C 0.01 Si 0.0 Mn.0 Fe.0 Ni Bal. Nb 1.7 Cr 17.0 Important base materials NiCrFe alloys such as NiCr15Fe (.81), NiCrFe (.851), creep-resistant austenitic steels such as X10NiCrAlTi-0 (1.87) and X5NiCrAlTi1-0 (1.58), cryogenic steels such as X8Ni (1.5) and dissimilar joints with operating temperatures >00 C and or subsequent thermal post treatment. Incoloy 800, Incoloy 800H, Incoloy 800HT, UNS N000, UNS N001, UNS N0075, UNS N07080, UNS N105, UNS N Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av M1 untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: e.g. M1 Welding position/ polarity PA; PB Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm A ALUNOX Manual 181

184 AX-FD-5 Standard EN ISO 115 AWS A5. AWS A5.M T Ni5 B M1 ENiCrMoT0- TNi 5-0 NiCrMoNb Area of application The AX-FD5 can be used for joint welding and plating nickel-based alloys of identical or similar characteristics but also for dissimilar joints such as stainless steels with nickel-based materials. Likewise for austenitic steels with % -% Mo. Special hints A special nickel based flux-cored wire with basic slag system ensures a good seam aspect and an optimum weld metal. The advantages of the AX-FD5 compared with solid wires are particularly evident in working in the PA/PB position. Composition of the weld metal (typical data in %) C Si Mn Fe Ni Bal. Mo.0 Nb. Cr 1.0 Important base materials Nickel chromium molybdenum alloys, e.g. NiCr Mo Nb (.85), NiCr1Mo (.858), NiCrMoCu (.18), NiCrMo7Cu (.17), X1NiCrMoCuN5-0-7 and their joints with unalloyed, low and high alloyed steel/cast steel as well as for corrosion-resistant claddings. Nickel steels tough at sub-zero, e.g. X8Ni (1.5) and dissimilar joints for operating temperatures exceeding 00 C. Inconel 5, NiCrofer 1hMo, Hastelloy G, Hastelloy G, Incoloy 800, UNS N05, UNS N0885, UNS N08, UNS N080 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 Impact strength Av (-1%C) M1 untreated 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: e.g. M1 Approvals (Request current scope if required) Product forms (others available on request) Spool Ø mm Welding position/ polarity MAG PA; PB 18 ALUNOX Manual

185 AX-FD-FeNi Standard EN ISO 1071 AWS A 5.15 TCZ NiFe-1M ENiFeT-Cl mod. Area of application The AX-FD-NiFe can be used for joint welding and overlay on components of grey cast iron, nodular cast iron and malleable cast iron. Also for joints of dissimilar composition such as cast iron with steel and cast steel. Repairs to valve bodies, machine frames, sliding rails and bearing seats. Special hints A special metal powder flux-cored wire for shielded gas welding. It is particularly suitable for welding on thick components. Composition of the weld metal (typical data in %) C Si Mn Fe Ni Bal. Important base materials Grey cast iron GJL 10-GJL 0, nodular cast iron GJS 8-GJS 0 as well as all types of malleable cast iron. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d %) 0 0 MAG M1 0 C [%] Applicable shielding gases (EN ISO 1175) MAG: e.g. M1 or argon with 8-0%He and 0.5-% CO Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO Product forms (others available on request) Spool Ø mm Ø mm Welding position/ polarity 1. mm PA, PB, PC, PF mm PA, PB A ALUNOX Manual 18

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188 Welding Consumables Flux-cored electrodes unalloyed FCW 11 FCW 1 FCW 1 FCW 0 low alloyed FCW 10 FCW 01 high alloyed AX-FD-DW07 AX-FD-DW08L AX-FD-DW08LP AX-FD-DW0L AX-FD-DW0LP AX-FD-DW0MoL AX-FD-DW0MoLP AX-FD-DW10 AX-FD-DW1L AX-FD-DW1LP AX-FD-DWA Flux-cored wire Flux-cored electrodes Like welding with a solid wire electrode, welding with fluxcored electrodes is a metal electric arc welding process with a melting electrode. The current sources and the feed unit used are the same, just like the hose, in some cases for particularly sensitive flux-cored wires Teflon is used instead of the usual steel cores. Flux-cored electrodes consist of a sheath and enclosed filling. Unlike to solid wire, the current is passed almost exclusively via a relatively thin sheath and not via the whole cross section. This leads to the current density with a flux-cored wire being very much higher than with a solid wire. The flux-cored wire melts off more quickly, the wire feed speed must be increased by 1- m/min compared with solid wire. This already leads to a time and efficiency advantage in the horizontal position. The electric arc of flux-cored electrodes is wider and more bell-shaped compared with the pointed and more vertical electric arc of solid wire electrodes. The weld zones are better fused, incomplete fusion is practically unknown. The somewhat larger weld pool means that the outgassing is better, the fluxcored wire is less susceptible to pores than solid wire, the susceptibility to spattering is likewise lower. 18 ALUNOX Manual

189 There are types of flux-cored electrodes, gas-shielded where the shielding gas is fed in from outside and the selfshielded which because of their filling generate their shielding gas themselves during the welding process. In practice these flux-cored wires are almost exclusively used for cladding. With the gasshielded types a distinction is made between slag-forming flux-cored wires i.e. after welding the seam is covered with slag and metal powder fluxcored wires without slag. Among the slag-forming there are rutile and basic flux-cored electrodes. Rutile flux-cored electrodes Rutile flux-cored electrodes have a very fine-dropping and almost spatterfree drop transfer. They weld exclusively in the spray-arc section. Root welds are therefore only possible with weld pool backing. There are types with rapidly and with slowly solidifying slag. Unalloyed and low alloyed fluxcored wires have almost exclusively rapidly solidifying slag. This slag supports the weld metal even before its final solidification and thus enables extremely economic welding with high current even in a constrained position (PF, PD, PE). Welding can be done at practically double the speed of welding with a solid wire. Rutile flux-cored wires with slowly solidifying slag are preferred for use in the high alloyed area. Because of the slow solidification the welding seam is better formed, it is smoother and cleaner. This means at the same time also less reworking. Use is however limited to welding positions PA, PB, PC. Basic flux-cored electrodes have somewhat coarser drops and are more susceptible to spattering than rutile. The weld metal is very crack resistant and has high toughness even at low temperatures. There is no limit to wall thickness. They are especially suitable for higher carburized steels and for energized constructions. With reduced power they can also be used in the root and constrained positions. Metal powder flux-cored electrode have a very fine-dropping and practically spatterfree drop transfer. They do not form any slag apart from some silicates and are therefore very good to use for automatic processes. They can support high currents and have at the same time very good gap bridging for root welding in the low current range. They are preferably welded in positions PA, PB, PC, in constrained positions the power must be reduced A ALUNOX Manual 187

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191 FCW 11 Standard EN ISO 17-A EN ISO 17-B AWS A5. T P C 1 H5 T55T1-1CA-H5 E71T1-C1A-CS1-H AWS A5. Rutile flux-cored electrode for welding under CO for joints on low alloyed steels in shipbuilding and steel construction. Easily solidifying slag gives an easily controllable weld pool, can be used with high power and because of this high deposition rate in all positions. Can also be used in vertical down position up to a wire diameter of 1. mm. Smooth spatterfree welding characteristics. Easily removable slag and finely rippled welding seam. Special hints Especially for welding under CO shielding gas, for mixed gas use FCW 1. Flow rate 1-18 ml/min. Typical analysis in % (weld metal) C 0.0 Si 0.0 Mn 1.0 Important base materials S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH- P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, GE00-GE0, shipbuilding steels: A, B, D, A -D ASTM A Gr. 101, 101; A 10 Gr. C; A 8 Gr. B, C, D; A 85 Gr. A, B, C; A 51 Gr. 101, 10; A 51 Gr. 0, 5, 70; A 588 Gr. B, C; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; API 5 L B, X, X5, X0, X5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG C1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: CO Approvals TÜV, DB, ABS, BV, DNV, GL, LR, RINA, TL, CE Mechanical properties of the weld metal according to EN ISO at -0 C Product forms Spool Ø mm 1.0 Other dim ensions on request A ALUNOX Manual 18

192 FCW 1 Standard EN ISO 17-A EN ISO 17-B AWS A5. T P M 1 H5 T55T1-1MA-H5 E71T1-M1A-CS1-H Application Rutile flux-cored electrode for welding under mixed gases for joints on low alloyed steels in steel and bridge construction, and for pipelines and in shipbuilding. Easily solidifying slag gives an easily controllable weld pool, can be used with high power and because of this high deposition rate in all positions. Smooth spatterfree welding characteristics. Easily removable slag and finely rippled welding seams. Special hints Especially for welding under mixed gases, for CO use FCW 11. Flow rate 1-18 ml/min. Typical analysis in % (weld metal) C 0.05 Si 0.0 Mn 1.0 Important base materials S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH- P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, GE00-GE0, shipbuilding steels: A, B, D, A -D ASTM A Gr. 101, 101; A 10 Gr. C; A 8 Gr. B, C, D; A 85 Gr. A, B, C; A 51 Gr. 101, 10; A 51 Gr. 0, 5, 70; A 588 Gr. B, C; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; API 5 L B, X, X5, X0, X5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength R m Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO at -0 C Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO) Approvals TL Product forms Spool Ø mm 1. Other dim ensions on request 10 ALUNOX Manual

193 FCW 1 Standard EN ISO 17-A EN ISO 17-B AWS A5.18 T M M H5 T55T15-1MA-H5 E70C-MH Application Slag-free metal powder flux-cored electrode with excellent welding characteristics in short and spray arc. When welding in spray arc almost spatterfree. Good restriking properties so especially suitable for robot welding. High deposition rate and high welding velocity. Finely rippled seam surface with only slight silicate formation, multilayer welding is possible without intermediate cleaning. Good modelling characteristics in the short electric arc area, very good gap bridging and therefore especially suitable for root welds. Preferably weld in positions PA, PB, in short electric arc also in constrained positions. Special hints Can be welded under mixed gases and CO. Flow rate 1-18 ml/min Typical analysis in % (weld metal) C Si Mn Important base materials S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH- P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, GE00-GE0, shipbuilding steels: A, B, D, A -D ASTM A Gr. 101, 101; A 10 Gr. C; A 8 Gr. B, C, D; A 85 Gr. A, B, C; A 51 Gr. 101, 10; A 51 Gr. 0, 5, 70; A 588 Gr. B, C; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; API 5 L B, X, X5, X0, X Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO at -0 C / 50 J at -0 C 7 Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO), CO Approvals CE Product forms Spool Ø mm 1.0 Other dim ensions on request A ALUNOX Manual 11

194 FCW 0 Standard EN ISO 17-A EN ISO 17-B AWS A5. T B M H5 / T B C H5 T T5 0MA H5 / TT5-0CA-H5 E70T5-M1A-CS1-H / E70T5-C1A-CS1-H Application Basic flux-cored electrode with high mechanical properties. Suitable for crack-proof and tough weld joints in the manufacture of pressure vessels, boilers, storage tanks, steel structures and ships. Apart from that for buffer layers during cladding on hard to weld steels as well as for higher carburized steels and energized structures with unlimited wall thickness. Finely rippled weld seams, X-ray proof. Special hints Can be welded under mixed gases and CO. Flow rate 1-18 ml/min. Typical analysis in % (weld metal) C Si Mn Important base materials S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N-S0N, S75M-S0M, P5GH-P55GH, P55N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH- P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, GE00-GE0, shipbuilding steels: A, B, D, A -D ASTM A Gr. 101, 101; A 10 Gr. C; A 8 Gr. B, C, D; A 85 Gr. A, B, C; A 51 Gr. 101, 10; A 51 Gr. 0, 5, 70; A 588 Gr. B, C; A Gr. A, C, D; A Gr. A, B, C; A 78 Gr. B; API 5 L B, X, X5, X0, X5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO at -0 C / 0 J at -0 C Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO), CO Approvals TÜV, TL Product forms Spool Ø mm 1.0 Other dim ensions on request ALUNOX ALUNOX Manual Manual

195 FCW 10 Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1Ni P C 1 H5 T55T1-1CA-N1-H5 E81T1-C1A-Ni1-H Application Rutile flux-cored electrode for welding under CO for joints on cold tough steels in plant, tank and pipeline construction. Easily solidifying slag gives an easily controllable weld pool, can be used with high power and because of this high deposition rate in all positions. Stable arc with low spattering. Easily removable slag and finely rippled welding seams. Special hints Especially for welding under CO shielding gas, flow rate 1-18 l/min Typical analysis in % (weld metal) C Si Mn Ni Important base materials S55JR, S55JO, S50JO, S55J, S55N-S0N, S55M-S0M, S55NL-S0NL, S55ML- S0ML, S0Q, S0QL, P55GH, P55N-P0N, P55NH-P0NH, L5NB-L15NB, L50QB, L5MB-L50MB, L0QB-L50QB, GE00-GE00, shipbuilding steels: A-E,A-E ASTM A 10 Gr. C; A 51 Gr. 101, 10; A 51 Gr. 5, 70; A 57 Gr., 50, 55, 0, 5; A 57 Gr. 70; A 588 Gr. B, C; A Gr. A, C, D, E; A Gr. A, B, C; API 5 L B, X, X5, X0, X5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG C1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: CO Mechanical properties of the weld metal according to EN ISO >7 at -0 C Approvals RINA Product forms Spool Ø mm 1.0 Other dim ensions on request A ALUNOX Manual 1

196 FCW 01 Standard EN ISO 17-A EN ISO 17-B AWS A5. T MoL P C 1 H5 T55T1-1C-M-H5 E81T1-C1A-A1H Application Rutile flux-cored electrode for welding under CO for joints on creep resistant steels in plant, tank and pipeline construction with operating temperatures up to 500 C. Easily solidifying slag gives an easily controllable weld pool, can be used with high power and because of this high deposition rate in all positions. Stable arc with low spattering. Easily removable slag and finely rippled welding seams. Special hints Especially for welding under CO shielding gas, flow rate 1-18 l/min. Typical analysis in % (weld metal) C Si Mn Mo Important base materials 1Mo, 0MnMoNi-5, S5JR-S55JR, S5JO-S55JO, S50JO, S5J-S55J, S75N- S0N, S75M-S0M, P5GH-P55GH, P55N-P0N, P85NH-P0NH, P15TR1-P5TR1, P15TR-P5TR, P15GH-P5GH, L5NB-L15NB, L50QB, L5MB-L50MB, L0QB- L50QB, GE00-GE00 ASTM A Gr. 101, 101; A 10 Gr. A, B, C; A 18 Gr. F1; A Gr. WP1; A 8 Gr. B, C, D; A 5 Gr. P1; A 5 Gr. B, C; 51 Gr. 101, 10; A 51 Gr. 70; A Gr. C; API 5 L B, X, X5, X0, X5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG C1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO at -0 C Applicable shielding gases (EN ISO 1175) MAG: CO Approvals Product forms Spool Ø mm 1. Other dim ensions on request 1. 1 ALUNOX ALUNOX Manual Manual

197 AX-FD-DW Standard EN ISO 17-A EN ISO 17-B AWS A5. T 18 8 Mn R M1 TS Z07-F M1 0 E07T0-G 0 Application Flux-cored electrode with filling containing rutile primarily for horizontal welding positions. T cored electrode represents excellent welding characteristics, self releasing slag, extremely l spattering and seam oxidation, finely rippled weld beads with good flank coverage and even penetration. Special hints Characteristics of the weld metal: capable of work hardening, very good cavitation resistanc crack-proof, thermal shock resistant, scale-resistant up to 850 C, insensitive to brittling abov 500 C, tough at sub-zero down to -100 C. Operating temperatures up to 50 C 1 Typical pure weld metal composition in % C 0.07 Si 0. Mn. Cr 1. Ni 8.1 P 0.0 S Important base materials The AX-FD-DW07 is suitable for high strength, unalloyed and alloyed structural, tempering armouring steels with and to each other; unalloyed and alloyed boiler or structural steels with alloyed Cr and Cr-Ni steels; heat-resistant steels up to 850 C; austenitic manganese steels each other and with other steels; cold tough sheet and tubular steels in combination with col austenitic materials. Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100%CO ) Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO 157 >50 >500 > Product forms (tolerances as per EN ISO 5) Spool 15kg Ø mm 1. Welding position/ polarity MAG PA; PB; PC A ALUNOX Manual 15

198 AX-FD-DW08L Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 L R M1 TS 08L-F M1 0 E08LT0-/08LT0-1 Application Flux-cored electrode for joint welds on corrosion resistant austenitic CrNi steels. The weld metal possesses high resistance to intercrystalline corrosion at operating temperatures up to 50 C; tough at sub-zero down to -10 C. Welding characteristics The AX-FD-DW08L can be welded almost spatterfree with smooth electric arc and forms smooth, fine-scaled seams with notchless transitions. It displays good flank coverage and secure penetration. The slag can be easily removed. Typical pure weld metal composition in % C Si Mn P S Cr 0.5 Ni.5 Important base materials 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10, 1.1 GX10CrNi18-8 ASTM A 1 Gr. TP0L, TP7; A 0 Gr. 0L, 7; A 1 Gr. TP1, TP7; A 0 Gr. WP0L, WP0, WP1, WP7; A 51 Gr. CPF, CPF8; A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm or 1.5kg Welding position/ polarity MAG PA; PB; PC 0. mm all positions 1 ALUNOX Manual

199 AX-FD-DW08LP Standard EN ISO 17-A EN ISO 17-B AWS A5. T1 L P M1 1 TS 08L-F M1 1 E08LT1-/E08LT1-1 Application Flux-cored electrode for joint welds on corrosion resistant austenitic CrNi steels with rutile slag for position welding. Because of the rapidly solidifying slag welding with high power in constrained position is possible. The weld metal possesses high resistance to intercrystalline corrosion at operating temperatures up to 50 C; tough at sub-zero down to -10 C. Welding characteristics The AX-FD-DW08LP can be welded almost spatterfree with smooth electric arc and forms smooth, fine-scaled seams with notchless transitions. It displays good flank coverage and secure penetration. The slag can be easily removed. Typical pure weld metal composition in % C Si Mn P S Cr 0.5 Important base materials 1.0 XCrNi1-11, 1.01 X5CrNi18-10, 1.11 XCrNiN18-10, 1.51 XCrNiTi18-10, 1.5 X5CrNiNb18-10, XCrNiNb18-10, 1.1 GX10CrNi18-8 ASTM A 1 Gr. TP0L, TP7; A 0 Gr. 0L, 7; A 1 Gr. TP1, TP7; A 0 Gr. WP0L, WP0, WP1, WP7; A 51 Gr. CPF, CPF8; A 7 Gr. CF; A 81 Gr. TP0L, 0, TP1, TP7 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm 1. Welding position/ polarity MAG PA; PB; PC; PD; PE; PF; PG ² ² Ni.5 Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 17

200 AX-FD-DW0L Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 L R M1 TS 0L-F M1 0 E0LT0-/E0LT0-1 Application Flux-cored electrode with filling containing rutile for welding dissimilar joints between high alloyed Cr and CrNi steels with unalloyed or low alloyed steels primarily for horizontal welding positions. Also for the first layer of weld coatings on unalloyed and low alloyed base materials. Welding characteristics The fine-dropping very intensive welding spray arc with little spattering, the secure penetration, the self releasing slag and the well covering seam formation lead to a high weld quality with at the same time short welding times. The weld metal is suitable for an operating temperature range of -0 C to 00 C. Typical pure weld metal composition in % C Si Mn Cr Ni P 0.01 S Important base materials The flux-cored electrode is suitable for high strength, unalloyed and alloyed construction and tempering steels with and to each other; unalloyed and alloyed boiler or structural steels with high alloyed Cr and CrNi steels (dissimilar joints) for steam boiler and pressure vessel construction. Weld coatings: for the first layer of corrosion resistant weld coatings to P5GH, P5GH, S55N, P5GH, S55N - S500N. For the first layer of corrosion resistant weld coatings to creep resistant, quenched and tempered fine grain structural steels. Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm kg or 1.5kg Welding position/ polarity MAG PA; PB; PC Ø 0.mm all positions 18 ALUNOX Manual

201 AX-FD-DW0LP Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 L P M1 1 TS 0L-F M1 1 E0LT1-/E0LT1-1 Application Flux-cored electrode with filling containing rutile for welding dissimilar joints between high alloyed Cr and CrNi steels with unalloyed or low alloyed steels for all welding positions. Also for the first layer of weld coatings on unalloyed and low alloyed base materials. Welding characteristics The fine-dropping very intensive welding spray arc with little spattering, the secure penetration, the self releasing slag and the well covering seam formation lead to a high weld quality with at the same time short welding times. The weld metal is suitable for an operating temperature range of -0 C to +00 C. 0 1 Typical pure weld metal composition in % C 0.0 Si 0.8 Mn 1.8 P 0.0 S 0.01 Cr 0.5 Ni.5 Important base materials The flux-cored electrode is suitable for high strength, unalloyed and alloyed construction and tempering steels with and to each other; unalloyed and alloyed boiler or structural steels with high alloyed Cr and CrNi steels (dissimilar joints) for steam boiler and pressure vessel construction. Weld coatings: for the first layer of corrosion resistant weld coatings to P5GH, P5GH, S55N, P5GH, S55N - S500N. For the first layer of corrosion resistant weld coatings to creep resistant, quenched and tempered fine grain structural steels. Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm 1. Welding position/ polarity MAG PA; PB; PC; PD; PE; PF; PG Mechanical properties of the weld metal according to EN ISO A ALUNOX Manual 1

202 AX-FD-DW0MoL Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 L R M1 TS 0LMo-F M1 0 E0LMoT0-/E0LMoT0-1 Application Flux-cored electrode with filling containing rutile for welding dissimilar joints between high alloyed Cr and CrNi(Mo) steels with unalloyed or low alloyed steels primarily for horizontal welding positions. The flux-cored wire is characterised in this area of application by particular resistance to hot-cracking with high dilution and is required for the 1st layer for Mo-alloyed weld coatings. Welding characteristics The fine-dropping very intensive welding spray arc with little spattering, the secure penetration, the self releasing slag and the well covering seam formation lead to a high weld quality with at the same time short welding times. The weld metal is suitable for an operating temperature range of - 0 C to 00 C. Typical pure weld metal composition in % C Si Mn Cr Ni <0.0 < Mo.5 Cu <0.5 P <0.0 S <0.0 Important base materials The flux-cored electrode is suitable for high strength, unalloyed and alloyed structural and tempering steels with and to each other; unalloyed and alloyed boiler or structural steels with high alloyed Cr, CrNi and clad steels. Ferrite-austenite joints for steam boiler and pressure vessel construction. Weld coatings: for the first layer of corrosion resistant weld coatings to P5GH, P5GH, S55N, P5GH, S55N - S500N. For the first layer of corrosion resistant weld coatings to creep resistant, quenched and tempered fine grain structural steels. Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm 1. Welding position/ polarity MAG PA; PB; PC 00 ALUNOX Manual

203 AX-FD-DW0MoLP Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 L P M1 1 TS 0LMo-F M1 1 E0LMoT1-/E0LMoT1-1 Application Flux-cored electrode with filling containing rutile for welding dissimilar joints between high alloyed Cr and CrNi(Mo) steels with unalloyed or low alloyed steels for all welding positions. The flux-cored wire is characterised in this area of application by particular resistance to hot-cracking with high dilution and is required for the 1st layer for Mo-alloyed weld coatings. Welding characteristics The fine-dropping very intensive welding spray arc with little spattering, the secure penetration, the self releasing slag and the well covering seam formation lead to a high weld quality with at the same time short welding times. The weld metal is suitable for an operating temperature range of -0 C to +00 C. Typical pure weld metal composition in % C 0.05 Si <1.0 Mn.0 Cr Ni 1 Mo Cu.5 <0.5 P <0.0 S <0.0 Important base materials The flux-cored electrode is suitable for high strength, unalloyed and alloyed structural and tempering steels with and to each other; unalloyed and alloyed boiler or structural steels with high alloyed Cr, CrNi and clad steels. Ferrite-austenite joints for steam boiler and pressure vessel construction. Weld coatings: for the first layer of corrosion resistant weld coatings to P5GH, P5GH, S55N, P5GH, S55N - S500N. For the first layer of corrosion resistant weld coatings to creep resistant, quenched and tempered fine grain structural steels Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool 15kg Ø mm 1. Welding position/ polarity MAG PA; PB; PC; PD; PE; PF; PG 8 A ALUNOX ALUNOX Manual Manual 01

204 AX-FD-DW10 Standard EN ISO 17-A EN ISO 17-B AWS A5. T 5 0 R M1 TS 10-F M1 0 E10T0-/E 10T0-1 Application Flux-cored electrode for heat-resistant rolled, forged and cast steels of similar composition, e.g. annealing shops, hardening shops, steam boiler construction, oil industry, ceramics industry. Fully austenitic weld metal. Preferred in the case of attacks by oxidising, nitrogenous gases and those with low oxygen content. Scale-resistant to 100 C. Tough at sub-zero down to -1 C Welding characteristics Because of the risk of brittling, the temperature range between C should be avoided. Typical pure weld metal composition in % C Si Mn Cr Ni <0. < P <0.0 S <0.0 Important base materials Austenitic heat-resistant materials 1.81 X15CrNiSi5-0, 1.85 X8CrNi5-1, 1.81 X15CrNiSi5-, 1.8 GX5CrNiSi0-1, 1.87 GX0CrNiSi5-1, 1.80 GX15CrNi5-0, 1.8 X0CrNi5-1, 1.88 GX0CrNiSi5-0 ASTM A 17 Gr. 10; A 18 Gr. F10; A 7 Gr. 10, 10S, 1; A 1 Gr. 10, 10S, 1; A 0 Gr. TP10S; A 580 Gr. 10, 10S, 1; Ferritic heat-resistant materials 1.7 X10CrAlSi1, 1.7 X10CrAlSi18, 1.7 X10CrAlSi5, GX0CrSi7, 1.70 GX0CrSi17 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Mechanical properties of the weld metal according to EN ISO Product forms Spool 15 kg Ø mm 1. Welding position/ polarity MAG PA; PB; PC 0 ALUNOX Manual

205 AX-FD-DW1L Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 1 L R M1 TS 1L-F M1 0 E1LT0-/E1LT0-1 Application Flux-cored electrode for joint welds on corrosion resistant austenitic clad steels in horizontal positions. The weld metal possesses high resistance to intercrystalline corrosion at operating temperatures up to 00 C; tough at sub-zero down to -10 C. Welding characteristics The AX-FD-DW1L can be welded almost spatterfree with smooth electric arc and forms smooth, fine-scaled seams with notchless transitions. It displays good flank coverage and secure penetration. The slag can be easily removed. 0 1 Typical pure weld metal composition in % C Si Mn P S Ni 1 Cr 1 Mo. Important base materials 1.01 X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNiMo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 18 Gr. F1, F1L, F1LN, F1Ti; A1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFMN; A 0 Gr. WP1, WP1L, WP1LN; A 580 Gr. 1, 1L; A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 5 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm or 1.5kg Welding position/ polarity MAG PA; PB; PC Ø 0.mm all positions 8 A ALUNOX Manual 0

206 AX-FD-DW1LP Standard EN ISO 17-A EN ISO 17-B AWS A5. T 1 1 L P M1 1 TS1L-F M1 1 E 1LT1-/E1LT1-1 Application Flux-cored electrode for joint welds on corrosion resistant austenitic clad steels in all positions. Because of the rapidly solidifying slag, welding in constrained position is possible. The weld metal possesses high resistance to intercrystalline corrosion at operating temperatures up to 00 C; tough at sub-zero down to -10 C. Welding characteristics The AX-FD-DW1LP can be welded almost spatterfree with smooth electric arc and forms smooth, fine-scaled seams with notchless transitions. It displays good flank coverage and secure penetration. The slag can be easily removed. Typical pure weld metal composition in % C Si Mn P S Ni 1 Cr 1 Mo. Important base materials 1.01 X5CrNiMo17-1-, 1.0 XCrNiMo17-1-, 1.0 XCrNiMoN17-11-, 1. XCrNiMo17-1-, 1.5 XCrNiMo18-1-, 1. XCrNiMo17-1-, 1. XCrNiMo17-1-, 1.0 GXCrNiMo1-11-, XCrNiMoTi17-1-, XCrNiMoNb17-1-, 1.58 X10CrNiMoNb18-1 ASTM A 18 Gr. F1, F1L, F1LN, F1Ti; A1 Gr. TP1, TP1L, TP1LN, TP1Ti; A 1 Gr. TP1, TP1J, TP1LN, TP1Ti; A 1 Gr. 1, 1L, 1Ti, 1Cb; A 51 Gr. CFMN; A 0 Gr. WP1, WP1L, WP1LN; A 580 Gr. 1, 1L; A 88 Gr. AISI 1, TP1L, TP1LN; A 88 Gr. UNS S100, UNS S10, UNS S15 Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool Ø mm kg Welding position/ polarity MAG PA; PB; PC; PD; PE; PF; PG 0 ALUNOX ALUNOX Manual Manual

207 AX-FD-DWA Standard EN ISO 17-A EN ISO 17-B AWS A5. T NL R M1 TS 0-F M1 0 E0T0-/E0T0-1 Application Compound steel flux-cored electrode with filling containing rutile for joint welding primarily in horizontal welding positions. The flux-cored electrode is particularly suitable for welding ferriticaustenitic compound steels. Alongside high strength and toughness properties, the weld filler is characterized by good resistance to flake crack corrosion and pitting. The weld filler can be used in the temperature range of -0 С to +50 С. Welding characteristics Preheating and heat finishing are not necessary for the weld metal. The interpass temperature should not exceed 150 C. Typical pure weld metal composition in % C Si Mn Cr Ni Mo.5 N P S Important base materials Compound steels of similar composition and dissimilar joints with austenitic high alloyed and unalloyed steels 1. XCrNiMoN-5-, 1. XCrNiN-, 1. XCrNiMoN-5- with 1.58 X10CrNiMoNb XCrNiMoN-5- with P5GH/ P5GH, S55N, P5GH, S55N, 1Mo ASTM A 88 Gr. UNS Material properties Welding process Shielding gas Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av MAG M1 0 C [%] [J] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) MAG: M1 (argon with 15-5 % CO ), C1 (100% CO ) Approvals (Request current scope if required) Product forms Spool 15kg Ø mm 1. Welding position/ polarity MAG PA; PB; PC 8 A ALUNOX Manual 05

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210 Welding Consumables Special Materials Solid wires/tig rods Fe-base AX-MaCr1 1.1 AX-MaCr AX-MaCo1 1.5 Continuous casting rods cobaltbase AX-Co1 rod Stellite 1 AX-Co rod Stellite AX-Co1 rod Stellite 1 AX-Co1 rod Stellite 1 Metal powders cobalt-base AX-Co1 P Stellite 1 AX-Co P Stellite AX-Co1 P Stellite 1 AX-Co1 P Stellite 1 Metal powders nickel-base AX-Alloy 0 P Alloy 0 AX-Alloy 50 P Alloy 50 AX-Alloy 0 P Alloy 0 AX-5 P Alloy IN 5 Metal powders iron-base AX-1 P Alloy 1 AX-1 P/LC Alloy 1L Magnesium AX-Mg1A AZ1A The Special Materials group includes alloys for cladding and joint welding that are not allocated to the classical welding consumables. AX-MaCr1 and AX-MaCr are alloys that are used for cladding stainless contact surfaces on gas, water and steam fittings for operating temperatures up to approx. 500 C. AX-MaCo1 is an alloy for cladding hot working tools, the hardness can be increased by artificial ageing to approx. 50 HRC. AX-Mg1A is used for welding magnesium and magnesium alloys, AX-Ti for welding titanium and titanium alloys. AX-Zn. and AX-Znal15 are used as spray wire for overlaying corrosion resistant zinc layers. Titanium AX-Ti.705 Spray wire AX-Zn. AX-ZnAl15 spray wire spray wire Special materials 08 ALUNOX Manual

211 The cobalt base continuous casting rods are used for overlaying corrosion, heat and wear resistant layers on fittings, valves, in combustion engines, conveyor screws, pumps and heavily stressed hot working tools. New in this manual are the cobalt, nickel and iron-base metal powders. The field of application of the cobalt-base powder corresponds to that of the continuous casting rods. The nickel-base powders AX- Alloy 0 P, AX-Alloy 50 P and AX-Alloy 0 P fall into roughly the same field of application. The metal powders AX-5 P, AX 1 P and AX 1 P/LC correspond in application to the comparable TIG rods, solid wires and bar electrodes. Cobalt-base continuous casting rods can be welded in the TIG or gas process. When gas welding an acetylene excess, flame adjustment :1, should be used. Depending on granulation, metal powders can be used in the plasma transferred arc process (PTA) or as flame spray powder. Plasma transferred arc welding (PTA) is a thermal coating process for overlaying wear and corrosion resistant layers. Similarly to the TIG process, the main electric arc burns between the tungsten electrode and the workpiece. It is ignited and stabilized by a pilot arc burning between tungsten electrode and copper anode. Main and pilot arc each have their own current source. By ionization of the argon gas in the electric arc a plasma gas with high energy density is generated. Argon is fed in through an external nozzle which as shielding gas protects the weld pool from the ambient air. The powder is fed in by dosing equipment with the aid of powder conveying gas (argon). Overlays with very low dilution (5-10%) and high efficiency (up to 0 kg/h) can be created. It is the same with all flame spray processes that no actual fusing with the base material takes place but, depending on the process, a more or less strong interlocking. This depends on the type of process and from the impact velocity. Before the spraying process the surface of the workpiece must be cleaned of all contaminants such as rust, grease and oil. In addition the surface must be roughened by shot-blasting or turning to achieve better interlocking. The main flame spraying processes are flame spraying, flame spray welding and plasma/high velocity flame spraying A ALUNOX Manual 0

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213 Standard EN ISO 1-A EN ISO 1-B EN 1700 DIN 8555 AWS A 5. Material number W Z17MoH/G Z17MoH SSZ0 S ZFe7 MSG -GZ-50-ZR/WSG -GZ-50-ZR ER0 mod. 1.1 AX-MaCr1 1.1 Area of application Filler rod/filler wire for overlaying stainless contact surfaces on gas, water and steam fittings of unalloyed or low alloyed steels and cast steel types for operating temperatures up to 500 C as well as for joints on steels of similar composition. High heat resistance, wear resistance, salt water and scale resistant up to 00 C. Special hints Stainless martensitic weld metal, preheating and interpass temperature for overlays depending on base material C; for joints C, then temper at 70 C/h. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Mo Ni Important base materials Rust and acid resistant steel of identical and similar characteristics: fitting parts, shafts, spindles, valves. Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Hardness Hardness Soft annealing Hardening M11 untreated 0 C [%] [HB] [HRC] h at C cooling off in furnace C chill, cooling off in oil or air Mechanical properties of the weld metal as per EN ISO and DIN after HT 70 C/h after HT 70 C/h 1 after HT 70 C/h 0 after HT 70 C/h 7-5 unannealed/as welded Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M11, M1, M1 Approval (Request current scope if required) Product forms (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm A ALUNOX Manual 11

214 AX-MaCr Standard EN ISO 1-A EN ISO 1-B EN 1700 DIN 8555 AWS A 5. Material number W Z17Mo/G Z17Mo SSZ0 S ZFe7 MSG -GZ-5-ZR/WSG -GZ-5-ZR ER0 mod Area of application Filler rod/filler wire for overlaying stainless contact surfaces on gas, water and steam fittings of unalloyed or low alloyed steels and cast steel types for operating temperatures up to 500 C as well as for joints on steels of similar composition. High heat resistance, wear resistance, salt water and scale resistant up to 00 C. Special hints Stainless martensitic weld metal, preheating and interpass temperature for overlays depending on base material C; for joints C, then temper at 70 C/h. Composition of the filler rod/filler wire (typical data in %) C 0.1 Si 0. Mn 0. Cr 17.5 Ni 0.5 Mo 1.1 Material properties Shielding gas Heat treatment Test temperature 0.%-yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Hardness Hardness M11 untreated 0 C [%] [HB] [HRC] Mechanical properties of the weld metal as per EN ISO and DIN after HT 70 C/h 0 after HT 70 C/h 15 after HT 70 C/h 00 after HT 70 C/h 5-5 unannealed/as welded Applicable shielding gases (EN ISO 1175) TIG: argon I1; MAG: Mixed gases e.g. M11, M1, M1 Approval (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm Rod Ø mm x ALUNOX Manual

215 Standard EN 1700 DIN 855 Workpc. no. S ZFe5 W/MSG -GZ-50-T 1.5 AX-MaCo1 1.5 Area of application High alloyed filler rod/filler wire, heat hardenable, very tough weld filler. For extremely wear resistant overlays on heavily stressed tools for cold and hot working. The weld metal as welded is very easily machinable by chip removing. Optimum heat wear and thermal shock resistance are achieved after artificial ageing. Special hints High alloyed, martensite hardenable, very tough weld filler. Machine welding zone to metallic plain, machine out any cracks completely. Preheat to C. 0 1 Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr Mo Ni Co 1.0 Ti 1. Important base materials Hardenable TIG or MAG overlays on cold or hot working tools such as punching tools, hot cutting tools, Al die casting moulds, cold forging dies, drawing, stamping and chamfering tools. Material properties Shielding gas Heat treatment Test temperature Argon untreated 0 C Mechanical properties of the weld metal as per EN ISO and DIN %-yield strength Rp 0. Tensile strength Rm Hardness untreated Hardness artificially aged [HRC] -h at 80 C [HRC] Applicable shielding gases (EN ISO 1175) TIG: argon I1, MAG: mixed gases e.g. M11, M1, M1, Approval (Request current scope if required) Product forms (other dimensions available on request) Spool Rod Ø mm Ø mm x1000mm A ALUNOX Manual 1

216 AX-Co1 rod Stellite 1 Standard EN 1700 DIN 8555 AWS A 5.1 R ZCo G/WSG 0-GO-55-CSTZ ERCoCr-C mod. Area of application Filler rod of a cobalt-chromium-tungsten alloy for corrosion resistant, heat and wear resistant hardfacings. Stellite alloy with high resistance to abrasion, oxidation and erosion. Eminently suitable to counter sliding stress of metal on metal. AX-Co 1 is suitable for TIG and gas welding. Depending on base material, a buffer layer with AX-07 is recommended. Special hints Hardest of the generally used cobalt base alloys. The weld metal is very abrasion, creep and heat resistant. The high hardness only allows machining by grinding. The alloy is corrosion resistant, especially against reducing acids and scale resistant to approx C. Excellent sliding properties and good polishing characteristics. Composition of the filler rod/filler wire (typical data in %) C Si Mn Cr W Fe Co Residue Important base materials For grinding and chaser mills, wear rings, wear elements in the chemical industry as well as salt and lye pumps. Rust and acid-resistant stainless steel: fitting parts, shafts, spindles, valves and for running and contact surfaces on fittings and valve seats and cones in combustion engines as well as for heavily stressed hot working tools without thermal shock load. Material properties Hardness at 0 C Hardness at 00 C [HRC] [HRC] 5-58 approx. 0 Applicable shielding gases (EN ISO 1175) TIG: argon I1 GAS: set acetylene excess (reducing flame) Approval (Request current scope if required) Product forms (other lengths on request) Rod Ø mm x1000mm 1 ALUNOX Manual

217 Standard EN 1700 DIN 8555 AWS A 5.1 R Co G/WSG 0-GO-0-CSTZ ERCoCr-A AX-Co rod Stellite Area of application Tough, high strength and heat resistant Stellite alloy for overlays where wear stress is accompanied by light impact stress and corrosion. AX-Co is the Stellite type predominantly used. Very well suited to workpieces that have to withstand pressure and abrasion under high temperatures. Scale resistant up to approx. 00 C. AX-Co is suitable for TIG and gas welding. Depending on base material, a buffer layer with AX-07 is recommended. Special hints Because of the Cr and W carbides embedded in the cobalt-base alloys, alongside high abrasion these alloys also resist heavy corrosion attacks. The weld metal is still easily machinable by cutting with tungsten carbide tools. Excellent sliding properties and good polishing characteristics, good toughness. Composition of the filler rod (typical data in %) C Si Mn Cr W Fe Co Residue Important base materials Particularly suitable for contact surfaces on fittings, valve seats and cones in combustion engines, heavily stressed hot working tools without thermal shock load, salt and lye pumps, rust and acid resistant fitting parts, shafts and spindles, grinding, stirring and boring tools as well as for metal on metal sliding surfaces Material properties Hardness at 0 C Hardness at 00 C [HRC] [HRC] 0- approx. Applicable shielding gases (EN ISO 1175) TIG: argon I1 GAS: set acetylene excess (reducing flame) Approval (Request current scope if required) Product forms (other lengths on request) Rod Ø mm x mm 7 8 A ALUNOX Manual 15

218 AX-Co1 rod Stellite 1 Standard EN 1700 DIN 8555 AWS A 5.1 R Co G/WSG 0-GO-50-CSTZ ERCoCr-B Area of application The cobalt-based alloy Co 1 is somewhat more wear resistant compared with the Co. The toughness and the hardness can be placed between the Co1 and Co. Particularly suitable for wear stress in combination with corrosion, scale resistant up to approx. 00 C. AX-Co1 is suitable for TIG and gas welding. Depending on base material, a buffer layer with AX-07 is recommended. Special hints Alongside high abrasion, this alloy also resists heavy corrosion stress. The weld metal is still machinable by cutting with tungsten carbide tools. Composition of the filler rod (typical data in %) C Si Mn Cr W Fe.0 Co Residue Important base materials The alloy is particularly suitable for machining tools in the hardwood, paper and plastics industries, for extruder worms, valve spindles, earth augers. For running and contact surfaces of fittings, hot pressing dies, high temperature liquid pumps, valve seats and plugs of combustion engines and billet shears, as well as for highly stressed hot working tools. Material properties Hardness at 0 C Hardness at 00 C [HRC] [HRC] 7-51 approx. 0 Applicable shielding gases (EN ISO 1175) TIG: argon I1 GAS: set acetylene excess (reducing flame) Approval (Request current scope if required) Product forms (other lengths on request) Rod Ø mm x mm 1 ALUNOX ALUNOX Manual Manual

219 Standard EN 1700 DIN 8555 AWS A 5.1 R Co1 G/WSG 0-GO-00-CKTZ ERCoCr-E AX-Co1 rod Stellite 1 0 Area of application The weld metal of these cast rods for TIG welding or gas welding is highly creep resistant and resistant to high temperatures, corrosion and oxidation. Good wear resistance, very good toughness and good thermal shock resistance is achieved with these filler rods. This alloy has excellent sliding properties and is strain hardenable to approx. 5 HRC. Special hints Alongside high abrasion and heavy corrosion, this alloy also resists impact load as well as extreme thermal shocks. The weld metal is very easily machinable by cutting with tungsten carbide tools. 1 Composition of the filler rod (typical data in %) C 0.5 Si 1.5 Mn 1. Cr 8.0 Mo.0 Ni.0 Fe.0 Co Residue Important base materials The alloy is particularly suitable for hot working tools with thermocycling, for contact surfaces on steam, water, gas and acid fittings, for extruder worms, valve spindles, earth augers. For high temperature liquid pumps, valve seats of combustion engines and billet shears. Material properties Hardness at 0 C Hardness at 00 C work-hardened [HRC] [HRC] [HRC] Applicable shielding gases (EN ISO 1175) TIG: argon I1 GAS: acetylene excess (reducing flame) Approval (Request current scope if required) Product forms (other lengths on request) Rod Ø mm x m Other lengths on request approx A ALUNOX Manual 17

220 AX-Co1P Stellite 1 Standard EN 1700 DIN 8555 AWS A 5.1 Alloyed metal powder, gas atomized Cobalt base hard facing, C-Cr-W alloyed P Co Type 0-55 CTZ Type CoCr-C Area of application For overlays or armouring of running and contact surfaces on gas, water, steam and acid fittings, heavily stressed hot working tools, valve seats and cones of combustion engines, grinding, stirring, conveying and boring tools, stamping, press moulds and extruder worms. Highly creep resistant, corrosion resistant, heat resistant up to 00 C, good wear resistance, excellent sliding and abrasion properties, high cavitation resistance, naturally hard, i.e. heat treatment only affects the hardness insignificantly, easy to polish, non-hardenable, weakly magnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Cr W Co Residue Material properties Hardness at 0 C Hardness at 500 C [HRC] [HRC] approx. 5 PTA welding in the nd layer approx. PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The weld metal is still machinable by turning with tungsten carbide tools, however grinding is recommended. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request. 18 ALUNOX Manual

221 Standard EN 1700 DIN 8555 AWS A 5.1 Alloyed metal powder, gas atomized Cobalt base hard facing, C-Cr-W alloyed P Co Type 0-0 CTZ Type CoCr-C AX-CoP Stellite Area of application For cladding or armouring of running and contact surfaces on gas, water, steam and acid fittings, heavily stressed hot working tools, valve seats and cones of combustion engines, grinding, stirring, conveying and boring tools, stamping and press moulds. High-temperature resistant, corrosion resistant, heat resistant up to 00 C, good wear and shock resistance, excellent sliding properties, high cavitation resistance, good toughness for hard alloys, good polishing characteristics, nonhardenable, non-magnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Cr W Fe Ni Co Residue Material properties Hardness at 0 C Hardness at 500 C [HRC] [HRC] approx. 1 PTA welding in the nd layer approx. PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. The spraying process should be carried out directly after the surface preparation. The weld metal is still machinable by turning with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request A ALUNOX Manual 1

222 AX-Co1P Stellite 1 Standard EN 1700 DIN 8555 AWS A 5.1 P Co Type 0-50 CTZ Type CoCr-B Alloyed metal powder, gas atomized Cobalt base hard facing, C-Cr-W alloyed Area of application For cladding or armouring of running and contact surfaces on gas, water, steam and acid fittings, heavily stressed hot working tools, valve seats and cones of combustion engines, grinding, stirring, conveying and boring tools, stamping, press moulds and extruder worms. High-temperature resistant, corrosion resistant, heat resistant up to 00 C, good wear resistance, excellent sliding and abrasion properties, high cavitation resistance, naturally hard, i.e. heat treatment only affects the hardness insignificantly, good polishing characteristics, non-hardenable, weakly magnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Cr W Co Residue Material properties Hardness at 0 C Hardness at 500 C [HRC] [HRC] approx. 8 PTA welding in the nd layer approx. 0 PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The weld metal is still machinable by turning with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request. 0 ALUNOX Manual

223 Standard EN 1700 DIN 8555 AWS A 5.1 Alloyed metal powder, gas atomized Cobalt base hard facing, C-Cr-Mo-Ni alloyed P ZCo1 Type 0-00 CKTZ Type CoCr-E AX-Co1P Stellite 1 Area of application For cladding or armouring of running and contact surfaces on gas, water, steam and acid fittings, heavily stressed hot working tools, valve seats and cones extruder worms. Hightemperature resistant, highly corrosion resistant, heat resistant up to 00 C, excellent sliding properties, excellent toughness for hard alloys, naturally hard, i.e. heat treatment only affects the hardness insignificantly, good polishing characteristics, non-hardenable, weakly magnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Cr Mo Ni Co Residue Material properties Hardness at 0 C Hardness at 00 C [HRC] [HB] approx. PTA welding in the nd layer approx. 0 PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The weld metal is machinable by turning with tungsten carbide tools, with pressure or shock load the hardness can increase by work hardening. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request A ALUNOX Manual 1

224 AX-Alloy 0P Alloy 0 Standard EN 1700 DIN 8555 AWS A 5.1 P Ni Type -0 CTGR Type NiCr-A Alloyed metal powder, gas atomized Nickel-base hard alloy, Cr-Si-B alloyed Area of application For coating running and contact surfaces on gas, water, steam and acid fittings, valve seats and cones for combustion engines, grinding, stirring, conveying and boring tools, stamping, press moulds and plungers in the glass industry. High-temperature resistant, corrosion resistant, good wear resistance, excellent sliding properties, high erosion and cavitation resistance, good polishing characteristics, resistant to thermal shocks, nonmagnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. Because of the selfflowing properties, this powder quality is very suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Si Cr Fe B Ni Residue Material properties Hardness at 0 C [HRC] approx. 0 PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual adhesive surface preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The weld metal is still machinable by turning with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request. ALUNOX Manual

225 Standard EN 1700 DIN 8555 AWS A 5.1 Alloyed metal powder, gas atomized Nickel-base hard alloy, Cr-Si-B alloyed P Ni Type -50 CTGR Type NiCr-B AX-Alloy 50P Alloy 50 Area of application For coating running and contact surfaces on gas, water, steam and acid fittings, valve seats and cones for combustion engines, grinding, stirring, conveying and boring tools, stamping, press moulds and plungers in the glass industry. High-temperature resistant, corrosion resistant, good wear resistance, excellent sliding properties, high erosion and cavitation resistance, good polishing characteristics, resistant to thermal shocks, non-magnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. Because of the self-flowing properties, this powder quality is very suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Si Cr Fe B Ni Residue Material properties Hardness at 0 C [HRC] approx. 50 PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. The spraying process should be carried out directly after the surface preparation. The weld metal is still machinable by turning with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request A ALUNOX Manual

226 AX-Alloy 0P Alloy 0 Standard EN 1700 DIN 8555 AWS A 5.1 P Ni1 Type -0 CTGR Type NiCr-C Alloyed metal powder, gas atomized Nickel-base hard alloy, Cr-Si-B alloyed Area of application For coating running and contact surfaces on gas, water, steam and acid fittings, valve seats and cones for combustion engines, grinding, stirring, conveying and boring tools, stamping, press moulds and plungers in the glass industry. High-temperature resistant, corrosion resistant, good wear resistance, excellent sliding properties, high erosion and cavitation resistance, good polishing characteristics, resistant to thermal shocks, nonmagnetic. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying. Because of the selfflowing properties, this powder quality is very suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Si Cr Fe B Ni Residue Material properties Hardness at 0 C [HRC] approx. 0 PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The overlay should be machined by grinding. Under special conditions turning with special tungsten carbide tools is still possible. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request. ALUNOX Manual

227 Standard EN ISO 187 AWS A 5.1 Alloyed metal powder, gas atomized Nickel-base metal powder, Cr-Mo-Nb-Fe alloyed S Ni 5 (based on) ER NiCrMo- (based on) AX-5 P Alloy IN 5 Area of application For cladding or coating valves for combustion engines, running and contact surfaces on gas, water, steam and acid fittings, heavily stressed hot working tools and parts for the chemical industry. The powder is also suitable for corrosion resistant cladding and coating on cast iron. High-temperature resistant, corrosion resistant, scale resistant, hot gas corrosion resistant, excellent sliding properties, good polishing characteristics, extremely high resistance against flake crack corrosion and hole corrosion, thermal shock resistant. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying (high velocity (HVOF) and plasma spraying). This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Si Mn Cr Mo Nb <0.05 <0.5 < Fe.0 Ni Residue General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. The spraying process should be carried out directly after the surface preparation. The weld metal is machinable with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request A ALUNOX Manual 5

228 AX-1 P Alloy 1 Standard EN ISO 1-A/EN ISO 1-B DIN 8555 AWS A 5. - / SS1 (basis) Type -00 CR ER 1 (basis) Alloyed metal powder, gas atomized Iron-base metal powder, Cr-Ni-Mo alloyed Area of application For cladding or coating of running and contact surfaces on acid, gas, water and steam fittings at operating temperatures up to 00 C, corrosion resistant coatings in the chemical industry, textile and cellulose industries, beverage production, dyeworks and artificial resin plants. Austenitic weld metal with low ferrite content, high corrosion resistance from the Mo addition particularly suitable for stresses from chloride containing media. With base materials of similar composition the weld metal is resistant to grain disintegration without quenching after welding, operating temperature up to max. 00 C. At higher temperatures applicability is only ensured with media that do not trigger intercrystalline corrosion (IGC). Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying (high velocity (HVOF) and plasma spraying). This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. Composition of the metal powder (typical data in %) C Cr Ni Mo Fe Residue Material properties Hardness at 0 C [HB] PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. They spraying process should be carried out directly after the surface preparation. The weld metal is machinable with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request. ALUNOX Manual

229 Alloyed metal powder, gas atomized Iron-base metal powder, Cr-Ni-Mo alloyed Standard EN ISO 1-A/EN ISO 1-B DIN 8555 AWS A 5. P 1 1 L / SS1L (basis) Type -00 CR ER 1L (basis) AX-1 P/LC Alloy 1L 0 Area of application For cladding or coating of running and contact surfaces on acid, gas, water and steam fittings at operating temperatures up to 00 C, corrosion resistant coatings in the chemical industry, textile and cellulose industries, beverage production, dyeworks and artificial resin plants. Austenitic weld metal with low ferrite content, high corrosion resistance from the Mo addition particularly suitable for stresses from chloride containing media. With base materials of similar composition the weld metal is resistant to grain disintegration without quenching after welding. Special hints Metal powder in spherical form for plasma cladding as well as for thermal spraying (high velocity (HVOF) and plasma spraying). This powder quality is not suitable for simultaneous and subsequent melting on during thermal spraying. 1 Composition of the metal powder (typical data in %) C Si Mn Cr Ni Mo < Fe Residue Material properties Hardness at 0 C [HB] PTA welding in the nd layer General working guidelines For cladding the preheat and interpass temperatures are to be determined according to the base material and dimension. For thermal spraying the surface is to be carefully cleaned of rust, grease and oil before the actual bonding base preparation. The bare metal surface should be roughened by shot-blasting, turning or grinding to enable good interlocking with the spray layer. The spraying process should be carried out directly after the surface preparation. The weld metal is machinable with tungsten carbide tools. Product forms PTA welding: µm Thermal spraying: 0-5 µm Other grain sizes on request The material is packed in plastic containers of 5 kg. Other packaging units on request A ALUNOX Manual 7

230 AX-Mg1A Standard DIN EN 175 AMS 50 Mg alloys AZ1A Area of application Solid wire electrode/ filler rod for the maintenance and repair of components of magnesium and magnesium alloys. Special hints Composition of the filler rod/filler wire (typical data in %) Mg Basis Al.5 Mn 0. Important base materials Magnesium alloys Zn 0.8 Material properties Welding process Heat treatment Test temperature Yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Modulus of elasticity Liquidus - solidus temperature Coefficient of thermal expansion Density MIG untreated 0 C [%] [GPa] [ C] [1/K] [at 0 C in kg/dm³] Mechanical properties of the weld metal according to EN ISO x Applicable shielding gases (EN ISO 1175) TIG/MIG: argon I1 Approval (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm Rod Ø mm x mm 8 ALUNOX Manual

231 Standard EN ISO 0 Material number: AWS A5.1 UNS S Ti 010 (Ti.).705 ERTi R5010 AX-Ti Area of application TIG filler rod for welding pure titanium and titanium alloys. The quality has high impact strength and is easily weldable and corrosion resistant in strongly oxidizing as well as medium reducing environments, saltwater-proof. Because of the high affinity to oxygen great care and the greatest possible cleanliness must be observed when welding. Additional gas shielding is to be ensured also during the cool down phase (trailing nozzle). Special hints Composition of the filler rod (typical data in %) Ti Fe C N Bal Important base materials Titanium alloys 1 Material properties Welding process Heat treatment Test temperature Yield strength Rp 0. Tensile strength Rm Elongation A (L = 5d) % 0 0 Impact strength Av Modulus of elasticity TIG untreated 0C [%] [J] 10 [psi] Mechanical properties of the weld metal according to EN ISO Applicable shielding gases (EN ISO 1175) TIG: argon I1 Approval (Request current scope if required) Product forms (other dimensions available on request) Rod Ø mm x mm 7 8 A ALUNOX Manual

232 AX-Zn. (spray wire) Standard DIN EN 117 Alloy designation Z1 (Pure zinc.5) Zn. Area of application Spray wire for overlays of zinc for electric arc wire spraying. Special hints Composition of the filler rod/filler wire (typical data in %) Zn Pb Cd Sn Cu Fe Basis <0.00 <0.00 <0.001 <0.001 <0.00 Al <0.001 Important base materials Material properties Tensile strength Rm Yield strength Rp 0. Elongation A 100mm Density Melting point [%] [g/cm³] [C ] >0 7.1 approx. 1 Applicable shielding gases (EN ISO 1175) Argon I1 Approval (Request current scope if required) Product forms (other dimensions available on request) Spool Ø mm ALUNOX Manual

233 Standard DIN EN 117 Alloy designation ZnAl15 (zinc with 1-1 %Al) ZnAl15 AX-ZnAl15 (spray wire) Area of application Spray wire for overlays of zinc-aluminium alloys for electric arc wire spraying. AX-ZnAl15 offers greater corrosion protection than Al-Zn. with lower consumption. Special hints 0 1 Composition of the filler rod/filler wire (typical data in %) Zn Al Cd Sn Cu Si Basis 1-1 <0.00 <0.001 <0.001 <0.1 Fe <0.05 Pb <0.00 Important base materials Material properties Tensile strength Rm Yield strength Rp 0. Elongation A 100mm 100mm Density Fusion range [%] [g/cm³] [C ] Applicable shielding gases (EN ISO 1175) Argon I > Approval Product forms (other dimensions available on request) Spool Ø mm.5 5 kg 7 8 A ALUNOX Manual 1

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236 AX Igniter AX Electrode Holder AX EasyGlide Liner AX Weld Pool Backing AX Manual AX-DRW Wire Roller Straightening Unit AX-Cera Accessories ALUNOX Manual

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238 ALUNOX Manual

239 AX-Anzünder Igniter A ALUNOX Manual 7

240 AX EasyGlideLiner Standard The AX EGL is a wire guidance liner functioning on a roller basis. We have often been asked to solve the problem of flawed wire feed technology. Driven on by this task we have launched our Easy Glide. This involves a wire conveying liner which replaces the well-known PTFE or PA liner. In the forefront here is the practically wear-free wire transport. The advantages are: - The wire roller bearing assembly is shown to have lower feeder current consumption by a factor of 5 and an intermediate feeder unit is superfluous. - This is accompanied by significantly better effectiveness because of the lower rolling contact friction. friction. - This in is turn accompanied results in even by conveying a significantly behaviour better even because at distances of lower of up rolling to 0 contact metres friction. and the - classical effectiveness This in turn stutter results is avoided. in even conveying behaviour even distances at distances of up of to up 0 to metres 0 metres to a stutter and the This in turn results in even conveying behaviour classical A decentralized stutter is structure avoided. of drums is now possible and is avoided. reasonable. -Because even at and of the classical relatively small size of only 5 mm outside only possible diameter and the reasonable. Easy Glide can be stowed in - A decentralized structure of drums is now possible and reasonable. cable decentralized ducts or because structure of the of drums robust is design also fitted only to the 5 hardware mm outside e.g. diameter robot arm. because of the -Because -Because of After flowing of the the relatively out relatively small of the drum, small size the welding size of only of Easy 5 mm filler wire Glide outside diameter the Easy Glide can be stowed in has robust enough design room also to to untwist the hardware and settle. e.g. cable stow in ducts cable or ducts because or fit of through the robust the robot design arm. also fitted to the hardware e.g. robot arm. - After flowing out out of the the filler drum, wire the out welding of the filler wire has drum enough enough room room to untwist to untwist and and settle. to settle. The cost saving is shown by the lower energy requirement, better efficiency from lower torques, The Die Kostenersparnis wear-free cost saving operation shown zeigt of the by sich The cost saving is shown by wire the durch the feed lower den lower unit, energy geringeren energy lower requirement, Energiebedarf, requirement, set-up times better better and less efficiency den besseren efficiency production from from waste. lower Wirkungsgrad torques, lower torques, wear-free operation of the wire feed unit, lower set-up times and less production waste. wear-free operation of the wire feed unit, lower set-up times and less production waste. Connection piece (kit) The Easy Glide is suitable for all welding filler wire materials and all diameters. Different wire feed speeds are no longer important. The Easy Glide consists of individual flexible links in the core and a robust external protective tube of PE plastic. The Easy Glide elements are made of Polyamide. The Easy Glide is designed in such a way that it can be indefinitely extended. For this the end caps are connected with patented couplings Technical data: Dimensions Ø 5 mm (tube) Ø 0 mm (end cap) Wire diameter: up to mm Weight: approx. 80 g / m Conveying distances: up to 0 metres 8 ALUNOX Manual

241 AX-Schweißerzange Electrode Holder A ALUNOX Manual

242 AX Weld Pool Backing Ceramic pool backings for one-side welding are opening up more and more areas of application. What started in the past with use in shipbuilding is today becoming increasingly important for pressure vessel, tank, bridge and plant construction. The advantages of the process have been recognized in many technical welding businesses. But where exactly are the particular advantages of one-side welding on ceramic? 1. Higher deposition rate from higher welding currents The weld pool backing enables the use of a higher welding current in the root layer. This means, for example during MAG welding, spatterfree welding in spray arc, when manual electric welding, the possibility of working with larger electrode diameters.. Easier seam preparation Broad recesses in the ceramics allow adjustment to fluctuating air gap dimensions. With some types of ceramics air gap widths up to 10 mm can be equalized. This reduces the time spent aligning the sheets.. No necessity for chamfering or grinding out the root layer Welding on ceramic pool backing creates a very good root quality so, unlike the traditional process with capping pass, the root stays an integral part of the seam and does not have to be ground out. Further advantages: lower filler metal consumption, less welding time.. Reliable weld penetration and high optical seam quality Higher welding currents during the root layer create a deep weld penetration with clearly reduced risk of fusion faults. Because of its good formation the root acquires the function of a capping pass. After removing the pool backing a shiny seam underside is visible with soft, notchless transition to the base material. 5. Forming effect on the seam underside When ceramics are used on self-adhesive aluminium foil a forming effect arises on the seam underside which can be used in particular in working stainless steels. The use of forming gases can often be dispensed with 0 ALUNOX Manual

243 Ceramic Weld Pool Backings Ceramic Weld Backings Type AX-TGS00/1 (Colouring: grey) AX Weld pool backing 0 1 Type: ceramic on self-adhesive aluminium strip with trapezoidal groove Length Groove width Groove depth Division 500 mm 1 mm 1.5 mm 0 x5 Z5 Ceramic Weld Pool Backings Ceramic Weld Backings 5 Type AX-HRG 500/10 (Colouring: grey) Type: ceramic on self-adhesive aluminium strip with semi-circular groove Length 500 mm Groove width 10 mm Groove depth 1.5 mm Division 5 x A ALUNOX Manual 1

244 AX Weld Pool pool Backing backing Ceramic Weld Pool Backings Ceramic Weld Backings Type AX-HRG 500/1 (Colouring: grey) Type: ceramic on self-adhesive aluminium strip with semi-circular groove Length 500 mm Groove width 1 mm Groove depth 1.5 mm Division 5 x 5 Ceramic Weld Pool Backings Ceramic Weld Backings Type AX-HRG 500/1 (Colouring: grey) Type: ceramic on self-adhesive aluminium strip with semi-circular groove Length 500mm Groove width 1mm Groove depth 1.5 mm Division 0 x 5 ALUNOX Manual

245 Ceramic Weld Pool Backings Ceramic Weld Backings Type AX-RG 500/7 - RG 500/ (Colouring: grey) AX Weld pool backing 0 1 Type: ceramic on self-adhesive aluminium strip cylindrical shape Length 500 mm I 500 mm Diameter.5 mm I.0 mm Division 0 I 5 mm Ceramic Weld Pool Backings Ceramic Weld Backings Type AX-RG 500/1 (Colouring: grey) 5 Type: ceramic on self-adhesive aluminium strip cylindrical shape Length 500 mm Diameter 11.5 mm Division A ALUNOX Manual

246 AX Manual Together with the list of all AX filler metals there are many useful things and help for the welder in the AX Manual. In future you should also find updates on them on our website ALUNOX Manual

247 AX-Wire Roller Straightening Unit Standard Wire roller straightening units assist the function of the smooth flow of a filler wire (aluminium) from a drum (80-1kg). The idea behind the AX-DRW is to provide a technical solution for process assurance. Maintenance is not necessary and operation (wire insertion) is very easily done. The filler wire is physically/mechanically reshaped in the AX-DRW to the effect that it loses all preacquired characteristic properties. Particularly for long-storage drum wires but also for K or D spools of all sizes. The AX-DRW is designed so that a variable belt tension is to be set. The AX-DRW is fixed firmly on the drum hood and secured against axial torsion. Entry into the AX-DRW is guided by a ceramic sleeve before the wire is guided through a pulley and runs to the sun wheel with notch/groove. With a wrap of min. 70 the wire is then passed on through a ceramic sleeve into the Easy Glide or the Teflon liner. The wrapping and fixing device of the wire on the sun wheel is performed by an O-ring. The grooved ball bearings, single row, with circular groove in outer ring act as bearings A ALUNOX Manual 5

248 AX-Cera Standard AX-Cera is a ceramic-based protective spray for your welding equipment and surfaces to be protected. Use More productivity and time saving. Thanks to its ingenious composition AX-Cera ensures that weld spattering cannot adhere to welding tips and gas nozzles. The welding process no longer needs to be interrupted for cleaning welding tips and gas nozzles - you can work more productively. Save money. Welding tips and gas nozzles are protected by AX-Cera not only physically but also thermally, which means that the parts have on average a four to five times higher service life. Seen over the year this can lead to significant cost savings. Weld more cleanly. As the gas nozzle does not get any spattering and the gas flow is not interrupted, you obtain a perfect welding seam every time. --> ALUNOX Manual

249 Robot-controlled MIG/MAG welding The use of AX-Cera in robot-controlled welding processes offers you not only all of the above advantages for automatic and semi-automatic MIG/MAG welding processes but over and above that some extra advantages. Savings in capital expenditure and consumables. If you use AX-Cera, grinding off spattering from welding tip and gas nozzle is no longer necessary. With the result that capital expenditure for expensive grinding/cleaning plants and the costs for antispatter agents can be dispensed with. Furthermore AX-Cera reduces wear of gas nozzles and welding tips, i.e. you save costs and consumables. Higher revenues. The downtimes associated with grinding and cleaning can as of now be used productively. By having your robot weld without interruption, you will increase your productivity and turnover. MIG/MAG SPOT-WELDING LASER/PLASMA Clamping jaws, devices and equipment Lower labour costs. By using AX-Cera you will provide clamping jaws, devices and equipment with a protective coating that prevents weld spatters from sticking to the surfaces. The labour-intensive removal of spatters at the end of the work shift and expensive cleaning chemicals are no longer necessary. The spatters can be effortlessly brushed off with a soft brush, the surfaces need no longer be thoroughly cleaned. Increased productivity. Working time that up to now has had to be spent manually removing welding spatters can now be used for production. This increases your productivity considerably. AX-Cera protects not only clamping jaws, devices and equipment. It can also be used for power cables, sensors, holders, metal pieces and jaws of spot welding plants where adhering spatters represent a perpetual problem. A one-off coating with AERODAG CERAMISHIELD can protect these applications for up to a week. Laser and plasma cutting machinery Laser and plasma nozzles are particularly sensitive to spatters as they easily interrupt the production process. A thin protective film with AX-Cera offers protection without impairing the operation of the equipment. Save costs. Plasma and laser nozzles are protected by AX-Cera physically and thermally, which means that the parts have on average a four to five times higher service life. Saving time and increasing productivity. Reliable continuous work processes without annoying downtimes increase your productivity A ALUNOX Manual 7

250 Useful information for the welder A.1. Assistance in the choice of welding consumables A.1.1 Selection table Alu A.1. Selection table Copper A.1. Selection table Nickel A.1. Selection table High alloyed A.1.5 Preheating and finishing of steels A.1. Subdivision of unalloyed and medium alloyed steels A.. Calculations A..1. Running lengths of the solid wires A... Number of rods per kg A... Deposition rate A... Electrode calculation number/metre A..5. Welding conditions A. Brief overview of the most important A.. AX materials Technical shielding gases A.5 Alloy groups, alloying elements, effect of the elements A. Packaging A.7 Welding positions A.8 Hardness comparison A. Welding technology standards A.10 Warranty clause / final remarks Appendix 8 ALUNOX Manual

251 A ALUNOX Manual

252 A.1 Aluminium alloys from technology EN no. EN abbreviation DIN abbreviation Material no AL.5 AL AL. AL. 1070A AL.7 AL A AL.8A AL.8A AlCu5.5MgMn 007 AlCuPbMgMn AlCuMgPb AlCuBipB AlCuBiPb A AlCuBiPb(A) 01 AlCuSiMg A AlCuSiMg(A) 017A AlCuMgSi(A) AlCuMg AlCuMg1 AlCuMg AlMg1(B) AlMg A AlMg1( C) AlMg5 AlMg AlMg1.5Mn 50 AlMgMn0.8 AlMgMn AlMg1.5( C) AlMg A ALMg1.5( D) A AlMg(B). 505 AlMg.5 AlMg AlMg AlMg.5Mn0.7 AlMg.5Mn AlMg AlMgMn0.8(A) 515A AlMg.5(A) 518 AlMg.5Mn0. AlMg.5Mn (Automotive) AlMg.5Mn0.7(A) 551 AlMg AlMgMn AlMgMn AlMg.7Mn AlMg AlMg AlMg1Si AlSiMg 005A AlSiMg(A) AlMgSi AlMgSiPb AlMgSiPb AlMgSi AlMgSi0,5F AlMg1SiCu.11 01A AlMg1SiCu(A) 0 AlMg0.7Si AlMgSi0.5F AlSi1MgMn AlMgSi AlZn,5Mg AlZn5MgCu AlZnMgCu AlZn5.5MgCu AlZnMgCu AlFeSi AlFeS 50 ALUNOX Manual ALUNOX Manual

253 A ALUNOX Manual 51 1

254 5 ALUNOX Manual 1

255 A.1.1. ALUNOX recommended filler metal. Material number Short Wires/rods Electrodes Welding name MIG/TIG suitability 0 Pure aluminium Al.8 Al.8 AX-1080 AX-1080 AX-EAlSi5 AX-EAlSi E-Al AX-1080 AX-EAlSi AlMn joints AL.5 Al AX-1080 AX-1080 AX-EAlSi5 AX-EAlSi AlMn0. AX AlMg joints AlMn1 AlMnCu AX-518 AX AlMg1 AlMg1.8 AlMg AX-55 AX-55 AX-55 AX-EAlSi1 AX-EAlSi1 AX-EAlSi AlMgMn0.8 AX-518 AX-EAlSi AlSi0.5 AlMgSi0.7 AlMgSi AX-0 AX-518 AX-518 AX-EAlSi1 AX-EAlSi1 AX-EAlSi AlMgSi1 AX-518 AX-EAlSi1 o.11 Cast AlSi joints AlMg1SiCu AX-518 AX-EAlSi1 o.581 G-AlSI1 AX-07 AX-EAlSi G-AlSI1Cu G-AlSi11 G-AlSi10Mg AX-07 AX-07 AX-07 AX-EAlSi1 AX-EAlSi1 AX-EAlSi G-AlSi10MgCu AX-07 AX-EAlSi G-AlSiMg G-AlSiMg AX-07 AX-0 AX-EAlSi1 AX-EAlSi5 + o 8.1 G-AlSi5Mg AX-0 AX-EAlSi G-AlSi8Cu G-AlSiCu G-AlMgSi AX-07 AX-07 AX-575 AX-EAlSi1 AX-EAlSi1 AX-EAlSi5 + + o Welding suitability + = particularly suitable o = suitable A ALUNOX Manual 5

256 5 ALUNOX Manual 1

257 A.1.. Copper. Recommended filler metal. Material number Short name Wires/rods MIG/ Welding suitability TIG or Soldering suitability Pure copper joints.000 OF-Cu AX-CuSn SE-Cu AX-CuSn G-SCuL50 AX-CuSn SW-Cu AX-CuAg G-CuL5 AX-CuAg SF-Cu AX-CuAg G-Cu AX-CuAg + CuZn joints.00 CuZn5 AX-LCuZn CuZn10 AX-LCuZn CuZn15 AX-LCuZn G-CuZn15 AX-LCuZn CuZn0 AX-LCuZn CuZn8 AX-LCuZn CuZn0 AX-LCuZn CuZn AX-LCuZn CuZn7 AX-LCuZn CuZn AX-LCuZn CuZn0 AX-LCuZn CuZn0Al AX-LCuZn CuZn8Sn1 AX-LCuZn CuZn1Si1 AX-LCuZn0 +.0 G-CuZn15Si AX-LCuZn CuZn7Al AX-LCuZn A ALUNOX Manual 55

258 Copper. Recommended filler metal. Material number Short name Wires/rods MIG/ Welding suitability TIG or Soldering suitability.050 CuZn8Sn1 AX-LCuZn CuZn5Ni AX-LCuZn CuZn0Al AX-LCuZn CuZn0Mn AX-LCuZn G-CuZn0Fe AX-LCuZn G-CuZn5Al1 AX-LCuZn G-CuZnAl AX-LCuZn G-CuZn5Al5 AX-LCuZn0 + CuNi joints.070 CuNi1Zn L-CuZn CuNi18Zn0 L-CuZn G-CuNi10 AX-CuNi10Fe CuNi5 AX-CuNi0Fe G-CuNi0 AX-CuNi0Fe +.08 CuNiMn1 AX-CuNi0Fe o.087 CuNi10Fe1Mn AX-CuNi10Fe CuNi0Mn1Fe AX-CuNi0Fe CuNi0Mn1 AX-CuNi0Fe + CuAl joints.01 CuAl5 AX-CuAl CuAl8 AX-CuAl G-CuAl AX-CuAl CuAlMn AX-CuAl8 +.0 G-CuAl8Mn AX-CuAl8 +.0 CuAl10Ni5Fe AX-CuAl8Ni o 5 ALUNOX ALUNOX Manual Manual

259 Copper. Recommended filler metal. Material number Short name Wires/rods MIG/ Welding suitability TIG or Soldering suitability.070 G-CuAlNi AX-CuAl8Ni CuAlNiFe AX-CuAl8Ni G-CuAl10Ni AX-CuAl8Ni CuAl11NiFe5 AX-CuAl8Ni G-CuAl11Ni AX-CuAl8Ni o CuSn joints.1010 CuSn AX-CuSn CuSn AX-CuSn CuSn AX-CuSn CuSn8 AX-CuSn G-CuSn10 AX-CuSn G-CuSn1 AX-CuSn G-CuSn1 AX-CuSn1 o.100 G-CuSn1Ni AX-CuSn1 o.1080 CuSnZn AX-CuSn o.108 G-CuSn10Zn AX-CuSn1 o.100 G-CuSn7ZnPb AX-CuSn1 o.10 G-CuSnZnNi AX-CuSn o.10 G-CuSn5ZnPb AX-CuSn o Welding suitability + = particularly suitable o = suitable A ALUNOX Manual 57

260 A.1. Nickel. Recommended filler metal. Material Short Wires/ Electrodes Flux-cored wire Welding number name rods suitability MIG/TIG.0 (S) NiCu0Fe AX-NiCu0 +.1 LC-NiCu0Fe AX-NiCu0 +.5 G-NiCu0Nn AX-NiCu NiCu0Al AX-NiCu NiCrMo1Al AX-5 AX-E5 AX-FD NiCr15Fe AX-5 AX-E5 AX-FD NiCrMoCu AX-5 AX-E5 AX-FD5 +.1 NiCrMo7Cu AX-5 AX-E5 AX-FD5 +.0 NiCr0Ti AX-8 AX-E8 AX-FD8 +.1 NiCr0TiAl AX-8 AX-E8 AX-FD8 +.1 NiCr1MoCu AX-5 AX-E5 AX-FD5 +.0 NiCr0CuMo AX-5 AX-E5 AX-FD5 +. NiCr15Fe7TiAl AX-5 AX-E5 AX-FD NiCr15Fe AX-8 AXE-8 AX-FD LC-NiCr15Fe AX-8 AX-E8 AX-FD NiCrFe AX-8 AX-E8 AX-FD NiCrMoNb AX-5 AX-E5 AX-FD NiCr1Mo AX-5 AX-E5 AX-FD5 +.8 NiCr015 AX-8 AX-E8 AX-FD NiCr800 AX-8 AX-E8 AX-FD NiCr10 AX-8 AX-E8 AX-FD8 +.5 NiCr0TiAl AX-8 AX-E8 AX-FD8 + Welding suitability + = particularly suitable o = suitable 58 ALUNOX ALUNOX Manual Manual

261 A.1. High alloyed. Recommended filler metal. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability XCr1 AX X7Cr1 / G-X7Cr1 AX XCrAII AX XCrNiI 1 XCrII AX (G)X1CrI AX GX8CrNiI (GX7CrN- 1MoI-1) AX XCrI7 AX-0 o 1.01 X00rI AX-10 o 1.0 X15Cr1 AX-10 o 1.07 GXOCr1 AX-10 o XI7CrNiI- AX-0 o 1.05 GXCrN1I7 AX-0 o GX8CrNiI AX-1.7 o 1.11 XCrMoI7-1 o 1.10 (G)X00rMoI o 1.1 XCrMoI7-1 / (G)X5Cr- Mo17 AX-1.1 o 1.01 X5CrNi18-10 AX-08L AX-E08AC AX-FD-DW08L A ALUNOX Manual 5 5

262 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1.0 XCrNi18-1 AX-08L AX-E08AC AX-FD-DW08L XCrNi1-11 AX-08L AX-E08AC AX-FD-DW08L GX5CrNI1-10 / GXCr- Ni18- AX-08L AX-E08AC AX-FD-DW08L XCrNiN18-10 AX-08L AX-E08AC AX-FD-DW08L GX1OCrNi18-8 AX-08L AX-E08AC AX-FD-DW08L XCrNiMo1- / XCr- Ni1- / GX5CrNi1- AX X5CrNiN1- AX-08L AX-E08AC AX-FD-DW08L XCrNiN18-7 AX-08L AX-E08AC AX-FD-DW08L X1CrNi5-1 AX-10 AX-E10AC AX-FD-DW10L + 1. GXCrNi8-10 AX-1 AX-E1AC GXOCrNi7- AX-551 o 1.7 GX8CrNiN-7 (GXCrNiN-7) AX XCrNiN X5CrNiMo17-1- AX-1L AX-E1AC AX-FD-DW1L XCrNiMo17-1- / GX- CrNiMoN18-10 AX-1L AX-E1AC AX-FD-DW1L X5CrNiMo1-5 1 GX- CrNiMo1-5-1 AX-1L AX-E1AC AX-FD-DW1L XCrNiMoN AX-1L AX-E1AC AX-FD-DW1L + 0 ALUNOX ALUNOX Manual Manual

263 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1.07 GX5CrNiMo1- AX GX5CrNiMo1-11- / GX- CrNiMo18-10 AX-1L AX-1AC AX-FD-DW1L XCrNIMoN5-7- AX GXCrNIMoI - AX XCrNiMo1-5-1 AX-1L AX-E1AC AX-FD-DW1L X5CrNIMoI8-11 AX-1L AX-E1AC AX-FD-DW1L + 1. XCrNiMoN17-1- AX-1L AX-E1AC AX-FD-DW1L XCrNiMo18-1- AX-1L AX-E1AC AX-FD-DW1L + 1. XCrNiMoI7-1- AX-1L AX-E1AC AX-FD-DW1L GXCrNiMoI8-1 AX-1L AX-E1AC AX-FD-DW1L XCrNiMo AX-17L AX-DW XCrNiMoNI7-1-5 AX-17L AX-DW GXCrNiMoN AX-17L AX-DW GXCrNiMoI7-1 AX-17L AX-DW XCrNiMoN7-5- AX- AX-E0 AX-FD-DWA + 1. XCrNiMoN-5- AX- AX-E0 AX-FD-DWA + 1. GXCrNiMo-8- AX- AX-E0 AX-FD-DWA A ALUNOX Manual 1

264 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1. GXOCrNiMo7-5 AX- AX-E0 AX-FD-DWA o 1.5 X1CrNiMoN5-5- / GX- CrNiMoN5-5- AX X1CrNiMoN5-- AX XCrMnNiMoN GXCrNiMoN-- (GX- CrN1MoN5--) + 1. GXCrN1MoN-7- / G- XCrNiMoN GX7NiCrMoCuNb5-0 AX-0L XCrNiMoCuWN5-7- AX XNICrCuMoT XNiCrMoCuNbO-18- AX-0L X5NiCrMoCuTIO-18 AX-0L XCrNiMoCuN5-- AX-0L XCrTiNb18 o XCrTi17 AX-10 o XCrNb17 AX-10 o 1.51 XCrTi1/XCrTi1 AX GXCrNIMoCuN-- AX ALUNOX ALUNOX Manual Manual

265 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability GXCrNiMoCuN5---/ CuN--- AX XINiCrMoCuN5-0-7 (XI- NICrMoCuN5-0-) GXNiCrMoCuNO-18 AX-0L GXNiCrMoCuN5-0 AX-0L XNiCrMoCuNO-1 8 AX-0L Xl N1CrMoCu5-0-5 AX-0L XCrNiTi18-10 AX-08L AX-E08AC AX-FD-DW08L XCrNiNb18-10 AX-08L AX-E08AC AX-FD-DW08L GX5CrNiNb1-11/ GX- 5CrNiNb18- AX-08L AX-E08AC AX-FD-DW08L XNiCrAlTi X1CrNiMoTi X1NiCrMoCu X1NiCrMoCu1-7- 1/ CuN1-7- AX XCrN1Mn- MoNbN GXCrNiMnMoN Nb AX XCrN1MoTi17-1- AX-1L AX-E1AC AX-FD-DW1L X100rNiMoTiI8-1 AX-1L AX-E1AC AX-FD-DW1L A ALUNOX Manual

266 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability XCrNiMoTi5-5 AX XCrNiMoNbl7-1- AX-1L AX-E1AC AX-FD-DW1L GX5CrNiMoNb1-11- / GX5CrNiMoNb18-10 AX-1L AX-E1AC AX-FD-DW1L XCrNIMoNb5-7 AX (G)XIOCrNiMoNbI8-1 AX-1L AX-E1AC AX-FD-DW1L GX7CrNiMoCuNb18-18 AX-0L X5NiCrMoCuNb-18 AX-0L X5CrNIMoT Heat-resistant steels GX00rSi AX-0 o 1.71 X10CrSi AX-0 o 1.71 X10CrAI7 (X100rAISI7) AX-0 o 1.7 X10CrAII (X100rAIS1I) AX-0 o 1.7 GX00rSi1 AX-0 o 1.70 GX00rSi17 AX-0 o 1.7 X100rAI18 (X100rAISi18) AX-0 o 1.75 GX00rSi o ALUNOX ALUNOX Manual Manual

267 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1.7 X8CrTi5 o 1.7 X100rAI (XlOCrAlSi5) o 1.77 GX00rSi o GX8CrNi1-10 AX-1L AX-E1AC AX-FD-DW1L X00rNiSi5- (XI5Cr- NiS15-) AX-551 o/+ 1.8 GX00rNi-5 AX-551 o 1 8 GX00rNiSi7- AX-551 o 1.85 GX5CrNiSil GX00rNiSI- AX-0L AX-E0AC AX-FD-DW0L GX8CrNiNb1-10 AX-08L AX-E08AC AX-FD-DW0L Xl5CrNiSiO-1 AX-0L AX-E0AC AX-FD-DW0L GX5CrNiSiO-1 AX-0L AX-E0AC AX-FD-DW0L X7CrNi-1 / XICr- Ni-1 (X1CrNi- AX-10 AX-E10AC AX-FD-DW10L GX00rNiSi5-1 AX-10 AX-E10AC AX-FD-DW10L GXI5CrNi5-0 AX-10 AX-E10AC AX-FD-DW10L X15CrNiSi5-0 (XI5Cr- NiS15-1) AX-10 AX-E10AC AX-FD-DW10L X1CrNi5-1 (X8Cr- Ni5-1) AX-10 AX-E10AC AX-FD-DW10L A ALUNOX Manual 5

268 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1.87 X8CrNiAITiO-0 AX o 1.88 GX0CrNiSi5-0 AX-10 AX-E10AC AX-FD-DW10L GX0N1CrSiNb8-18 AX GX0NiCrSiNb5-5 AX GX0NiCrSi5-5 AX GX10NiCrNb-0 AX XI0N1Cr-0 AX X1NiCrSi-1 (XINiCrSi5-1) AX GX0NiCrSi8-18 AX X10NiCrAIT1-0 (X10NiCrAlTi-1) AX XN1CrNbCe-7 o X1CrNiTi18- (X10CrNiTi18- AX-1.8 AX- 1.1 AX-E X1CrNiM0Nb X8CrN1SiN1-11 AX-0 AX-E0AC AX-FD-DW0L +.81 NiCrl5Fe (NiCrl5Fe8) AX-8 AX-ENi8B AX-FD-Ni LC-NiCrl5Fe AX-8 AX-ENi8B AX-FD-Ni NiMolCrl5W + ALUNOX ALUNOX Manual Manual

269 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability.851 NiCrFe AX-8 AX-E8 AX-FD NiCrM0Nb AX-5 AX-E5 AX-FD NiCrlMo AX-.5 + High-temperature resistant steels 1.0 X1OCrMoVNb-1 AX X11CrMoWVNb-1-1 AX XCrNiMo XICrMoI-1 AX-1. o 1. XOCrMoV1-1 AX-1. o 1. XCrMoV1-1 AX-1. o 1. X1CrMoV1-1 AX-1. o 1.1 GXCrMoV1-1 AX-1. o 1.5 XOCrMoWVI-1 AX-1. o 1.8 XCrNi18-11 (XCrNi18-1O) AX-1.8 AX-08 AX-E XCrNiN18-11 AX-1.8 AX-08 AX-E X8NiCrAITi-1 AX X8CrNiNb A ALUNOX Manual 7

270 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability 1.8 GX7CrNiNb X8CrNiMoNb (G)X8CrNiMoVNb NiCrOTi AX-8 AX-ENi8B AX-FD-Ni8 +.5 NiCrOTiAI AX-8 AX-ENi8B AX-FD-Ni8 + Alloyed stainless steel structural steels Ni1 / 10N GNi1 / GS-lONil (G)X8Ni Ni1/X1Ni GXIONi5/GS-lONil G-XCrNi18-10 (GXCrNi18-10) AX-08L AX-E08AC AX-FD-DW08L GX5CrNiNb18-10 AX-08L AX-E08AC AX-FD-DW08L XCrNiN18-10 AX-08L AX-E08AC AX-FD-DW08L X5CrMnNiN18- AX-08L AX-E08AC AX-FD-DW08L XCrNiMoN18-1 AX-08L AX-E08AC AX-FD-DW08L + 8 ALUNOX ALUNOX Manual Manual

271 Filler metal recommended by ALUNOX. High alloyed. Material Short name Wires/rods Electrodes Flux-cored wire Welding number MIG/TIG suitability High-temperature resistant and corrosion resisting steels/alloys.0 NiCrIMoIW +.05 N1CrMo1AI AX NiCrIMo1W +.10 NiMolCrlTi AX NiCrOT1 AX-8 AX-E8 AX-FD-Ni8 +.1 NiCrOTiAI AX-8 AX-ENi8 AX-FD-Ni8 +. NiCr5FeAIY AX NiCrFe AX Xl CrNiMoN--7 AX NiCr00uMo AX NiCrColMo AX-.7 +/o A ALUNOX Manual

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273 A.1.5 Preheating and finishing steels. Steel quality Wall thickness in Preheating before Heat treatment after mm welding welding and interpass temperature 0 StE55 to StE 15 >0 StE55, StE80, >0 StE0, StE550, >1 StE50 to StE0 >8 St.5.8, St5.8 <15 H I, H II, >15 to 0 C., C.8 >0 17Mn 1Mn5 <15 1Mn >15 to 0 H IV >0 <15 15Mo >15 to 0 >0 1CrMo <8 >8 to 0 >0 <8 10CrMo10 >8 to 0 >0 1MoV <15 >=15 X10CrMovNb1 <8 >=8 >0 min.(max.150 min.) C 50 to 580 C not necessary not necessary >75 C not necessary >100 C >1h at 50 to 580 not necessary >15 min. 50 to 580 C >75 C >0 min. 50 to 580 C >15 C >1h at 50 to 580 not necessary not necessary >75 C not necessary >100 C >1h 50 to 0 C >75 C >15 min. 00 to 700 C >150 C >0 min. 00 to 700 C >00 C >1h at 00 to 700 C >75 C >15 min. 50 to 750 C >00 C >0 min. 50 to 750 C >50 C >1h at 50 to 750 C 150 C >h 700 to 70 C 00 C 00 C >h at 780 C 50 C X0CrMoV11 <8 >=8 00 C 50 C Cool down from welding heat to 100 C, then anneal at 70 C for h A ALUNOX Manual 71

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275 A.1. Breakdown of unalloyed and medium alloyed steels. 1. Steels with a specified minimum yield strength ReH <= 0 N/mm² and a composition in %: C <= 0.5 Si <= 0.0 Mn <= 1.70 Mo <=0.70 b) S <= 0.05 P<= 0.05 Cu <= 0.0 b) Ni <= 0.5 b) Cr <= 0. (0. for casting materials) b) Nb <= 0.05 V <= 0. 1 b Ti <= Steels with a specified minimum yield strength ReH < 75 N/mm² 1. Steels with a specified minimum yield strength 75 N/ mm < ReH <= 0 N/mm² 1. Normalized fine grain structural steels with a specified minimum yield strength ReH > 0 N/mm² 1. Steels with an increased resistance to atmospheric corrosion the composition of which may exceed the requirement for the individual elements of Group 1.. Thermomechanically rolled fine grain structural steels and cast steel with a specified minimum yield strength ReH > 0 N/mm²..1 Thermomechanically rolled fine grain structural steels and cast steel with a specified minimum yield strength 0 N/mm² < ReH >= 0 N/mm². Thermomechanically rolled fine grain structural steels and cast steel with a specified minimum yield strength ReH > 0 N/mm². Tempered and precipitation-hardened steels, but no stainless steels, with a specified minimum yield strength ReH > 0 N/mm².1 Tempered steels with a specified minimum yield strength 0 N/mm² <= ReH <= 0 N/mm². Tempered steels with a specified minimum yield strength ReH > 0N/mm². Precipitation-hardened steels but no stainless steels. Low vanadium alloyed Cr-Mo-(Ni) steels with Mo <= 0.7% und V <= 0.1%.1 Steels with Cr <= 0. % und Ni <= 0.7 %. Steels with Cr <= 0.7 % and Ni <= 1.5 % 5. Vanadium-free Cr-Mo steels with C=0.5% 5.1 Steels with 0.75 % < Cr <= 1.5 % and 0.7 % <= Mo 5. Steels with 1.5 % < Cr <=.5 %, 0.7 % < Mo <= 1.% 5. Steels with.5 % < Cr <= 7.0 %, 0. % < Mo <= 0.7% 5. Steels with 7.0 % < Cr <= 10.0 %, 0.7 % < Mo <= 1.%. High vanadium-alloyed Cr- Mo-(Ni) steels.1 Steels with 0. % < Cr <= 0.75 % and 0.7 % <= Mo and V<= 0.5%. Steels with 0.75 % < Cr <=.5 %, 0.7 % < Mo <= 1.% and V <= 0.5%. Steels with.5 % < Cr <= 7.0 %, Mo <= 0.7 % and 0.5% <= V <= 0.55 %. Steels with 7.0 % < Cr <= 1.5 %, 0.7 % < Mo <= 1.% and V <= 0.5% A ALUNOX Manual ALUNOX Manual 7

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277 A..1 Running lengths. In metres. Medium and unalloyed (15 kg) to order Mediumunalloyed (500 kg) to order 0 High alloyed (15 kg spool) to order Mediumunalloyed (50 kg) to order 1 High alloyed (1.5 kg spool) to order High alloyed (50 kg) to order Running lengths in metres of the different materials on spools size 00 Weight in g/m Copper (15 kg spool) Weight in g/m Aluminium (7 kg spool) Aluminium ( kg spool) Weight in g/m Diamet er in mm Running lengths in metres of the different materials in drums Weight in g/m Copper (00 kg) Weight in g/m Aluminium (1 kg) Aluminium (15 kg) Weight in g/m Diamet er in mm to A ALUNOX Manual 75

278 A.. Number of rods per kg Diameter in mm Aluminium Copper High alloyed Gas welding rods to order 1 to order to order to order to order 5 7 ALUNOX Manual

279 A.. Characteristic values Steel 0.8 mm Gas 8/18 Welding voltage V Rate m/min Sheet thickness Welding current A A ALUNOX Manual 77

280 A.. Deposition rate Process mm A. V. kg/h. Standard electrode High recovery electrode Solid wire / /5.5 Flux-cored wire / / / / / ALUNOX ALUNOX Manual Manual

281 A.. Electrode quantity calculation required: given: number of electrodes n fillet weld t=mm Seam length of a fillet weld component Seam length of 15 components 550 mm x 15 = 850 mm electrodes per 1000 mm (from table) 550 mm 850 mm mm =.5 electrodes Seam type unilateral I Seam double-sided double-sided V Seam 0 V Sheet thickness Gab width 1,5 1,0 1,5,0 Number of electrodes per meter ø mm,5 ø mm,5 ø mm 5, Root,,,5,,, 11,5 t= Fillet weld t= t=5,,7, A ALUNOX Manual 7 7

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283 A. Chemical composition Short overview of the most commonly used AX-HL materials AWS/ASME Mat. no. DIN 855 SFA-5. C max Si Mn Cr Ni Mo Nb min. S max P max Other 1.00 SG X8 CR 1 ~ ER SG X CRNi 1 Nl ER 08 L (Si) SG X5 CRNiNb 1 Nb ER 7 (Si) x C SG X CRNiMo 11 Nl ER 1 L (Si) SG X5 CRNiMo 11 Nb ER 18 (Si) x C SG X10 CRNiMn 188 ER 07 (Si) SG X CRni 1 ER 0 L (Si) SG X10 CRNi 0 ~ ER 1 0,1 0,5 1, , SG X1 CRNi SG X1 CRNi 1 ER 0 (mod) , SG X1 CRNi 50 ~ ER SG X CRNiMon ~ ER N 1.51 G X CRNiMoCu 05 ~ ER 85 0,0 0, 1, 0 5,5 1,5 Cu A ALUNOX Manual 81

284 Short overview of the most commonly used AX-ML materials ALUNOX Material no. AWS A5.18/ 5.8 EN C Si Mn Mo Cr Ni Cu SG-II zinc ~ ER-70 S- G Si Al 0.1 Ti 0.1 Zr 0.1 SgMo 1.5 ER-80 S-G G/W MoSi NiMo ER-100 S-G MnNi1Mo NiMoCr ER-100 S-G MnNi1CrMo NiMoCr 0 ~ ER-110 SG MnNiCrMo CuNi ~ ER-80 S MnNi1Cu Cromo ER-80 S-B G/W CrMo1Si Cromo 1.78 ER-80 S-B G/W CrMoSi (Typical data % of the filler metal) 8 ALUNOX Manual

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287 A. Shielding gases Extract of the standard EN ISO 1175 Symbol Shares in volume terms % Group Id No. Oxidizing Inert Reducing CO O Ar He H I M Res. 0, Res. M Res Res. 0- Res. M Res. -10 Res. M Res. Res. -10 Res Res Res. M Res Res Res. M Res. Res Res. C Res. Res. 0-0 C Res A ALUNOX Manual 85

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289 A.5 Alloy composition Composition Application Alloy Group 1 unalloyed up to 0.% C Application is recommended wherever no or low alloyed with particularly high demands are made on more than 0.% C and hardness and wear resistance; soft up to max. 5% alloying overlays on filling and buffer layers. As a constituents Cr, Mn, rule the weld metal can be machined by Mo, Ni in total. cutting after welding or in annealed state and is hardenable. Alloy Group unalloyed with more Because of the higher carbide content than 0.% C or low these materials display greater wear alloyed up to 0.% C resistance than Group 1. Machining by and with more than cutting is not always possible. max. 5% alloying constituents Cr, Mn, Alloy Group alloyed with the Adequate elevated temperature hardness properties of hot remains up to temperatures of approx. 500 working steels. C. Use is mostly made in hardened and annealed state. Before machining by cutting must be close annealed. When welding preheating and slow cool down is recommended to avoid cracks. Alloy Group 5 alloyed with more than These weld metals are suitable for scale 5% Cr and low carbon resistant overlays also with S-containing content up to around gases; they are also rustproof from 1% 0.% C. Cr. Depending on C and Cr content they cannot always be machined by cutting. Alloy Group alloyed with more than Compared with Alloy Group 5 higher 5% Cr and higher hardnesses but lower rust resistance is carbon content (around achieved. This Group is used where there 0. to.0% C). is simultaneously occurring wear stress by abrasion and impact. The weld metal is air hardening and mostly only workable by grinding. Preheating to C is recommended A ALUNOX Manual 87 87

290 Composition Application Alloy Group 7 Mn austenite with 11 18% Mn and more than 0.5% C and up to % Ni. By work hardening the hardness increases in a relatively thin surface layer but the core remains tough; this results in high wear resistance during stresses that have a work hardening effect: pressure, rolling, impact and shock. As at C brittling occurs from carbide precipitations, as low a heat input as possible is to be ensured and sufficiently high cooling down speed (e.g. welding in water bath) to be provided. Stress reduction by hammering the weld is advantageous. Alloy Group 8 Cr- Ni- Mn austenite These materials are tougher but with lower work hardening capability than those in Group 7. The rust resistance is good. Because of their lack of susceptibility to cracking they are often placed as a buffer layer between base materials and overlay materials that otherwise would not form a sufficient bond. Machining by cutting is Alloy Group Alloy Group 10 CrNi steels (rust, acid and heat resistant). high C content and high Cr alloyed with and without additional carbide-forming elements They can be overlaid onto similar steels as well as onto unalloyed or low alloyed steels and are used for large-area, corrosion and heat resistant claddings. The weld metal is easily machinable by cutting; it can be work-hardened and has high toughness. With increasing C content the hardness, the resistance to sanding wear, sensitivity to impact and shock and susceptibility to cracking also increase. Accordingly the facing height should be reduced and for less stressed surfaces only partly applied (e.g. mesh). An e.g. austenitic buffer layer equalizes stresses between base material and overlay. Preheating and slow cool down decrease the susceptibility to cracking. The weld metal is only workable by grinding. 88 ALUNOX ALUNOX Manual Manual

291 Composition Application Alloy Group 0 Alloy Group 1 Alloy Group Co base, Cr-W alloyed with or without Ni and Mo. Carbide base (sintered, cast or filled). Ni base, Mo-alloyed with or without Cr. The Akrit hard welding alloys are used particularly in cases where, alongside purely mechanical wear stress, also corrosion, erosion, cavitation or scaling stress is present. High elevated temperature hardness is the salient property of this group. Machining by cutting is only possible using tungsten carbide tools. Finishing is normally carried out by grinding. In this connection too high a pressure, temperature rise and thus the occurrence of grinding cracks should be avoided. Preheating to C and The properties of the Geomant filler metals are determined on the one hand by the very high hardness of the carbides and on the other hand by the soft, tough basic matrix. When welding the duration of the temperature effect is to be kept short to limit the melting of the carbides. If necessary the base material must have sufficient hardness from a buffering layer to resist the penetration of the carbide grains under high impact stress. Preheating to This alloy group is characterized by very good hot working properties. The weld metal is high-temperature, acid and scale resistant. If the increase of hardness is not achieved during the operation, it can be hardened either by hammering or artificial ageing. In as welded state, machining by cutting is possible A ALUNOX Manual 8 8

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293 A.5 Alloy Groups Group: 1 Hardenable Weld metal characteristic: Unalloyed or alternatively low alloyed steel up to 0.%C, max. 5% alloyed constituents. Welding characteristics: Hardenable / Moderate wear resistance at Me: 1,,, Application: tracks, agricultural machinery parts, parts, tractor tractor belts, belts, running running wheels wheels for for interference Interference fit, fit, bearung bearing location. location. Weld metal typical data in %: C 0. Cr 0- Mn 0.5- Mo 0-1 Ni 0- Other: Hardness: HB Machinability: sp Preheating: none Group: Hardenable Weld metal characteristic: Unalloyed or alternatively low alloyed steel up to 0.%C, max. 5% alloyed constituents. Welding characteristics: Satisfactory WR at Me: 1,,,. WR with increasing C-content increasingly hardenable. Application: screw conveyors, fan wheels, mixers, interference fit and slide bearings in agricultural machinery and mining components. Weld metal typical data in %: C 0. Cr 0-5 Mn 0.5- Mo 0-1 Ni 0- Other: Hardness: approx. 500 HB Machinability: spni Preheating depending on filler material: C Group: Hot Working Steels Weld metal characteristic: weld metal alloyed with W, Cr, sometimes with Mo, Ni, V (Co). Welding characteristics: creep resistant also at Me + (mostly used in hardened and annealed state). Application: hot working tools, dies, shears, block tong tips, if high temperatures arise, roller coatings. Weld metal typical data in %: C Cr 1-5 W 1-10 V Mo 0- Ni 0-5 Hardness: 8-5 HRC Machinability: spw Preheating depending on filler material: preheating of the base material and slow cool down after welding. Welding position horizontal (PA) or slightly raised. A 7 8 A ALUNOX Manual 1 ALUNOX Manual 1

294 Alloy Groups Group: High Speed Steels Weld metal characteristics: weld metal alloyed with W, Cr, V sometimes with Co or Mo, W and V. Welding characteristics: good cutting, even better with Co content. Hardenable. Application: cutting tools, mandrels, shear blades, cutting, drill bit edges, turning chisels, milling cutters. Weld metal typical data in %: C Cr - Co 0-15 Mo 0-10 W V 0- Hardness: 58-5 HRC Machinability: spw. Preheating depending on filler material: heat input in line with the requirements applying to the base material. The weld metal is normally annealed once or twice. Group: 5 Chromium steels with low C-content Weld metal characteristic: Cr-content varies from 5-0%, C-content up to 0.%. Welding characteristics: Rustproof + lower wear resistance (WR) at Me+Me7. Hardenable. Application: overlays that (even with sulphureous gases) are scale-resistant and from 1% Cr also rustproof, e.g. valves, plungers. Weld metal typical data in %: C 0. Cr 5-0 Ni 0-5 Mo 0- Si 1- Hardness: HB Machinability: spni Preheating depending on filler material: heat input in line with the requirements applying to the base material. If Si, scale and heat resistant at Me. Group: Steels with high C-content Weld metal characteristics: Cr-content varies from 5-18%, C-content up to 0.- %. Welding characteristics: good cutting, wear resistance (WR) at. Hardenable Application: cutting tools, shear blades, rollers for cold rolling mills, press dies, punching tools etc. Weld metal typical data in %: C Cr 5-18 Mo 0- Hardness: HB Preheating depending on filler material: preheating of the base material to C, Machinability: schl Welding position: horizontal (PA) or slightly raised. ALUNOX ALUNOX Manual Manual

295 Alloy Groups Group: 7 Corresponding to manganese steel Weld metal characteristic: Mn austenite with 11-18% Mn and more than 0.5% C and up to % Ni. Welding characteristics: work hardenable, WR at Me7 and Me 1, or Me:Mi. Application: surfacing large areas, e.g. wear plates (also in mains welding method), crusher plates, bucket teeth, bolts etc. Weld metal typical data in %: C Cr 0- Mn Ni 0- Hardness, after compression hardening: HB Machinability: sp (hard metal) grinding possible, (risk of cracks) Preheating depending on filler material: weld as cold as possible. Hammering the weld metal advantageous. Group 8 Alloys of Group 7, in addition good rust resistance Weld metal characteristic: Cr-Ni-Mn austenite. Weld metal is tougher than AG7. Welding characteristics: Non magnetizable, rustproof and work hardenable, WR at Me:Me: 1,,,,7 also Me: 15 Application: crusher parts for not too heavy stress, switch rails, intersections, tracks, etc. Weld metal typical data in %: C 0.5 Cr 18-0 Mn 5-8 Ni 5- Hardness (natural hardness): HB Machinability: sp Preheating: none Group: Stainless Cr-Ni steels Weld metal characteristic: stainless Cr-Ni steels Welding characteristics: corrosion resistant, non magnetizable (only fully austenitic) Application: corrosion- and heat resistant overlays, cladding boiler bases and mountings in the chemical industry. Weld metal typical data in %: C 0. Cr 1-0 Mo 0-5 Ni 8-5 Nb/Ta: Hardness (natural hardness): HB Machinability: sp Preheating: none A ALUNOX Manual ALUNOX Manual

296 Alloy Groups Group: 10 Ledeburitic Cr-C-Fe alloys Weld metal characteristic: Cr-C-Fe alloys. High C content or high Cr alloyed, with or without Co, Mo, W. Welding characteristics: creep resistant (hot working steels) at Me:Me and Me 1a, WR at Me:Mi very high. Application: Repairs in mines and steel works equipment, cladding on machinery parts in construction and agriculture, bucket teeth, mixer parts, worm extruders etc. Weld metal typical data in %: C Co 0-5 Cr 7-5 Mo 0- W 0-5 Hardness (natural hardness): HB Product form: E, Wpa (welding paste) Preheating: none Information for choosing the correct alloy group. Machinability: sp: in welded or annealed state can usually be machined by cutting. spni: machining by cutting not always guaranteed! spw: machining by cutting in close annealed state schl: (mostly) only machinable by grinding. Machinability: Me: 1 metal:metal-lubricant-friction wears Me: metal:metal-lubricant-rolling-wear Me: metal:metal-dry-friction-wear Me: metal:metal-dry-rolling-wear Me: 5 metal:metal-grain-friction-wear Me: metal:metal-grain-rolling-wear Machinability: Me: 7 metal-metal-shock-wear Me Mi : metal: mineral-dry-friction-wear Me 1a: metal-friction-blasting-wear Me 1b: metal-diagonal-blasting-wear Me 1c: metal-impact-blasting-wear Me 15: metal-suction-wear (cavitation) ALUNOX ALUNOX Manual Manual

297 A.5. Alloy element Alloy element Division factor Cr,Co,Mn,Ni,Si,W Al,Cu,Mo,Pb,V, C,Ce,N,P,S 100 B A ALUNOX Manual 5 5

298 A.5. Effect of the elements Aluminium ( Al ) Increased deformation capacity, insensitivity to ageing and scale resistance. Promotes fine grain development Chromium ( Cr ) Increases tensile strength and yield strength, hardenability, heat resistance, high pressure hydrogen resistance, scale resistance and wear resistance. Decreases impact strength, thermal conductivity and heat expansion. Leads to corrosion resistance with more than 1%. Carbon ( C ) Increases tensile strength and yield strength. Decreases elongation, impact strength and thermal conductivity. At more than 0.% leads to critical hardness increase. Copper ( Cu ) Increases yield strength and hardenability. Decreases critical cool down speed. Promotes weather resistance. Manganese ( Mn ) Increases tensile strength and yield strength, hardenability and heat expansion. Decreases thermal conductivity. Leads to austenite structure with more than 1% with simultaneous high C-content. Molybdenum ( Mo ) Increases tensile strength and yield strength, heat resistance and hardenability, decreases temper brittleness, scale resistance and susceptibility to pitting. Leads to fine grain development. Nickel ( Ni ) Increases impact strength and heat expansion. Decreases thermal conductivity. Leads to austenite structure with more than 7% in chemically resistant steels. Niobium ( Nb ) For stabilizing chemically resistant steels and filler materials to intercrystalline corrosion. Phosphorus ( P ) Leads to temper brittleness (cold fracture, brittle fracture) - Allowed quantities in the steel have no effect on its mechanical properties and welding suitability. Oxygen ( O ) Promotes brittling. Decreases toughness. ALUNOX Manual

299 Effect of the elements Sulphur ( S ) Leads to red or hot shortness. Allowed quantities in the steel have no effect on its mechanical properties and welding suitability. Silicon ( Si ) Increases tensile strength and yield strength. Scale resistance and wear resistance. Decreases thermal conductivity. Leads to viscosity of the weld pool (pore formation) at more than 0.%. Nitrogen ( N ) Leads to brittling (susceptibility to ageing) Allowed quantities in the steel (around 0.00 to 0.008%) have no effect on its mechanical properties and welding suitability. Titanium ( T ) For stabilizing chemically resistant steels to intercrystalline corrosion. Vanadium ( V ) Increases heat resistance, temper resistance, high pressure hydrogen resistance and wear resistance. Decreases overheating sensitivity. Leads to grain refinement Tungsten ( W ) Increases toughness, heat resistance, temper resistance and wear resistance at high temperatures. Decreases grain growth and scale resistance A ALUNOX Manual 7 7

300 Alloy Groups Differences between unalloyed and high alloyed materials. The high alloyed materials differ physically from the unalloyed or low alloyed steels with respect to specific weight, heat expansion, thermal conductivity, mechanical properties and electrical resistance. Mechanical properties: for the high alloyed steels in cold rolled state tensile-strength + elongation are higher than with the usual unalloyed steels, the yield strengths are approximately the same. These properties can still be significantly changed by cold working. Thermal expansion: For ferritic / martensitic is about the same as with the unalloyed materials. For austenites it is about 50% higher. This creates greater shrink stresses and with thin sheets slight warping. Thermal conductivity: For the austenitic materials is only 1/ of the unalloyed steel; that means it must be worked with around 0% less energy input when welding. Preheating can be omitted for austenites. Ferritic, martensitic and COMPOUND steels Materials are to be for the most part preheated; The heat consumption is around 10 % below that of low alloyed steels. Also heat treatment must be ensured, particularly with martensitic steels. 8 8 ALUNOX Manual ALUNOX Manual

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303 A. Product forms Product forms (tolerances as per EN ISO 5 apply) Please request from us any different dimensions for the product forms listed here. ALUNOX keeps the usual MIG and TIG qualities permanently in stock in large quantities. 0 Dimensions: - MIG - filler wires (various spool forms) o 0.*) o 0.8 o 1.0 o 1. o 1. o.0*) o.*) - TIG filler rods o 0.8*) o 1.0 o 1. o.0 o. o. o.0 o 5.0 o.0*) - SAW filler wires o 1. o. o. o.0 o FC flux-cored wires o 1.0 o 1. o 1. o.0 o. o.8 *) = on request Other dimensions and versions on request -> Spool forms and packaging units under product forms PU A ALUNOX ALUNOX Manual 01 01

304 Product forms Spool Weight (kg) Flange /a (mm) Core /b (mm) Mandrel dim. Width /d /c (mm) (mm) D100 1/ D00 5/ D00 15/ KS00 15/ K00 15/ Adapter 8 K H500 max H50 max H70 max D100 D00 D00 D00 D00 0 ALUNOX ALUNOX Manual Manual

305 Product Forms Drum Weight (kg) Height (mm) Diameter Form Features (mm) 0 Alu square finger ring + core Alu square finger ring + core Alu round holder + core CuSi round holder + cylinder CuSi round holder + cylinder High alloyed I round finger ring Medium alloyed I round finger ring Medium alloyed II square finger ring Superpak square finger ring Electrodes Length Pack Carton Weight Ø in mm mm, approx. kg, approx. kg, approx. per 1000 items, kg, approx., , , , ,00 50, 8,00 50, 15 8 A ALUNOX Manual 0

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307 A.7 Welding positions PA.flat position PB.horizontal 0 1 PE.overhead PA.horizontal overhead 5 7 PG.vertical downwards PF.vertical upwards PA.diagonal 8 A ALUNOX Manual 05 05

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309 A.8 Härtevergleichstabelle Comparative hardness table Vickers Brinell Rockwelwelwell Rockw Vickers Brinell Rock- Rockw Vickers Brinell Rock- Rockw Vickers Rockwell Rockw HV HB HRC HV HB HRC HV HB HRC HV HRC kg/mm² kg/mm² kg/mm² kg/mm² kg/mm² kg/mm² kg/mm² , ,. 0 5, , 1. 5, , , 1. 0,8.8 70, , , , , , , , , ,5 5 8, 70 1, , , , ,1 70, ,7 770, ,8 85 7, , , , 70, , , ,5 800, , , ,1 810, , ,7 80, ,8 10 1, , , 15 8, , 80 5, , 0 0, , , ,7 5 0, , 0 10, ,5 870, ,1 5 1, , ,8 0 18, , , 5, , , , , A ALUNOX Manual ALUNOX Manual Handbuch 07 07

310 A. Welding technology standards Overview of EN standards for filler metals: EN standard Standard Title EN 0 Wire electrodes and deposits for gas shielded metal arc welding of non alloy and fine grain steels. EN ISO 50 Covered electrodes for manual metal arc welding of non-alloy and fine grain steels. EN 75 + EN 70 Solid wires, solid wire-flux and tubular cored electrode-flux combinations for submerged arc welding of non alloy and fine grain steels. Fluxes for submerged arc welding. EN 757 Covered electrodes for manual metal arc welding of high strength steels. EN 758 Tubular cored electrodes for metal arc welding with and without a gas shield of non-alloy and fine grain steels. EN 15 Covered electrodes for manual metal arc welding of creep-resisting steels. EN 100 Covered electrodes for manual metal arc welding of stainless and heat resisting steels. EN 18 Rods, wires and deposits for tungsten inert gas welding of non alloy and fine grain steels. EN 170 Wire electrodes, wires and rods for metal arc welding of creep-resisting steels. 08 ALUNOX ALUNOX Manual Manual

311 Welding technology standards 0 EN 1071 Flux-cored electrodes for gas shielded metal arc welding of creep-resisting steels. EN ISO 1 Wire electrodes, strip electrodes, wires and rods for arc welding of stainless and heat resisting steels. EN 17-A Tubular electrodes for metal arc welding with or without shielding gas of stainless and heat resisting steels. EN ISO 18 Wire electrodes, wires, rods and deposits for gas shielded arc welding of high strength steels. EN 155 Tubular electrodes for gas shielded metal arc welding of high strength steels. EN 15 Rods for gas welding of non alloy and creep-resisting steels. The European standards given above are or have been adopted by the national standardization institutes and are thus identical in content to the national standards A ALUNOX Manual ALUNOX Manual 0 0

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320 Legal Notice Warranty We have carefully selected and checked all the information but expressly point out that we can assume no liability for these details and we expressly recommend that you check the materials before starting the welding tasks on your own responsibility for your special requirements. Warranty for the suitability for a specific purpose requires in all cases an express agreement in writing. Issue Q/01 Printed in Germany 18 ALUNOX Manual 18 ALUNOX Manual

321 0 1 5 ALUNOX Schweißtechnik GmbH Gießerallee 7a D-7877 Willich Tel + (15) 5-0 Fax + (15) A ALUNOX Manual 1

322 v1.8. v1.8. ALUNOX Schweißtechnik ALUNOX GmbH Schweißtechnik GmbH Gießerallee 7a D-7877 Gießerallee Willich 7a D-7877 Willich Tel + (15) 5-0 Fax Tel + (15) Fax + (15)