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WELDING HANDBOOKWELDING COMPANY2009

Overall IndexLists of Welding Consumables10For Mild Steel and 490MPa High Tensile Strength SteelFor Weather Proof Steel83For 590-780MPa High Tensile Strength Steeland Low Temperature SteelFor Heat-Resistant Low-Alloy Steel97155For Stainless SteelFor Hardfacing207265For Cast IronFor Nickel-Based Alloy287293Highly Efficient Welding ProcessesAppendix23313327 For your further information of welding consumable specifications, classifications, approvals andpackages, please contact the nearest Kobelco office or sales representative.

NotificationThe purpose of changing the designation systemWe, Welding Company of Kobe Steel, Ltd., thank you very much for your continuous patronage of ourproducts and services. We have changed the designation system of welding consumable as described inthe following from April 2008. However, the technical design of the products is not changed.New group brand names and the corresponding productsAll KOBELCO welding consumables are designated with “Trade Designation” and are grouped into thefollowing three new groups on the basis of the characteristics of individual products as detailed below.(1)(Famili-Arc)A coined word produced by combining “Familiar” and “Arc.”Welding consumables grouped into this group are used for general welded structures made of mildsteels and high tensile strength steels that have the tensile strength of less than 590 MPa.(2)In recent years, we have found some other companies’ products that have the same brand names asours and false certificates that misrepresent our company’s certificates in Japan and the Asian countries.In order to cope with this problem, we have taken legal actions against the impostors that could beverified and have required them to change their product names. However, it is difficult in the traditionalproduct designation system to protect all of our products from imitation. Hence, we have established thenew designation system of welding consumable to ensure the trademark right in main countries and tomake our products identifiable more clearly, in which the particular group brand name, “Trademark,” isput on the head of an individual “Trade Designation.”The new designation system is not only to prevent counterfeit products in Japan and overseas countries,but also to prevent our customers and users from suffering such a trouble in terms our products.This modification may cause customers and users to modify their relevant documents. We sincerelyhope for your understanding of the abovementioned situation and for your cooperation with us.(Trust-Arc)A coined word produced by combining “Trust” and “Arc.”Welding consumables grouped into this group are used for such steels that require highly crediblequalities as high tensile strength steels with the tensile strength of 570 MPa and higher, lowtemperature steels, and heat-resistant low-alloy steels.(3)(Premi-Arc)A coined word produced by combining “Premium” and “Arc.”Welding consumables grouped into this group are used for high-alloy steels, stainless steels, andnonferrous metals.The new group brand name (referred to as “Trademark” hereinafter) is put on the head of an individualtrade designation. The trade designations are made by modifying the traditional brand names inaccordance with the new designation system in which the position of hyphen is reviewed so that ahyphen comes after one letter or two letters. That is, the new brand name consists of “Trademark” and“Trade designation” as shown in the following. We are determined to control all the trade designations sothat they can clearly be identified.Examples of new and old brand namesOld brand name2New brand name(1) B-10B-10(2) MG-50MG-50(3) TGS-50TG-S50(4) MGS-50MG-S50(5) ZERODE-44Z-44(6) CMA-106NCM-A106N(7) DW-308DW-308Note: The trademarks may be used with the following symbols in this booklet.[F]: FAMILIARC ; [T]: TRUSTARC ; [P]: PREMIARC .3

ForewordAbbreviations and marks with definitionsNote the following preliminary information on use of this welding handbook.This welding handbook uses the following abbreviations and marks if necessary.1. Standards for welding consumables are abbreviated as followsJIS: Japanese Industrial StandardAWS: American Welding Society’s StandardEN: European NormASME: American Society of Mechanical Engineers’ Standard2. Classifications for welding consumables are used in accordance with the following rulesWelding consumables are classified in accordance with basically the mechanical and/or chemicalrequirements of the standards, excluding such requirements as size, length, marking andidentification manners. For details please contact the nearest Kobelco office or salesrepresentative.3. The test conditions of mechanical properties and hardness are as follows(1) Unless otherwise specified, impact values are obtained with Charpy 2mm-V notch specimens.(2) Unless otherwise specified, tension test and hardness test are carried out at room temperature.(3) Unless otherwise specified, tension test and hardness test are carried out in the as-weldedcondition.(4) The gauge length of tensile specimens is 4 x D (where D is the diameter) for testing at roomtemperature.(5) Unless otherwise specified, postweld heat treatment is followed by furnace cooling.(6) Unless otherwise specified, the testing method is as per AWS standard.(7) All mechanical and chemical data are given separately as “Example” (one of the manufacturer’slaboratory test data) and “Guaranty” (the guaranty value as per AWS standard). Tensilestrength and 0.2% offset strength are rounded as SI unit.4. The weight per piece of covered electrode shows an approximate weight4Abbrev.and CAWGDGMAWGSGTAWHHAZHFHIHTHvI PTIVL(L)MSNEDefinitionAlternating current or Air coolingAmpereAll positionsAs-weldedBalanceCooling rateDistance between electrodesDirect currentDC, electrode negativeDC, electrode positiveDiameterElectrogas arc weldingElongationExtension of wireFlat positionFurnace coolingFlux-cored wireFlux Cored Arc WeldingGroove designGas Metal Arc WeldingGroove sizeGas Tungsten Arc WeldingHorizontal positionHeat-affected zoneHorizontal filletHeat inputHigh tensileHardness (Vickers)Interpass temperatureImpact valueLengthLeading electrodeMild steelNumber of electrodeAbbrev.and markNLNRODOQOSOSWPolPre. P DefinitionNumber of layerNot requiredOuter diameterOil quenchingOffset strengthOne-side weldingPolarityPreheatPlate thicknessPostweld heat treatmentReduction of areaRedrying conditionsRoot gapRoom temperatureSubmerged arc weldingShielding gasShielded metal arc weldingStress reliefSolid wireTrailing electrodeTungsten inert gasTensile strengthTest temperatureVoltageVertical-down positionVertical-up positionWelding positionWater quenchingYield pointMaximumMinimum5

Warning and Caution in WeldingPay your attention to the following warnings and cautions for your safety and health during welding andrelated operationsWARNINGBe sure to follow safety practices stated in the following inorder to protect welders, operators and accompanied workersfrom a serious accident resulting in injury or death.CAUTIONFumes and gases generated during welding are dangerous toyour health.Welding in confined spaces is dangerous because it can be acause to suffocation by oxygen deficient. Be sure to follow safety practices stated in the following when you use weldingconsumables. Be sure to follow safety practices stated in the instruction manual of welding equipmentwhen you use it.WARNINGElectric shock can kill. Do not touch live electrical parts (A covered electrode held with an electrode holder and awelding wire are electrically live). Wear dry, insulated gloves. Do not wear torn or wet gloves. Use an electric shockpreventing device (e.g., open-circuit-voltage-reducing device) when welders or operatorswork in confined or high-level spaces. Use also a lifeline when welders or operatorsconduct welding at a high-level space. Follow safety practices stated in the instruction manual of welding machines before use.Do not use a welding machine the case or cover of which is removed. Welding cablesmust have an adequate size for the capacity expected. Welding cables must be kept inan appropriate condition and a damaged cable must be repaired or replaced with newone. Keep your head out of the source of fumes or gases to prevent you from directlybreathing high density fumes or gases. Use local exhaust ventilation, or wear respirators in order to prevent you from breathingfumes and toxic gases which cause toxication, poor health and suffocation by oxygendeficient. Use general ventilation during welding in a workshop. Particularly during welding inconfined spaces, be sure to use adequate ventilation or respirators, and welding shouldbe done at the presence of a trained supervisor. Do not conduct welding at where degreasing, solvent cleaning, spraying, or paintingoperations are carried out nearby. Welding work accompanied by these operations maycause generation of harmful gases. Use adequate ventilation or respirators with special attention during welding plated andcoated steels. Use respirators, eye safety glasses and safety leather gloves when using welding fluxesin order to prevent you from flux dust.CAUTIONArc rays can injure eyes and burn skin. Wear hand shields with an adequate shade grade during welding operations andsupervising the welding work. Select the correct shade grade for filter lenses and filterplates suitable for exact welding work by referring the standard JIS T81 41. Wear suitable protectors for protecting you from an arc ray; e.g., safety leather glove forwelding, long sleeve shirt, foot cover, leather apron. Use, at need, shade curtains for welding by surrounding the welding areas in order toprevent accompanied workers from arc rays.67

CAUTIONCAUTIONFire and explosion can take place.The tip of a welding wire and filler wire can injure eyes, faces, etc. Never conduct welding at areas adjacent to highly inflammable materials. Removecombustibles so that spatters cannot ignite them. If combustibles cannot be removed,cover them with a noninflammable material. Do not weld vessels or pipes which contain combustibles or being sealed. Do not put a hot weldment close to combustibles right after welding finished. When welding ceilings, floors, walls, remove combustibles put at the other side of them. Any part of a welding wire, with exception of the potion appropriately extended from thetip of the torch, must be free from touching the electrical circuit of the base metal side. Fasten cable joints and seal them with an insulation tape. The cable of the base metalside should be connected as close as possible to the welding portion of the work. Prepare fire-extinguishing equipment at where welding is carried out, in order to copewith a possible accident.CAUTIONFlying spatter and slag can injure eyes and cause skin burns.High temperature heat of welding can cause skin burns. When take off the tip of a wire fastened in the spool, be sure to hold the tip of the wire. When check the wire feeding condition, do not direct the welding torch to your face.CAUTIONFalling down or dropping welding consumables can injure you. Wear safety shoes and pay your attention not to drop welding consumables on your bodywhen carrying and handling them. Keep yourself in a correct posture not to cause a crickin your back while handling them. Follow the handling instructions shown on the surface of the pail pack wire packageswhen handle them. Pile up welding consumables in a correct way so as not to cause falling or dropping whilethey are stored or carried. Wear safety glasses, safety leather gloves for welding, long sleeve shirts, foot covers,leather aprons, etc. Do not touch weldments while they are hot.89