FILARC flux - Esab

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FILARC flux- andmetal- coredwelding wiresFILARC ceramicweld metal supportsContents page 4Previous pageNext pageSince its introduction for shipbuilding, useof ceramic weld metal supports for fast rootpass deposition has spread to bridge building,pressure vessels, general steel componentconstruction and other areas of fabrication.This has been accompanied byincreasing use of flux and metal-coredwires to gain optimum productivity.Process advantages are summarised as:• Higher welding currents possible, somuch increased root pass depositionrate.• High quality root runs with dependablepenetration and smooth profile.• Applicable in 1G, 2G, 3G up positions.• Gouging, grinding and sealing of backside are avoided.• Welder qualification easier to acquire.FILARC ceramic weld metal supports haveno adverse influence on weld metal compositionand mechanical properties. They aredry and insensitive to moisture absorption,leaving consumables' low-hydrogen performanceunaffected.The FILARC range presented here comprisesthe most commonly used types, coveringthe majority of applications in any type ofindustry. The range comprises grey andbrown ceramic blocks/strips.Grey types are of a harder ceramic, with ahigher melting point and a lower slag productionthan brown types. Grey types aremore prone to cracking by thermal expansion,and therefore always need a carrier inthe form of a rail or adhesive strip.Brown types can be applied without a carrierand, in addition, can be cut.Types with a concave groove are employedfor processes producing no or relativelysmall amounts of slag, such as GMAW withsolid wire, and FCAW with basic flux-coredor metal-cored wires.Rectangular grooves are needed to accomodatethe higher slag production fromspecial basic stick electrodes as FILARC35B, rutile flux-cored wires and SAW fluxes.Both types are supplied as loose ceramicblocks, as blocks mounted in rigid metal railsfor straight joints, or as blocks on self-adhesivealuminium tape or fitted on wire. Blockson tape are available as semi rigid forstraight joints, and flexible for curved jointsas in ship hulls, tanks, vessels and pipes.Centerline cracking on ceramic backingWhen welding root runs on ceramic backingstrips, centerline cracking may occur athigh heat inputs. This is a characteristicaspect of all rutile cored wires.The concave bead shape promotes anunfavourable solidification, making the weldprone to hot cracking, especially whenshrinkage forces are high. For crack freewelding, following guidelines should beobserved:• Apply a joint angle of 45-60°C andapprox. 5mm root opening.• Use ceramic strips with a rectangulargroove to accomodate the slag. Thegroove width must be around 15mm.• Use welding currents below 180A(Ø1.2mm). This gives a more or less ovalweld pool, instead of the unfavourablearrow shape.• Minimize weaving to avoid excessivebead thickness, while keeping the arc infront of the weld pool to obtain sufficientpenetration.130
FILARC flux- andmetal- coredwelding wiresFILARC ceramicweld metal supports, continuedContents page 4Selection FILARC Dimensions, mm Assembly Type Applicationtable type A B C D LengthPrevious pageNext pageDCABPZ1500/33 16.0 0.9 35 9.0 100 loose block grey All-position for:PZ1500/41 16.0 0.9 35 9.0 1000 rail grey FILARC flux-coredPZ1500/76 16.0 0.9 35 9.0 500 tape grey wires and submergedPZ1500/10 16.0 0.9 35 9.0 100 loose block brown arc weldingPZ1500/03 16.0 0.9 35 9.0 1000 rail brown (MMA) FILARC 35BPZ1500/31 11.5 1.1 25 7.0 150 loose block greyPZ1500/40 11.5 1.1 25 7.0 900 rail greyPZ1500/79 11.5 1.1 25 7.0 600 tape greyDCABPZ1500/32 13.2 1.3 25 7.0 150 loose block grey All-position for:PZ1500/43 13.2 1.3 25 7.0 900 rail grey FILARC metal-coredPZ1500/78 13.2 1.3 25 7.0 600 tape grey wires, basic flux-PZ1500/00 13.2 0.8 25 7.0 150 loose block brown cored wires andPZ1500/88 13.2 0.8 25 7.0 900 rail brown solid wiresDCABAll-position + flexiblePZ1500/81 13.0 1.5 30 7.0 500 tape grey types for:block 25mm Straight or curvedPZ1500/61 13.3 0.9 30 7.0 500 tape brown plates, use:block 20mm FILARC flux-coredPZ1500/42 13.3 0.9 30 7.0 1000 wire brown wires and submergedblock 20mm arc welding(MMA) FILARC 35BDCABAll-position + flexiblePZ1500/80 16.0 1.5 30 7.0 500 tape grey types for:block 25mm Straight or curvedPZ1500/06 13.2 0.8 30 7.0 500 tape brown plates, use:block 20mm FILARC metal-coredPZ1500/02 13.2 0.8 30 7.0 1000 wire brown wires, basic fluxblock20mm cored wires andsolid wires131
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FILARC flux - Esab

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