MIG and flux-cored welding guide (PDF) by weloveike

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									MIG (GMAW) and Flux-Cored                                                         Welding Wire Thickness Charts
(FCAW) Wire                                                                            Material           MIG Solid Wire Size          Gasless Flux-Cored Wire Size
                                                                                     Thickness        .023”     .030”       .035”       .030”     .035”     .045”
MIG and flux-cored welding offer advantages over other welding
                                                                                  22 Gauge (.031)
processes, especially for the novice. With these two processes, the
welding machine creates an arc between the work piece (what you                   20 Gauge (.037)
want to weld) and a continuously consumable electrode (the “wire”                 18 Gauge (.050)
in these wire welding processes). The operator need only focus on                 16 Gauge (.063)
directing the MIG gun at the joint and proper motion. Most welding                14 Gauge (.078)
machines that can MIG weld can also flux-cored weld.                              1/8” (.125)
                                                                                  3/16” (.188)
                                                                                  1/4” (.25)
Welding Wire/Method Recommendations
 Wire Type             Considerations
                                                                                  WFS Range Relationships For Short
                       May be used with CO2 or 75% Argon/25% CO2
                       (C-25), SteelMIX®, SteelMIX® 3 or SteelMIX® Extra          Circuit Transfer on Steel
                       CO2 gas provides deeper penetration                          Wire Size       Amperage Range       Wire Feed Speed Range
 Solid Carbon-Steel    75% Argon/25% CO2 has less spatter than CO2.                   .023”              30-90                  100-400
 ER70S-6               SteelMIX(s) have less than either                              .030”             40-145                   90-340
                       Indoor use with no wind                                        .035”             50-180                   80-380
                       For auto body, manufacturing, fabrication                      .045”             75-250                   70-270
                       Welds thinner materials (22 gauge) than flux cored wires
                       No shielding gas required
 Flux Cored/           Excellent for outdoor windy conditions                     Rule of Thumb Metal Thickness -
 Carbon-Steel          For dirty, rusty, painted materials                        Amperage Needed
 E71T-GS               Hotter than solid wires, welds to 18 gauge materials and
                       thicker                                                                                                      Rule Of Thumb
                                                                                  Gauge Number      Nearest Fraction Of An Inch       Amperage
                       Must be used with Argon, AluMIX™, or other Argon/
                                                                                       18                   3/64” = .047                  47
 Solid Aluminum        Helium mixes
                                                                                       16                   1/16” = .062                  62
 ER-4043               Recommended to be used with spool guns for best                 14                   5/64” = .078                  78
 ER-5356               results
                                                                                       12                   1/10” = .100                 100
                       5356 is harder for stronger welds and easier feeding            10                    1/8” = .125                 125
 Solid Stainless       Use with StainMIX™ 3 or Helium/Argon/CO2 mixtures                8                   5/32” = .156                 156
 Steel ER308/308L      For 301, 302, 304, 305 and 308 stainless base metals             6                   3/16” = .187                 187




Recommended Airgas Shielding Gases                                                     Rule of Thumb: Calculating Wire
Small Machines - Mild Steel Applications                                               Feed Speed
• Argon 75% - CO2 25%
  - Available in various cylinder sizes
                                                                                         1 ampere for every .001 thickness
Mid-Size Machines – Mild Steel Applications
• Argon 75% - CO2 25%                                                                    1/8” material = .125 = 125 Amperes
  - Various size cylinders                                                               Wire Burn Off:
  - Will allow short circuit transfer only
                                                                                         .023 - 3.5” wire/amp - 125 amps = 437 IPM
• Airgas Gold Gas® SteelMIX®
  - Will allow short circuit and spray transfer                                          .030 - 2” wire/amp - 125 amps = 250 IPM
  - Various size cylinders                                                               .035 - 1.6” wire/amp - 125 amps = 200 IPM
Mid-Size Machines – Stainless Steel Applications                                         .045 - 1” wire/amp - 125 amps = 125 IPM
                                                                                                                                                                      Filler Metals
• Airgas Gold Gas® StainMIX™ 3
  - Will allow short circuit and spray transfer
  - 300 cf size cylinders only                                                         An example of how to determine wire feed
• Airgas Gold Gas® StainMIX™                                                           speed (WFS) in inches per minute (IPM) is
                                                                                       below. A wire diameter size .035” is chosen to
Mid-Size Machines – Aluminum Applications                                              weld on 1/8” steel material. Use a “ballpark”
• Argon                                                                                amperage setting of 125 amps.
  - For all thickness below 1/4 inch
  - Available in various cylinder sizes
                                                                                          Calculate
• Airgas Gold Gas® AluMIX™
  - For all thickness above 1/4 inch                                                                 125 amps
  - Available in 300 cf size cylinders                                                              x 1.6 wire feed speed per amp
                                                                                                     200 IPM required wire feed
                                                                                                          speed setting



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                MIG Welding
                1. Keep a 1/4 – 3/8 in. stickout (electrode extending from the tip of the        8. Be sure to match your contact tube, gun liner and drive rolls to the wire
                   contact tube) (Refer to Diagram 1).                                               size you are using.
                2. For thin metals, use a smaller diameter wire. For thicker metal, use a        9. Clean the gun liner and drive rolls occasionally, and keep the gun nozzle
                   larger wire and a larger machine. See machine recommendations for                 clean of spatter. Replace the contact tip if blocked or feeding poorly.
                   welding capacity.                                                             10. Keep the gun straight as possible when welding, to avoid poor wire
                3. Use the correct wire type for the base metal being welded. Use stainless          feeding.
                   steel wires for stainless steel, aluminum wires for aluminum, and steel       11. Use both hands to steady the gun when you weld. Do this whenever
                   wires for steel.                                                                  possible. (This also applies to Stick and TIG welding, and plasma cutting.)
                4. Use the proper shielding gas. Please refer to the “Selection of Shielding     12. Keep wire feeder hub tension and drive roll pressure just tight enough to
                   Gases” tables on page 4.                                                          feed wire, but don’t overtighten.
                5. For steel, use ER70S-6 wire when more deoxidizers are needed for              13. Keep wire in a clean, dry place when not welding, to avoid picking up
                   welding on dirty or rusty steel.                                                  contaminants that lead to poor welds.
                6. For best control of your weld bead, keep the wire directed at the leading     14. Use DCEP (reverse polarity) on the power source (on solid wire).
                   edge of the weld pool.                                                        15. A drag or pull gun technique will give you a bit more penetration and a
                7. When welding out of position (vertical, horizontal, or overhead welding),         narrower bead. A push gun technique will give you a bit less penetration,
                   keep the weld pool small for best weld bead control, and use the smallest         and a wider bead. (Refer to Diagram 3).
                   wire diameter size you can.




                             Diagram 1                                         Diagram 3
                                                                                               Push                          Perpendicular                        Drag
                                                                                                      10°                                                  10°
                                                                Too Short




                                                                                                 Electrode directed                                    Electrode pointed
                                                                 Normal                           ahead of bead                                         back into bead

                                                                                                                           Direction Of Welding




                                                                Too Long




                                      Electrode Extensions (Stickout)
                                                                                               (A) Push Technique       (B) Gun Perpendicular     (C) Drag (Pull) Technique

                                                                                                             Effect of Electrode Position and Welding Technique
                              Diagram 2
                                     Argon + CO2          CO2




                                      Penetration Patterns for Steel
Filler Metals




                                                                                                  MIG (GMAW) Gun and Weld Area
                MIG (GMAW) Voltage - Bead Changes




       148                                      2006/2007 Radnor Products Catalog
Modes of MIG (GMAW) Transfer                                                                                        Short Circuit Transfer (SCMT)
The term modes of transfer is used to describe the process by which the                                             Short circuit transfer gets its name from the welding
wire electrode is melted and deposited into the puddle. The most common                                             wire actually “short circuiting” (touching) the base
way to classify metal transfer is according to the size, frequency, and                                             metal many times per second. When the welding
characteristics of the metal drops being transferred. There are three modes                                         gun trigger is pressed, the electrode wire feeds
of metal transfer that we will discuss here:                                                                        continuously from the wire feeder, through the gun,
• Short Circuit Transfer                                                                                            and to the arc area, shortcircuiting to the base metal,
                                                                                                                    exploding and establishing an arc. While welding, this
• Globular Transfer                                                                                                 cycle can repeat itself between 20 and as much as
• Spray Transfer                                                                                                    250 times per second.
The stability of the welding arc and the metallurgical changes in the
electrode wire are dependent on the mode of transfer. Welding procedures
                                                                                                                    Spray Transfer
are categorized according to the mode of transfer.                                                                A spray transfer “sprays” a stream of tiny molten
                                                                                                                  droplets across the arc, from the electrode wire to
                                                                                                                  the base metal. These molten droplets are usually
                         Globular Transfer                                                                        smaller than the diameter of the unmelted electrode
                                                                                                                  wire. The arc is said to be “on” all of the time, once an
                         A globular transfer for GMAW is often referred to                                        arc is established. The spray transfer uses relatively
                         as the state of transfer between short-circuiting                                        high voltage (24 volts or higher depending upon the
                         and spray arc transfer. Large “globs” of weld metal                                      type of shielding gas), wire feed speed and amperage
                         transfer across the arc in a gravity transfer. The                                       values, compared to short circuit transfer. Because
                         droplets are usually larger than the electrode wire.            of the high voltage, wire feed speed and amperage, there is a resulting high
                         Although the electrode wire is pinched off at the               current density. The high current density produces high metal deposition
                         arc, globular transfer does not achieve a true spray            rates. The high degree of heat in the spray arc weld puddle makes for a
                         transfer. Globular is a more unstable transfer, with a          larger weld puddle that is more fluid than the weld puddle for short circuit
                         less smooth weld bead appearance.                               transfer. Because of this heat and the size of the weld puddle, spray transfer
Globular transfer can, in many cases, yield more spatter. Since spatter is               is somewhat limited in welding positions. The heat and size of the weld
waste, it is not a desirable side effect of globular transfer. Globular transfer         puddle also limits spray transfer to material 1/8” or thicker. Welding steel with
can also cause cold lapping or incomplete fusion due to the large metal                  spray transfer is usually done in the flat position, and the horizontal fillet weld
droplets splashing metal out of the puddle.                                              position. Horizontal position spray arc welds are lap and T- joint fillet welds.

Typical Operating Procedures                                                 Short Circuit Transfer Welding Parameters
                            Wire                          Melt-                              Electrode       Welding         Arc Voltage                    Travel Shielding
    Diameter, Polarity      Feed          Arc      Approx. Off                  Material     Diameter         Current         (Electrode     Wire Feed      Speed Gas Flow
     CTWD1 Transfer        Speed        Voltage Current   Rate                Thickness1 (inches) (Amps-DC)                     Positive)   Speed (IPM) (IPM)            (CFH2)
  Mode Shielding Gas       in/min       (volts)          lbs/hr
                                                    (amps)                       24 ga.         .030”          35-50             15-17         85-100       12-20         15-20
  .035”, DC+                                                                     22 ga.         .030”          40-60             15-17         90-130       18-22         15-20
          3/8-1/2”             100        18           80   1.6
                                                                                 20 ga.         .025”          55-85             15-17         70-120       35-40         15-20
   Short Circuit Transfer      150        19          120   2.4
         100% CO2              250        22          175   4.0                  18 ga.         .035”         70-100             16-19        100-160       35-40         15-20
          1/2-3/4”             375        23          195   6.0                   1/16”         .035”         80-110             17-20        120-180       30-35         20-25
      Spray Transfer           500        29          230   8.0                   5/64”         .035”        100-130             18-20        160-220       25-30         20-25
    90% Ar/10% CO2             600        30          275   9.6                    1/8”         .035”        120-160             19-22        210-290       20-25         20-25
  .045”, DC+                                                                       1/8”         .045”        180-200             20-24        210-240       27-32         20-25
           3/8-1/2”            125        19          145   3.4                   3/16”         .035”        140-160             19-22        210-290       14-19         20-25
   Short Circuit Transfer      150        20          165   4.0                   3/16”         .045”        180-205             20-24        210-245       18-22         20-25
         100% CO2              200        21          200   5.4                    1/4”         .035”        140-160             19-22        240-290        11-15        20-25
           1/2-3/4”            350        27          285   9.2
      Spray Transfer           475        30          335  12.5                    1/4”         .045”        180-225             20-24        210-290       12-18         20-25
    90% Ar/10% CO2             500        30          340  13.2              Note: Single-pass flat and horizontal fillet positions. Reduce current 10 to 15% for vertical and
  .052”, DC+                                                                 overhead welding.
            3/4-1”             300        30          300  10.6              1 For fillet and groove welds - for fillet welds, size equals metal thickness; for square groove
      Spray Transfer           320        30          320  11.5              welds, the root opening should equal 1/2 the metal thickness.
    90% Ar/10% CO2             485        32          430  17.1              2 Shielding gas is CO2 or 75% Ar / 25% CO2                                                           Filler Metals
  1/16”, DC+
            3/4-1”             210        25          325  10.7
      Spray Transfer           235        27          350  12.0
    90% Ar/10% CO2             290        28          430  14.8
Note: Procedures in the shaded areas are procedures for short
circuiting mode using 100% CO2. When using 75% Argon, 25% CO2
for short circuit transfer, reduce voltage by 1 to 2 volts
1 CTWD (Contact Tip to Work Distance). Subtract 1/16” for MIG short
arc, 3/16” for axial spray to calculate Electrical Stickout.




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                Spray Transfer Welding Parameters
                                                   Electrode     Welding      Arc Voltage Wire Feed     Travel       92% Ar /
                  Material                         Diameter       Current     (Electrode       Speed    Speed      8% CO2 Gas
                 Thickness      Type of Weld1       (inches) (Amps-DC)         Positive)        (IPM)   (IPM)       Flow (CFH)
                   18 ga.           Fillet             .045         280            26            350     190            25
                                Square Groove          .045         270            25            340     180            25
                    16 ga.          Fillet             .045         325            26            360     150            35
                                Square Groove          .045         300            28            350     140            35
                    14 ga.          Fillet             .045         325            27            360     130            35
                                Square Groove          .045         325            29            360     110            35
                                Square Groove          .045         330            29            350     105            35
                    11 ga.          Fillet             1/16         380            28            210      85            35
                                Square Groove          .045         350            29            380     100            35
                    3/16”           Fillet             1/16         425            31            260      75            35
                                Square Groove          1/16         425            30            320      76            35
                                Square Groove          1/16         375            31            260      70            35
                     1/4”       Square Groove          1/16         475            32            340      55            35
                1 For mild carbon and low alloy steels - on square groove welds, backing is required.



                AWS MIG (GMAW) Electrode/Rod Classification                                               AWS MIG (GMAW) Electrode/Rod Classification
                System – Aluminum                                                                         System – Stainless Steel




                                                                                                          Designation System for Stainless Steel
                Designation System for Aluminum Alloys                                                    Suffix                 Additional Requirements
                                                                                                          L                      Has a lower carbon content
                 Alloy Series        Principle Alloying Element
                                                                                                          LSi                    Higher silicon, lower carbon content
                 4XXX                Silicon
                 5XXX                Magnesium


                AWS MIG (GMAW) Electrode/Rod Classification                                               AWS FCAW Electrode/Rod Classification System
                System – Steel                                                                            – Tubular Wire
                                                                  6
Filler Metals




                Chemical Composition of Solid Wire Using CO2 Sheiding Gas
                                                                                              Impact                                 Chemical Composistion
                     AWS           Tensile Strength    Yield Strength    % Elongation     Strength Min.
                 Classification       ksi (MPa)          ksi (MPa)        min. in 2”       ft-lbs at °F          C         Mn             Si           P            S    Cu
                    ER70S-3            72 (500)           60 (420)            22             20 @-20          .06-.15    .90-1.40       .45-.70       .025        .035   .50
                    ER70S-6            72 (500)           60 (420)            22             20 @-20          .07-.15    1.40-1.85     .80-1.15       .025        .035   .50

       150                                        2006/2007 Radnor Products Catalog
                                                     ArcPlus 6 — AWS ER70S-6 Carbon Steel MIG Wire
                                                                             ArcPlus 6 is a copper-coated solid wire     Welding Positions
                                                                             that has higher levels of manganese and
                                                                             silicon when compared to a general-
                                                                             purpose wire such as ER70S-3. ArcPlus
                                                                             6 provides excellent tolerance to rust
                                                                             and mill scale, improved wetting and
                                                                             bead shape characteristics in a highly         1G             2F                  2G
                                                                             fluid weld puddle.



                                                                                                                           3G            3Gi                  4G




Advantage Radnor                                            Typical Applications                                     Conformance
• Butt and fillet welding of carbon steel sheet             • HVAC ductwork                                          • AWS A5.18, ER70S-6
  and plate                                                 • Heavy equipment                                        • ASME SFA-5.18: ER70S-6
• Superior wire surface finish for the best                 • Structural, automotive, and general fabrication
  feedability and arc performance
• Optimal manufacturing process to precisely
  control chemical composition
• ArcPlus 6 wire is packaged in a 33-pound
  adapterless wire basket, 44-pound fiber                                                                               Typical Operating
  spools, and 550-pound cardboard drums
                                                                                                                        Procedures
                                                                                                                                                 Current (Amps)
                                                                                                                              Polarity          .035”         .045”
                                                                                                                                 DC+            40-200        60-300


Mechanical Properties
As Welded AWS A5.18, ER70S-6

                                                                                                                                          Charpy V-Notch
                                 Yield Strength                         Tensile Strength                   Elongation                      ft lbf (Joules)
                                   psi (MPa)                               psi (MPa)                          (%)                         @-20ºF (-29ºC)
       Required                         58,000                               70,000                             22                               20
 Test Results
      As-Welded             64,000 - 70,000 (440-485)            80,000 - 70,000 (550 - 585)               22% - 28%                      26 - 37 (35 - 40)


                                                                                                                                                                       Filler Metals
Deposit Composition                                                                                                                      Recommended
                             %C               % Mn             % Si              %P               %S                                     Airgas Shielding
   Radnor ER70S-6          .06-.15          1.40-1.85        .80-1.15            .025            .035                                    Gases
  AWS Requirements                                                               max.            max.                                    • Gold Gas® SteelMIX®
    Test Results          .07-.015          1.40-1.85       0.80-1.15         0.025 max        .035 max
                                                                                                                                         • Gold Gas® SteelMIX® 3
                                                                                                                                           Sheet/Gauge
                                                                                                                                         • Gold Gas® SteelMIX®
Diameter/Packaging                                                                                                                         (Automated) Extra
                                                                                                                                         • Argon / CO2 Mixture
       Diameter           33-lb. Wire        44-lb. Fiber    550-lb. Twist                                                                 (75% - 25%)
       (Inches)             Basket              Spool         Free Drum
                                                                                                                                         • CO2
         .035             64004065               64004060      64004075                                                                  • Argon / Oxygen Mixture
         .045             64004066               64004061      64004076                                                                    (Spray Transfer)

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                                                                       6 — AWS ER70S-6 Mild Steel MIG Wire
                                                                                                      A top copper-coated, mild steel                    Welding Positions
                                                                                                      MIG wire, Radnor® 6 is an excellent
                                                                                                      choice for welding on metals with a
                                                                                                      low to medium presence of surface
                                                                                                      contaminants such as rust or mill scale.
                                                                                                      It is a low carbon, high manganese, and
                                                                                                      very high silicon wire that exhibits very          1G/1F                  2G               2F
                                                                                                      good puddle fluidity, bead profile and
                                                                                                      spatter control.


                                                                                                                                                         3G/3F           3G3Fi                 4G/4F




                                                                                                                                                           5G              5Gi                 6G

                Advantage Radnor                                                Typical Applications                                                     Conformance
                • Excellent spatter control and bead profile                    • Applications which require greater cleaning                            • AWS A5.18-93: ER70S-6
                • Highly resistant to copper flaking, which can                   action through increased levels of silicon and                         • ASME SFA-5.18: ER70S-6
                  clog liners and contact tips                                    manganese compared to the levels provided by
                • The surface treatment is designed to provide                    a typical ER70S-3 or ER70S-4 wire
                  smooth trouble-free feeding performance                       • Industrial, farming, construction, and mining
                • Copper coating provides superior arc-starting                   equipment
                  characteristics, for long contact tip life                    • Automotive repair
                                                                                • Single pass welds on sheet metal applications
                                                                                • Multiple pass welds on thick sections
                Mechanical Properties                                           • All-position welding
                As Welded AWS A5.18-93

                                                                                                                                                                      Charpy V-Notch ft lbf (Joules)
                                               Tensile Strength psi (MPa)                   Yield Strength psi (MPa)                      Elongation (%)                     @-20ºF (-29ºC)
                 Required AWS A5.18-93                70,000 (483) min.                         58,000 (400) min.                             22 min.                            20 (27) min.
                 Test Results
                       As-Welded                        85,500 (555)                                 64,200 (443)                               29                                 65 (88)


                Deposit Composition – 2-lb. Spool Only
                                            %C           % Si          % Mn                                                    Typical Operating Procedures
                    Requirements
                    AWS A5.18-93                     Not Specified                                                                                                  Current (Amps)
                     Test Results           .07           .80          1.45                                                        Polarity      .023”      .030”       .035”        .045”       .052”
                                                                                                                                    DC+          25-90     30-120       40-175       60-300     250-430
                Deposit Composition – 11-lb. Spool up to 500-lb. Drum
Filler Metals




                                             %C          % Mn          % Si          %S              %P          %Cu
                    Requirements           .06-.15     1.40-1.85     .80-1.15        .035            .025        .50
                                                                                     max.            max.        max.
                                                                                                                                                                          Recommended
                    AWS A5.18-93
                     Test Results           .08          1.44          .84           .007            .008        .25                                                      Airgas Shielding
                                                                                                                                                                          Gas
                Diameter/Packaging                                                                                                                                        • Gold Gas® SteelMIX®
                                                                                                                                                                          • Gold Gas® SteelMIX® 3
                                                                                                                         500-lb.                                            Sheet/Gauge
                                   2-lb.     11-lb.         33-lb.         33-lb.           44-lb.          44-lb.        Twist
                 Diameter        Plastic    Plastic         Steel          Plastic          Steel           Fiber         Free                                            • Gold Gas® SteelMIX®
                 (Inches)         Spool      Spool          Spool          Spool            Spool           Spool         Drum                                              (Automated) Extra
                    .023        64001200   64001202                                                                                                                       • Argon / CO2 Mixture
                    .030        64001206   64001208                                                                                                                         (75% - 25%)
                    .035        64001212   64001214       64004011        64004042     64004016          64004020       64004035                                          • CO2
                    .045        64001218   64001220       64004012        64004043     64004017          64004021       64004036                                          • Argon / Oxygen Mixture
                    .052                                                               64004018          64004022       64004037                                            (Spray Transfer)
       152                                           2006/2007 Radnor Products Catalog
                                                      4043, 5356 — AWS ER4043, ER5356 Aluminum MIG Wire

                                                              Radnor® ER4043                                                   Welding Positions
                                                                        ®
                                                              Radnor 4043 is a great choice for the welding of
                                                              heat-treatable base alloys and more specifically
                                                              the 6XXX series alloys. It has a lower melting point
                                                              and more fluidity than the 5XXX series filler alloys
                                                              and is preferred by welders because of its favorable                    1G               2F             2G
                                                              operating characteristics. ER4043 type wires are also
                                                              less sensitive to weld cracking with the 6XXX series
                                                              base alloys. Radnor® 4043 is suitable for sustained
                                                              elevated temperature service, i.e. above 150°F.
                                                              Radnor® ER5356                                                      3G              3Gi                4G
                                                                        ®
                                                              Radnor ER5356 is our most popular aluminum MIG
                                                              wire. It is a great general-purpose filler alloy designed
                                                              for the welding of 5XXX series alloys when 40,000 psi
                                                              (276 MPa) tensile strength is not required.


Advantage Radnor                                              Typical Applications                                             Conformance
• All-position aluminum MIG wire.                             • Sheet metal applications on the appropriate                    • AWS A5.18: ER4043, ER5356
• Superior wire surface finish for the best                     aluminum base metals.                                          • ASME SFA-5.18: ER4043, ER5356
  feedability and arc performance.                            Radnor® 4043:
• Optimal manufacturing process to precisely                  • Bicycle frames
  control chemical composition.
                                                              • Automotive frames and drive shafts
• State-of-the-art testing equipment to ensure
  trouble-free performance of the weld wire.                  Radnor® 5356:
                                                              • Automotive bumpers and supports
                                                              • Formed truck panels
                                                              • Structural frames in the shipbuilding industry.

Deposit Composition
                        % Al        % Si        % Fe         % Cu       % Mn      % Mg      % Cr      % Zn      % Ti          % Be
   Radnor ER4043       Balance     4.5-6.0       .08         .30         .05       .05        —       .10         .20         .0008
  AWS Requirements                               max         max         max       max                max         max          max

     Test Results      Balance      5.26         .015        .006           .01    .03        —       .001        .009     <.0002

   Radnor ER5356       Balance      .25          .40         .10        .05-.20   4.5-5.5   .05-.20   .10      .06-.20        .0008
  AWS Requirements                  max          max         max                                      max                      max

     Test Results      Balance      .05          .09         .03            .12    4.56      .08      .003        .15         .007


Diameter/Packaging – ER4043
                                                                                                               Typical Operating Procedures
      Diameter          1-lb. Plastic        3-lb. Plastic     16-lb. Plastic
      (Inches)             Spool                Spool              Spool                                                                       Current (Amps)

         .030            64001500             64001501              64001506                                       Polarity           .030”    .035”        3/64”    1/16”    Filler Metals
         .035            64001502             64001503              64001508                                         DC+             60-100   100-160   150-200     180-280
         3/64            64001504             64001505              64001510
         1/16                  —                  —                 64001511
                                                                                                                                                  Recommended
                                                                                                                                                  Airgas Shielding
Diameter/Packaging – ER5356                                                                                                                       Gas
                                                                                                                                                  • Argon
      Diameter          1-lb. Plastic        3-lb. Plastic     16-lb. Plastic                                                                     • Gold Gas® AluMIX™
      (Inches)             Spool                Spool              Spool
         .030            64001512             64001513              64001518
         .035            64001514             64001515              64001520
         3/64            64001516             64001517              64001522
         1/16                                                       64001523


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                                                                    ER308/308L — Stainless Steel MIG Welding Wire

                                                                                        Radnor® ER308L                                     Welding Positions
                                                                                        ER308L is used for welding types 304,
                                                                                        304L, 308, and 308L stainless steels. It is
                                                                                        very similar to ER308, but has a carbon
                                                                                        content held to a max of .03% to avoid
                                                                                        carbide precipitation.                                   1G            2F                  2G



                                                                                                                                                3G           3Gi                  4G




                Advantage Radnor                                              Typical Applications                                         Conformance
                • Capable of x-ray quality welds.                             • Sheet metal applications on the appropriate                • AWS A5.9: ER308L
                • Manufactured under lot control. Certificate of                stainless steel base metals.                               • ASME SFA-5.9: ER308L
                  Test is available upon request.                             • High-pressure piping and tubing.


                Mechanical Properties
                As Welded AWS A5.9: ER308L

                                                                                                                                                              Charpy V-Notch
                                                 Yield Strength                        Tensile Strength                     Elongation                         ft lbf (Joules)
                                                   psi (MPa)                              psi (MPa)                            (%)                            @-20ºF (-29ºC)
                                                       Not                                     Not                              Not                                Not
                       Required                      Specified                               Specified                        Specified                          Specified
                 Test Results
                      As-Welded                          —                                    83,000                             40                                  —




                Deposit Composition                                                                                           Typical Operating Procedures
                                         %C          % Si        % Mn        % Ni     % Cr                                                                    Current (Amps)
                   Radnor ER308L                             Not Specified                                                            Polarity        .023”         .030”         .035
                  AWS Requirements
                                                                                                                                          DC+         35-70         50-100       100-150
                     Test Results        .019        .46         1.72        10.10   20.80
Filler Metals




                Diameter/Packaging
                                                                                                                                                      Recommended
                       Diameter          2-lb. Plastic       5-lb. Plastic
                       (Inches)             Spool               Spool
                                                                                                                                                      Airgas Shielding
                                                                                                                                                      Gas
                         .023             64001461            64001496
                                                                                                                                                      • Gold Gas® StainMIX™ 3
                         .030             64001463            64001497
                                                                                                                                                      • Gold Gas® StainMIX™
                         .035             64001465            64001498




       154                                      2006/2007 Radnor Products Catalog
                                                       ER308/308L, ER309/309L, ER316/316L —
                                                       Stainless Steel MIG Welding Wire
                                                                                Radnor® by McKay®                                    Welding Positions
                                                                                ER308/308L, ER309/309L,
                                                                                ER316/316L
                                                                                Packaged exclusively for Radnor by McKay
                                                                                this high-quality stainless steel MIG welding                             2F               2G
                                                                                wire is packaged in 30-lb. spools for use in
                                                                                                                                         1G
                                                                                the construction industry or for those who
                                                                                use larger quantities of filler metal.


                                                                               Conformance                                            3G              3Gi                 4G
                                                                               • AWS A5.9: ER308/308L, ER309/309L,
                                                                                 ER316/316L
                                                                               • ASME SFA-5.9: ER308/308L, ER309/309L,
                                                                                 ER316/316L

Radnor® by McKay®                                                 Radnor® by McKay®                                           Radnor® by McKay®
ER308/308L                                                        ER309/309L                                                  ER316/316L
308/308L stainless steel solid wire is used to                    309/309L stainless steel solid wire is used for             316/316L stainless steel solid wire is formulated
weld Types 201, 302, 304 and 308 stainless                        joining similar 309L alloys or for joining 300-             with molybdenum for increased pitting corrosion
steels. It can also be used for joining some                      series stainless steels to carbon or low alloy              resistance and low carbon for better intergranular
dissimilar 300 series steels. 308/308L has a low                  steels.                                                     corrosion.
carbon content to help prevent intergranular
corrosion.

Mechanical Properties
                                                                                                                                                Charpy V-Notch - ft lbf (Joules)
                                               Tensile Strength - psi (MPa)           Yield Strength - psi (MPa)      Elongation % in 2”            @ Room Temperature
             AWS Specification                        Not Specified                         Not Specified                Not Specified                    Not Specified
    Test Results As-Welded: ER308/308L                85,000 (587)                              58,000 (400)                    36                          96 (130)

    Test Results As-Welded: ER309/309L                87,000 (600)                              59,000 (407)                    40                         100 (136)

    Test Results As-Welded: ER316/316L                86,000 (593)                              57,000 (393)                    36                          82 (111)


Deposit Composition
                            % C1      % Cr          % Ni         % Mo       % Mn         % Si          %P      % Cu    % Fe                          Recommended
      Radnor ER308L         .03       19.5-        9.0-11.0       .75       1.0-2.5     .30-.65        .03     .75    Balance                        Airgas Shielding
     AWS Requirements       max       22.0                        max                                  max     max                                   Gas
        Test Results         .02        20.5         10.5          .3        1.7           .4          .002    .21    Balance                        • Gold Gas®
                                                                                                                                                       StainMIX™ 3
      Radnor ER309L         .03       23.0-         12.0-         .75       1.0-2.5     .2-.652        .03     .75    Balance
                            max       25.0          14.0          max                                  max     max                                   • Gold Gas®
     AWS Requirements
                                                                                                                                                       StainMIX™                   Filler Metals
        Test Results         .02        24.0         13.5          .2        2.1           .4          .001    .27    Balance

      Radnor ER316L         .03       18.0-         11.0-        2.0-3.0    1.0-2.5      .3-.63        .03     .75    Balance
     AWS Requirements       max       20.0          14.0                                               max     max

        Test Results         .02        19.0         12.5         2.5        1.7           .4          .002    .28    Balance
1
  AWS Requirements for % C for: ER308 - .08 max; ER309 - .12 max; ER316 - .08 max
2
  ER309 AWS Requirement is .30-.65;
3
  ER316 AWS Requirement is .30-.65                                                                                         Typical Operating Procedures
Diameter/Packaging                                                                                                                                              Current (Amps)

                           ER308/308L           ER309/309L          ER316/316L                                                  AWS Class      Polarity        .035”      .045”
         Diameter          30-lb. Plastic       30-lb. Plastic      30-lb. Plastic                                                               DC+           60-200     75-225
         (Inches)              Spool                Spool               Spool                                                   ER308/308L

           .035              64004426             64004434              64004442                                                ER309/309L       DC+           60-200     75-225

           .045              64004427             64004435              64004443                                                ER316/316L       DC+           60-200     75-225


                                                                    Visit Us Online at www.airgas.com                                                                         155
                                                                      ER308LSi, ER309LSi, ER316LSi —
                                                                      Stainless Steel MIG Welding Wire
                                                                                               Radnor® by McKay®                                   Welding Positions
                                                                                               ER308LSi, ER309LSi,
                                                                                               ER316LSi
                                                                                               Packaged exclusively for Radnor by McKay
                                                                                               this high-quality stainless steel MIG welding                             2F               2G
                                                                                               wire is packaged in 30-lb. spools for use in
                                                                                                                                                       1G
                                                                                               the construction industry or for those who
                                                                                               require large amounts of material in larger
                                                                                               quantities.

                                                                                               Conformance                                          3G               3Gi                 4G
                                                                                               • AWS A5.9: ER308LSi, ER309LSi,
                                                                                                 ER316LSi
                                                                                               • ASME SFA-5.9: ER308LSi, ER309LSi,
                                                                                                 ER316LSi

                Radnor® by McKay® ER308LSi                                       Radnor® by McKay® ER309LSi                                 Radnor® by McKay® ER316LSi
                308L HiSil is a stainless steel solid wire with 308L             A modified version of 309L stainless steel solid           Featuring a silicon level that is higher than 316L,
                chemistry that has been modified to offer a higher               wire, 309L HiSil has increased silicon levels to           316L HiSil stainless steel wire also provides
                silicon level for increasing weld puddle fluidity, as            overcome the typical sluggish nature of 300-               better wetting action, particularly for GMAW
                well as for ensuring tie-ins and potentially higher              series stainless steel welding puddles.                    processes.
                welding speeds.



                Mechanical Properties
                                                                                                                                                              Charpy V-Notch - ft lbf (Joules)
                                                              Tensile Strength - psi (MPa)           Yield Strength - psi (MPa)     Elongation % in 2”            @ Room Temperature
                           AWS Specification                         Not Specified                         Not Specified               Not Specified                     Not Specified
                  Test Results As-Welded: ER308LSi                   86,000 (593)                          57,000 (393)                       42                           92 (125)

                  Test Results As-Welded: ER309LSi                   87,000 (600)                          56,000 (386)                       36                           92 (125)

                  Test Results As-Welded: ER316LSi                   87,000 (600)                          57,000 (393)                       38                           95 (129)


                Deposit Composition
                                           %C        % Cr          % Ni         % Mo       % Mn         % Si       %P        % Cu    % Fe                           Recommended
                  Radnor ER308LSi          .03       19.5-        9.0-11.0       .75       1.0-2.5     .65-1.0     .03        .75   Balance                         Airgas Shielding
                  AWS Requirements         max       22.0                        max                               max        max                                   Gas
                     Test Results           .02        20.0         10.0         0.3         1.6         .80       .002       .19   Balance                         • Gold Gas®
                                                                                                                                                                      StainMIX™ 3
                  Radnor ER309LSi          .03       23.0-         12.0-         .75       1.0-2.5     .65-1.0     .03        .75   Balance
                                           max       25.0          14.0          max                               max        max                                   • Gold Gas®
                  AWS Requirements
                                                                                                                                                                      StainMIX™
Filler Metals




                     Test Results           .02        24.0         13.0          .2         1.7         .85       .001       .09   Balance

                  Radnor ER316LSi          .03       18.0-         11.0-        2.0-3.0    1.0-2.5     .65-1.0     .03        .75   Balance
                  AWS Requirements         max       20.0          14.0                                            max        max

                     Test Results           .02        19.0         12.5         2.5         1.7         .85       .002       .40   Balance


                                                                                                                                         Typical Operating Procedures
                Diameter/Packaging                                                                                                                                             Current (Amps)
                                           ER308LSi             ER309LSi             ER316LSi                                                 AWS Class       Polarity        .035”      .045”
                       Diameter           30-lb. Plastic       30-lb. Plastic       30-lb. Plastic
                       (Inches)               Spool                Spool                Spool                                                  ER308LSi         DC+           60-200     75-225

                          .035              64004430             64004438              64004446                                                ER309LSi         DC+           60-200       —

                          .045              64004431             64004435              64004447                                               ER316LSiL         DC+           60-200     75-225

       156                                        2006/2007 Radnor Products Catalog
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