Dear Mr. Saravanan,
Thank you for your inquiry and providing details about your project requirements. Achieving BV Certification for your welding process is crucial, and I understand the challenges you faced with obtaining TYPE approval certification for 308L SAW Wire & Flux in Korea.
Given your current stock of SMP-S308L & OK Flux 10.92 ESAB SeAH, along with the welding parameters and testing conditions you outlined, here are some suggested welding parameters to help control heat input and meet the specified criteria for successful impact, corrosion, and ferrite tests:
Voltage: Adjust voltage settings to maintain stable arc and penetration while avoiding excessive heat input. Typically, a voltage range of 26-30 volts should be suitable for your application.
Current: Set the welding current to achieve the desired deposition rate and weld bead profile. For your specific setup, a current range of 400-500 amps may be appropriate.
Travel Speed: Control the travel speed to regulate heat input and ensure proper fusion. Aim for a travel speed of around 30-40 cm/min for optimal results.
Wire Feed Speed: Adjust the wire feed speed to maintain a consistent weld pool and deposition rate. A wire feed speed of 5-7 m/min should be suitable for the 4mm diameter SAW wire.
Stick-Out: Maintain a consistent stick-out distance to ensure proper shielding and arc stability. Aim for a stick-out distance of 25-30 mm for your setup.
Interpass Temperature Control: Implement preheating and interpass temperature control measures to prevent excessive heat buildup and maintain mechanical properties. Monitor and limit the interpass temperature to a maximum of 150-200°C, depending on the material and welding conditions.
Welding Technique: Employ a suitable weaving technique to ensure uniform distribution of heat and proper fusion throughout the weld joint.
Post-Weld Heat Treatment (PWHT): Consider implementing PWHT as needed to relieve residual stresses and enhance mechanical properties, particularly for critical applications such as impact testing at low temperatures.
It's important to conduct pre-weld and post-weld inspections to verify the integrity of the welds and ensure compliance with BV Certification requirements. Additionally, perform thorough testing, including impact, corrosion, and ferrite tests, according to relevant standards and specifications to validate the quality and performance of the welded joints.
If you have any further questions or need additional assistance, please feel free to reach out.
Best regards,
Amol K.Betkar
On Thu, 18 Apr 2024 at 19:08, PARAI Reaction Channel <saravanshyla@gmail.com> wrote:--Dear Mr.Amol,Thank you so much for your detailed explanation of both flux types.As our project requires BV Certification, we tried for obtaining TYPE approval cert for 308L SAW Wire & Flux , but we could not able to obtain in Korea, as it was stopped in Dec 2022 for SS weld rods.So with our current stock , that is SMP-S308L & OK Flux 10.92 ESAB SeAH , the korean brand, we are going tomake tests with 25mm SS304L Plate , SINGLE V Butt Joint, GT(6mm)+SM(9mm)+SAW combination and especially the SAW 4mm Dia, we are going to weld about 10mm weld metal thk from mid to capping.So, can you suggest the perfect welding parameters for SAW, to control heat input, the Max. Interpass Tempr. in order to make a successful Impact test at -196 Deg C, Corrosion, ferrite tests.Thank you again.Best Regards,Saravanan Sornam,ANSAN,S.KoreaOn Thu, Apr 18, 2024 at 5:03 PM Amol Betkar <amolbetkar90@gmail.com> wrote:Dear Saravanan Sornam,
In response to your inquiry regarding the metallurgical disparities between OK Flux 10.92 and OK Flux 10.93 during multi-run Submerged Arc Welding (SAW) on a test plate, particularly concerning Impact testing at -196°C, Ferrite Test, and Corrosion test, I am pleased to provide you with detailed technical insights.
OK Flux 10.92 is a widely utilized flux for SAW welding of stainless steel vessels due to its neutral composition and the chromium alloy contribution it provides during welding. This flux is known for its compatibility with 308L wire and its ability to maintain a stable arc, resulting in high-quality welds.
On the other hand, OK Flux 10.93 offers distinct characteristics that may influence the welding process and subsequent metallurgical properties. While specific data on OK Flux 10.93 may vary based on manufacturer specifications and formulation, I can provide general insights into potential differences.
Flux Composition: The composition of OK Flux 10.93 may differ from OK Flux 10.92, potentially affecting its interaction with the base metal and the formation of slag during welding. Variations in flux components can impact weld penetration, bead shape, and overall weld quality.
Alloying Elements: OK Flux 10.93 may contain different alloying elements or concentrations compared to OK Flux 10.92. These alloy additions can influence the metallurgical characteristics of the weld, including its strength, toughness, and corrosion resistance.
Impact Testing: The choice of flux can influence the behavior of welds during impact testing, particularly at low temperatures such as -196°C. Flux composition and its interaction with the base metal can affect the ductile-to-brittle transition temperature and the fracture toughness of the weld metal.
Ferrite Test and Corrosion Resistance: Flux selection can impact the formation of ferrite in the weld microstructure, which is critical for controlling mechanical properties and corrosion resistance. Differences in flux composition may result in variations in ferrite content and distribution, affecting the weld's susceptibility to corrosion in offshore environments.
To fully assess the performance of OK Flux 10.93 in comparison to OK Flux 10.92, comprehensive testing should be conducted, including weld procedure qualification, mechanical testing, and corrosion evaluation. These tests will provide valuable data on the suitability of OK Flux 10.93 for your specific offshore project requirements.
In conclusion, while both OK Flux 10.92 and OK Flux 10.93 offer benefits for SAW welding of stainless steel vessels, careful consideration of their respective properties and performance characteristics is essential to ensure optimal weld quality and integrity.
Should you require further assistance or clarification on this matter, please do not hesitate to contact me.
Best regards,
Amol K.Betkar
On Wed, 17 Apr 2024 at 20:02, atul jha <atulkrjha21@gmail.com> wrote:This cryogenic wire 19.9 earlier developed by sandvik and latter sandvik acquired by esab ask for supplier what is brand name of sandvik 15 W flux now , now means it is 10.92 or 10.93 and do PQR with sandvik wire cryo 19.9 and sandvik 15W flux ( ask for equivalent from esab).Although my suggestion is go for Nippon( Japan make) wire and flux as it is best in class as it has unmatched surface finish like mirror and awesome impact values looking for quality but cost will be a factor .I have no commercial interest just sharing my experience.RegardsAtul jha--On Wed, Apr 17, 2024, 17:16 PARAI Reaction Channel <saravanshyla@gmail.com> wrote:Dear Welding experts,--For one of our Offshore Projects in Korea, we have a vessel of 304L material with Impact Test at -196 Deg C as per Project Spec.So, to weld SAW , SFA 5.9 Class ER308L 4mm Dia, we are going to use ESAB SeAH, a top brand in Korea.I heard and mostly used the SAW 308L wire with OK Flux 10.92 for many SS vessel fabrication , because this Flux is of neutral type and the alloy element gives Cr during welding and got this message from the catalogue.Metallurgically, What major difference will occur between OK 10.92 and OK 10.93 during multi run SAW welding on a test plate and Impact testing at -196 Deg C, Ferrite Test, Corrosion test etc., will be done in the lab.Please advise me soon.Regards,Saravanan Sornam,ANSAN-Si,S.Korea
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----Best regards,Amol K.BB.E(Mech), CSWIP 3.2.2, NACE CIP 1 & ASNT LII(4M)
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----Best regards,Amol K.BB.E(Mech), CSWIP 3.2.2, NACE CIP 1 & ASNT LII(4M)
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