All Position Nickel Based Gas
Shielded Flux Cored Wires for
Scrubber Component Welding
www.stoody.com
Scrubber Equipment
Most coal and oil fired power plants have units called “Flue
Gas Desulfurization Units (FGD’s)” that are installed along
with new power plants or are retrofitted on to existing plants.
These units “scrub” the sulfur dioxide from the flue gases and
thus significantly reduce the probability of “acid rain” when
the gases are released to the atmosphere. As the process
involves significant exposure to corrosive compounds, the
equipment is usually fabricated using various grades of
high alloy stainless steels and in some cases, nickel based
alloys. High alloy stainless steels include alloys such as 317L,
254SMO1, AL6XN2, 2205, 2507 and Nickel based alloys such
as Alloys C276, C22 and C20003 and 59.
Advantages of using
Nickel Based Flux Cored Wires
Stoody Nickel Based Flux Cored Wires comprise a family of
wires that can be used to weld and clad in those applications
where Nickel based solid wires for GMAW and stick electrodes for SMAW of equivalent composition are commonly
used. The major advantages of the Stoody flux cored wires
over the solid wire and stick electrode processes are:
• Out-of-Position (OOP) Weldability: The Stoody wires incorporate a slag system that enable them to be run at significantly higher deposition rates when welding out-of-position
when compared to solid wires or stick electrodes. Typical
deposition rates are 1.5 - 2 times higher than gas metal arc
welding with solid wire and 2-3 times higher than SMAW.
• Although the wires are designed primarily for OOP welding,
they can also be used for welding in the flat/horizontal positions with higher deposition rates and better weld profiles
than can be obtained with SMAW/GMAW.
• Gases used are typically Ar-CO2 mixtures such as (75-25)
although pure CO2 has also been used. These gases are
cheaper than gases typically used for solid wire welding
such as pure Argon, Tri-mixes, etc.
• OOP welding can be performed with standard constant voltage power sources. The ability to pulse is not required.
• Weld deposits have excellent X-ray quality and do not suffer
from the common defects associated with GMA welding of
nickel alloys such as lack of fusion, cold shuts etc.
• Process can be fully automated for various base material
thicknesses thus minimizing potential for operator error.
Welding Filler Materials
In most cases, the stainless steel base materials are welded
with “overmatched” nickel based filler materials for corrosion
resistance on critical components. This is because micro
segregation of elements such as chromium and molybdenum in the weld metal results in inferior corrosion resistance
when compared to the base material of like composition. As
segregation of these elements in nickel based weld metals is
significantly lower, high alloy stainless steels are welded using
nickel alloy filler metals such as 625 and C276. Nickel alloy
base materials such as C276 and C22 may be welded either
using matching filler metals or overmatching filler metals such
as Alloy 59.
1 Registered Trademark of Outokumpu
2 Registered Trademark of Allegheny Ludlum Inc.
3 Registered Trademark of Haynes International
page 2
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Canada Customer Care: 905-827-4515 /
FAX
FAX
800-535-0557
800-588-1714
Welding Parameters (Typical)
Welding Parameters/
Deposition Rates
Stoody Nickel based flux cored wires can be welded in a
manner similar to stainless flux cored wires. Conventional
constant voltage power sources are adequate and there is
no need for pulsing. Wires typically operate in the spray mode
with 75Ar/25CO2 shielding and semi-spray with 100% CO2.
Typically the Ar-CO2 mixture is preferred for OOP whereas
100% CO2 results in better penetration in thick section welds.
Typical deposition rates are shown in the chart. These are
significantly higher than those for OOP welding with coated or
solid wire electrodes.
Typical Applications
Overmatching Flux
Cored Wire
AL-6XN
–
Stoody 625LI-T1*,
C276-T1
2205
Stoody 2209-T1
Stoody 625LI-T1*,
C276-T1
2507
Stoody 2594-T1
Stoody 625LI-T1*,
C276-T1
254SMO
–
Stoody 625LI-T1*,
C276-T1
C276
Stoody C276-T1
Stoody ENiCrMo13-T1
C22
Stoody 622-T1
Stoody ENiCrMo13-T1
Wire Feed
Speed
ipm (m/min)
1/16” (1.6mm) 225/250
26/27
Flat
250-275
(6.3-6.9)
1/16” (1.6mm) 200/225
25/26
VUP
200/250
(5.0-6.3)
0.045” (1.2mm) 175/200
25/26
Flat
375/400
(9.4-10.0)
0.045” (1.2mm) 150/175
25/26
VUP
300/325
(7.5-8.2)
Welding parameters can be modified to meet low heat input requirements for specific base material/filler material combinations. Contact
Stoody for specific procedures.
Suggested flux cored wire grades are shown below for the
specific base materials. The choice of a filler material/process
different from what is specified may require engineering
approval.
Base Material Matching Flux Cored Wire
Current Voltage (amps)
(volts)
Deposition Rates
Voltage: 25-26 volts
Electrical stick-out: 3/8-1/2” (9-12mm)
18
1/16" (1.6mm)
16
Deposition Rate (lbs./hr)
Constant Voltage DCEP
Electrical Stick-Out: 3/8-1/2” (9-12mm)
0.045" (1.2mm)
14
12
10
8
6
4
2
*LI (low Iron) signifies an Iron content of less than 1% (typically 0.3%)
0
0
100
200
300
400
Current (amps)
AWS Classifications
Most Stoody Nickel base flux cored wires conform to classifications in AWS A5.34:2007. It is expected that ENiCrMo13-T1
will be included in the next revision of A5.34.
International Customer Care: 940-381-1212 /
www.stoody.com
FAX
Packaging
These wires are vacuum packaged and are available on 33 lb
(15 kg.) layer level wound wire spools.
940-483-8178
page 3
Vertical-up seam in duplex 2205 steel welded using .045” Stoody 625LI-T1 flux cored wire.
Typical Wire Compositions and Mechanical Properties
2209-T1
2594-T1
625LI-T1
C276-T1
622-T1
ENiCrMo13-T1
Product
Classification
AWS A5.22-2010
E2209-T1/-4
AWS A5.22-2010
E2594-T1-1/-4
AWS A5.34-2007
ENiCrMo3T1-1/-4
AWS A5.34-2007
ENiCrMo4T1-1/-4
C
Mn
Si
Cr
Ni
Mo
Nb
W
Fe
Yield Strength,
ksi (MPa)
Tensile Strength,
ksi (MPa)
Elongation, (%)
Charpy Impacts
ft-lbs. (joules)
Part Number,
1/16” (1.6mm)
Part Number,
0.045” (1.2mm)
Other
0.03
0.8
0.8
23.5
9.0
3.2
–
–
Bal
0.03
0.8
0.6
24.0
8.9
4.1
–
–
Bal
0.03
0.4
0.3
22.0
Bal
9.2
3.8
–
0.3
0.02
0.4
0.2
15.4
Bal
15.6
–
3.8
5.2
AWS A5.34-2007
Matches
ENiCrMo10T1-1/-4 composition of
AWS A5.11-2010
ENiCrMo-13
0.02
0.02
0.5
0.3
0.2
0.2
21.3
23.5
Bal
Bal
13.8
15.8
–
–
3.1
–
5.0
0.4
101 (697)
98.5 (680)
76 (524)
68 (452)
70 (470)
73.5 (507)
122 (842)
27.5
at -40˚F (-40˚C),
33 (46)
11892100
126 (870)
25
at -40˚F (-40˚C),
33 (46)
11998000
117 (807)
35
at -320˚F (-196˚C),
50 (70)
11977300
106 (705)
42
at -320˚F (-196˚C),
31 (42)
11964300
103 (685)
27
–
110 (760)
33
–
11965700
–
11892000
11998100
11977400
11953700
11953800
11994300
N=0.18%, FN=50 N=0.23%, FN=45
NOTICE - Failure to follow manufacturer’s directions for use may result in equipment or material failure and void any applicable warranty. The data provided or referenced
herein is provided for informational purposes only, without guarantee or warranty and represents “typical” results when Stoody products are used in accordance with internal
Stoody procedures. Other tests and procedures may produce differing results. Stoody expressly disclaims any liability resulting from reliance on this data.
PROTECT YOURSELF AND OTHERS - Users should read and follow all recommended guidance on health and safety from their employer, the supplier, the manufacturer,
and government authorities. These, at a minimum include the Warning Labels on the products and the Material Safety Data Sheets ("MSDS"). The MSDS and additional
safety information may be found on materials or links at: www.stoody.com.
U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 • Canada Customer Care: 905-827-4515 / FAX 800-588-1714
International Customer Care: 940-381-1212 / FAX 940-483-8178 • www.stoody.com
A Global Cutting & Welding Market Leader™
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