All-positional rutile cored wires for higher productivity

The PZ6138 family consists of all-positional rutile, low-hydrogen, flux-cored wires for applications involving the welding of thick steel components and with impact toughness requirements down to -60degC. It is based on the PZ6138, which has been widely applied in offshore fabrication for decades. These wires are alloyed with 0.9 per cent Ni. PZ6138 and PZ6138 SR are designed for use in Ar/CO2 mixed gas, whereas PZ6138S SR is used in pure CO2. Types with the suffix SR provide good low-temperature toughness after stress relieving. All types are successfully CTOD tested - the SR types at temperatures as low as -40degC.

ESAB says the wires are extremely welder-friendly, with a soft, spatter-free arc that always operates in the spray arc mode. Moreover, it is easy to obtain flat welds with good penetration and smooth wetting into the plate edges. Slag is brittle and easily removed, leaving behind a smooth rutile weld appearance. Typical positional welding defects such as lack of fusion and slag inclusions are avoided due to the spray arc operation. In addition, the wires have a good tolerance to poor joint preparation and high-quality, one-sided root runs are made economically on ceramic backing.

The wire formulation provides a fast-freezing slag that supports the weld pool well in positional welding, enabling deposition rates that ESAB says cannot be equalled by stick electrodes or solid wires. Deposition rates in vertical up welding can reach up to 4kg/h (100 per cent duty cycle), so ESAB claims this makes it the most productive consumable available for manual welding in this position. Welding parameters are optimised for each welding position to provide maximum productivity, but a single setting can be selected for all-positions (230A), making it convenient for fit-up work.

Diffusible hydrogen satisfies the EN H5 class tested under the conditions prescribed in the classification standard, remaining low over a wide parameter envelope.

Follow the link for more information about ESAB's Filarc PZ6138 all-positional rutile cored wires.