MAN B&W

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Welding Ident No.: 0690709-4

Selection and Handling of Consumables for Welding

This document is valid for existing engine Production Specification

types on order as of the date of this docu-
ment: 0690709-4.8

Engine types: January 2018

All two-stroke engine types
Info No: 391204

Structure No: 21-0002

Replaces: 0742818-8

Scope and Field of Application

This document contains requirements, to the
welding personnel in order to choose adequate
welding processes and consumables for weld-
ing of welded structures in MAN B&W diesel en-
gines, made of steels S18R, S18F, S17R, S20FX
and similar steel.

Examples of consumables are included and

guidelines for handling and storage these are
described.

Document history
Date Designer  Checked AC Revision change Revision
1977-11-16 PK MW 0
2012-01-09 THR EBH Z3 Updated to new layout. Changes to Production Specification 6
2014-01-21 THR EBH Z3 Section 2 and 8 are added 7
2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany MAN Diesel & Turbo
Registered with the Danish Commerce and Companies Agency under CVR-no. 31611792 (referred to as “MAN Diesel & Turbo”). Teglholmsgade 41, 2450 Copenhagen SV, Denmark
This document is the property of MAN Diesel & Turbo and is to be treated as confidential by the party to whom it has been submitted by Phone +45 33 85 11 00
MAN Diesel & Turbo, and may not be disclosed to any third party without the specific prior written permission of MAN Diesel & Turbo. E-mail [email protected]
This document may be a translation of an original English language document. In case of any discrepancy between the original Web www.mandieselturbo.com
English language document and this translation, it is always the original English language document which shall prevail.
The original English language document may have been replaced by a later version, in which case only such later version shall be valid.
Production Specification 0690709-4.8

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Contents Changes in this revision:

1. References �����������������������������������������������������������������������������3
2. Safety during production�������������������������������������������������������3
3. Abbreviations �������������������������������������������������������������������������3
4. General requirements�������������������������������������������������������������4
5. Handling of welding consumable�������������������������������������������7
5.1. SMAW - Shielded Metal Arc Welding 7
5.2. FCAW - Flux Cored Arc Welding 8 Text is added in section
5.3. GMAW - Gas Metal Arc Welding 9 5.2.1.
5.4. SAW - Submerged Arc Welding 9
6. Robotic welding ���������������������������������������������������������������������9
7. One-side welding on ceramic backing��������������������������������� 10
8. Hydrogen contend of consumables������������������������������������� 10

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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1. References
MAN B&W Production Recommendations:
No 0742618-7; Code for Welding and Allied Processes.

MAN B&W Safety Regulation:

No. 0743744-9; Safety during Arc Welding.

MAN B&W Material Specification: S17R, S18F, S18R, S20FX.

European Standards: EN 24063, EN 439, EN 440, EN 499, EN 756, EN 758, EN 760 and EN 1011
Recommendations for welding of metallic materials. General guidance for arc welding.

International Standards: ISO 636, ISO 2560, ISO 4063, and ISO 6947.

American Welding Society: AWS A5.1, AWS A5.2, AWS A5.17, AWS A 5.18 and AWS A5.20.

German Norms: DIN EN 499, DIN 8557, DIN 8559, DIN 32526, and DIN 32522.

2. Safety during production

All local safety requirements must be followed.

Please acquire Safety Data Sheets for all components handled during production. Please also see
MAN B&W Safety Regulation No. 0743744-9; Safety during Arc Welding.

3. Abbreviations
Consumables: Electrodes, wires, cored wires, and fluxes:
ƒƒ SMAW: Shielded Metal Arc Welding, Process 111 (EN 24 063, ISO 4063).
ƒƒ FCAW: Flux Cored Arc Welding, Process 136 + 137 (EN 24 063, ISO 4063).
ƒƒ GMAW: Gas Metal Arc Welding, Process 131 + 135 (EN 24 063, ISO 4063).
ƒƒ SAW: Submerged Arc Welding, Process 121 + 122 (EN 24 063, ISO 4063).

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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4. General requirements
The required mechanical properties and hydrogen scale of consumables for welding of S17R,
S18F, S18R and S20FX are listed in table 1, see the respectively material sheets.

Table 1: Requirements to mechanical properties and hydrogen scale.

Tack welds and root Filling-up welds and final

Minimum requirements
passes passes
Tensile Strength (Rm.) 480 N/mm2 480 N/mm2
Yield Stress (Re) 350 N/mm2 350 N/mm2
Elongation (A) 20 % 20 %
Temperature for minimum impact
- 20°C 0°C
value of 27 J
Chemical composition of elec-
trode coating (SMAW), and flux Basic No special requirements
in wire (FCAW)
Hydrogen content, cm 3/100g de-
Max. 10 Max. 10
posited weld metal

It is important to choose consumables that give high weld metal quality.

A small degree of overmatching is an advantage. Overmatching ensures that if the structure is

overloaded, the parent metal deforms before the weld metal.

In table 2 and 3 are listed consumables which can be recommended for welding the above men-
tioned materials. The examples of consumables should be considered as a proposal only, as many
brands of product may be suitable for the purpose and be in accordance with relevant standards,
see table 4.

The selected consumables for use must be approved by the classification society involved.

Table 2: Recommended consumables Tack welds and Root passes.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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Process Tack welds and root passes (use Basic consumable)*

Alloy Rods Dual FILARC ESAB Tubrod

Example of make Shield T5 PZ 6130 OK 15.00
FCAW
Ø 1,2 CO2 Ø 1,6 CO2 Ø 1,2 CO2
(136)
AWS A5.20: AWS A5.20: AWS A5.20:
Classification
E 71 T5 E71 T5 E71 T5
ESAB OK 48.04 Kobe LB-52-18 Hyundai S-7016
SMAW Examples of make
Ø 3,25 Ø 3,25 Ø 3,25
(111)
Classification AWS A5.1: E 7018 AWS A5.1: E 7018 AWS A5.1: E 7016

* Rutile FCAW can be used provided that the manufacturer checks the root runs by PT or MT for
cracks before they weld the next runs.

Table 3: Recommended consumables: Filling and Capping.

Process Filling and capping

Example of make, ESAB OK

Kobe G-80 Hyundai S-777MX
Wire AUTROD 12.20
Example of make, ESAB OK
Kobe US-36 Hyundai H 14
SAW Flux FLUX 10.81
(121) Classification,
AWS A5.17:EL12 AWS A5.17:EH14 AWS A5.17:EH14
Wire
Classification, AWS A5.17-89: AWS A5.17-89: AWS A5.17-89:
Flux F7A(P)0-EM 12, F7(6)A(P)2-EH 14 F7A(P)2-EH 14
FILARC PZ 6113 Kobe DW100 Hyundai SF 71
FCAW Example of make
Ø 1,2/ Ø 1,4 CO2 Ø 1,2/Ø 1,4 CO2 Ø 1,2/Ø 1,4 CO2
(136)
Classification AWS A5.20: E 1T1 AWS A5.20:E 1T1 AWS A5.20:E 1T1
ESAB FEMAX Kobe Hyundai
SMAW Examples of make OK 33.80 Zerode 43F 7024 F
(111) Ø 4, Ø 5 Ø 4, Ø 5 Ø 4, Ø 5
Classification AWS A5.1: E 7024 AWS A5.1 E 7024 AWS A5.1 E 7024

Welding processes to be used.

Generally tack welding and lifting brackets are to be welded by basic low-hydrogen electrodes
welding (SMAW) or basic flux-cored wire (FCAW) in order to ensure a high quality in these welds
(High resistance to cracks, high resistance against restraint, high strength etc.).

Table 4: Recommended processes.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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Recommended process Alternative process

Tack welding / welding

FCAW (136) Basic SMAW (111) Basic
of lifting brackets.
FCAW (136) Basic.
Root passes. SMAW(111) Basic
FCAW (136) Rutile *
SAW (121) For long welds more FCAW (136) Rutile or
Filling and capping
then 1,5 m. in flat position SMAW(111) Rutile/basic
Repair FCAW (136) Basic SMAW (111) Basic
Other welds FCAW (136) Rutile SMAW (111) Rutile/basic

* Can be used provided that the manufacturer checks the root runs by PT or MT for cracks before
they weld the next runs.

For filling and capping, submerged arc welding (SAW) is strongly recommended at locations with
flat position and for weld seams with a length of more than approximately 1.5 meter.

Note! That multi passes deposits made at moderate welding current have, as a general rule,
better mechanical properties than one or two layer deposits made at high current in
similar plate thickness.

Rutile flux-cored wire (FCAW) is then to be recommended for all other welds.
Gas metal arc welding, (MIG/MAG-welding GMAW) (135) is an alternative, however with a lower
productivity. If using GMAW, the short arc (short-circuiting) area must be avoided, because of the
risk of lack of fusion, which means only flat or horizontal-vertical position (PA or PB, see ISO 6947).

A process giving a smooth transition to the base material should be used for the final pass.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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5. Handling of welding consumable

5.1. SMAW - Shielded Metal Arc Welding

5.1.1 Electrode handling

Electrodes are to be supplied in sealed moisture proof packages. Unopened packages are to be
stored in a dry, closed storage room with a temperature of min. 20°C. Preferable the storage room
should be dehumidified.

If the electrodes are stored in a place where it is colder than in the welding shop, electrodes ought
to be taken from the cold store into the welding shop and allowed to get the same temperature as
the surroundings, before opening the package.

When a package of basic covered electrodes has been opened, the electrodes must be put into
a quiver at approximately 70°C.

5.1.2 Electrode handling, low hydrogen electrodes

When welding with low hydrogen electrodes or when welding in surroundings with high humidity
or experiencing cracking problems / bad welding quality, this procedure can be used as improv-
ing action:

See also attachment 1: Handling of low hydrogen electrodes.

Non-vacuum-packed basic electrodes:

Baking:
Before use the electrodes must be baked in a ventilated oven according to makers recom-
mendation. Typically at 320°C for 2 hours.

Daily storage oven:

After baking the electrodes must be transferred to the daily storage oven which is kept at
150°C.

The welder should fetch electrodes, from the daily storage oven, for no more than 4 hours
consumption.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

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Production Specification 0690709-4.8

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Electrical quiver at welding site:

The electrodes must immediately be transferred to small electrically heated quivers with a
constant temperature of about 70°C.

The welder must not take out electrodes, from the small quivers, for more than 10 minutes
consumption.

Any wet or defective electrodes MUST be scrapped and removed from the welding shop.

Rebaking:
After maximum 4 hours in the small quiver, the electrodes must be returned for rebaking.(at
320°C). The electrodes can be recycled maximum 5 times.

Vacuum-packed low hydrogen electrodes:

Vacuum-packed electrodes are easier to handle, as they do not need to be baked or stored in
ovens etc. The only precaution to take is not to break the sealing before use.

Just before opening a vacuum packed box of electrodes, the hour and date of opening time is to
be noted on the package, and then they should be used within a specific number of hours, typi-
cally 12 hours, depending on the manufacturers prescriptions.

Vacuum-packed basic electrodes are strongly recommended for repair jobs.

Note! Always consult the supplier of the consumable for their directions.

5.2. FCAW - Flux Cored Arc Welding

5.2.1 Wire handling

There is a large difference in the different FCAW wires ability to resist picking up of moisture from
the surroundings.

The manufacturer’s guidelines for handling and storing of wires must always be followed.

Unopened and opened packages are to be stored in a dry storage room, following the manufac-
turer’s guidelines.

Cover the coils that are opened when not in use, to avoid any contamination of the wire surface.

When not used for more than 3 days. The wire has to be put in a closed plastic bag, together with
a moisture absorbing paper, and stored in the same way as described above - or as recommended
by the manufacturer.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

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Production Specification 0690709-4.8

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Any signs of rust on the wire indicate that storage and handling conditions have not been appropri-
ate. Wires with rust or other moisture damage must be scrapped.

The manufacturer must have a certificate from the supplier of FCAW wire that states the hydrogen
contents in the FCAW wires used in the workshop.

5.3. GMAW - Gas Metal Arc Welding

5.3.1 Wire handling

Same as subsection 5.2.1.

5.4. SAW - Submerged Arc Welding

5.4.1 Wire handling

Same as subsection 5.2.1.

5.4.2 Flux handling

The fluxes may pick up some moisture during handling, storage or transportation.

Note! Always consult the supplier of the consumable for their directions.

Transportation:
During transportation of fluxes maximum two pallets should be stapled to prevent crushing of the
grains.

Note! Increased arc voltage gives increased flux consumption. If the flux contains alloying el-
ements, the amount transferred to the weld metal will increase as the arc voltage in-
creases.

6. Robotic welding
When selecting wire, make sure it is suitable for the used welding position. If possible use the
FCAW-process. Do not use the GMAW-process when welding vertical up.

The material used for fit-up has to be the same as used welding on the robot.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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7. One-side welding on ceramic backing

By using ceramic backing materials it is possible to increase productivity, by way of:
ƒƒ Higher welding current possible.
ƒƒ Avoidance of back gouging or grinding-out, and root sealing run.
ƒƒ Simpler edge preparation.
ƒƒ Fully dependable root pass penetration and smooth root profile.

To suit all joint configurations the range of ceramic strips are wide.

Note! Always consult the supplier of the ceramic backing for their directions.

Typical configurations:

Figure 1: Figure 2: Figure 3:

8. Hydrogen contend of consumables

The workshop must possess a certificate concerning the hydrogen contend of the consumables
used in the workshop.

The workshop must process and follow the manufacturers guidelines for storage of the consuma-
bles used in the workshop.

The workshop must calculate if preheating is necessary according to EN 1011.

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding
Production Specification 0690709-4.8

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Attachment 1: Handling of basic, low hydrogen electrodes.

Inspection and immediate transfer to storage room

Storage room, 20-30°C, dry conditions

Electrodes in sealed original package

Ventilated baking oven

320°C for 2 hours
320°C

Daily storage
150°C Ventilated baking oven 150°C

Return after max. 4 hours

Rebake max. 5 times

Take out electrodes for max.

10 minutes consumption

70°C

Discard wet and defective

electrodes
Electrically heated small quivers
70°C, max 4 hours

Date Designer  Checked AC Revision change Revision

2018-01-24 THR EBH Z3 Text is added in section 5.2.1 8

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0690709-4. Section and Handling of Consumables for Welding