Section 6 Consumables for use in electro-slag and electro-gas welding

6.1.1 The requirements for the approval of consumables used for electro-slag or electro-gas welding (including consumable nozzles, where applicable) are generally as detailed in Ch 11, 4 Wire-flux combinations for submerged-arc automatic welding for two-run submerged-arc welding consumables, except as otherwise detailed in this Section.

6.1.2 For each grade, approval may be restricted for use with specific compositional types of steel. For Grades 1Y, 2Y, 3Y, 4Y, 2Y40, 3Y40 and 4Y40 this will normally be in respect of the grain refining element content, and tests on niobium grain refined steel will normally qualify for use also on steels treated with aluminium or vanadium or combinations of these elements.

6.1.3 Superscript numbers are applied to the ‘Y’ of higher strength steel consumables, e.g. 2Y¹, to indicate the type of parent steel for which approval is applicable as follows:

6.1.4 Each strength level requires separate approval involving the welding and testing of two butt weld assemblies of different thickness. The greater thickness will determine the maximum approved thickness.

6.2.1 Two butt weld test assemblies are to be prepared, one with plates 20 to 25 mm in thickness and the other with plates 35 to 40 mm in thickness. The steel used is not to be of any higher grade (impact toughness) than that for which approval is required. The limitations of Ch 11, 6.1 General 6.1.2 need to be considered in this Section. The chemical composition of the plate, including the content of grain refining elements, is to be reported.

6.2.2 The welding conditions and the edge preparation adopted are to be in accordance with the recommendations of the manufacturer and are to be reported in detail. The manufacturer's maximum recommended gap between plates is to be used in making the test assemblies.

6.2.3 It is recommended that the assemblies are subjected to radiographic examination to identify any defects before the preparation of any test specimens.

6.2.4 Test specimens as follows, and as shown in Figure 11.6.1 Butt weld test assembly for electro-slag or electro-gas welding, are to be prepared from each test assembly:

1. Two longitudinal tensile test specimens.

2. Two transverse tensile test specimens.

3. Two bend test specimens.

4. Two macro-sections.

5. Two sets of three impact test specimens notched in accordance with Figure 11.6.2 Position of Charpy V-notch impact test specimens.

Figure 11.6.1 Butt weld test assembly for electro-slag or electro-gas welding

6.2.5 The chemical analysis of the weld metal in each assembly is to be determined and reported. This is to be supplied by the manufacturer and is to include the content of all significant elements. The results of the analysis are not to exceed the limit values specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case.

6.2.6 The results of all transverse tensile and impact tests are to comply with the requirements given in Table 11.4.3 Requirements for butt weld tests (wire-flux combinations) as appropriate. The position of fracture of the transverse tensile test is to be reported. The Charpy V-notch impact test requirements are as for the two-run technique in Table 11.4.3 Requirements for butt weld tests (wire-flux combinations).

6.2.7 The results of all longitudinal tensile tests are to comply with the requirements of Table 11.4.2 Requirements for deposited metal tests (wire-flux combinations).

6.2.8 The bend test specimens are to be in accordance with Ch 11, 4.6 Butt weld test assemblies (two-run technique) 4.6.7 and Table 11.4.3 Requirements for butt weld tests (wire-flux combinations). Each surface of the weld is to be tested in tension.

Figure 11.6.2 Position of Charpy V-notch impact test specimens

6.3.1 Annual tests are to consist of at least one butt weld test assembly using plate material 20 to 25 mm in thickness.

6.3.2 The assembly is to be prepared and tested in accordance with Ch 11, 6.2 Butt weld test assemblies except that only the following tests are required:

1. One longitudinal tensile test.

2. One transverse tensile test.

3. Two bend tests.

4. Two sets of three Charpy V-notch impact tests; one set with the notch at the centre of the weld (Figure 11.6.2 Position of Charpy V-notch impact test specimens, (1) In the centre of the weld metal), and one set with the notch in the weld metal 2 mm from the fusion line (Figure 11.6.2 Position of Charpy V-notch impact test specimens, (2) In the weld metal, 2 mm from the fusion line).

5. Chemical analysis.

6. One macro-section.

6.3.3 Where a consumable or combination is approved for a range of steels with different specified minimum strength levels, steel of the highest strength level is to be used for the preparation for the assembly required by Ch 11, 6.3 Annual tests 6.3.1.