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Dissimilar Metals Welding

WPS for Carbon Steel to 300 series Stainless by Rich2001
Posted: 19 May 05

GTAW (TIG) Welding Procedures (Amperage, Voltage & Filler) for Carbon Steel (P1) to 300 series Stainless Steel (P8.

Base Metal    "Type 301, 302, 304 TO CARBON STEEL P1-P8"                    
Weld Joint (mm)    -    -    -    -    -    -
Thickness    1.6    2.5    3.2    4.8    6.4    12.7
Weld Position    Flat    Flat    Flat    Flat    Flat    Flat
Filler Wire (mm)    -    -    -    -    -    -
Filler Wire Specification    AWS A5.9    AWS A5.9    AWS A5.9    AWS A5.9    AWS A5.9    AWS A5.9
Filler Wire Class    ER 309    ER 309    ER 309    ER 309    ER 309    ER 309
Square Butt    1.6    1.6 or 2.4    2.4    3.2    4    6
Lap Fillet    1.6    1.6 or 2.4    2.4    3.2    4    6
Intside Corner Fillet    1.6    1.6 or 2.4    2.4    3.2    4    6
Outside Corner Fillet    1.6    1.6 or 2.4    2.4    3.2    4    6
Double Fillet Tee    1.6    1.6 or 2.4    2.4    3.2    4    6
Single Bevel Corner    -    -    -    -    4    -
Single Vee Butt    -    -    -    -    4    6
Double Vee Butt    -    -    -    -    -    6
Filler Wire Extension    -    -    -    -    -    -
Extension    -    -    -    -    -    -
Electrode & Cup    -    -    -    -    -    -
Electrode Type     Tungsten (EWTh-1/-2)    Tungsten (EWTh-1/-2)    Tungsten (EWTh-1/-2)    Tungsten (EWTh-1/-2)    Tungsten (EWTh-1/-2)    Tungsten (EWTh-1/-2)
Diameter (mm)    1.6    1.6    1.6    2.4 to 3.2    3.2    3.2 or 4.0
Number of Passes    1    1    1    1    1 to 2    2 to 3
Gass Nozzle Cup Type    Ceramic    Ceramic    Ceramic    Ceramic (butt/corner)    Water-cooled    Water-cooled
-    Ceramic    Ceramic    Ceramic    Water-cooled (lap/tee)    Water-cooled    Water-cooled
Current (amps)    -    -    -    -    -    -
Current Type    DC neg    DC neg    DC neg    DC neg    DC neg    DC neg
Square Butt    80-100    100-120    120-140    200-250    275-350    350-450
Lap Fillet    100-120    110-130    130-150    225-275    300-375    375-475
Intside Corner Fillet    80-100    100-120    120-140    200-250    275-350    350-450
Outside Corner Fillet    80-100    100-120    120-140    200-250    275-350    350-450
Double Fillet Tee    90-100    11-130    130-150    225-275    300-375    375-475
Single Bevel Corner    -    -    -    -    275-350    -
Single Vee Butt    -    -    -    -    275-350    350-450
Double Vee Butt    -    -    -    -    -    350-450
Welding Speed (mm/sec)    -    -    -    -    -    -
Square Butt    5.1    5.1    5.1    4.2    2.1    hard to predict
Lap Fillet    4.2    4.2    4.2    3.4    2.1    hard to predict
Intside Corner Fillet    5.1    5.1    5.1    4.2    2.1    hard to predict
Outside Corner Fillet    5.1    5.1    5.1    4.2    2.1    hard to predict
Double Fillet Tee    4.2    4.2    4.2    3.4    2.1    hard to predict
Single Bevel Corner    -    -    -    -    2.1    hard to predict
Single Vee Butt    -    -    -    -    2.1    hard to predict
Double Vee Butt    -    -    -    -    -    hard to predict
Gas    Argon    Argon    Argon    Argon    Argon    Argon
Gas Flowrate (L/min)    5    5    5    6    6    7
Gas Pressure (kPa)    140    140    140    140    140    140
Gas Nozzle Limits (ceramic)    up to 250 amps    up to 250 amps    up to 250 amps    up to 250 amps    -    -
(water-cooled)    -    -    -    > 250 Amps    > 250 Amps    > 250 Amps
Out of Position Welding    -    -    -    -    -    -
Vertical and Overhead Current    reduce by 10-20%    reduce by 10-20%    reduce by 10-20%    reduce by 10-20%    reduce by 10-20%    reduce by 10-20%

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