Storage & handling

recommendations for
consumables
Handbook
COVERED ELECTRODES, SOLID MIG/MAG WIRES, CORED WIRES,
TIG RODS AND SAW/ESW WIRES, STRIPS AND FLUXES
Environmental care - sound welds page 3
Covered MMA electrodes page 6
Covered MMA electrodes in VacPac page 11
MIG/MAG/SAW wires, TIG Rods and
strips page 13
Cored wires page 16
SAW and strip cladding fluxe page 18
DISCLAIMER
Whilst all reasonable efforts have been made to ensure
the accuracy of the information contained in this
handbook at the time of going to press, ESAB gives
no warranty with regard to its accuracy or
completeness. It is the responsibility of the reader to
check the accuracy of the information contained in this
handbook, read product labels and equipment
instructions and comply with current regulations. If the
reader is in any doubt with regard to the proper use of
any technology they should contact the manufacturer
or obtain alternative expert advice. ESAB accepts no
responsibility or liability for any injury, loss or damage
incurred as a result of any use or reliance upon the
information contained in this handbook.
2
Contents
Maximum storage time
If the recommended storage
conditions described in the
individual consumables sections in
this handbook are adhered to, the
maximum storage time for all the
consumbles covered in this
handbook is 3 years. After this time
the product should be thoroughly
checked before use.
Disposal
The majority of the packaging used
by ESAB are designed for
environmental friendly recycling.
Any product, residue (slag),
disposable container, liner or other
packaging should be disposed of in
an environmentally acceptable
manner, in full compliance with
federal and local regulations.
Please address your local disposal
company for prescribed disposal.
Information on product and
residues are given in the Safety
Data Sheets available through
www.esab.com.
The broad range of consumables
sold by ESAB are manufactured
under a strict ISO 9001 quality
assurance programme. Moreover,
with IS0 14001 worldwide
certification, the companys high
quality consumables are preferred by
industries for their ability to minimise
welding defects. Special packaging,
such as Marathon Pac
TM
and
VacPac
TM
has also been developed
to make handling even more rational
for the customer.
ESAB is one of the few international companies with a
global ISO 14001 certification. Every ESAB product is
produced to the same environmental standard with every
step taken to minimise environmental impact, from the
cradle to the grave.
3
Environmental
care - sound welds
Marathon Pac is folded flat after use for mimimal disposal space.
4
indicative of a large amount of gas
being formed, which is then
trapped in the solidifying weld
metal. Hydrogen is also a
contribution to cracks in welds or
the HAZ. Hydrogen in combination
with residual tensile stresses and
crack sensitive steels can cause
cold cracking several hours or days
after welding. High strength steels
and constructions with high levels of
residual tension are more sensitive
to hydrogen cracking. For these
applications ESAB recommend
using methods and consumables
that give low hydrogen levels
together with adequate procedures
Quality of welds.
Porosity is formed by entrapment of
discrete pockets of gas in the
solidifying weld pool. The gas may
originate from poor gas shielding,
surface contaminants such as
moisture, rust or grease, or
insufficient deoxidants in the parent
metal, electrode or filler wire. A
particularly severe form of porosity
is wormholes, caused by gross
surface contamination or welding
with damp electrodes.
Characteristically, wormholes are
elongated pores which produce a
herring bone appearance on the
radiograph. Wormholes are
(Tair - Tmetal)*
O
C
Relative Humidity
%
(Tair - Tmetal)
O
C
Relative Humidity
%
0
100 12
44
1 93
13
41
2
87
14
38
3
81
15
36
4 75 16 34
5*
70* 18
30
6
66 20 26
7
61 22 23
8
57 24 21
9
53 26
18
10
50
28 16
11
48 30
14
Dew point conditions versus relative humidity
* Difference in temperature between work piece or consumable and the air temperature
5
condense will form for a number of
given differential temperatures. *
Example - If the relative humidity in
the weld area is 70%, the base
metal and electrode must be no
colder than 5

C below the air
temperature to prevent moisture
condensation.
This can happen when plates or
electrodes come from a colder
workshop, warehouse or from the
outside.
for pre-heating, work temperature
and post weld heat treatment. It is
important to note that there can be
other significant sources of
hydrogen e.g. moisture from the
atmosphere or from the material
where processing or service history
has left the steel with a significant
level of hydrogen.
Hydrogen may also be derived
from the surface of the material or
the consumable, or from oil and
paint etc.
The below chart shows the relative
humidity at which detrimental water
Storage conditions
All covered electrodes are sensitive
to moisture pick-up. High moisture
contents in the coating can cause
porosity or hydrogen cracking.
However, the pick up rate will be
very slow when stored under
correct climatic conditions:
5 - 15C: max 60% RH
15 - 25C: max 50% RH
>25C: max 40% RH
At low temperatures, the humidity
level can be maintained at low levels
by ensuring a storage temperature of
at least 10C above the outside
temperature. Cold packs should be
allowed to reach ambient
temperature before being opened.
At high temperatures, low humidity
levels can be maintained by air
dehumidification.
If electrodes are stored under the
described storage conditions, they
can be kept for maximum of three
years.
ESAB electrodes can be supplied
in different packaging types
depending on the type and grade.
Shrink film paper box, this is not
completely airtight, so moisture
from the surrounding
atmosphere can enter the box
and be picked up by the
coating.
Plastic capsules have a lid and
tape, moisture will permeate
through at very low rates and be
picked up by electrode coatings.
Therefore, if there is any doubt
about whether an electrode is dry
enough, it should be re-dried
according to instructions shown on
the label before use.
VacPac vacuum packaging
provides a complete protection
against moisture provided the
package is intact (vacuum
maintained). If this is the case,
no re-drying is needed before
use.
6
Covered MMA electrodes
Redrying
Low hydrogen covered basic
electrodes should be re-dried
before use whenever there are
application requirements relating
to weld metal hydrogen content
and/or radiographic soundness
(not needed for VacPac).
Acid rutile stainless electrodes
and all types of basic electrodes
may produce pores in the weld
metal if they have not been
stored in sufficiently dry
conditions. Re-drying the
electrodes will restore their
usability.
Mild steel rutile and acid
electrodes normally need no
re-drying.
Cellulose electrodes must not
be re-dried.
Electrodes, which are seriously
damaged by moisture, cannot
be restored to their original
condition by baking and should
be scrapped.
Redrying conditions
Redrying and holding temperatures
and holding times are specified on
the package label.
The redrying temperature is the
temperature in the bulk of the
electrodes. The redrying time is
measured from the point at which
the redrying temperature has
been reached.
Do not stack more than four layers
of electrodes in the redrying oven.
It is recommended not to redry
covered electrodes more than
three times.
A summary of recommended
redrying conditions for ESAB
electrodes is given in table on the
next page.
7
8
Recommended redrying temperatures, holding time two hours for OK electrodes.
80C 150C 200C 250C 300C 350C 350C
OK 92.78 OK 50.10** OK 39.50 OK 33.60 OK 62.53 OK 38.48 OK 67.43
OK 61.25 OK 33.80 OK 68.82 OK 38.65 OK 67.50
OK 61.35 OK 33.81 OK 83.50 OK 38.95 OK 67.51
OK 61.35 Cryo OK 67.13 OK 83.53 OK 48.00 OK 67.52
OK 61.50 OK 67.20 OK 84.78 OK 48.04 OK 67.53
OK 61.85 OK 68.37 OK 84.80 OK 48.05 OK 67.60
OK 63.35 OK 68.53 OK 92.82 OK 48.08 OK 67.62
OK 63.85 OK 68.55 OK 94.25 OK 48.15 OK 67.70
OK 67.15 OK 69.33 OK 48.18 OK 67.71
OK 67.45 OK 69.63 OK 48.30 OK 68.17
OK 67.55 OK 84.76 OK 48.50 OK 68.25
OK 67.75 OK 84.84 OK 48.60 OK 68.81
OK 310Mo-L OK 92.05 OK 48.65 OK 73.08
OK 68.15 OK 92.15 OK 48.68 OK 73.15
OK 69.25 OK 92.55* OK 53.00 OK 73.35
OK 83.27 OK 94.35 OK 53.18 OK 73.46
OK 83.28 OK 53.35 OK 73.68
OK 83.65 OK 53.68 OK 74.46
OK 84.42 OK 53.70 OK 74.70
OK 84.52 OK 55.00 OK 74.78
OK 84.58 OK 61.20 OK 75.75
OK 85.58 OK 61.30 OK 75.78
OK 85.65 OK 61.80 OK 76.16
OK 86.08 OK 61.81 OK 76.18
OK 92.18 OK 61.86 OK 76.26
OK 92.26 OK 62.73 OK 76.28
OK 92.45 OK 62.75 OK 76.35*
OK 92.58 OK 63.20 OK 76.96
OK 92.59 OK 63.30 OK 76.98
OK 92.60 OK 63.34 OK 78.16
OK 92.86 OK 63.41 OK 83.29
OK 63.80 OK 86.28
OK 64.30 OK 86.30
OK 64.63 OK 92.35
*1h drying time **3h drying time
Equipment for storage and
redrying of electrodes
The PK 1 is a light and handy dry-
storage container for electrodes. It
is easy to carry around. The storage
temperature is around 100
O
C.
The PK 5 is a combined drying and
dry-storage system for most types
of electrode. The drying time at full
effect is one to seven hours
depending on the type of
electrode.The temperature is
thermostatically controlled and
ranges from 50-300
O
C. The
electrodes should be stored in the
PK 5 without packaging.
The SK 40 is a dry-storage cabinet
with four removable shelves for
storing electrodes. The electrodes
should be stored without packing.
The cabinet is equipped with a
thermometer, thermostat and
control lamp.
PK 1 dry-storage container
SK 40 dry-storage cabinet
PK 5 drying equipment
9
Discoloration in the
coating
If the colour of the electrodes
changes during storage, they
should be scrapped or an ESAB
representative should be contacted.
Damaged coating
Physically damaged electrodes
where sections of the coating are
missing will not perform correctly
and should be scrapped. The PK 410 is a robust cabinet for
the drying and dry storage of
electrodes. The drying temperature
can be regulated between 0
o
C and
450
o
C. The dry-storage
temperature is around 150
o
C. The
PK 410 is equipped with a control
lamp, electronic thermometer and
electronic thermostat. The PK 410
also has a seven-day timer. The
timer makes it possible to
automatically change from drying
to dry storage for selected times
and temperature ranges.
PK 410 drying cabinet
10
No re-baking, no holding
ovens, no quivers.
MMA electrodes from VacPac can
be used straight from the package
without the need to re-bake them
and store them temporarily in
holding ovens and quivers. Upon
opening, fresh and dry electrodes
are guaranteed when the vacuum is
maintained.
Electrodes of low moisture
absorption type (LMA, classified as
H4 or H5), re-absorb moisture
slowly from the air. The safe
exposure time for this type of
electrode is 12 hours* after opening
the VacPac with the foil left in place.
* Valid at standard AWS test
conditions of 26.7 C and 80% RH.
How to handle VacPac
To protect the vacuum foil, avoid
using a knife or any other sharp
object when opening the outer
package. Keep the electrodes
inside the package and do not take
out more than one electrode at a
time. Low moisture absorption type
electrodes (LMA) that have been
exposed to the atmosphere in an
opened VacPac for more than 12
hours (26.7C and 80% RH) should
be discarded or re-dried.
VacPac is available in various packaging sizes to suit
fabricators individual consumption of MMA electrodes.
11
Covered MMA
electrodes in VacPac
Area to note date and
time of opening the
VacPac
Ducted plastic box and
aluminium foil can be
separated for disposal and
recycling.
The plastic box only
produces carbon dioxide
and water when incinerated.
Plastic box protects the
electrodes. It can be
re-sealed for further use
within the time intervals
specied for ESAB VacPac
electrodes.
Without VacPac With VacPac
Central store
max. 50C
Shop store
max. 50C
Welding
Central store
Baking
R
e
m
a
i
n
i
n
g
e
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c
t
r
o
d
e
s
Shop store
Quiver
Welding
Greatly simplified storage and
handling for major savings
Complete product
information on label
12
Solid MIG/MAG wires, TIG rods
and SAW wires should be stored
in dry conditions in original sealed
undamaged packaging as supplied.
Contact with water or moisture
should be avoided. This could take
the form of rain or the condensation
of moisture on a cold wire. To avoid
condensation, keep the wire in the
original packaging and, if necessary,
leave the wire to warm up to at
least the ambient temperature
before opening the package. Other
hydrogen-containing substances,
like oil, grease and corrosion or
substances that could absorb
moisture must also be avoided on
the surface of the wires. Spooled
wire is supplied packed in plastic
bags and partly used spools
should be replaced into a plastic
bag for storage to prevent surface
13
MIG/MAG/SAW wires, TIG
rods and strips
lifting straps from the octagonal
drum and fold it completely flat for
easy and space saving storage until
collection. Also note that Marathon
Pac protects your welding wire from
contamination.
Recommended conditions of storage
for all solid wires are minimum
temperature of 15C and humidity
of maximum 60% RH.
Aluminium wires
Atmospheric conditions affect weld
quality. Moisture (H
2
O) is a prime
source of hydrogen. At arc
temperatures, water breaks down
releasing hydrogen atoms that
cause porosity in weldments.
Aluminium, which is allowed to
repeatedly come into contact with
water, will eventually form a
hydrated oxide (AIOH) coating.
Moisture from condensation present
on either the electrode or the base
metal can cause two problems
during welding:
contamination. Wire should be
stored at ambient conditions of
temperature and humidity, and
dusty areas should be avoided
when wire is not enclosed in some
type of dust-protecting packaging
or equipment.
Wire for TIG (GTAW) welding
should be protected from dust and
airborne contamination after removal
from the packaging. The package
for TIG wires consist of a rigid fibre
tube with a plastic lid that can be
closed again after breaking the
sealing. The tube is PE coated and
provides a very good moisture
protection. The package is also
very stable and user friendly.
Marathon Pac bulk drums for MIG/
MAG welding is designed for fast,
efficient handling and ease of
eventual recycling. VCI paper inside
every drum and protective foil
around each pallet is protecting the
wire against moisture during
transport and storage.
Once empty, simply remove the
14
15
should be cleaned and brushed
with a clean stainless steel brush
prior to welding. ESAB
recommends mild alkaline solutions
and commercial degreasers that do
not evolve toxic fumes during
welding. Welders should wipe joint
edges with a clean cloth dipped in
a volatile petroleum based solvent.
All surfaces must be thoroughly
dried after cleaning.
Strips
Welding operators must keep
strips as clean and protected as
possible. This includes careful and
proper storage and handling all
stock to prevent dust and organic
compounds including body oils
contaminating the strip surface.
Porosity caused by hydrogen
generated from the breakdown
of water or from the breakdown
of hydrated oxide (AIOH) present
on the metal surfaces.
Entrapment of the actual oxide
(AIOH) present on the metal
surfaces, in the weldment.
In an aluminium welding shop, the
uniformity of air and metal
temperatures is important
especially when the relative
humidity is high. Electrode and
base metal should be allowed to
stabilise to the weld area
temperature. The electrode should
not be opened in the weld area for
24 hours after entry from a cooler
storage area. The base metal
Cored wires should be stored in
their unopened and undamaged
original packaging. Failure to do
this may seriously reduce the
durability of the consumables.
Storage times should be kept to a
minimum and stock rotation should
be used.
Non and low alloyed cored wires
are not susceptible to rapid
moisture absorption since the core
ingredients are protected from the
atmosphere but the sheath. Strict
QA procedures ensure all of
ESABs cored wires contain low
levels of moisture in the as
manufactured condition.
To maintain the low moisture levels
cored wires should be stored under
correct conditions. Poor storage
conditions can be detrimental to
their performance and shelf life.
Inadequate storage conditions can
lead to surface rusting or
contamination of the wire to the
extent that feedability and diffusible
hydrogen levels are adversely
affected.
Stainless steel cored wires are
more sensitive to moisture pick
up. Therefore the spools are
vacuum packed in Aluminium foil
pouches. The storage
recommendations are the same as
for unalloyed and low-alloyed
cored wires.
16
Cored Wires
cold wire. To avoid condesation the
relative humidity and temperature
shall be monitored and the
temperature should not fall below
the dew point (listed in table on
page 5).
Other hydrogen-containing
substances like oil, grease and
corrosion or substances that could
absorb moisture must also be
avoided on the wire surface.
Deteriorated product
Cored wires that are rusty, have
suffered from serious water and
moisture contamination, or have
been exposed to he atmosphere
over long periods of time cannot be
restored in their original condition
and should be discarded.
ESAB ceramic weld metal supports
have no adverse influence on weld
metal composition and mechanical
properties. They are dry and
insensitive to moisture absorption,
leaving consumables low-hydrogen
performance unaffected.
For stainless steel cored wires
extra attention is required in order
to ensure that they are returned to
the correct storage conditions the
end of the working period.
Wires should not be left on welding
machines or out of the store for
prolonged periods, especially
overnight, since condensation of
moisture from the air may lead to
rapid surface deterioration. Always
replace wires in their original
packaging and return them to
controlled storage areas.
If a wire has been left on the
equipment for a long period of
time, it is good practice to run off
at least one layer of wire to remove
the worst of any surface oxidation
or contamination that may have
occurred.
All cored wires should avoid direct
contact with water or moisture.
This could take the form of rain or
the condensation of moisture on a
17
ESAB uxes, agglomerated and
fused, have a guaranteed
as-manufactured moisture content
from production. This moisture
content is controlled by internal
ESAB specications. Before
transport, each pallet is shrink
wrapped in plastic foil. This
precautionary action is done in order
to maintain the as-manufactured
moisture content for as long as
possible. Flux should never be
exposed to wet conditions, such as
rain or snow.
Storage
Unopened ux bags must be
stored in maintained storage
conditions as follows:
T: 20 +/- 10C Relative humidity:
as low as possible - not
exceeding 60%.
Fluxes delivered in aluminium
lined BigBags can be stored
under more severe climatic
conditions, because the
packaging protects the flux
reliably from moisture pick-up, as
long as it is unopened and
undamaged.
The content of unprotected ux
hoppers must, after an 8 hours
shift, be placed in a drying
cabinet or heated ux hopper at
a temperature of 150 +/- 25C.
Remaining ux from opened
bags must be placed at a
temperature of 150 +/- 25C.
Re-cycling
Moisture and oil must be
removed from the compressed
air used in the re-cycling system.
Addition of new ux must be
done with the proportion of at
least one part new ux to three
parts re-cycled ux.
Foreign material, such as
millscale and slag, must be
removed by a suitable system,
such as sieving
Re-drying
When handled and stored as
above, the ESAB uxes can
normally be used straight away.
In order that customers
can use fluxes without
prior redrying, ESAB has
equipped the BigBags
with an aluminium liner,
reliably protecting the
flux from moisture, even
in tough climates such
as around the equator.
The complete BigBag,
including the aluminium
liner, is fully recyclable
(EN 13431).
The new moisture pro-
tected BigBags have
a very well defined
discharge spout which
can be closed during
the flux flow.
18
SAW and strip cladding
fluxes
JS 200 Flux storage silo
- Keeps flux dry and clean
- Adjustable temperature
between 100 and 300C
- Capacity: 200 l
- Supply voltage: 220V,
1 phase; output: 2 kW
In severe applications, stipulated
by the applicable material
specication, re-drying of the ux
is recommended.
Furthermore, if the ux has
somehow picked up moisture,
re-drying can return the ux to
its original moisture content.
Re-drying shall be performed as
follows: Agglomerated uxes:
300 +/- 25C for about 2-4
JK 50 Powder Dryer
- Redries flux at max. 500C
for about 3 hours
- Then automatically drops
temperature to pre-set value
(max. 200C) and stores flux
- Capacity: 50 l
- Supply voltage: 400V, 3 phase;
output: 3.7 kW
hours. Fused uxes: 200 +/-
50C for about 2-4 hours.
Redrying must be done either in
equipment that turns the flux so
that the moisture can evaporate
easily or in an oven on shallow
plates with a flux height not
exceeding 5 cm.
Re-dried ux, not immediately
used, must be kept at 150 +/-
25C before use.
19
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ESAB AB
Box 8004, SE-402 77 Gteborg, Sweden.
Phone: +46 31 50 90 00. Fax: +46 31 50 93 90.
E-mail: [email protected]
www.esab.com
ESAB operates at the forefront of welding and
cutting technology. Over one hundred years of
continuous improvement in products and
processes enables us to meet the challenges
of technological advance in every sector in
which ESAB operates.
Quality and environment standards
Quality, the environment and safety are three
key areas of focus. ESAB is one of few
international companies to have achieved the
ISO 14001 and OHSAS 18001 standards in
Environmental, Health & Safety Management
Systems across all our global
manufacturing facilities.
At ESAB, quality is an ongoing process
that is at the heart of all our production
processes and facilities worldwide.
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representation and an international network
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benefits of ESAB quality and unrivalled
expertise in materials and processes
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they are located.
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ting technology and systems.
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