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The Use of Magnesia in

Welding Applications

David Fedor

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Pioneer With Market-Leading Technology

A global manufacturer and market leader with 120 years of expertise. Distinguished by an unwavering commitment to customers, employees and shareholders.

Founded in 1895

$2.5B in revenue in 2015

HQ in Cleveland, Ohio, U.S.

47 manufacturing facilities in 19 countries

Distribution to over 160 countries

9,000+ employees worldwide

EQUIPMENT AUTOMATION FUME

CONTROL CUTTING ACCESSORIES CONSUMABLE

(filler metals)

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47 Factories in 19 Countries

Apparatus

LOS ANGELES, CALIFORNIA

Equipment

SAN DIEGO, CALIFORNIA

Gas Apparatus

GAINESVILLE, GEORGIA

Consumables

MASON, OHIO

Consumables

MENTOR, OHIO

Equipment & Consumables

TORONTO, CANADA

Consumables

MISSISSAUGA, CANADA WORLD HEADQUARTERS

CLEVELAND, OHIO

Equipment, Consumables

& Automation

Consumables & Accessories

TIJUANA, MEXICO

Equipment & Consumables

TORREON, MEXICO

Equipment & Consumables

MEXICO CITY, MEXICO

Consumables

BOGOTÅ, COLOMBIA Consumables

SAO PAULO, BRAZIL

Consumables

MARACAY, VENEZUELA Consumables

JAKARTA, INDONESIA

Consumables

CHENNAI, INDIA

HEADQUARTERS

SHANGHAI, CHINA

Equipment & Consumables

Consumables

NANJING, CHINA

Consumables

ZHENGZHOU, CHINA

Consumables

JINZHOU, CHINA

Equipment

ESSEN, GERMANY

Consumables

NIJMEGEN, NETHERLANDS

Consumables & Gas Apparatus

DZIERZONIOW, POLAND

Equipment

BIELAWA, POLAND

Consumables

SHEFFIELD, UNITED KINGDOM

Consumables

CHERTSEY, UNITED KINGDOM

Consumables

ROUEN, FRANCE

Consumables

LISBON, PORTUGAL

HEADQUARTERS

BARCELONA, SPAIN

CONSUMABLES

SWIETOCHLOWICE, POLAND

CONSUMABLES

ISTANBUL, TURKEY

Consumables

AREZZO, ITALY

Equipment

GENOA, ITALY

Consumables

LUAN COUNTY-CHINA

GLOBAL HEADQUARTERS

Lincoln Electric

Cleveland, Ohio USA

Consumables

MTNSENSK, RUSSIA

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Diversified Products and Reach

Net Sales by Product Area Net Sales by Region

Consumables (filler metals)

62%

Equipment

38% North

America

60%

South America

Asia Pacific

Harris Products Group

Europe

15%

11%

9%

5%

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28 Consumables Factories in 17 Countries

Consumables

MASON, OHIO

Consumables

MENTOR, OHIO

Consumables

TORONTO, CANADA

Consumables

MISSISSAUGA, CANADA

CLEVELAND, OHIO

Consumables

Consumables

TIJUANA, MEXICO

Consumables

TORREON, MEXICO

Consumables

MEXICO CITY, MEXICO

Consumables

BOGOTÅ, COLOMBIA Consumables

SAO PAULO, BRAZIL

Consumables

MARACAY, VENEZUELA Consumables

JAKARTA, INDONESIA

Consumables

CHENNAI, INDIA

SHANGHAI, CHINA

Consumables

Consumables

NANJING, CHINA

Consumables

ZHENGZHOU, CHINA

Consumables

JINZHOU, CHINA Consumables

NIJMEGEN, NETHERLANDS

Consumables

DZIERZONIOW, POLAND

Consumables

SHEFFIELD, UNITED KINGDOM

Consumables

CHERTSEY, UNITED KINGDOM

Consumables

ROUEN, FRANCE

Consumables

LISBON, PORTUGAL

CONSUMABLES

SWIETOCHLOWICE, POLAND

CONSUMABLES

ISTANBUL, TURKEY

Consumables

AREZZO, ITALY

Consumables

LUAN COUNTY-CHINA

Consumables

MTNSENSK, RUSSIA

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World-Class Arc Welding Products

Welding

Consumables

65% Welding

Equipment

35%

Arc Welding Processes:

GMAW (Gas Metal Arc Welding)

SMAW (Shielded Metal Arc Welding)

FCAW (Flux Cored Arc Welding)

SAW (Submerged Arc Welding)

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World-Class Arc Welding Products

Welding

Consumables

65% Welding

Equipment

35%

Magnesia Usage:

FCAW

• Small number of products

SAW

• All products

DBM annual consumption

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World-Class Arc Welding Products

Welding

Consumables

65% Welding

Equipment

35%

Magnesia Usage:

Flux A Flux B

SiO2

AlO2O3

MgO

MgO CaF2

MnO

SiO2

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4 SAW Flux Factories in 4 Countries

CLEVELAND, OHIO

Consumables

Consumables

SAO PAULO, BRAZIL

Consumables

ZHENGZHOU, CHINA

Consumables

ROUEN, FRANCE

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SAW – Submerged Arc Welding

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Flux and Slag

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SAW Electrode

• Current carrying wire

• Melted by the welding arc and

deposited into the weld joint

• Different alloyed wires available for

different weld strengths

• Steel, Stainless Steel, Nickel, and

hard facing wires are available

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SAW Flux

• Protects molten metal from

atmospheric oxidation

• Removes impurities from the weld

metal and solidifies as slag

• Flux can also be used to add

alloying elements to weld metal

–Active flux

–Neutral flux

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Making SAW flux

1. Weigh mix

2. Dry blend

3. Add silicate

4. Process in kiln

5. Size and screen

6. Package

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Submerged Arc Processes

• Single Arc

• Tiny Twin Arc

• Tandem Arc

• Multiple Arc

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SAW - Single Arc

• Simplest

• Automatic or

Semiautomatic

• Used with Travel

Carriage, Manipulator,

Tractor or Hand Held

• DC +, DC - or AC

• Wire Sizes up to 7/32

inch

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SAW - Tiny Twin Arc

• Two Wires - One Power

Source, One Wire Drive and

One Control

• DC +, DC -, AC

• Use on Light Gauge and

Heavy Plate

• Wire Sizes: .045 to 3/32”

• 40% Higher Deposition

Rates than Single Arc

• Up to 50% Faster Travel

Speeds than Single Wire

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SAW - Tandem Arc

• Two Wires - Two Power

Sources

• Lead Wire is DC+ or AC

• Trail Wire is AC

• 25 to 100% Increases in

Deposition and Travel

Speeds Over Single Arc

• Typically used on ¼”

and Larger Plate

Thicknesses

• Used with Travel

Carriage, Manipulator or

Tractor

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SAW – Multiple Arc

• Three to five wires

• Fast travel speeds

• High Deposition

• DC+ or AC on lead

arc and AC trailing

arcs

• Up to six power

supplies may be

needed

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SAW Welding Variables

Heat Input (operating parameters) influences cooling rate

• Current – Controls penetration

• Voltage – Controls bead width and shape

• Travel Speed – Controls bead shape and penetration

• Polarity

– DC+ , DC- , AC

• Machine Output

– CC, CV

Cooling rate and chemistry define

microstructure (mechanical properties)

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Industries using SAW

• Pipelines

• Pipe mills

• Ship Building

• Offshore

• Structural

• Heavy Fabrication

• Repair

• Power Generation

• LNG

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SAW - Advantages

• High Deposition Rates

• Typically Deep Penetration

• High Operating Factor

• Low Hydrogen Welds

• Fast Welding Speeds

• High Quality Welds

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SAW - Limitations

• Portability (External

Shielding Flux

Required)

• Flat position only

(Except for 3 o’clock

welds)

• Operator Skill

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SAW - Limitations

• Tight Fit-Up Required

• Abrasive Nature of Flux

on Machinery

• Housekeeping and

Storage of Flux

• Slag

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SAW Flux Slag

• Solidification temperature and

viscosity are important slag

properties

• Shape and appearance of finished

weld

• Pock marking

• Slag removal

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Magnesia Specifications

A128 A166

MgO 85 - 94% 93% min.

SiO2 3.0 - 6.0% 4.0% max.

CaO 1.5 - 5.5% 2.6% max.

Fe2O3 2.5% max. 1.5% max.

Al2O3 2.0% max. 1.5% max.

C 0.04% max. 0.05% max.

S 0.01% max. 0.01% max.

P 0.01% max. 0.01% max.

Chemistry

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Magnesia Specifications

Chemistry

Boron • Sea water vs mined material • B recovery in weld deposit • Must be disclosed if present in in deposit

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Magnesia Specifications

Chemistry

• Dead burned material • Weight Loss in Ar @2000° F (1093° C) • In Ar atmosphere, weight loss without oxidation • Moisture pickup

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Magnesia Specifications

Chemistry - TGA Results

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Magnesia Specifications

Chemistry - DTA Results

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Magnesia Specifications

Delayed Hydrogen Cracking

• Strength of steel • Joint configuration • Welding procedure • Ambient conditions • H content of welding consumables

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Magnesia Specifications

% Passing Thru

Mesh microns A1283 A1284 A128G A1661 A1662

-16M 1000 100 100

-20M 850 99 min 99 min

-30M 600 90 min 100

-40M 425 99 min 100

-60M 250 100 99 min

-100M 150 98 max 50 - 80 50 - 80

-200M 75 50 max 95 max 60 max 40 max 35 - 65

-325M 45 20 max 75 - 85

Particle Size

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Thank you

Questions?