Topic Welding Industry / Technical Discussions / Welding Monel to Carbon Steel By ewpatnode Date 07-13-2004 14:20 Looking for a procedure for welding Monel ASTM A494 Grade M-30C to A 106 Carbon Steel. Monel 400 is easy to machine (class B). The alloy can easily be cold formed, with forces between those of carbon steel and grade 304 stainless steel. Electrode 190 between two sections of MONEL alloy 400. plate and between sections of alloy 400 and carbon steel. The issue for many Monel welding projects, however, is that qualified TIG welders who have experience working with Monel are rare. Thanks. For nickel chrome welds on carbon steels ERNiCr-3 is a common consumable. For service inquiries, contact service@arcmachines.com. Titanium contents are added to control porosity with these welding processes. Arc Machines welcomes the opportunity to discuss your specific needs. While all types of arc welding can be used on Monel alloys, some welding processes are known to work better than others. Arc Machines, Inc. has decades of experience leading the orbital welding industry—and we put that expertise to work for you. What type of … Monel-400 was employed as a SG tube material in early CANDU reactors, and has been in use as a tube material for the SGs of RAPS-1&2, MAPS-1&2 and primary system heavy water heat exchangers of RAPS-1&2, MAPS-1&2 and NAPS-1&2.Monel-400 was selected and used because of: • available experiences with fossil fuel plant feedwater heaters, • excellent resistance to many corrosive environments, According to ASTM A 494 Table 2; weldable grades such as M-30C are left as as cast (No Heat Treat). Monel 400, for instance, is used to manufacture marine parts that must resist corrosion from saltwater as well as chemical processing valves, tanks, pumps, pipes, and—unexpectedly—valves for high-quality musical instruments that need to resist the corrosive action of spit. It is also used for surfacing of steel. Cracking is especially likely with open-groove welding that requires multiple passes using wide-ranging weave patterns to fill the joint. Inert shielding gas like argon provides a medium that prevents the surrounding atmosphere from contacting the molten Monel. These properties make Monel alloys incredibly valuable in industrial applications; however, Monel is also very expensive by weight and typically it is only used where no other metal or alloy is suitable. These hot-dipped welding monel carbon steel are ideal for seamless construction uses. It is also suitable for the welding of Monel 400 to copper-nickel alloys and carbon steels. Inconel 718 . And it … The filller metal must be austenitic, and ferritic filler metals must not be used. A494 M30C can have weldability issues if it is not refined/heat treated correctly at the foundry. This is due to its tenacious oxide coating, and while this is a desirable material trait, the oxide makes the material more challenging to weld. All welding procedures are dual certificated for ASME IX and BS EN 288 and cover a wide range of materials in varying thickness and where appropriate, diameters. For dissimilar applications think about minimum weld dilution. MONEL 190: Welding Monel 400 to low alloys, Copper and Copper-Nickel alloys to steel: ECuNi: SM: MONEL 187: Welding of 70:30 grades of wrought and cast Copper-Nickel alloys ENiCrFe-2: SM: INCOWELD-A: Welding of Incoloy 800 and 800HT, dissimilar steels and Nickel alloys : ENiCrFe-3: SM: INCONEL-182: Welding of alloy 600 and 601, 800, 800 HT and dissimilar combinations E NiCrM0-3: … What type of filler should we be using? We have been having problems with the Monel cracking during welding. However, even with this precision control, it still takes detailed welding procedure specifications (WPS), a high level of engineering expertise, and a highly skilled welder with experience dealing with this alloy in order to create reliable welds. Table 1: Carbon and Low-Alloy Steel Welding Consumables for SMAW Process Base Material Carbon Steel Carbon-Molybdenum Steel 1and 1 1/4 Cr-1/2 Mo Steel 2 1/4 Cr-1Mo Steel 5Cr- 1/2 Mo Steel 9Cr-1Mo Steel Carbon steel AB AC AD AE AF AG Carbon-Molybdenum Steel C CD CE CF CH 1 and 1 1/4 Cr - 1/2 Mo Steel D DE DF DH The electrode is capable of producing weld deposits that meet stringent radiographic requirements. A project or a manufacturing center can be equipped with more than one orbital weld head, enabling it to weld multiple Monel joints simultaneously. Engineering Department | Arc Machines, Inc. The welding data and weld production schedules generated at one location can be used to program automated weld heads at many other locations in order to produce the same consistent high-quality welds over and over while reducing labor costs. Moreover, the demanding industries that use Monel most often require a level of precision, reliability, and repeatability that is not attainable with manual welding. Gas shielded methods of arc welding have several characteristics that make them preferred for use with Monel. Hydrofluoric acid is commercially available in concentrations ranging from 30 to 70% and as anhydrous HF. The 309L-16 is ideal for welding the 300 and 400 grades of stainless to carbon steel, welding the clad side of 18/8 clad steels, applying stainless linings to carbon steel shells, welding CH-20 and HH castings, and as a buildup material for marine propeller shafts. If by any chance I burn the Monel cladding during welding and happen to come in contact with carbon steel, what are the things i need to take care? Nickel and its alloys are used in a very wide range of applications - from high temperature oxidation and creep resistance service to aggressive corr… We have been having problems with the Monel cracking during welding. Looking for a procedure for welding Monel ASTM A494 Grade M-30C to A 106 Carbon Steel. The Monel is a casting that is suppose to be weldable. The ERNiCu-7 bare welding electrode/ rod can be used in the GTAW (TIG), GMAW, SAW and PAW processes for the welding of Monel 400 (UNS N04400) materials of ASTM B127(plate), ASTM B163(seamless tube), ASTM B165(seamless pipe), and ASTM B164(rod, bar & wire). Deposition control with the automated process aids in distortion control and a nearer to net shape product, helping to reduce excess material waste. ERNi Cu 7. 14320 Arminta Street, Monel 400 has excellent strength at subfreezing temperatures without undergoing a ductile-to-brittle transition. Look at specialmetals.com and nidi.org to research this. Arc Machines, Inc. is a recognized leader in automated GTAW welding, which offers a reliable, precise way to weld Monel, Inconel®, and a wide variety of other metals and alloys. The heat of the welding process can be changed by using a mixture of argon and helium, or argon and hydrogen as well. Inconel 600. Of the two types of gas shielded arc welding processes, GTAW is the superior of the two methods for the level of control it offers. It provides the ability to keep arc lengths very short, to guide the weld puddle precisely, and to reduce the build-up of heat in the metal. Addressing Welding Challenges with 400-Series Stainless Steel July 1, 2018 They usually contain 10.5- to 20-percent chromium, nickel content below 1 percent, limited carbon content and trace amounts of other elements for stabilization and corrosion … The gas can be pumped into the interior of a pipe or a pressure vessel, and the weld can be shielded from both sides. Panorama City, CA 91402, GTAW Tungsten Electrode Types: Selecting an Electrode for TIG Welding, Ground and Polished Tungsten Electrodes for High-Purity Welding, Orbital Welding Service to Support High-Spec Projects, Meeting the Challenges of Aviation Welding, Techniques to Improve Pipeline Welding Productivity, Welding Fume Safety: How to Reduce the Risks of Fume Exposure. There are approximately five different alloys that are traded as Monel®, each with different identifying numbers. Weight loss technique during the dissolution of pure Cu, 90/10 and 70/30 Cu-Ni alloys and of Mone1400 in strongly aerated 0.1 M HCl at 25 °C and 60 °C was investigated by Shams El Din 12et al. before welding; right side cleaned with solvent and dirty cloth exhibits cracking. Ultimately, welding Monel comes down to the ability of the welder to control a molten puddle that has very little ability to flow without putting excessive heat on a single point. Monel 400® is a high performance alloy of nickel and copper (with trace amounts of iron, manganese, carbon, and silicon). Powered by mwForum 2.29.2 © 1999-2013 Markus Wichitill. Sharp tools, slow speeds and deep uninterrupted cuts to remove the work hardened layer are needed. Based on different materials, pipe caps include carbon steel cap, stainless steel cap, and alloy steel cap etc. This ability to shield from both sides ensures a smoother interior weld surface and offers very little chance for nitrogen, oxygen, or carbon to contaminate the weld as long as the joint is prepared properly beforehand. Monel alloy 400- SS 316L joints were used for handling high pressure oxygen gas for service. . The Carbon content of AR400 steel is only 0.30% but the addition of 0.8-0.9% chromium gives it a lot more hardness and abrasion properties than low carbon steel has. Duplex (includes comprehensive corrosion testing) TIG and MMA. All of these benefits make automated orbital GTAW welding the best way to weld Monel and other exotic alloys. What is the phosphorous and sulphur content of the Monel and CS base metals? You might try buttering the CS side of the joint with E7018 to provide a barrier layer, then finish the weld with ENiCu-7. We doesn't provide welding monel 400 products or service, please contact them directly and verify their companies info carefully. Monel 400 Stub End – Stub Ends are fittings used in place of welded flanges where rotating back up flanges are desired. My question is What is the best filler metal to weld Monel to Monel? The combination of Monel 400 and low carbon steel2 was Monel 400 End Caps – End Cap, Carbon Steel cap, Stainless Steel Caps, ANSI, ISO, JIS and DIN Standards, Measures 1/2 to 56 Inches. Monel also becomes contaminated if the molten weld pool is exposed to the atmosphere, and without inert shielding, contamination is harder to avoid. The weld metal is resistant to corrosion by sea water, salts, and reducing acids. MONEL Welding Electrode 190 is used for shielded-metal-arc welding of MONEL alloys 400, R-405, and K-500. ERNiCu-7 is used for GMAW, GTAW, and SAW welding of Monel 400 and Monel K500. Shielded Metal Arc Welding (SMAW) or stick welding is by far the most common type of arc welding. Stainless steels (304 & 316 types) TIG, Flux cored MIG and MMA. (Alloys with copper contents 60% or more are called cupronickel.). The tungsten electrode at the center of GTAW welding keeps the arc very focused and the heat localized to the weld. Another trait common to most Monel alloys is maintaining strength across a wide range of temperatures. Flux Core, Bare wire mig, and stick welding can all get the job done. There is likely a variety of nickel based filler alloys that may be used to make the monel-to-CS dissimilar metal weld. Gas shielded arc welding also allows for more control of the heat input into the metal. As a result, it’s especially important that the welding of Monel alloys be performed correctly and as near net shape as possible the first time for the sake of the project timetable and budget. I contacted specialmetals to verify that the filler that we are suing is correct and it is. Should we be preheating the monel? They’re not only experts in the use of our products, but also in creating specialized services and training for your company’s needs. The weld rod is "MONEL Welding Electrode 190". However, Monel is a nonferrous alloy of nickel and copper with some unique properties. Now I need to weld a Monel fittings to the Monel side. Another unique characteristic of Monel is that each of the metals that combine to form this alloy has a slightly different melting and cooling point, which can cause separation when melted. It is face centred cubic and undergoes no phase changes as it cools from melting point to room temperature; similar to a stainless steel. A common trait of Monel alloys is their resistance to corrosive elements. Monel can be welded with SMAW using a high-nickel electrode and direct current. They are both alloys containing approxi-mately one-third of copper and two-thirds of nickel, K-Monel containing in addition 2-0-4-0 per cent aluminium and 0-25-1-0 per cent titanium, by virtue of which the alloy can be hardened by heat treatment. Welding and welding training and qualification are discussed as well as arc management during the welding process. Contact us to arrange a meeting. The Guardians team is just one of Arc Machine’s ways of guaranteeing the success of our products and your operation. that the dissimilar combinations of Monel 400 and low carbon steel has been employed in oil gasification plants where the weldments are vulnerable to high temperature corrosion. Welding Neck Flange,Slip on Flange,Threaded Flange PRESSURE CLASS 300,400,600,900,1500,2500 BS 4504 SEC 3.1 Welding Neck Flange,Hubbed Slip on Flange,Hubbed Threaded Flange,Lapped Pipe End Flange,Plate Flange,Loose Plate Flange,Loose Plate With Weld Neck Flange,Blank Flange PRESSURE CLASS PN 2.5 TO PN 40 BS 4504[PART 1]SS Long weld Flange Duplex Steel Flange Monel 400 … Comparing orbital welding versus manual welding makes it clear that automated orbital welding offers a more efficient form of GTAW welding as well as the ability to pre-engineer and program parameters such as arc voltage, travel speed, and filler wire feed rate. Joining Monel is best accomplished through electric arc welding. Machinability. Stronger than pure nickel, Monel alloys are resistant to corrosion by many agents, including rapidly flowing seawater. Plain carbon steel can withstand the anhydrous acid and is extensively used in rail cars carrying anhydrous HF. Nickel is a relatively simple metal. 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