African Fusion November 2017

Oerlikon Clearinox low Cr VI emissions

affected by several factors such as trans- fer mode, amperage, voltage, and CO 2 content in Argon-based shielding gas. Consequently, welding conditions have to be set up carefully according to the applications and workplace. Fume analysis The chemical analysis of fume has been done as indicated in section 4.3 follow- ing the international standard. Fume for MMA electrodes has been collected using diameter 3.2 mm and diameter 1.2 mm for FCW. The reduction of concentration of Cr VI in the fume is very significant for Clearinox range versus standard prod- ucts (up to 60%) for both MMA and FCW as shown in Table 3. The effect of Na, K reduction vs. Li addition in coating and in flux compo- sition for FCW has been demonstrated by the high reduction of hexavalent chromium in fume. We have also confirmed by conse- quence the different balance in con- centration of alkaline into the chemi- cal composition of the fume. Some examples are indicated in the Table 4. The results of the analysis demon- strate that under laboratory conditions, thenewClearinox consumables produce less particulatewelding fume containing less hexavalent Chromium than stan- dard products. Consequently, based on the data generated, the Cr VI emission at the source is 4 times less (Table 4) for Clea- rinox MMA and 3 times less for Clearinox FCAW versus standard products. Welding performance The operative performances (weld- ability) of the new Clearinox range was compared to the current standard range. Clearinox E 308L, 309L and 316L electrodeswere all tested in flat (PA) and horizontal fillet (PB) welding positions, with DC+ polarity. The base material 304L plate’s thickness and amperages involved are indicated in Table 6. The new Clearinox range displays a very stable, spatter-free and smooth arc metal transfer. The strike and cold re-strike are very good. The weld bead is almost flat, having a preferred silver colour with fine and regular ripples. The weld pool is very clear and visible during welding, enabling the electrode to be easily controlled. Slag removal is very good, sometimes self-releasing. Even during the comparative weld-

Photo 2: Nice weld bead appearance for Clearinox; lower fume emission vs. Standard (black area surrounding the bead).

Type Product

Concentration in fumes (%m/m) Fe Mn Ni Cr Total

% reduction

Cr VI 4.07 1.64 1.32

Standard MMA308L Clearinox E308L Standard FCW309L Clearinox F309L PF Standard FCW316L Clearinox 316L PF

4.7 3.6 0.3 6.7 4.6 0.5 11.6 3.3 1.6

4.6 5.2 9.1

-

MMA

60

-

18.3 4.1 3.0 13.3 0.49

63

FCW

11.4 7.9 1.3

7.2

0.52

-

18.0 10.1 2.6 10.2 0.19

63

Table 3: Chemical composition of fumes.

Type Product

K element (%m/m)

Na element (%m/m)

Li element (%m/m)

Standard 308L Clearinox E308L Standard 316L

28.8

1.9 1.3 5.8 3.6

0.4 4.1

MMA

2.7

10.5

< 0.1

FCW

Clearinox 316L PF 1.1

1.2

Table 4: Alkaline concentration in fume. ing session, visually lower quantities of fumes were noticed across the new range. The coating resistance was also tested with respect to: falling; bending; and vibration. These tests demonstrated that the negative effect on coating resis- tance givenby the various Li-basedbind- er compounds were overcome by using the new Clearinox coating formulation. The coating of Clearinox electrodes was found to be robust when abrasion or bending stresses are applied. When subjected to shock (falling), though slightly inferior compared to standard types, the coating adherence on thewire rod is still very good. Conclusions Based on the double-coated concept, a new range of stainless MMA electrodes has been developed. When compared to standard stainless MMA electrodes, the fume emission rate of the new products is 30 to 40% lower and the concentration of hexavalent chromium Cr VI in fumes is strongly reduced by up to 60% less. Ex- pressed inmg/minute of fume emission,

the new Clearinox E electrode range displays four-times lower hexavalent chromium (CrVI) levels. A new range of flux-cored wires has also been developed. The fume emission rate for Clearinox F range is slightly reduced compared to standard flux-cored stainless steel wire(10-15%) while hexavalent Cr VI levels in fume is significantly reduced (60%). Expressed inmg/minute of fume emission, the new Clearinox F range generates three-times less hexavalent chromium Cr VI . These new of welding consumables all display physical, operational and mechanical performances at the same level and sometimes superior levels when compared to standard products presently used on the market. Ref : Griffiths T, and Stevenson AC: De- velopment of stainless steel welding electrodes having a low level of toxic chromium in the fume; The 5 th Interna- tional Symposium of the Japan Welding Society, AdvancedTechnology inWelding, Materials Processing and Evaluation, 5JWS-IV-3, Tokyo, April 1990.

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November 2017

AFRICAN FUSION