IS 10178: CO2 gas shielded metal arc welding of structural steels - Recommendations

15 Pages·1995·1.5 MB·English

by  Bureau of Indian Standards

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“The Right to Information, The Right to Live” “Step Out From the Old to the New”
IS 10178 (1995): CO2 gas shielded metal arc welding of
structural steels - Recommendations [MTD 12: Welding
Applications]
“!ान $ एक न’ भारत का +नम-ण”
Satyanarayan Gangaram Pitroda
““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee””
“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै”
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”

IS ‘Wl78’: 1995

Indian Standard
COzGASSHIELDED METAL-ARCWELDINGOF
STRUCTURALSTEELS-RECOMMENDATIONS
( First’ Revision
)
l
SCI 25*160*10 : 77.080.10

.
Q SIB 1995
BUREAU OF INDIAN STANDARDS
KANAM ,NAVAHB 9 RUDAHAB HAHS RAFAZ GRAM
WEN IHLED 110002
0
Noyember 1995
Price Group 5
.
*
crA gnidleW snoitacilppA dna lamrehT gnittuC lanoitceS ,eettimmoC DTM 12
DROWEROF
sihT naidnI dradnatS ( tsriF noisiveR ) was adopted yb the uaeruB of naidnI ,sdradnatS after the
draft dezilanif yb the crA gnidleW snoitacilppA dna lamrehT gnittuC lanoitceS eettimmoC had neeb
devorppa yb the lacigrullateM gnireenignE noisiviD .licnuoC
sihT dradnats was tsrif dehsilbup ni 1981. elihW gniweiver the dradnats ni the thgil of ecneirepxe
$ deniag gnirud these ,sraey the eettimmoC dediced ot esiver ti ot gnirb ti ni enil htiw the tneserp
secitcarp gnieb dewollof yb the naidnI .yrtsudnI
ehT CO3 gas dedleihs cra-latem gnidlew si gnimoceb ylgnisaercni ralupop ni the noitacirbaf of ,sreliob
erusserp ,slessev s’pihs ,lluh etc. sihT dradnats has neeb prepared as a ediug ot the ,yrtsudni gnilaed
htiw the laciteroeht dna lacitcarp aspects of the process.
nI siht ,noisiver gniwollof segnahc evah neeb :edam
a) edortcelE noisnetxe seulav evah neeb ,deifidom
)b lacipyT gnitlem rates evah neeb ,deifidom dna
c) sliateD of gnidlew processes hguorht hgih tnerruc seuqinhcet evah neeb .deifi~dom
elihW gnitalumrof siht ,dradnats yrassecen ecnatsissa has osla neeb devired morf the gniwollof
:snoitacilbup

CO, gnidleW of .leets ehT gnidleW ,etutitsnI ,notgnibA *.KU

roF the esoprup of gnidiced whether a ralucitrap tnemeriuqer of siht dradnats si deilpmoc ,htiw the
lanif ,eulav devresbo or ,detaluclac gnisserpxe the tluser of a test, llahs eb dednuor off ni ecnadrocca
htiw SI 2 : 1960 seluR‘ for gnidnuor off laciremun seulav ( revised J’. ehT rebmun of tnacifingis secalp
deniater ni the dednuor off eulav dluohs eb the emas as that of the deificeps eulav ni siht .dradnats
k-510178:1995
Indian Standard
CO2 GASSHIELDEDMETAL-ARCWELDINGOF
STRUCTURALSTEELS-RECOMMENDATIONS
(F irst Revision )
1 EPOCS 5.2 nobraC sagedixoid llahs mrofnoc ot SI 307 : 1966.
sihT dradnats srevoc snoitadnemmocer no ,tnempiuqe 6 TNEMPIUQE
,selbamusnoc lareneg erudecorp dna euqinhcet for
8.1 Power ecruoS
citamotua-imes dna citamotua nobrac edixoid gas
dedleihs latem arc gnidlew of elbadlew larutcurts
ehT CO2 gas dedleihs arc gnidlew process si decneulfni
,sleets gnidulcni sebut dna wolloh .snoitces
yb the citats daol ciksiretcarahc dna the cimanyd -reporp
2 SECNEREFER seit of power .ecruos ylnO gnidlew srotareneg or -cer
sreifit gnivah talf ot ylthgils gnipoord A-V
ehT gniwollof naidnI sdradnatS are yrassecen stcnujda scitsiretcarahc dna good cimanyd seitreporp are
ot siht :dradnats .elbatius roF retteb gnirotinom of gnidlew ,retemarap
SI No. Title the power ecruos llahs etaroprocni retemtlov dna -ma
.retem
307 : 1966 nobraC edixoid ( dnoces revision )
6.2 Wire Feed Unit
:218 1957 yrassolG of smret gnitaler ot -dlew
gni dna gnittuc of slatem 6.2.1 ehT eriw feed tinu stsisnoc of a feed ,rotom sets
of feed dna evird srellor dna eriw gnidiug .tnemegnarra
:0301 1989 nobraC leets sgnitsac for lareneg
ehT feed rates yrav morf 2 ot 10 .nim/m tI llahs evah
gnireenigne sesoprup ( fourth
proper speed rotaluger ot evig mrofinu dna htooms feed
revision )
tsomla tuohtiw ,aitreni morf eriw leer ot the gnidlew
2002 : 1992 leetS setalp for erusserp slessev for nug dna ot the gnidlew .enoz sA ti slortnoc the gnidlew
etaidemretni dna hgih erntarepinet ,tnerruc siht aspect si erom tnatropmi nehw rehgih
ecivres gnidulcni sreliob ( thinl egnar of feed rates are .desu ehT tinu llahs evah elbatius
revision ) gnitrats dna gnippots slortnoc dna na gnihcni .hctiws
2062 : 1992 leetS for lareneg larutcurts -ruP 6.2.2 roF gnidlew niht sheets, the eriw gnideef ecived
poses (fourth revision ) yam eb detaroprocni otni eht gnidlew gun flesti -ane
gnilb mrofinu eriw gnideef neve htiw ylemertxe niht
3600 mrificurC tellif llew elisnet test
eriw and gnicudorp mrofinu ytilauq .sdlew tI shall eb
(Part 1) : 1995 ( dnoces r evision ) thgil hguone ot eb dervueonam yb eht rotarepo tuohtiw
6419 : 1971 gnidleW sdor and erab sedortcele eugitaf ni citamotua-imes .gnidlew
for gas dedleihs arc gnidlew of
6.3 ehT Welding Gun
larutcurts leets
6560 : 1972 munedbyloM dna muimorhc The welding nug llahs evah ’potS‘-’tratS‘ hctiws dna
munedbylom wol yolla leets -dlew erusne mrofinu tropsnart of .eriw A wolloh elbac -noc
gni rods dna esab sedortcele for gnitsis of a larips-eriw sdael the eriw edortcele morf
gas dedleihs arc gnidlew feed srellor ot the .nug enO tnerruc lanimret si -noc
detcen ot the tcatnoc elzzon hguorht hcihw passes the
3 YGOLONIMBET .edortcele ehT tcatnoc elzzon si dednuorrus yb a gas
roF the esoprup of siht dradnats the snoitinifed nevig ni ,elzzon hcihw llahs time wolf of gnidleihs gas neewteb
SI 812 7591: llahs .ylppa the elzzon dna the ecafrus of the tnerap latem tuohtiw
.ecnalubrut ehT nug si detnuom no the gnillevart -rac
4 TNERAP LATEM egair ni citamotua .gnidlew
sihT dradnats seilppa ot CO2 gas dedleihs cra-latem 6.3.1 ehT gnidlew nug yam rehtie eb gas delooc or
gnidlew gnidulcni gniyalrevo ytilauqelbadlewfo -curts water .delooc ehT snug dluohs detar-eb yletauqeda for
larut sleets gnimrofnoc ot SI 2062 : 1992, SI 1030 : the dednetni suounitnoc tnettimretni esu nihtiw -simrep
1989, SI 2002 : 1992 dna ralimis .sleets elbis, erutarepmet stimil of .egasu
ETON riA- gnilooc si yllareneg tneiciffus up *pt
5 GNIDLEW SELBAMUSNOC
400 ,A evobA 400 A retaw gnilooc si yrassecen
yllaicepse rof citamotua gnidlew ( 100 tnecrep ytud
5.1 ehT erab eriw sedortcele llahs mrofnoc ot
elcyc .)
SI 6419 : 1971, dna SI 6560 : 1972 as .etairporppa
1
IS -10178 : 1995
6.4 Mains and Control Unit 7.3 dednemmoceR elzzon ot work ecnatsid for suoirav
tnerruc slevel are nevig :woleb
Main unit llahs tsisnoc of a evitcetorp remrofsnart dna
a reifitcer ot ylppus tnerruc ot the lortnoc .tinu tI yam Current Nozzle to Work Distance
eb detaroprocni ni the reifitcer power ecruos flesti or A mm
yam eb a separate tinu ni case of .srotareneg ehT 50 - 150 13
evitcetorp remrofsnart si deriuqer for ytefas dna ot
150 - 350 15
elbane gnidlew work no sreliob dna .sknat
350 - 400 18
6.4.1 ehT lortnoc tinu sniatnoc lla gnillortnoc dna
gnihctiws ,stnemele the erusserp operated hctiws for 8 POLuuTY
gnilooc water fi( ,)desu dionelos evlav for gnisaeler
CO2 gas gnirud the gnidlew processes dna other -noc The edortcele si yllareneg detcennoc ot evitisop .elop
slort ekil sremit for gnidlewtops dna citamotua gnidlew ylnO ni cases hcus as ,gniyalrevo evitagen elop si
processes. ehT eriw feed tinu si yllareneg delpuoc htiw d&emoc ot the edortcele ni order ot take egatnavda of
rehgih gnitlem rates dna wol .noitartenep
.ti ehT eriw feed rotaluger si osla desuoh ni .ti
6.5 Instruments and Ancillary Equipment 9 JOINT PREPARATION
The flow rate of CO2 gas dluohs eb etauqeda ot niatbo 9.1 euD ot deep ,noitartenep laiceps edge -araperp
a naelc .dlew sihT sdneped no lareves factors hcus as noit for niht setalp si ton .deriuqer roF ,elpmaxe
gnidlew ,tnerruc gnidlew speed, edortcele retemaid htiw a 1.6 mm retemaid ,edortcele 12 mm kciht
tnioj yrtemoeg dna lacol .snoitidnoc tI yllareneg seirav setalp nac eb gnidlew htiw erauqs ttub tnioj htiw(
morf 15 ot 22 .nim/sertil a tnioj gap of 3 )mm morf htob sedis at a gnidlew
tnerruc of 330 ot 370 A laixa yarps refsnart -inhcet
65.1 A elbatius gas retem-wolf si detnuom tsuj after
.euq htiW rekciht setalp or renniht sedortcele ti si
the erusserp rotaluger dna gas heater. yllareneG ?;OC
tneiciffus ot evah a steep tnioj-V htiw na dedulcni
gas si nward morf srednilyc dna the heater llahs eb elba
elgna of 30 ot 400.
ot tneverp CO2 eci noitamrof eud ot gas .noisnapxe ehT
wolf retem dluohs evig tcerid etar-wolf sgnidaer for 9.2 nehW noitaraperp of the noisuf faces si yrassecen
CO2 gas ni nim/sertil dna dluohs evah proper evitcetorp siht llahs eb enod yb ,gniraehs ,gnippihc ,gninihcam
gnittuc-sag or yna other dohtem dedivorp the -eriuqer .
gnirevoc tsniaga .egakaerb
stnem of 9.3 are deilpmoc .htiw
63.2 ehT gnilooc ecived for water delooc gnidlew ,nug
stsisnoc of a pmup ,rotomhtiw a water knat dna a heat 9.3 Fusion Faces
.regnahcxe roF gas delooc torches gnidleihs gas flesti
lliw looc the torch. 93.1 Fusion faces llahs eb htooms dna free morf ,gals
,noitanimal sehcton or other seitiralugerri hcihw thgim
6.53 ehT eriw feed tinu gnola htiw the lortnoc tinu dna eb the esuac of defects or dluow affect ylesrevda the
the gnidlew nug are detnuom no a gnillevart egairrac ni ytilauq of dlew dna the .pihsnamkrow
case of citamotua .gnidlew ehT gnillevart speed of
egairrac llahs eb yletinifni elbaluger nihtiw gnidieweht 9.3.2 noisuF faces dna the secafrus tnecajda ot the
tnioj for a ecnatsid of at tsael 50 mm no rehtie edis
speed .egnar
of the tnioj llahs eb free morf yvaeh ,elacs ,erutsiom
7 ELECTRODE EXTENSION ,lio tniap or yna other ecnatsbus hcihw thgim affect
the ytilauq of the dlew or edepmi the progress
7.1 ehT free dne gnidurtorp tuo of tcatnoc elzzon of .gnidlew
seirrac hgih tnerruc seitisned revo( 100 .)2mm/A nA
9.4 lacipyT sliated of tnioj are nevig ni selbaT 1
esaercni ni siht htgnel stluser ni the esaercni of gnitlem
ot 4.
rates. ,revewoH the tnerruc-cra sllaf htiw esaercni ni the
gnidurtorp .htgnel sihT si ylralucitrap elbaeciton nehw
10 WELDING POSITION
gnidlew ni deep sevoorg where a worran tnioj -araperp
noit stimil the access of the ,elzzon evissecxE -durtorp
tI si elbissop ot dlew lla sepyt of stnioj ni lla
gni htgnel ,lliw therefore, dael ot kcal of noitartenep
gnidlew noitisop yb CO2 gas gnidlew process. roF
sselnu laiceps seuqinhcet are desu as ni sag-worran
tluciffid snoitisop ekil lacitrev dna daehrevo -dlew
.gnidlew
,gni sedortcele pu ot 1.2 mm retemaid htiw rewol
7.2 dednemmoceR seulav of edortcele noisnetxe are gnidlew egatlov )V32-91( dna tnerruc )A551-OS(
nevig woleb for suoirav tnerruc :slevel are
used.
Current Electrode Extension
A mm 11 BACKING AND FIT-UP
50 - !151 31-01 fI gnikcab spirts are ton ot eb ,desu ecnarelot no root
gaps dna tnemngila of parts dluohs eb deniatniam
05.? - 3.50 81-31
ylesolc ot lortnoc .noitartenep lacipyT sliated of stnioj
350 - 400 12-81 are nevig ni selbaT 1 ot 4.
3
IS 10178 : 1995
Table 1 Typical Welding Conditions For Butt Joints in the Flat Position (Manual)
( Clauses 9.4, 11,14.1 and 14.2 )
lairetaM Wire Weldiig Arc WiFe Wddklg No. of Joint Rod Root Gap Remarks
Thick- Diameter Current Voltage Feed SF& Passes Pre- Face
ness Rate paration
mm mm/min mm/min 77 mm
(1) :; A x (5) (6) (7> (8) - (10) (11)
1 0.8 60 18 2500 450 1 SCB - - -
1.6 0.8 80 18 3400 600 1 ,SCB - - -
3 0.8 120 20 5500 450 1 SEOB - 0.8 -
1.2 140 20 3000 600 1 SEOB - 0.8 -
6 1.2 150 20 3 250 350 2 ssv-40° - - -
1.2 350 32 12 500 450 1 *SEOB - 0.8 HCT
10 1.2 150 20 3 250 2.50 3 ssv-4o” - 0.8 -
1.6 37@ 32 5000 350 1 *ssv-30° 1.5
20 1.2 350 32 12 500 250 3 DSV-40° 3 - HCT
1.6 430 34 6300 250 3 DSV-40° 3 - HCT
40 1.6 430 34 6300 250-350 I DSV40° 3 - HCT
75 1.6 430 34 6306 250-350 26 DSV-480 3 - HCT
SCB - Square close butt SSV - Single side V ‘Backiog strip
SEOB - Square edge open butt DSV - Double side V HCT - High current technique
NOTE -Refer 6.3 for gas flow rates.
Table 2 Typical Welding Conditions for Butt Joints in the Vertical Position (Manual)
(Ciauses 9.4, 11, 14.1 and 14.3 )

of
Material Wii Welding A S-C Wirr Feed Welding No. Joint Root Root
Ildclawss JXametw current Vo ltage Rate Speed Passes PlTparation Face Gap
G mmlmin mm/mm “I”, “I m
7 ?G A (5) (6) (7) (8) (9) (10)
1 0.8 60 18 2500 450 1D SCB - -
-- -
1.6 0.8 80 18 3400 600 1D SCB
3 0.8 120 20 5500 450 1D SEOB - 1.5
6 1.2 150 20 3 250 2.50 2D SSV-60” - 1.5
10 1.2 150 20 3 250 150 3u SSV-60“ - 1.5
20 1.2 150 20 3 250 150 40 ssv-60” - 1.5
1.6 160 22 1900 150 4u DSV-60“ - 1.5
40 1.2 150 20 3250 120 7u DSV-60” - 1.5
1.6 160 22 1900 120 7u DSV-60’ - 1 s
75 1.6 160 22 1900 80 25U DSV-60’ - 1.5
SCB - Square close butt DSV - Double side V D - Vertical down
SBOB - Square edge opeo butt SSV - Single side V U - Vertical up
NOTE-Refer 6.5 for gas flow rates.
IS 10178 : 1995
elbaT 3 lacipQ‘ gnidleW Conditions for Butt Joints in F’lat Position (Automatic)
9.4,11,14.1 dna 14.4.2 )
(Clauses
lairetaM iiw eiiw of
‘Ihick- Diameter Wcm-rent eldi egatloV Arc deF WSepledeidn g sessaPNo. JPm- oint RFaoocte RGoaopt Remarks
ness etaR lMCitarpp
mm ninhmm nimlmm
(1) (5) (6) Q 18(
- -
1 1 501 02 3 052 0031 1 BCS
2 1 531 02 005.4 008 1 BOES 8.0 -
3 1 561 22 0095 056 1 BOES
6 6.1 053 23 0035 063 1 BCS‘
01 6.1 053 23 0035 002 2 BCS
081 2 ”o3-VSS‘
02 6.1 034 43 a36 051 2 ’03-VSD 6
53 0.2 007 24 0065 001 4 aOS-VSD 6
120
-
50 0.2 057 64 0006 08 6 ’01-USD 01 TCH
051 6-RR
BCS - erauqS esolc ttub VSS - elgniS edis V RR - tooR suidar
BOES - erauqS egde nepo ttub DSV - elbuoD edis V ICH - hgiH tnerruc euqinhcet
DSU - Double edis U * gnikcaB pirts
ETON - refeR 5.6 rof sag wolf .setar

12 TACKING .retemaid nI htob the cases the drop refsnart ycneuqerf
sesaercni htiw the esaercni of gnidlew .tnerruc erehT
kcaT sdlew llahs eb edam as y,ltneuqerf dna as osla stsixe a lacitirc tnerruc evoba hcihw the latem
llams as ,elbissop tey egral hguone ot dnatshtiw the refsnart takes ecalp ni enif drops tuohtiw gnikam short
gnidlew stresses tuohtiw .gnikcarc ehT gnikcat .stiucric sihT lacitirc tnerruc ,eulav of ,esruoc si -pa
euqinhcet dluohs diova a ypmul dloc start. ehT elbaicerp naht~rehgih that ni gnidleW-GIMeht process.
dellifnu craters nac eb dediova yb kcab .gnicart nA esaercni of egatlov sekam the drop refsnart coarser.
gnikcaT si yllareneg enod htiw a short gnitiucric ehT ssol of gniyolla stnemele of edortcele si ssel nehw
arc ecnis lla lanoitisop gnidlew snoitidnoc are gnidlew si enod htiw renniht seriw dna rewol arc -lov
.deriuqer tages that si for enif drop .refsnart sihT si eud ot shorter
noitcaer emit of drop htiw the negyxo ni arc -somta
13 WELDING PROCESS phere. sA hcus rewol arc segatlov of 20 ot 30 V are
.dednemmocer ehT gnidlew tnerruc si detceles so as ot
13.1 nI CO, ,gnidlew latem refsnart ni ,lareneg takes
evig tnerruc seitisned neewteb 100 dna 200 2mm/A of
ecalp rednu short .stiucric tI si ni the mrof of llams
the .edortcele hcuS hgih tnerruc seitisned tluser ni
drops for sedortcele pu ot 1.2 mm retemaid dna ni the
rehgih gnitlem rates.
mrof of coarse drops for sedortcele revo 1.2 mm
IS 10178 : 1995
Table 4 Typical Welding Conditions for Fillet Welds ni talF noitisoP
( Clauses 9.4, 11 dna 14.1 )
teiF eziS Leg
Wire Welding Arc Voltage Wire Feed Welding No. of
Length Diameter Current Rate Speed P2lSSeS
mm/min mmlmin
T TT c$ K (9 (6’ (7)
2 0.8 60 18 3000 420 1
3 0.8 1.55 21 10 ccl0 640 1
1.0 180 24 6 SO0 760 1
1.2 150 21 4000 480 1
6 0.8 115 20 6 500 130 2
1.0 140 22 4800 150 1
1.2 180 24 SO00 2cNl 1
10 0.8 15s 21 10 000 90 2
1.0 230 26 9400 140 2
1.2 210 31 8600 160 1
1.6 350 32 5300 180 1
20 1.2 170 21 4 700 25 4
1.2 300 35 10 m so ~3
1.6 270 26 3600 40 3
1.6 350 32 5300 50 2
25 1.2 170 21 4 700 20 9
1.2 300 35 10 coo 40 6
1.6 270 26 3600 20 8
1.6 250 32 5 300 25 4

NOTE-Refer 6.5 for gas flow rates.
lacipyT gnitlem rates are nevig ni elbaT 5. 13.1.1 gnidnepeD no the lacitirc tnerruc for a ralucitrap
edortcele retemaid two sepyt of seuqinhcet are -nedi
Table 5 Melting Rates
:deifit
( esualC 13.1 )
a) cra-trohS ,euqinhcet dna
)b tnerruc-hgiH .euqinhcet
Electrode ClJnwl~ Melting Rate
Diameter A kPm 13.2 crA-trohS euqinhceT
mm
nI siht ,euqinhcet the latem refsnart nekat ecalp ni a
(1) (2) (3) niatrec cilcyc ,rennam hcihw si decrofnier hguorht a
gnidnopserroc noitacifidom of power .secruos
0.8 50 -180 0.5 - 2.8
13.2.1 yB lanoitnevnoc arc gnidlew process, ti si -fid
1.0 70 - 22s 0.75 - 3.5
tlucif ot dlew sheets of ssenkciht ssel naht 3 .mm
1.2 SO-270 1.0-5.2 esuaceB of regnol gnicra emit neewteb the laudividni
short stiucric gnitaeh( ,)emit rednu lausu arc gnidlew
1.6 160-400 1.7 - 9.2
snoitidnoc the latem at the dne of the elbamusnoc
2.0 220 - 475 2.5 - 10.0 edortcele reaches gniliob .erutarepmet sihT stluser ni
5