18
Packaging type Product consistency and colour White HD-polyethylene plastic White gel
container (approval according to UN- recommendation)
Pickling Gel for Stainless Steel
Identification:
Classifications
Shelf life
Storage
Application data
Chemical composition Vol . %
Packaging data
Protective clothing
13 months when stored in unopened original containers at 0°C.
Container should be stored indoors at 0°C.
They should be kept in an upright position with the lids tightly closed.
The storage area should be clearly defined and beyond the access of unauthorised persons.
Pickling chemicals are sensitive to high temperatures.
Caution: Storage temperatures higher than 45°C must be avoided since they accelerate the ageing process and destroy the product. Pickling chemicals give best result when they are fresh.
Stir the gel to a smooth consistency.
Spread a thick layer on to the work surface using the brush supplied.
Allow the gel to remain for 50-90 minutes.
Rinse off the reminding gel using fresh water.
The waste water, after rinsing, contains acids and heavy metals, and must hence be treated according to local wastewater requirements before discharge.
This can be done with neutralising agent or slaked lime.
The waste water treatment should adjust the pH value of the clear water, pH 6,5-10, and precipitate heavy metals into a sludge which should be sent for waste disposal.
Recommended temperature limits for application: 10°C - 40°C.
NB. Do not pickle in direct sunlight.
Users should wear rubber boots, protective gloves, rubber apron and face visor.
MSDS available on request .
pH: 0 flamable: No
Do not contain chloride containing agents such as hydrochloric acid (HCL)
ASTM A-380 A1 BS CP-312
Hydrofluoric acid Nitric Acid Binder
(Hf) HNO3
0,5–5 8–0 Rest
Container Net Weight Product No . Containers
Content per container per container per carton
litre ,5 kg 095-661778 4 including 4 brushes
3.01
PICKLING GEL
During welding of stainless steel the weld and the adjacent area to the weld will become exposed to the air at elevated temperature. The result will be oxidation ranging from light tinting to a blue and black scale. A corresponding chromium depletion in the metal below the oxide also occurs. If this is not removed, corro-sion will be the result. Unitor Pickling Gel is used to remove this oxides and the underlying chromium depleted layer. It also removes surface micro slag particles and other contaminates which may cause local corrosion.
Pickling restores completely the materials corrosion resistance.
Application
Pickling products are hazardous substanc-es that must be handled with care. The pickling area should be ventilated. Users should wear protective gloves and face visor. Ref.: Material Safety Data Sheet.
1. Pretreat oxides; slag and weld defects mechanically, preferably when the welds are still warm and the weld oxides less hard.
. Give the area to be pickled time to cool down to below 40°C after welding.
3. Organic contaminants such as grease, oil and paint have to be removed.
4. Stir the gel to a smooth consistency and spread a thick layer on to the work piece using the brush supplied.
5. The work piece should be cold when the gel is applied, although the air tem-perature must not be below + 5°C (41°F).
Do not pickle in direct sunlight.
6. The gel should be allowed to remain for at least 50 minutes. For Mo-alloyed steels this time should be extended. If necessary the gel may be allowed to remain on the work piece over night as there is no risk for corrosion.
7. After appropriate time, rinse off the reminding gel using fresh water. If nec-essary brush the weld with a stainless steel wire brush.
8. Pickling residuals and rinse water should be neutralised to pH-7 i.e. with Neutralising Agent, and then rinsed with water. For the deposit of heavy metals, local water pollution control regulations should be consulted
9. The bottles must be stored in an upright position with the lid tightly closed.
Storing temperature 0°C. Storage temperature higher than 45°C must be avoided since this accelerate the age-ing process.
Stir the gel before use
Apply with the brush
Leave the paste to work
3.01
184
NIfE-334 N
Nickel Iron Electrode for Cast Iron
Classifications
Approvals Type of current Welding positions
Materials to be welded
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
AC
DC+/-PA PB PC PF PG PE, PD
For welding and repair DIN 1691 DIN 1692 DIN 1693
G G 10 GTS-35-10 G GG-40
G G 15 GTS-45-06 G GG-50
G G 0 GTS-55-4 G GG-60
G G 5 GTW-35-04
G G 30 GTW-40-05
G G 35 GTW-45-07
GTW-S 38-1
Imprint Unitor NIFE-334 N / NiFe-C1
AWS A5 .15 DIN 8573
E NiFe-C1 E NiFe-1-BG 11
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
3. 350 68 . 096-69951 6
4.0 350 51 .4 096-69950 6
Re-drying temperature: 00 °C (39 °F) for two hours.
Diameter Current Arc time **/ Deposition rate** Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal** Danish Std .
3. 75–100 90 0.9 45
4.0 85–160 70 1.8 30 3
* MSDS available on request.
** 90% of max. amperage
Tensile strength yield strength Elongation Hardness
MPa MPa % HB
375 300 1 180
Ni fe C
47.0 - 56.0 4.0 - 48.0 1.4 - .0
N.A.
3.01
NIfE-334 N
The Unitor NIFE-334 N electrode has been specially developed for cold welding of different types of cast iron especially nodular cast iron, mal-leable cast iron and grey cast iron.
The cold welding process is normally used on large, complicated cast iron parts where the use of heat would involve considerable risk of trans-verse fractures. In the cold welding process, the heat transfer to the base material is kept to a minimum by welding only very short beads (–3 cm) at a time, the bead being peened and allowed to cool before welding the next bead. Smaller parts may be hot welded i.e. preheated to approx.
500°C and continuously welded. The weld metal is easily machineable.
Prepare the damage area in the fol-lowing manner:
– Use crack detector to find the end of the crack fracture.
– Drill a hole at the end of the crack, using a 3 mm drill, to prevent fur-ther fracturing during welding.
The same welding procedure applies as for Nickel-333 N.
When welding oily cast iron, Unitor electrode CH--38 should be used to prepare the grooves. This is a special electrode for gouging without the use of oxygen. As well as forming a suitable welding groove, this process also burns out the oil contained in the carbon flakes, which are present in all types of cast iron. If the oil is not burnt off, it will have a tendency to surface during welding and form pores in the deposit.
After gouging with Unitor CH-2. The oily deposits in the welding area have evaporated.
Large complicated parts should be cold welded.
Smaller parts, free to expand, may be hot welded.
NB: Allow to cool off slowly.
A crack in cast iron. The carbon flakes in the metal are saturated with oil.
3.01
186
NICKEL-333 N
Nickel Electrode for Cast Iron
Identification:
Classifications
Approvals Type of current Welding positions
Materials to be welded
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
AC
DC+/-PA PB PC PF PG PE, PD
For welding and repair DIN 1691 DIN 1692 DIN 1693
G G 10 GTS-35-10 G GG-40
G G 15 GTS-45-06 G GG-50
G G 0 GTS-55-4 G GG-60
G G 5 GTW-35-04
G G 30 GTW-40-05
G G 35 GTW-45-07
GTW-S 38-1
N.A.
Imprint Unitor NICKEL-333 N / Ni-C1
AWS A5 .15 DIN 8573
E Ni-C1 E Ni-BG 11
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
.5 300 11 .0 096-699496 6
3. 350 68 . 096-699504 6
Re-drying temperature: 80 °C (176 °F) for two hours.
Diameter Current Arc time **/ Deposition rate** Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal** Danish Std .
.5 55–110 50 0.8 90
3. 80–140 65 1. 45
* MSDS available on request.
** 90% of max. amperage
Tensile strength yield strength Elongation Hardness
MPa MPa % HB
300 100 1 150
Ni fe C
9.0 - 95.0 3.0 - 5.0 0.8 - 1.6
3.01
NICKEL-333 N
Unitor NICKEL-333 N is a special electrode for cold welding of oily cast iron.
Prepare the damaged area in the fol-lowing manner:
Use a crack detector to determine the actual length of the crack or fracture.
Drill a hole at the end of the crack, using a 3 mm drill, to prevent further fracturing during welding.
AC or DC negative or positive polarity may be used. Use a fairly short arc.
Hold the electrode almost at a right angle to the work and weld in short beads of –3 cm at a time. When a bead is completed, it must be peened to counteract shrinkage. Start from the crater and work backwards to the starting point.
Allow the weld to cool before continu-ing. A general rule is that the welding area should be hand warm before welding the next bead of –3 cm (cold welding).
When repairing a crack which has not split the workpiece into two separate parts, always weld from the outer ends of the crack and inwards.
The thickness of the material is the deciding factor in choosing between 333 N or NIFE-334 N. NICKEL-333 N is for use on thinner materials, or as a first bead on oily cast iron, to be followed by beads welded with NIFE-334 N. NIFE-334 N is used for multibead welding on heavy gauge materials.
Start welding at the end of the crack and work inwards.
Weld in short beads.
Drill a 3 mm hole at the end of the crack.
After welding, the bead’s tendency to shrink can cause cracking. Peening the bead counteracts the shrinkage forces.
2–3 cm
3.01
188
TINBRO-341
Electrode for Copper Alloys
Identification:
Classifications
Approvals Type of current Welding positions
Materials to be welded
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
DC+
PA PB PC PF PE, PD
Copper and copper alloys i .e .:
Brass Bronze Tin-Bronze Leaded Gun-metal Steel Castiron
Seawater resistant deposit N.A.
Imprint Unitor TINBRO-341
AWS A5 .6 DIN 8555
~ E Cu SnC E 30-UM-150-C
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
3. 350 4 1.4 096-606458 6
Re-drying temperature: 00 °C (39 °F) for one hour.
Diameter Current Arc time / Deposition rate Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal Danish Std .
3. 70–90 63 1.33 43 6
* MSDS available on request.
Tensile strength yield strength Elongation Hardness Recovery
MPa MPa % HB %
350–400 0-60 15–5 100–150 103
Cu Sn Mn
Rest 7.5–9.5 1
3.01
TINBRO-341
Unitor TINBRO-341 is a tin-bronze elec-trode for DC welding, positive polarity.
Areas of application include joining of brass and tin-bronze as well as join-ing these to steel and cast iron.
Clean the welding area thoroughly to remove any oily deposits, oxidation, etc. Machine or grind off fatigued material. When making joints, a 3 mm gap should be used. When material thickness is more that 4 mm, make an 80° welding groove with V or x profile.
It is recommended that larger copper alloy parts should be pre-heated to 300–500°C. This will facilitate welding, and welding current can be reduced.
Use a short arc and hold the elec-trode almost at right angles to the work. On parts requiring thin surfac-ing, weave the electrode from side to side, covering an area of up to three times the electrode diameter.
Parts not be overheated, or where minimum fusion with the base mate-rial is required, welding should be carried out at 80–110 Amps.
The electrodes must be stored in a dry place and must be handled care-fully to avoid damage of the coating.
TINBRO-341 is not recommended for welding Yorcalbro (aluminium-brass) or Cunifer (copper-nickel, cupro-nick-el). For welding these materials, the following processes should be used:
yorcalbro
For dimensions up to approx. 4", braze with AG-60 and Albro Flux 63 PF. For larger dimensions, use TIG welding with Ialbro 37 MF.
Cunifer
Small parts should be brazed with AG-60 and AG-AG-60/45 Flux-5 PF. Larger dimensions should be TIG welded with Icuni 30 39.
3.01
190
ALBRONZE-344
Electrode for Copper Alloys
Identification:
Classifications
Approvals
Type of current Welding positions
Materials to be welded
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
AC DC+
PA PB PC PF PE, PD
Copper and copper alloys i .e .:
Bronze Aluminium bronze Steel Cast iron
Seawater resistant deposit N.A.
Imprint Unitor ALBRONZE-344
AWS A5 .6 DIN 8555
~ E Cu Al A E 31-UM-150-C
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
3. 350 46 1.3 096-606457 6
Re-drying temperature: 50 °C (48 °F) for one hour.
Diameter Current Arc time / Deposition rate Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal Danish Std .
3. 80–160 81 0.9 48 6
* MSDS available on request.
Tensile strength yield strength Elongation Hardness Recovery
MPa MPa % HB %
550 350 10 140–170 103
Cu Al Mn fe
Rest 7 1. .8
3.01
ALBRONZE-344
Unitor ALBRONZE-344 is a bronze electrode made specially for joining and cladding of bronze alloys as well as for joining these metals to steel and cast iron. It is also used for weld-ing glidweld-ing surface overlays on steel.
The welded deposit has high strength properties and good resistance against cavitational wear and corro-sion in seawater. The deposit has low coefficient of friction and excellent weldability.
Applications include ships’ propel-lers, pumps, pump parts, bearing shells, condensers, valves and turbine blades.
Clean the welding area thoroughly and remove all oxidation. Machine or grind off fatigued metal. Make a suitable welding groove using a 60–90° angle.
The groove can be formed by grinding.
Pre-heating is normally not required but it may be necessary to pre-heat large workpieces up to 150°C. The temperature must not exceed 00°C during welding. When surfacing steel parts, AC or DC positive polarity may be used. The pre-heating requirement will depend on the size and type of the base material.
Use a short arc. Hold the electrode almost at right angles to the work-piece and use a weaving movement.
The length of each stroke should not exceed three times the electrode dia-meter. Remove the slag from the bead with chipping hammer and wire brush before starting on the next bead. Cast cupro-aluminium parts and similar materials must be annealed after welding by heating the welding area to 650°C. The workpiece must then be allowed to cool down slowly to below 500°C to ensure that the metal does not lose any of its properties.
Unitor ALBRONZE-344 is not recom-mended for welding Yorcalbro and Cunifer pipes.
3.01
19
ALUMIN-351 N
Electrode for Aluminium
Identification:
Classifications
Approvals
Type of current Welding positions
Materials to be welded
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
DC+
PA PB PC PF
For welding forged and cast aluminium alloy containing more than 7% Si as main alloying element.
G-Al Si 5 Mg (3.341) G-Al Si 10 Mg (3.381) G-Al Si 10 Mg (Cu) (3.381) G-Al Si 1 (3.581) G-Al Si 1 (Cu) (3.583) G-Al Si 11
G-Al Si 9 Mg G-Al Si 9 Cu 3 G-Al Si 7 Mg G-Al Si 6 Cu 4
Also applicable as surfacing electrode.
N.A.
Imprint Unitor ALUMIN-351 N
DIN 1732 EL-AlSi1
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
3. 350 71 1.0 096-699538* 6
* This box is placed inside a vacuum metal pouch.
Re-drying temperature: In vacuum packing and therefore no need for re-drying.
Opened packages: 80 °C for 1 hour.
Diameter Current Arc time **/ Deposition rate** Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal** Danish Std .
3. 70–110 3 0.7 164 3
* MSDS available on request.
** 90% of max. amperage
Tensile strength yield strength Elongation Impact value
MPa MPa % ISO-V (J)
160 13
Al Si fe
86.0 - 89.0 11.0 - 13.5 max. 0.50
3.01
ALUMIN-351 N
Unitor ALUMIN-351 N is used for join-ing and buildjoin-ing up aluminium parts with a thickness of more than mm sheets, sections, tubes, pistons, cast-ings (covers), gangways, etc. When welding materials more than 3 mm thick, a 60° V-groove and an air gap of 1–3 mm should be used.
Grooves and the surrounding area must be thoroughly cleaned. Thin parts should be backed up before welding.
Use DC, positive polarity setting.
Large parts or castings should be pre-heated to approx. 300°C. Hold the electrode almost vertically the work-piece, the tip at a slight angle to the weld direction. It is preferable to weld in the flat position. Use as short arc as possible and weld rapidly. If welding is interrupted, remove the slag and overlap the end of the bead by about 1 cm when re-striking.
All slag must be cleaned off the fin-ished weld with brush and water.
Aluminium electrodes absorb moisture very easily and must be stored in a dry, preferably moisture-controlled, place.
When first received the electrode box is placed inside a vacuum metal pouch.
Aluminium or magnesium?
It may be difficult to determine wheth-er a part is aluminium or magnesium.
Magnesium parts must not be welded (magnesium bomb!). Use the following test to determine whether a part is aluminium or magnesium:
File a few shavings onto a small piece of paper. Hold the paper over a flame.
If the fillings spark or seem to explode in the flame, the material is magne-sium. If there are only a few sparks here and there, and most of the fillings just glow, the material is aluminium alloyed with magnesium, and may be
Cover plate ears welded back on
Hold the electrode almost at right angles to the workpiece, or at a slight angle to the weld direction
Note: Use the shortest possible arc .
Joining a cast aluminium cover. Such parts should be pre-heated to approx. 300°C if possible
NB. When welding with Aluminium electrodes: Arrange suitable ventilation or use Fresh Air kit mounted in face shield.
3.01
194
CH-2-382
Electrode for Chamfering
Identification:
Classifications
Approvals Type of current Welding positions
Materials to be chamfered
All weld metal composition
Typical mech . properties of weld metal
Packaging data Welding data
Steel/Cast steel
Stainless steel/Cast stainless steel Cast iron
Copper/Copper alloys Aluminium/Aluminium alloys N.A.
AC
DC+/-PA PB PC PG PE, PD
N.A.
N.A.
Imprint Unitor CH--38
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
3. 350 36 1.4 096-606459 6
Re-drying temperature: 10 °C (48 °F) for one hour.
Diameter Current Arc time / Deposition rate Electrodes per fume class*
mm . range, A electrode, sec . Kg/h kg weld metal Danish Std .
3. 160–80 57 – – 7
* MSDS available on request.
N.A.
3.01
CH-2-382
Gouging Technique
1 . Hold the electrode vertically and press lightly against the workpiece.
The arc will strike after a few seconds.
2 . Hold the electrode at an angle of 15–0° to the workpiece.
3 . Direction of travel.
4 . Warning!
Do not cut down into the work-piece. Should this happen inadver-tently, move the electrode back and lower to correct angle.
5 . Work downwards when cutting into a vertical surface, otherwise as shown in figures 1–3.
6 . If a deeper groove is required, pro-ceed as in this sketch.
4 2
3
5
6 1
3.01
196
ACA-384
Electrode for Air Carbon Arc Gouging
Identification:
Classifications
Approvals Type of current Welding positions
Materials to be gouged
All weld metal composition
Metal removal capasity
Packaging data Welding data
Gouging and cutting of all electrically conductive materials.
Can be used to groove, gouge, cut, bevel or pierce any material.
N.A.
DC+
PA PB PC PG PE, PD
N.A.
N.A.
Copper coating over black carbon
Diameter Length Electrodes Net weight Product No . Boxes
mm . mm . per box per box per box per carton
6.3 305 90 1.7 096-699546 3
8.0 305 50 1.5 096-699553 3
15 x 5 305 5 1.4 096-699561 3
Re-drying temperature: 180 °C (356 °F) for 10 hours.
Note: The copper coating will oxidize during the process, but this will not influence the performance of the product.
Diameter Current Air pressure (bar) fume class*
mm . range, Amps . (Consumption 400–900 l/min) Danish Std .
6.3 00–350 At electrode holder 6–9 (80 psi) 7
8.0 00–450 At electrode holder 6–9 (80 psi) 7
15 x 5 400–600 At electrode holder 6–9 (80 psi) 7
* MSDS available on request.
Diameter Approx . kg/electrode*
mm .
6.3 0.45
8.0 0.68
3.01
ACA-384
Unitor ACA-384 is a DC electrode for
Unitor ACA-384 is a DC electrode for