Lincoln Electric INNERSHIELD Series Welding Instruction Manual
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Lincoln Electric INNERSHIELD Series Welding Instruction Manual

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INNERSHIELD
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ELECTRODES
Welding Guide

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Summary of Contents for Lincoln Electric INNERSHIELD Series

  • Page 1 INNERSHIELD ® ELECTRODES Welding Guide...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFETY PRECAUTIONS ......3-11 INTRODUCTION ........... PRODUCT ADVANTAGES....... 13-15 RECOMMENDED EQUIPMENT .......15 WELDING PREPARATIONS ......16-17 Choose the Proper Innershield Gun ......16 Prepare the Work............17 Optimizing Feeding............17 WELDING TECHNIQUES ......18-24 Set the CTWD..............18 Set the Wire Feed Speed (WFS) .........19 Start the Arc..............19 Set the Voltage ............19 Travel Speed ...............19...

  • Page 3: Safety Precautions

    Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 4 FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 1.c. Do not add the fuel near an open flame welding arc or when the engine is running.
  • Page 5 ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
  • Page 6 ELECTRIC SHOCK can kill. (Cont’d) kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: • Semiautomatic DC Constant Voltage (Wire) Welder. • DC Manual (Stick) Welder. •...
  • Page 7 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
  • Page 8 WELDING SPARKS can cause fire or explosion. (Cont’d) 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.
  • Page 9 CYLINDER may explode if damaged. (Cont’d) 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f.
  • Page 10 b. Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c.
  • Page 11 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie. 8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de...

  • Page 12: Introduction

    This allows for excellent feedability. Lincoln Electric also fills the wire in a proprietary manner. This step ensures that you get the right amount of fill in every inch of wire. Lincoln Electric is the worldwide leader in Innershield. You can see that when you use our products, meet with our sales reps, or call the factory for support.

  • Page 13: Product Advantages

    PRODUCT ADVANTAGES INNERSHIELD FEATURES • Can be used in wind speeds of up to 30 mph without losing mechanical properties. • Gas bottles are unnecessary. • Stiff wire with high column strength. BENEFITS OVER GAS-SHIELDED PROCESSES • Innershield does not require gas shielding. •...
  • Page 14 PRODUCT LIMITATIONS SEISMIC APPLICATIONS: Constant voltage (CV) power sources are recommended for use with all Innershield electrodes. NR-211-MP THICKNESS RESTRICTIONS: Wire Diameter Max. Plate Thickness .035”, .045” (0.9, 1.2mm) 5/16” (7.9mm) .068”, 5/64”, 3/32” 1/2” (12.7mm) (1.7, 2.0, 2.4mm) NR-212 is designed to be used on plate up to 3/4” (19.1mm) thick.

  • Page 15: Recommended Equipment

    PRODUCT LIMITATIONS INTERMIXING When Innershield (FCAW-S) weld deposits are intermixed with weld deposits from other welding processes, a decrease in weld metal Charpy V-notch (CVN) toughness properties may occur. For applications requiring CVN properties, intermix testing with the specific electrodes is recommended to ensure the intermixed weld metal meets the required CVN requirements.

  • Page 16: Welding Preparations

    INNERSHIELD GUNS CHOOSE THE PROPER INNERSHIELD GUN Lincoln Innershield Guns Rated Amperage, Duty Cycle and Wire Sizes Innershield Guns Fume Extraction Guns K115-1, -2, -3, -4, -5 Guns with K206 Gun 350 Amps at 60% 82° Nozzle 450 Amps at Duty Cycle 60% Duty Cycle Wire Size: .062–3/32"(1.6-2.4mm)

  • Page 17: Prepare The Work

    WELDING PREPARATIONS PREPARE THE WORK Clean the joint by removing excessive scale, rust, moisture, paint, oil and grease from the surface. As with all welding applications, joint cleanliness is necessary to avoid porosity and to attain the travel speeds indicated in the procedures. Tack weld with Innershield wire or Fleetweld®...

  • Page 18: Welding Techniques

    WELDING TECHNIQUES SET THE CONTACT TIP TO WORK DISTANCE (CTWD) WARNING: When inching, the wire is always electrically “hot” to ground, except on wire feeders with a “cold inch” feature. CTWD is measured from the end of the contact tip to the work. Maintain this length within ±1/8”...

  • Page 19: Set The Wire Feed Speed (Wfs)

    WELDING TECHNIQUES SET THE WIRE FEED SPEED Adjust the wire feed speed using the WFS control on the wire feeder. Set to the suggested procedures. See pages 30-39. The approximate amperage corresponding to each WFS at the specified CTWD is also listed in the table. Amperage depends on wire feed speed and CTWD.

  • Page 20: Loading 13-14 Lb. Coils On A 2" Spindle

    WELDING TECHNIQUES LOADING 13-14 LB. (5.9-6.5 kg) COILS ON A 2” (50mm) SPINDLE 1. Remove the locking collar and the cover plate from K435 spindle adapter. 3. Unpack the 14 lb. (6.4kg) coil of wire. Be sure not to bend the side tabs of the coil liner.

  • Page 21: Handling Poor Fitup

    WELDING TECHNIQUES HANDLING POOR FITUP Innershield bridges gaps better than most welding processes. When using NS-3M at 3” (76mm) CTWD, temporarily increasing the visible CTWD to as much as 3-1/4” (83mm) helps reduce penetration and burnthrough to bridge gaps. Poor fitup may require a small, temporary increase in visible CTWD or a reduction in WFS setting.

  • Page 22: Making Vertical Up Welds

    WELDING TECHNIQUES MAKING VERTICAL UP WELDS Use 5/64” (2.0mm) size and less. NR-202 NR-203M NR-203MP NR-203 Nickel (1%) NR-211-MP NR-212 NR-232 NR-233 Smaller sizes, 5/64" and less are recommended for all position welding. When welding out-of-position, don’t whip, break the arc, move out of the puddle or move too fast in any direction.

  • Page 23: Making Downhill And Vertical Down Welds

    WELDING TECHNIQUES Vertical Up Fillet and Lap Welds 1. Make larger welds with the following techniques: a. On 1/4” (6mm) welds, a short side-to-side motion is usually sufficient. b. On larger welds, use a triangular weave (see number 1 in the sketch below) with a distinct hesitation at the outer edges for the first pass.

  • Page 24: Working With Ns-3M

    WELDING TECHNIQUES WORKING WITH NS-3M To calculate electrical stickout, subtract 1/4” from CTWD. .120" (3.0mm) NS-3M When using the long CTWD of 3” to 4” (75 to 100mm), the long length of wire beyond the contact tip has greater electrical resistance.

  • Page 25: Operating Guide

    OPERATING GUIDE Well made Innershield welds have excellent appearance. TROUBLESHOOTING To Eliminate Porosity (In order of importance) 1. Clean the joint from moisture, rust, oil, paint and other contaminants 2. Decrease voltage 3. Increase CTWD 4. Increase WFS 5. Decrease drag angle 6.

  • Page 26: Effect Of Operating Variables

    OPERATING GUIDE To Minimize Arc Blow (In order of importance) Arc blow occurs when thr arc stream does not folow the shortest path between the electrode and the workpiece. Move work connection locations Decrease drag angle Increase CTWD Decrease WFS and voltage Decrease travel speed To Eliminate Stubbing (In order of importance) Stubbing occurs when the wire drives through the molten...

  • Page 27: Welder Qualification Test

    OPERATING GUIDE 3. Increasing WFS also increases the maximum voltage which can be used without porosity. Lowering the WFS requires lowering the voltage to avoid porosity. As the WFS is increased, the arc voltage must also be increased to maintain proper bead shape. Travel Speed If arc voltage, WFS and CTWD are held constant, travel speed variations have the following major effects:...

  • Page 28: Storing Innershield Electrode

    STORING INNERSHIELD ELECTRODES In general, Innershield electrodes will produce weld deposits which achieve diffusible hydrogen levels below 16 ml per 100 grams deposited metal. These products, like other products which produce deposits low in diffusible hydrogen, must be protected from exposure to the atmosphere in order to;...
  • Page 29 STORING INNERSHIELD ELECTRODES Innershield Products Used for Applications Requiring More Restrictive Hydrogen Control (-H Electrodes) The AWS specifications for flux-cored electrodes, AWS A5.20 and A5.29, state that “Flux-cored arc welding is generally considered to be a low hydrogen welding process”. Further, these specifications make available optional supplemental designators for maximum diffusible hydrogen levels of 4, 8 and 16 ml per 100 grams of deposited weld metal.
  • Page 30 NR-211-MP WELDING PROCEDURES HORIZONTAL, FLAT, DOWNHILL AND VERTICAL DOWN Plate Size – T (in) 1 4 GA 10 GA Pass Electrode 5/64” NR-211-MP MP DC( – ) .068" NR-232 DC( – ) Polarity CTWD 1” 1” Wire Feed Speed (in/min) Arc Volts Travel Speed (in/min) As Req’d...

  • Page 31: Welding Procedures

    NR-232 .068” WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS – OPEN ROOT Plate Size – T (in) 3/4 and up Pass 2 & up Electrode .068" NR-232 DC( – ) Polarity CTWD 1– 1-1/2 " 3/4 – 1" Drag Angle 5 –...
  • Page 32 NR-232 .068” WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size – T (in) 5/16 3/8 & Up Leg Size – L (in) 5/16 over 5/16 Pass As req’d Electrode .068" NR-232 DC( – ) Polarity CTWD 3/4 – 1" Drag Angle 0 –...
  • Page 33 NR-232 .068” WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size – T (in) 3/4 & up Pass 2 & up Cap Passes (Horizontal) Electrode .068" NR-232 DC( – ) Polarity CTWD 1 – 1-1/2" 3/4 – 1-1/4" Drag Angle 5 –...
  • Page 34 NR-232 .072” WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size – T (in) 5/16 3/8, 1/2 & up Leg Size – L (in) 3/8 & up 5/1 6 Pass As req’d Electrode .072" NR-232 DC( – ) Polarity CTWD 3/4 – 1" 3/4 –...
  • Page 35 NR-232 .072” WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS – STEEL BACKUP Plate Size – T (in) 3/8 & up Pass 2 & up Electrode .072" NR-232 DC( – ) Polarity CTWD 3/4" 3/4” 3/4” Drag Angle 0° 5 – 20° 5 –...
  • Page 36 NR-232 .072” WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size – T (in) 3/4 & up Pass 2-cap Cap Passes (Horizontal) Electrode .072" NR-232 DC( – ) Polarity CTWD 1-1/4 – 1-1/2” 3/4 – 1-1/4” 3/4 – 1-1/4” Drag Angle 5 –...
  • Page 37 NR-232 5/64” WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size – T (in) 5/16 Over 1/2 Leg Size – L (in) 5/16 Over 3/8 Pass As req’d Electrode 5/64" NR-232 DC( – ) Polarity CTWD 3/4" 3/4" 7/8" 7/8" Drag Angle 0°...
  • Page 38 NR-232 5/64” WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size – T (in) 3/8 & up Pass 2 & up Electrode 5/64" NR-232 DC( – ) Polarity CTWD 1-1/4 – 1-1/2” 1” Drag Angle 5 – 30° 5 – 30° Wire Feed Speed 65 –...
  • Page 39 NR-232 5/64” WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS – STEEL BACKUP Plate Size – T (in) 3/8 & up Pass 2 & up Electrode 5/64" NR-232 DC( – ) Polarity CTWD 1" 1" Drag Angle 0 – 30° 0 –...
  • Page 40 OPERATING PARAMETERS Wire Polarity, AWS Class. Wire Feed Approx. Deposit CTWD In (mm) Speed Voltage Current Rate Wire Weight in/min (m/min) (volts) (amps) lbs/hr (kg/hr) .120" NR-1 or NR-5 (3.6) 18.4 (8.3) (DC+) E70T-3 (4.1) 22.0 (10.0) 1-3/8" (35) (6.1) 33.0 (15.0) 2.63 lbs/1000”...
  • Page 41 OPERATING PARAMETERS Wire Polarity, AWS Class. Wire Feed Approx. Deposit CTWD In (mm) Speed Voltage Current Rate Wire Weight in/min (m/min) (volts) (amps) lbs/hr (kg/hr) 5/64” NR-202 (1.3) (0.9) (DC-) E71T-7 (2.5) (2.3) 1-1/4” (32) (3.8 (3.8) 1.09 lbs/1000” (5.1) 11.4 (5.2) (5.8)

  • Page 42: Operating Procedures

    OPERATING PARAMETERS Wire Polarity, AWS Class. Wire Feed Approx. Deposit CTWD In (mm) Speed Voltage Current Rate Wire Weight in/min (m/min) (volts) (amps) lbs/hr (kg/hr) 5/64" NR-207 & NR-207-H 70 (1.8) (1.5) (DC-) E71T8-K6 (2.3) (2.0) 1-1/8" (29) (2.8) (2.5) 1.04 lbs/1000"...
  • Page 43 OPERATING PARAMETERS Wire Polarity, AWS Class. Wire Feed Approx. Deposit CTWD In (mm) Speed Voltage Current Rate Wire Weight in/min (m/min) (volts) (amps) lbs/hr (kg/hr) .068” NR-232 (2.7) (1.8) (DC-) E71T-8 (3.8) (2.4) 1" (25) (5.0) 23.5 (3.2) .75 lbs/1000” (7.4) 11.4 (5.2)
  • Page 44 OPERATING PARAMETERS Wire Polarity, AWS Class. Wire Feed Approx. Deposit CTWD In (mm) Speed Voltage Current Rate Wire Weight in/min (m/min) (volts) (amps) lbs/hr (kg/hr) 7/64” NR-311 (2.5) 10.0 (4.5) (DC-) E70T-7 (3.7) 14.5 (6.6) 1-3/4" (44) (6.1) 25.5 (11.6) 2.05 lbs/1000”...

  • Page 45: Operating Procedures

    OPERATING PROCEDURES The suggested operating parameters listed in this publication are not intended to serve as specific procedures for any application. These suggested procedures represent the approximates the procedure range of each individual electrode. Arc voltage and/or wire feed speed may need to be adjusted depending upon welding position, type of weld, base steel surface condition or other factors.

  • Page 46: Innershield Gun Parts

    INNERSHIELD GUN PARTS Full Size Drawings* of Parts for K126 and K206 Guns Insulated Insulated Guide for Guide for K126 K126 KP1995-1 KP2090-1 for 2” (51 mm) for 2 3/4” CTWD. (70 mm) Length: CTWD. 1 7/8” (48 mm) Length: 2 3/4”...

  • Page 47: Innershield Gun Parts

    INNERSHIELD GUN PARTS Full Size Drawings* of Parts for K115, K116 and K289 Guns Insulated Guide for K115 & K116 Insulated KP1971-1 Guide for K115 for 1 1/2” (38 mm) & K116 3/32 & CTWD. 120 NS-3M KP1965-1 for 2 3/4” (70 mm) CTWD.

  • Page 48: Lincoln Welding School

    LINCOLN WELDING SCHOOL NEED WELDING TRAINING? The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland, Ohio. Over 100,000 men and women have graduated from this premier school.
  • Page 49 Low Hydrogen Pipe Module: GMAW/FCAW/SMAW 1 Week GTAW/SMAW 1 Week Qualification Test Training: AWS Test Semi-Automatic Flux Cored Arc Welding Self Shielded (FCAW) 1 Week 3/8” AWS Fillet Test: Shielded Metal Arc Welding (SMAW — Stick) 1 Week AWS Test Shielded Metal Arc Welding (SMAW - Stick) 1 Week ASME Test...
  • Page 50 NOTES – 50 –...
  • Page 51 NOTES – 51 –...
  • Page 52 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

This manual is also suitable for:

Innershield nr-203mInnershield nr-203 nickelInnershield nr-211-mpInnershield nr-203mpInnershield nr-212Innershield nr-232 ... Show all

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