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voestalpine Böhler Welding offers welding consumables and equipment for the manual, semi-mechanized welding of pipelines.

A broad range of products are available depending on the welding processes you want to use:

  • A wide range of coated electrodes includes types for high-efficiency vertical welding with a cellulosic coating and low-hydrogen basic types that can be used both vertical down and vertical up.
  • A wide range of products for semi and fully mechanized welding includes solid wires and rods, self-shielded and gas-shielded flux cored wires and submerged arc wire/flux combinations for double jointing.

The range covers standard applications:

  • Carbon steel pipeline with high strength steel grades up to API X60/EN L415MB, high tensile grades up to API X100/ENL690MB,

Corrosion Resistance Alloy pipeline (CRA) from standard stainless-steel grades, duplex and super duplex stainless steel, nickel alloy 625 and clad pipes in alloys 316L, 625 and 825.

Welding with Cellulosic Covered Electrodes

To prevent hydrogen induced cracking, it is necessary to preheat pipes before starting to weld and to maintain an interpass temperature during the welding of individual beads.

In view of the often difficult site conditions, preheating at 150°C (300°F) is generally recommended. This applies to all wall thicknesses up to 25 mm (1”) and weld metals up to class E9010 (FOX CEL 90). Lower preheat and interpass temperatures may be selected when welding thin-walled pipes.

The diagram below shows minimum required preheat temperatures, as a function of wall thickness and electrode type. This refers to both the preheating and interpass temperatures.

Cellulosic electrodes are mainly operated on direct polarity. The welding equipment must have a dropping characteristic and a high open circuit voltage. Terra MP 350 RC is the ideal choice for this application. Recommended joint preparations are listed here below.

The root pass is a critical part of any pipe weld that requires perfect penetration. Electrode diameter, travel speed and amperage must be selected to match the pipe diameter and wall thickness. 3.2 mm (1/8“) diameter electrodes are recommended for pipe diameters up to about 250 mm (10“) and wall thicknesses up to 8 mm (5/16“).  Choose 4 mm (5/32“) diameter electrodes for larger sizes.

Welding is performed in vertical-down direction, with the electrode in good contact with both beveled plate edges.

Line-up clamps should be removed only after completing the root pass around the entire circumference and, when welding larger diameter pipes, only after completing the hot pass has been completed.

The hot pass should be welded immediately after application of the root pass, but never later than 10 minutes. This is particularly important for high-strength line pipe grades to prevent underbead cracking in the base material.

To avoid slag inclusions, the root pass must be ground before the hot pass is started. The use of a relatively high welding current is advantageous because this achieves good penetration so that any remaining slag inclusions are re-melted and at the same time ensures that the root pass is thoroughly annealed.

Filler layers beads are sufficiently flat and free from undercut and slag inclusions when the electrode is applied with a slight circular or stepping motion, especially in positions 12 to 2 o‘clock, 12 to 10 o‘clock, 4 to 6 o‘clock and 8 to 6 o’clock. Weaving of max. 2xØ is recommended for all other positions.

The cover pass is executed with a slight weaving of the electrode. The weld should not overlap the groove edge by more than 1.5 mm (1/16“). If the cover pass is executed correctly, weld reinforcement is about 1 to 2 mm (1/16“).

Welding with Basic Covered Electrodes with Vertical Down Technique

In combination with basic vertical-down electrodes (BVD), root passes can be welded with either cellulosic or basic vertical-up electrodes. If root passes are welded with cellulosic electrodes in the vertical-down progression, hot passes shall preferably be welded with cellulosic electrodes as well.

The interpass temperature influences the metallurgical processes that take place in the deposit during solidification and cooling and thus to a certain extent also influences the mechanical properties of the basic vertical down weld metal. It is generally recommended to keep the interpass temperature in the range of 100°C-200°C (210°F-392°F) during the entire welding process.

Basic vertical-down electrodes can only be operated with direct current. Welding machines must have a dropping characteristic and a high open-circuit voltage. The Terra MP 350 RC is the ideal choice for this application. Filler passes are executed with electrodes of 3.2 mm, 4.0 mm and 4.5 mm diameter, depending on the pipe thickness. The high current ensures sufficient penetration and satisfactory economy of the process. Slight weaving is always recommended, as this prevents short-circuiting the arc.

When welding thick-walled pipe, it is recommended to apply two to three beads side by side, remove all the slag before applying the next bead and keep the arc as short as possible. The cap is deposited with a slight weaving technique, with a maximum weave of twice the electrode diameter.

Product Overview

Welding Consumables for Pipeline

Product Name Industry Application Base Material / Consumable Alloy type AWS EN/ISO Welding Process
BÖHLER FOX BVD 85 Basic vertical-down welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.5 / SFA-5.5, E8045-P2 H4 R / E8018-G H4 R 2560-A, E 46 5 1Ni B 4 5 H5 SMAW
BÖHLER FOX BVD 90 Basic vertical-down welding L485/X70, L555/X80 A5.5 / SFA-5.5, E9018-G H4 R / E9045-P2 H4 R (mod.) 18275-A, E 55 5 Z2Ni B 4 5 H5 SMAW
BÖHLER FOX BVD 100 Basic vertical-down welding L555/X80, L625/X90 A5.5 / SFA-5.5, E10018-G E10045-P2 (mod.) 18275-A, E 62 5 Z2Ni B 4 5 SMAW
BÖHLER FOX EV PIPE Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E7016-1 2560-A, E 42 4 B 1 2 SMAW
BÖHLER FOX EV 50-W Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E7016-1H4R 2560-A, E 42 5 B 1 2 H5 SMAW
BÖHLER FOX BVD 85 Basic vertical-down welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.5 / SFA-5.5, E8045-P2 H4 R / E8018-G H4 R 2560-A, E 46 5 1Ni B 4 5 H5 SMAW
BÖHLER FOX BVD 90 Basic vertical-down welding L485/X70, L555/X80 A5.5 / SFA-5.5, E9018-G H4 R / E9045-P2 H4 R (mod.) 18275-A, E 55 5 Z2Ni B 4 5 H5 SMAW
BÖHLER FOX BVD 100 Basic vertical-down welding L555/X80, L625/X90 A5.5 / SFA-5.5, E10018-G E10045-P2 (mod.) 18275-A, E 62 5 Z2Ni B 4 5 SMAW
BÖHLER FOX EV PIPE Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E7016-1 2560-A, E 42 4 B 1 2 SMAW
BÖHLER FOX EV 50-W Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E7016-1H4R 2560-A, E 42 5 B 1 2 H5 SMAW
BÖHLER FOX EV 50 Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60 A5.1 / SFA-5.1, E7018-1H4R 2560-A, E 42 5 B 4 2 H5 SMAW
BÖHLER FOX EV 50 PIPE Basic vertical-up welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60 A5.1 / SFA-5.1, E7016 2560-A, E 42 3 B 3 2 SMAW
BÖHLER FOX EV 60 Basic vertical-up welding L360/X52, L390/X56, L415/X60, L450/X65 A5.5 / SFA-5.5, E8018-C3H4R 2560-A, E 46 6 1Ni B 4 2 H5 SMAW
BÖHLER FOX EV 60 PIPE Basic vertical-up welding L415/X60, L450/X65 A5.5 / SFA-5.5, E8016-GH4R 2560-A, E 50 4 1Ni B 1 2 H5 SMAW
BÖHLER FOX EV 65 Basic vertical-up welding L415/X60, L450/X65, L485/X70 A5.5 / SFA-5.5, E8018-GH4R 18275-A, E 50 6 1NiMo B 4 2 H5 SMAW
BÖHLER FOX EV 70 PIPE Basic vertical-up welding L485/X70, L555/X80 A5.5 / SFA-5.5, E9016-GH4R 18275-A, E 55 4 ZMn2NiMo B 1 2 H5 SMAW
BÖHLER FOX EV 70 Basic vertical-up welding L485/X70 A5.5 / SFA-5.5, E9018-GH4R 18275-A, E 55 6 1NiMo B 4 2 H5 SMAW
BÖHLER FOX EV 75 Basic vertical-up welding L555/X80 A5.5 / SFA-5.5, E10018-GH4R 18275-A, E 62 6 MnNiCrMo B 4 2 H5 SMAW
BÖHLER FOX EV 85 Basic vertical-up welding L625/X90, L690/X100, L830/X120 A5.5 / SFA-5.5, E11018-GH4R 18275-A, E 69 6 Mn2NiCrMo B 4 2 H5 SMAW
BÖHLER FOX CEL Cellulosic welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E6010 2560-A, E 38 3 C 2 1 SMAW
BÖHLER FOX CEL + Cellulosic welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.1 / SFA-5.1, E6010 2560-A, E 38 2 C 2 1 SMAW
BÖHLER FOX CEL Mo Cellulosic welding L390/X56, L415/X60 A5.5 / SFA-5.5, E7010-A1 2560-A, E 42 3 Mo C 2 5 SMAW
BÖHLER FOX CEL 70-P Cellulosic welding L390/X56, L415/X60 A5.5 / SFA-5.5, E7010-P1 2560-A, E 42 3 C 2 5 SMAW
BÖHLER FOX CEL 75 Cellulosic welding L390/X56, L415/X60 A5.5 / SFA-5.5, E7010-P1 2560-A, E 42 3 C 2 5 SMAW
BÖHLER FOX CEL 80-P Cellulosic welding L415/X60, L450/X65, L485/X70 A5.5 / SFA-5.5, E8010-P1 2560-A, E 46 3 1Ni C 2 5 SMAW
BÖHLER FOX CEL 85 Cellulosic welding L415/X60, L450/X65, L485/X70 A5.5 / SFA-5.5, E8010-P1 2560-A, E 46 4 1Ni C 2 5 SMAW
BÖHLER FOX CEL 90 Cellulosic welding L485/X70 A5.5 / SFA-5.5, E9010-P1 2560-A, E 50 3 1Ni C 2 5 SMAW
Pipeshield X60 Solid wire welding L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.18 / SFA-5.18, ER70S-6 14341-A, G 42 4 M21 3Si1 / G 42 2 C1 3Si1 GMAW
Pipeshield X65 Solid wire welding L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.18 / SFA5.18, ER70S-G 14341-A, G 46 5 M21 Z3Si1 / G 42 4 C1 Z3Si1 GMAW
Pipeshield X70 Solid wire welding L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70 A5.18 / SFA5.18, ER70S-6 14341-A, G 46 4 M21 4Si1 / G 46 2 C1 4Si1 GMAW
Pipeshield X80 Solid wire welding L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65, L485/X70, L555/X80 A5.28 / SFA-5.28, ER80S-G [ER80S-Ni1(mod.)] 14341-A, G 50 6 M21 Z3Ni1 / G 46 4 C1 Z3Ni1 GMAW
Pipeshield X90 Solid wire welding L415/X60, L450/X65, L485/X70, L555/X80 A5.28 / SFA5.28, ER90S-G 16834-A, G 55 6 M21 Mn3Ni1Mo / G 55 4 C1 Mn3Ni1Mo GMAW
Thermanit GE-316L Si Solid wire welding Alloy type 316L A5.9 / SFA-5.9, ER316LSi 14343-A, G 19 12 3 L Si GMAW
Thermanit 22/09 Solid wire welding Duplex stainless steel A5.9 / SFA-5.9, ER2209 14343-A, G 22 9 3 N L GMAW
Thermanit 25/09 CuT Solid wire welding Super duplex stainless steel A5.9 / SFA-5.9, ER2594 14343-A, G 25 9 4 N L GMAW
Pipeshield X625 Solid wire welding Alloy type 625 A5.14 / SFA-5.14, ERNiCrMo-3 18274, S Ni 6625 (NiCr22Mo9Nb) GMAW
BÖHLER ER 70 S-2 Manual TIG welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60 A5.18 / SFA5.18, ER70S-2 GTAW
BÖHLER EMK 6 Manual TIG welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60 A5.18 / SFA5.18, ER70S-6 636-A, W 42 5 W3Si1 GTAW
BÖHLER EML 5 Manual TIG welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60 A5.18 / SFA5.18, ER70S-3 636-A, W 46 5 W2Si1 GTAW
BÖHLER Ni 1-IG Manual TIG welding L360/X52, L390/X56, L415/X60, L450/X65 A5.28 / SFA5.28, ER80S-G 636-A, W 46 5 W3Ni1 GTAW
BÖHLER NiMo 1-IG Manual TIG welding L450/X65, L485/X70, L555/X80 A5.28 / SFA5.28, ER90S-G 16834-A, W 55 6 1Mn3Ni1Mo GTAW
BÖHLER NiCrMo 2,5-IG Manual TIG welding L625/X90, L690/X100 A5.28 / SFA5.28, ER110S-G 16834-A, W 69 6 1Mn3Ni2.5CrMo GTAW
Thermanit GE-316L Manual TIG welding Alloy type 316L A5.9 / SFA-5.9, ER316L 14343-A, W 19 12 3 L GTAW
Thermanit 22/09 Manual TIG welding Duplex stainless steel A5.9 / SFA-5.9, ER2209 14343-A, W 22 9 3 NL GTAW
Thermanit 25/09 CuT Manual TIG welding Super duplex stainless steel A5.9 / SFA-5.9, ER2594 14343-A, W 25 9 4 NL GTAW
Thermanit 625 Manual TIG welding Alloy type 625 A5.14 / SFA-5.14, ERNiCrMo-3 18274, S Ni 6625 (NiCr22Mo9Nb) GTAW
diamondspark X52 RC-Pipe Flux Cored Wire welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.20 / SFA-5.20, E71T-1M/T-9M/T-12M JH4 17632-A, T 46 4 P M21 1 H5 FCAW
BÖHLER Pipeshield 71 T 8-FD Flux Cored Wire welding (self-shielded) L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.29/SFA-5.29, E71T8-A4-K6 17632-A, T38 3 Z Y NO 1 H10 FCAW
BÖHLER Pipeshield 71.1 T 8-FD Flux Cored Wire welding (self-shielded) L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.29/SFA-5.29, E71T8-A4-Ni1 FCAW
diamondspark X60 RC-Pipe Flux Cored Wire welding L360/X52, L390/X56, L415/X60, L450/X65 A5.29 / SFA-5.29, E81T1-Ni1M-JH4 117632-A, T 50 6 1Ni P M21 1 H5 FCAW
diamondspark X70 RC-Pipe Flux Cored Wire welding L450/X65, L485/X70 A5.29 / SFA-5.29, E91T1-K2M-JH4 18276-A, T55 5 Mn1.5Ni P M21 1 H5 FCAW
BÖHLER Pipeshield 81 T8-FD Flux Cored Wire welding (self-shielded) L450/X65, L485/X70 A5.29 / SFA-5.29, E81T8-G 17632-A, T46 3 Z Y NO 1 H10 FCAW
diamondspark X80 RC-Pipe Flux Cored Wire welding L485/X70, L555/X80, L625/X90, L690/X100 A5.29 / SFA-5.29, E101T1-K2M-JH4 18276-A, T 62 4 Mn1.5Ni P M21 1 H5 FCAW
BÖHLER Pipeshield 91 T8-FD Flux Cored Wire welding (self-shielded) L555/X80 A5.29 / SFA-5.29, E91T8-A4-G FCAW
FOXcore 316L-T1 Flux Cored Wire welding Alloy type 316L A5.22 / SFA-5.22, E316LT1-4(1) 17633-A, T 19 12 3 L P M21 (C1) 1 FCAW
FOXcore 2209-T1 Flux Cored Wire welding Duplex stainless steel A5.22 / SFA-5.22, E2209T1-4(1) 17633-A, T 22 9 3 N L P M21 (C1) 1 FCAW
FOXcore 2594-T1 Flux Cored Wire welding Super duplex stainless steel A5.22 / SFA-5.22, E2594T1-4(1) 17633-A, T 25 9 4 N L P M21 (C1) 2 FCAW
FOXcore 625-T1 Flux Cored Wire welding Alloy type 625 A5.34 / SFA-5.34, E NiCrMo3T1-4 12153, T Ni 6625 P M21 2 FCAW
diamondspark X60 MC-Pipe Metal Cored Wire welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.18 / SFA-5.18, E70C-6M H4 17632-A, T 46 4 M M21 1 H5 MCAW
diamondspark X70 MC-Pipe Metal Cored Wire welding L415/X60, L450/X65, L485/X70 A5.28 / SFA-5.28, E80C-Ni1 H4 17632-A, T 46 6 Z M M21 1 H5 MCAW
diamondspark X80 MC-Pipe Metal Cored Wire welding L485/X70, L555/X80, L625/X90 A5.28 / SFA-5.28, E90C-K3 H4 18276-A, T 55 6 1NiMo M M21 1 H5 MCAW
Thermanit GE-316L - Marathon 431 Double joint welding Alloy type 316L A5.9 : ER316L 17633-A, S 19 12 3 L SAW
Thermanit 22/09 - Marathon 431 Double joint welding Duplex stainless steel A5.9 : ER2209 14343-A, S 22 9 3 N L SAW
Thermanit 625 - Marathon 444 Double joint welding Alloy type 625 A5.14 :ERNiCrMo3 18274, S Ni 6625 (NiCr22Mo9Nb) SAW
Union S 2 Si - UV 418 TT Double joint welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52 A5.17 : F7A8-EM12K / F6P8-EM12K 14171-A, S 42 5 FB S2Si H5 SAW
Union S 3 Si - UV 418 TT Double joint welding L175/A25, L210/A, L245/B, L290/X42, L320/X46, L360/X52, L390/X56, L415/X60, L450/X65 A5.17 : F7A8-EH12K / F7P8-EH12K 14171-A, S 46 6 FB S3Si H5 SAW
Union S 2 NiMo 1 - UV 418 TT Double joint welding L415/X60, L450/X65, L485/X70 A5.23 : F8A10-ENi1-Ni1 - F8P10-ENi1-Ni1 14171-A, S 50 6 FB SZ2Ni1Mo0.3 H5 SAW
Union S 3 NiMo 1 - UV 418 TT Double joint welding L450/X65, L485/X70 A5.23 : F9A8-EF3-F3 / F9A8-EF3-F3 26304-A, S 55 6 FB S3Ni1Mo H5 SAW
Union S 3 NiMoCr - UV 418 TT Double joint welding L485/X70, L555/X80, L625/X90, L690/X100 A5.23 : F11A8-EG-F6 / F11P4-EG-F6 26304-A, S 69 6 FB SZ3Ni2.5CrMo H5 SAW
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