GOST 28555-90
GOST 28555−90 ceramic Fluxes for arc welding of carbon and low-alloy steels. General specifications
GOST 28555−90
Group В05
STATE STANDARD OF THE USSR
CERAMIC FLUXES FOR ARC WELDING
CARBON AND LOW ALLOY STEELS
General specifications
Bonded fluxes for submerged arc welding of carbon and low-alloy steels.
General specifications
OKP 59 2952
Valid from 01.01.1992
before 01.01.1997*
________________
* Expiration removed
Protocol N 7−95 Interstate Council
for standardization, Metrology and certification.
(IUS N 11 1995).
Note the «CODE»
INFORMATION DATA
1. DEVELOPED AND INTRODUCED by the Academy of Sciences of the Ukrainian SSR
DEVELOPERS
L. M. Lobanov, doctor of engineering. Sciences; I. K. pokhodnya, d-R tekhn. Sciences (head of subject); V. V. Golovko, PhD. tech. Sciences; J. M. Usikov, PhD. tech. Sciences
2. APPROVED AND put INTO EFFECT by Decision of the USSR State Committee on management of quality and standards from
3. INTRODUCED FOR THE FIRST TIME
4. REFERENCE NORMATIVE AND TECHNICAL DOCUMENTS
| The designation of the reference document referenced |
Item number |
| GOST 12.1.005−88 |
1.2.6.2 |
| GOST 12.1.007−76 |
1.2.6.2 |
| GOST 12.3.003−86 |
1.2.6.6 |
| GOST 380−88 |
4.5.2 |
| GOST 2226−75 |
1.4.1 |
| GOST 6613−86 |
4.2 |
| GOST 6996−66 |
4.6.7, 4.6.8, 4.8 |
| GOST 7122−81 |
4.8 |
| GOST 9078−84 |
5.2 |
| GOST 9557−87 |
5.2 |
| GOST 14192−77 |
1.3.2 |
| GOST 15102−75 |
5.2 |
| GOST 15150−69 |
5.3 |
| GOST 15846−79 |
5.4 |
| GOST 18225−72 |
1.4.1 |
| GOST 20435−75 |
5.2 |
| GOST 21650−76 |
5.2 |
| GOST 21929−76 |
5.2 |
| GOST 22225−76 |
5.2 |
| GOST 22536.0−87 |
4.9 |
| GOST 22536.1−88 |
4.9 |
| GOST 22536.2−87 |
4.9 |
| GOST 22536.3−88 |
4.9 |
| GOST 22536.4−88 |
4.9 |
| GOST 22536.5−87 |
4.9 |
| GOST 22536.14−88 |
4.9 |
| GOST 24597−81 |
5.2 |
| GOST 26663−83 |
5.2 |
This standard applies to ceramic fluxes for automatic arc welding of carbon and low-alloy steels.
1.TECHNICAL REQUIREMENTS
1.1. Ceramic fluxes shall be made in accordance with the requirements of the present standard and technical conditions on fluxes of specific brands of technological regulations approved in the prescribed manner.
1.2. Features
1.2.1. Granulometric composition of the flux shall be as given in table.1.
Table 1
| The size of granules of the flux, mm |
Sift through a mesh N 025 (GOST 6613),% |
The residue on the mesh is N 2 (GOST 6613),% |
| 0,25−2,00 |
Not more than 5 |
No more than 8 |
1.2.2. Fluxes must not contain foreign impurities. The particle components included in the composition of the flux, are foreign impurities.
1.2.3. Relative humidity ready of flux at the time of packaging should be not more than 0.1%.
1.2.4. Welding-technological properties of flux residues while respecting the modes and conditions of welding set specifications on the flux of a particular brand, and in the absence of the magnetic blast should meet the following requirements:
the arc should be easy to get excited and stably burn;
welding roller should be flat, smooth surface with a bulge no more than 4 mm and a smooth transition to the base metal;
the slag should provide a good formation of beads of weld metal and easily removed after cooling;
pores, cracks, and tears on the surface of the weld bead. are not allowed.
1.2.5. The chemical composition of the weld metal or weld metal, mechanical properties of the weld metal or weld metal, the presence of internal defects permitted must comply with the requirements of technical conditions on the flux the specific brand.
1.2.6. Safety requirements
1.2.6.1. Work with fluxes in their production, sorting, packaging, quality control and application may be accompanied by the release of dust containing manganese, silicon and fluorides. Flux dust refers to chemically hazardous and harmful production factors. In terms of impact on the human body flux dust is toxic, irritating and sensitizing. Ways of penetration of flux of dust into the body through the respiratory system, skin and mucosa.
1.2.6.2. For the prevention of occupational diseases and to ensure optimal conditions during the holding flux of the works cited in claim
The content of main harmful substances in the air when handling fluxes should not exceed permissible concentration (MPC) given in table.2.
Table 2
The name of the substance |
MPC, mg/m |
Hazard class |
| Manganese in welding aerosol at its mass: | ||
| up to 20% |
0,2 |
II |
| from 20 to 30% |
0,1 |
II |
Manganese oxide (in terms of | ||
| spray disintegration |
0,3 |
II |
| Silicon dioxide amorphous mixture of oxides of manganese in the form of an aerosol of condensation from each of them not more than 10% by weight |
1 |
III |
| Hydrogen fluoride (calculated as F) |
0,5/0,1 |
I |
| Carbon monoxide |
20 |
IV |
| Hydrofluoric acid salt (F): | ||
| fluorides of sodium, potassium, ammonium, zinc, tin, silver, lithium and barium | 1/0,2 | II |
):
Notes:
1. If the column «MPC, mg/m» given two values, this means that the numerator of the given maximum, and the denominator — the time-weighted average MPC.
2. For silicon dioxide the above value of the MPC for the total weight of the aerosol.
3. When the duration of operation in atmospheres containing carbon monoxide not more than 1 h, the maximum permissible concentration of carbon monoxide can be increased to 50 mg/m. Re-work under conditions of high content of carbon monoxide in the air of working zone can be an interval of at least 2 h.
1.2.6.3. Gross of allocation of the most harmful substances when using fluxes shall conform to the requirements of technical conditions on the flux the specific brand.
1.2.6.4. Working with the fluxes must be provided with PPE in accordance with standard industry regulations approved in the established order.
1.2.6.5. The definition of harmful substances in the air of working zone is carried out in accordance with the guidelines approved by the Ministry of health of the USSR.
1.2.6.6. When applying flux should be guided by the requirements of GOST 12.3.003 and sanitary rules during welding, surfacing and cutting of metals of the Ministry of health of the USSR.
1.3. Marking
1.3.1. Each packing should be attached label or marked by stencil showing:
the trademark or name of manufacturer and its trademark;
the legend of flux;
the date of manufacture.
designation of normative-technical documentation on this grade of flux.
1.3.2. Transport marking under GOST 14192 with the application of manipulation signs: «Caution, fragile!» and «Afraid of dampness».
1.4. Packaging
1.4.1. The flux should be Packed in four-layer or five-layer bags according to GOST 2226 brand NM made in jute bags according to GOST 18225. Filled bags should salivates machine.
Allowed packing flux in a different container, ensuring the preservation of its quality during transportation and unloading.
1.4.2. Gross mass per package must not exceed 50 kg.
2. ACCEPTANCE
2.1. Acceptance of the flux is conducted by the parties.
2.2. The party should consist of a flux of the same brand, made of constant technology from charge materials of some parties and be accompanied by a document about quality that contains:
trademark or name of manufacturer and its trademark;
designation of the flux;
batch number;
the weight of the party;
the date of manufacture of the party;
the results of determination of chemical composition of weld metal or weld metal and the mechanical properties indicating the brand of the welding wire;
stamp of technical control Department.
2.3. The weight of the batch shall be not more than 20,000 kg.
2.4. To check the quality of the flux is carried out the following tests:
check the uniformity of the flux;
determination of moisture flux;
inspection of welding-technological properties of the flux;
determination of chemical composition of weld metal or weld metal and mechanical properties.
2.5. To determine the quality of the flux from the party selected sample — not less than five packaging units.
2.6. If unsatisfactory test results of at least one of the indicators it is carried out re-tests on twice the number of samples taken from the same batch.
The results of repeated tests spread to the entire party.
3. TEST METHODS
3.1. For testing of samples of equal portions taken at least 10 kg. Selected flux is thoroughly mixed.
For testing samples are taken:
for determination of granulometric composition — 100 g;
to determine the uniformity — 100 g;
to determine the moisture — 100 g;
to determine weldability — 2 kg;
to determine the chemical composition and mechanical properties of the weld metal or weld metal — 4 lbs.
When selecting a flux for the first three tests, the weighting is carried out with an accuracy not more than 0.1%, the last two not more than 1%.
3.2. Particle size distribution of fluxes is determined by sieving the sample using appropriate test sieves for (60±5) and the subsequent weighing accuracy up to 0.1% residue on sieve N 2 according to GOST 6613, and sifting through a sieve N 025 GOST 6613.
The relative mass balance or sifting flux that does not meet the requirements listed in the table.1, percentage calculated by the formula
where ,
— mass of the sieve residue with mesh # 2 or sifting through a sieve with mesh N 025, respectively, g;
— the weight of the portion,
3.3. The homogeneity of the flux is controlled by visual inspection without the use of magnifying devices.
3.4. To determine the moisture flux sample was placed in pre-dried a Cup and kept at a temperature of (300±10) °C in a drying oven (60±5) min. After cooling in a desiccator for (40±5) min the sample is weighed with an accuracy of 0.005%.
Humidity flux () in percent is calculated by the formula
where is the initial mass of sample, g;
— final mass of sample, g.
The final result of the analysis be the arithmetic mean of results of two parallel measurements, the difference of which must not exceed 0.05%.
3.5. Check the welding-technological properties of flux
3.5.1. Inspection of welding-technological properties is carried out by performing control of the deposition rate.
3.5.2. The surfacing is performed on a plate of steel grade st3sp according to GOST 380 with a minimum thickness of 10 mm and a size not less than 300x100 mm.
3.5.3. The surface of the plate must be cleaned from rust, oil and other contaminants.
3.5.4. The welding should be performed in the middle of the plate. The length of the deposited bead should be at least 200 mm. the Welding should be carried out in compliance with the conditions and terms established by normative-technical documentation on fluxes of specific brands, at a temperature below 10 °C.
3.5.5. The ease of initiation and stability of arc burning, the correctness of the rollers, as well as easy slag removal are controlled by visual observation in surfacing samples.
3.5.6. Control of the surface of the deposited bead in the absence of surface pores, cracks and tears is carried out visually. Inspection should be carried out over the entire area of the weld surfaces .with the exception of crater parts after thorough slag removal.
3.5.7. Allowed to evaluate the welding-technological properties of the flux when performing the first pass of welded joints according to claim 4.6.
3.6. Determination of mechanical properties of the weld metal or weld metal
3.6.1. To check the mechanical properties of the weld metal or weld metal is collected a butt joint of two steel plates of size not less than 300x100 mm.
3.6.2. For determining the mechanical properties of the weld metal structural elements for welding prepared butt joints shall be as given in hell.1. Butt splice going to pin bars is at least 70х40х8 mm.
Damn.1
Damn.1
3.6.3. Structural elements of the weld metal shall be as given in hell.2.
Damn.2
Damn.2
3.6.4. In determining the mechanical properties of the weld metal structural elements prepared for welding the edges of plates with pre-welded the remaining pad must match that shown on the devil.3. Inserts are collected for welding with lead strips not less than 70х40х8 mm. as pin straps can be used by the remaining lining.
Damn.3
Damn.3
3.6.5. Structural elements of weld metal shall be as given in hell.4.
Damn.4
Damn.4
3.6.6. Welding of butt joints should be in the lower position at a temperature below 10 °C. Not less than 35 mm start and end of each welding pass to be performed on the output rails. When performing multiple-pass weld, the welding direction should be changed with each successive pass. When welding without preheating each passage should be performed after cooling of the metal previously completed part of the weld to a temperature below 250 °C, if other requirements are not established in the technical conditions on the flux the specific brand.
3.6.7. From butt weld to test the mechanical properties of the weld metal or weld metal cut out two samples for tensile tests of type II and three samples for testing the impact strength (toughness) type VI or IX according to GOST 6996.
When testing the flux, designed for welding steels with tensile strengths in excess of 480 MPa, the number of samples of class II should be increased to three, and samples of type IX to five.
Clipping samples is carried out mechanically in accordance with the scheme given on features.5.
Damn.5
Damn.5
Samples for tensile tests, as well as working part samples for testing the impact strength shall be made completely of weld metal or weld metal in accordance with the requirements of GOST 6996.
3.6.8. Testing of mechanical properties of the weld metal or weld metal is carried out in accordance with GOST 6996. The testing conditions and evaluation of their results shall comply with the requirements of GOST 6996 or technical conditions on the flux the specific brand.
3.7. If regulatory and technical documentation on the flux of a specific brand provided validation for the special properties of the welded joint, the size of the plates must be increased accordingly or shall be made an additional weld joint in accordance with the technical requirements.
3.8. The sample for chemical composition analysis of the weld metal or weld metal is taken in the form of chips according to GOST 7122 of butt welded joints made according to claim 4.6, or in finishing the machining of discontinuous samples (type II according to GOST 6996). Samples for the spectral analysis of the chemical composition of the weld metal or weld metal cut from the location given on features.5.
Prior to sampling may be performed ezuprechnaya heat treatment of the weld metal or weld metal.
3.9. The chemical composition of the weld metal or weld metal is determined according to GOST 22536.0 to GOST 22536.1, 22536.2 GOST, GOST 22536.3, 22536.4 GOST, GOST 22536.5, GOST 22536.14.
Allowed the use of other methods of analysis if their metrological characteristics are not inferior to the characteristics of the techniques included in the above standards.
If there is disagreement as an estimate of the flux test is carried out according to GOST 22536.0, 22536.1 GOST, GOST GOST 22536.2 22536.3, 22536.4 GOST, GOST 22536.5.
4. TRANSPORTATION AND STORAGE
4.1. The flux must be transported in covered vehicles by any kind of transport in accordance with cargo carriage regulations applicable to each mode of transport.
4.2. Allowed the flux to be transported in containers according to GOST 15102, 20435 GOST, GOST 22225, and packages according to GOST 21929 formed on the flat pallets according to GOST 9557, GOST 9078 or other regulatory-technical documentation. Dimensions of packages — according to GOST 24597. Means of fasteners according to GOST 21650. The formation of packages according to GOST 26663.
4.3. Transportation and storage fluxes is carried out in accordance with the storage group G2 according to GOST 15150.
4.4. Transportation and storage fluxes sent to the far North regions or equated to them, — according to GOST 15846, group 146.
5. MANUFACTURER’S WARRANTY
5.1. The manufacturer guarantees that the fluxes to the requirements of this standard under the conditions of transportation, storage and use of regulated by this standard.
5.2. Warranty period of storage fluxes in the package manufacturer — 12 months. from the date of manufacture.
6. APPLICATION NOTES
6.1. Before applying the flux must be dried at a temperature of (400±20) °C for (125±15) min. the thickness of the flux layer should not exceed 60 mm.
6.2. Drying of the flux is carried out in electric furnaces. Allowed the use of furnaces with other heat sources and other heat treatments, if after drying, the flux meets the requirements of this standard.
6.3. After drying and cooling, the flux in the period before it is actually used when welding can be stored in a special tightly sealed bins in a heated dry rooms or in rooms with temperature not below 17 °C and a relative humidity above 80% no more than one day. Storage of flux after drying for a longer period of time in a drying Cabinet at a temperature of 100−120 °C.
