Wire_catalgue

The Company MIGAL.CO – your key to perfect welding! MIGAL.CO (former MIGWELD) was founded in January 2000, is locatec in Landau/Isar, Bavaria and a manufacturer of high quality filler metals for MIG- and TIG-welding. Wires from MIGAL.CO have excellent wire-feeding characteristics due to a certain surface treatment during manufacturing. Robot quality - constant products The prerequisite for successful welding with industrial robots in the large scale production is a constant product, which ensures equal arc characteristics from batch to batch. Our quality assurance already starts during the extraction of the aluminum ore Bauxit. Always the same supply chain from ore to the wire rod with a diameter of 9.5 mm provides alloys with the permanently identical fingerprint of the trace elements. For the drawing of the wires, exclusively high-quality, non-slip drawing machines are used. This means that a separate speed-controlled drive is available for each die. The thus reliably avoided slip ensures optimum surface quality. Aluminium ore - Bauxit Aluminium oxide Strip from the casting wheel For latest details regarding the content of this page see www.migal.co Aerial photo MIGAL.CO GmbH Production site and offices Non-slip drawing machine 3

MIGAL.CO Quality Tolerance of diameter and surface purity According to the standard DIN EN ISO 544 the maximum tolerance of a 1.2 mm wire electrode of GMAW welding must not exceed +0.01/-0.04 mm from its nominal value. Diameter [mm] Deviation Area of cross section [mm2] Deviation 1,21 0,83% 1,15 1,65% 1,20 0,00% 1,13 0,00% 1,18 -1,67% 1,09 -3,31% 1,16 -3,33% 1,06 -6,48% MIGAL.CO only uses drawing dies made from diamonds and this puts us in a position to keep the diameter tolerance constant within +0.0/-0.02 mm. Hence, the maximum deviation of the wire feed speed is limited to 3.31%. Under practical conditions this means that the arc length correction doesn‘t require adjustment after changing to a new batch of wire. This is of utmost importance with all mechanized and robotic welding. The surface cleaning at MIGAL.CO is done by a multiple, mechanical and cutting process, which is known by experts under the term “shaving”. In opposite to chemical cleaning processes this guarantees cleanest surfaces, nothing but pure metal! The wire diameter and the ovality of the wire are permanently laser-controlled during the production process and deviations lead to warnings or to a stop of the production line. Twist-free wires in For optimum processing of wire electrodes for MSG welding, these must be free of twist. This ensures a precise positioning of the wire electrode end the TCP (tool-center-point), especially in robot welding, and avoids the formation of knots when barrels are unwound. The wire drawing machines used at MIGAL.CO have special devices to adjust the freedom from twist. Diameter control by laser Respooler for twist-free drums Twist-free drawing machine For latest details regarding the content of this page see www.migal.co 4

Quality Control Residual analysis - precision in surface coating Pure Aluminium does not glide through wire feeding systems and obtaining a simultaneous compromise between superior gliding characteristics and utmost surface purity is certainly the secret of each manufacturer. This is also true for MIGAL.CO, even though we believe to have an extraordinary useful solution to this challenge. Naturally, mistakes that lead to surface impurities can happen in every production plant, but nonetheless poor storage or dirty wire feed systems may lead to unclean wires as well. With Aluminium this is particularly sensitive due to the problems with Hydrogen (see page 37) in opposite to most other metals and often very critical during practical applications of welding. Therefore, we have wondered a lot how we could be able to judge about the surface cleanliness of wires quickly and at user’s sites. This has led us to the development of our residual analyser. Using a fast and stepless adjustable inverter power source we heat the wire until shortly below the melting point. The surface impurities evaporate and are collected by a special extraction device. The quantity of fume is measured with an optical sensor. The measuring results are displayed graphically and numerically on a PC user interface and may be documented as required. Residual analyzer The analyser is portable and can be used right at the user. If difficulties i. e. porosity occur, we are quickly able to assess the surface impurities of wire electrodes. Residual analyzer panel For latest details regarding the content of this page see www.migal.co 5

Quality Control Welding robot and digital image radiography The only decisive criterion in the assessment of the product quality of filler metals is provided by the welding test with subsequent radiography. A specially designed industrial robot with statistical process analysis combined with a digital X-ray system enables us to demonstrate the quality of processing and the freedom of porosity of our products before delivery. Spectral analysis, tensile test and coefficient of friction Digital image radiography In our laboratory, we can also control the chemical composition of our products at any time, determine the tensile strength, yield strength and elongation of the wires, and measure the friction coefficient of the wire electrodes. X-ray cabinet Welding robot Spark emission spectrography Measurement of the coefficient of friction For latest details regarding the content of this page see www.migal.co Tensile test 6

Quality Control Standard vacuum packaging of MIGAL.CO welding wire At the ISF - Welding and Joining Institute at the RWTH Aachen University, „Investigations of the influence of the material-dependent properties of aluminum wire electrodes on the stability and the welding results of GMAW-processes“ were conducted from 2013 to 2016. These came to the clear conclusion that only such wires lead to pore formation in the weld metal, on which condensation has taken place. Condensation due to rapid changes in ambient temperatures and atmospheric humidity occurs additionally to the storage, especially during transport, without influence of the manufacturer or receiver. The plastic packings of wire electrodes used to date for MSG welding wires are by no means dense and this leads to condensation conditions, hydrogen absorption and subsequent pore formation during welding. MIGAL.CO, as first manufacturer in the world, has consistently decided to pack all wire electrodes on coils of 0.5 - 40 kg in aluminum composite foil and vacuum. This ensures the control of the unsealed packaging by the user and a safe protection of the wire electrode against hydrogen absorption, even during storage or transport during condensation conditions. B300 vacuum packaging For latest details regarding the content of this page see www.migal.co S300 before welding 7

The Centre of Technology Know how: We deliver not only the product, but also the solution! Arc welding technology Progress of microelectronics has enabled further development of the technological „welding arc“ tool considerably during the last years. New process variants like high-deposition GMAW, MIG-brazing, welding with flattened wires or GMAW-AC processes have been developed. At the same time already known processes i. e. Plasma-MIG-welding are being reminded of and new hybrid-processes like Laser-MIG- welding are invented. These advances in arc welding technologies can be used to improve quality and productivity of welded structures, which get more important due to global competition. Also thermal cutting has new developments i. e. high focus plasma cutting which provides cuts that don’t require any further refinish. The general conditions and parameters of these new processes can not be found in literature and there is a lack of practical experience. There are just too many combinations of materials, welding positions, joint designs, tolerances and requirements to the joint. To find the right answer for each specific application there is only one way: Try! In order to “try” professionally and to be able to offer new and profitable solutions to our costumers we have established our centre of technology. Here we are able to use and compare different arc processes under practical conditions and we can evaluate the joints by destructive and non-destructive testing. Even more important, these solutions are found within short notice and on the basis of industrial available products which makes them immediately applicable in industrial environments. In order to provide the entire range of destructive and non-destructive testing to our costumers we establish partnerships with various universities and institutes related to welding and thermal cutting. The facilities in our centre of technology include among others a CNC-cutting machine, a six-axis industrial robot with external axis, longitudinal and circumferential welding machines, power sources for various welding processes, equipment for joint preparation and destructive testing. For latest details regarding the content of this page see www.migal.co 8

The Internet E-Commerce We have been using the world wide web right from the beginning and have it woven deeply into our business processes. Our costumers are able to download information directly from our databases and get their requested data precisely, quickly and of course round the clock. Certificates We supply all our consumables with a certificate according to EN 10204-3.1. These certificates may be downloaded, even after years, by www at any time in superior quality. Just by surfing to www.migal.co, entering the batch number of the consumable and then selecting the diameter and spool type the certificate appears as a pdf-File and may be locally stored or printed as necessary By these means an optically perfect and properly designated document is provided. Stocklist Our webpages are linked to the PPS computer systems directly. This makes it possible to show the quantities of each product in our warehouse in kilograms. For latest details regarding the content of this page see www.migal.co 9

The Internet Metal supplements - always up-to-date The metals, of which our filler metals are made from, are traded on the international stock markets, and this causes daily fluctuations of its prices. This is the reason why our sales prices are always divided in a base price and a variable supplement. The supplement is calculated from the changes of the relevant metal prices in the past month. We will inform you about the basics of these calculations on request. CAUTION: The application of the metal supplements is always based on the month of delivery, and not on the date of order. Our homepage offers much more information like a material calculator to find the best filler metal for given base metals, a dew point calculator, as well as additional product and application information. Just surf to www.migal.co and have a look! For latest details regarding the content of this page see www.migal.co 10

Spools and Packaging Eco-Drum - your key to an ecological package Our Eco-Drum is designed for all users of mechanized and robotic welding applications. It is mainly used for alloys of the 1000 and 4000 material group. The Eco-Drum contains 80 kg of Aluminium wire or 200 kg of Copper wire. Of particular interest to bulk users is certainly CuSi3 1.0 mm which is used in a great scale for MIG-brazing. The Eco-Drum makes it possible to use a bulk supply without the otherwise necessary expensive and maintenance prone unwinding equipment. An integrated window provides visual wire end control. The drum is just paper and can be burned or disposed of as waste paper. Dimensions: Diameter 515 mm Height without decoiling hood 800 mm Height with decoiling hood 1.120 mm Eco-Drum with Decoiling Hood on Multi-Purpose-Carriage UFTW1 Jumbo and JumboXL - for real bulk users The Jumbo-Drum and the JumboXL-Drum are the bulk packs for all large consumers of aluminium welding wire. All alloys from our Aluminium and Copper consumables can be reeled off out of our Jumbo-Drums. The Jumbo-Drum contains 140 kg of Aluminium wire or 200 kg of Copper wire, the JumboXL-Drum 240 kg of Aluminium wire. Even wire diameters of 1.0 mm and alloys of the 5000 series can be decoiled without any problem. Due to the bigger diameters of these drums the wire comes nearly straight of the pack and is especially suitable for laser welding. Jumbo-Drum with Decoiling Hood on Multi-Purpose-Carriage UFTW1 Jumbo and JumboXL are ecological as well and may be disposed of easily. An integrated control window enables a visual wire end control. Dimensions Jumbo-Drum: (LxWxH): 600 x 600 x 900 mm without decoiling hood heigth with decoiling hood 1.250 mm Dimensions JumboXL-Drum: Diameter 750 mm Height without decoiling hood 800 mm Height with decoiling hood 1.120 mm JumboXL-Drum with Decoiling Hood on Multi-Purpose-Carriage UFTW2 For latest details regarding the content of this page see www.migal.co 12

Spools and Packaging Physical design of the welding system when using drums A trouble free use of drums needs much know-how and experience. Already the physical design of the welding system must be adapted to drums. An example of a robotic cell is shown here. We like to support you already during the planning stage of your robotic system - just ask us. The basic criteria for successful wire-feeding is shown in the image. α1=90° α2=90° n α=∑α i i=1 Fin Fout = Fin * eα*μ Fout α4=90° α3=180° Schematic layout of a robotic welding cell with bulk-wire supply and the related forces due to friction For greater distances from the drum to the wire feeder we recommend our Rolliner. For further information about the Rolliner and suitable accessories for wire drums e. g. decoiling cones, wire end sensors, wire feed conduits and transport aids ask for our catalogue „Your Key To Perfect Wire Transport“. For latest details regarding the content of this page see www.migal.co 13

Indicative tables Chemical compositions Aluminium alloys Single values are maximum values (%) Unspecified elements Be Ti Zr B Single Total Al Cr Cu 0,04 0,05 Mn 0,03 0,05 Mg 0,03 0,05 5,80 - 6,80 0,20 - 0,40 0,02 0,10 0,50 - 0,80 0,80 - 1,20 0,01 0,15 0,40 0,15 0,20 0,20 - 0,50 0,15 Zn 0,04 0,07 0,10 0,10 0,10 0,10 0,20 0,0003 0,03 0,0003 0,10 - 0,20 0,0003 0,10 - 0,20 0,10 - 0,25 0,0003 0,10 - 0,20 0,0003 0,005 0,01 0,0003 0,0003 0,0003 0,0003 0,0003 0,15 0,15 0,15 0,15 0,15 0,10 - 0,20 MA 1070 MA 1450 MA 2319 MA 4018 MA 4020 MA 4043 MA 4046 MA 4047 MA 5087 MA 5183 MA 5356 MA 5554 MA 5556 MA 5754 MA 6063 Si 0,20 0,25 0,20 6,50 - 7,50 2,50 - 3,50 4,50 - 6,00 Fe 0,25 0,40 0,30 0,20 0,20 0,60 9,00 - 11,00 0,50 11,00 - 13,00 0,60 0,25 0,40 0,25 0,25 0,25 0,40 0,20 - 0,60 0,40 0,40 0,40 0,40 0,40 0,40 0,35 0,05 0,03 0,30 0,03 0,30 0,05 0,10 0,10 0,10 0,10 0,10 0,10 0,70 - 1,10 4,50 - 5,20 0,05 - 0,25 0,25 0,50 - 1,00 4,30 - 5,20 0,05 - 0,25 0,25 0,05 - 0,20 4,50 - 5,50 0,05 - 0,20 0,10 0,0003 0,06 - 0,20 0,50 - 1,00 2,40 - 3,00 0,05 - 0,20 0,25 0,0003 0,05 - 0,20 0,60 - 1,00 5,00 - 5,50 0,05 - 0,20 0,20 0,0003 0,05 - 0,20 0,50 0,10 2,60 - 3,60 0,30 0,45 - 0,90 0,10 0,20 0,10 0,0003 0,15 0,0003 0,20 - 0,30 0,04 - 0,06 0,05 0,03 0,03 0,05 0,05 0,02 0,05 0,05 0,05 0,05 0,05 0,05 0,05 0,05 0,05 ≥ 99,70 ≥ 99,50 Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest 0,15 0,15 0,10 0,15 0,15 0,15 0,15 0,15 0,15 0,15 0,15 0,15 0,15 Cu Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest Rest Other Total 0,40 0,40 0,50 0,50 0,50 0,40 0,50 0,50 0,40 0,10 Ti Fe P 0,50 - 2,50 3,00 - 5,00 1,50 2,00 - 4,00 0,20 - 0,50 0,50 - 2,00 0,007 0,20 - 0,50 0,40 - 1,00 0,02 0,05 0,02 0,015 0,10 0,30 0,03 0,10 0,10 - 0,35 0,40 Copper alloys Single values are maximum values (%) Al Si ML CuAl8 6,00 - 8,50 0,20 Ni Mn 0,50 ML CuAl8Ni2 7,50 - 9,50 0,20 0,50 - 2,50 0,50 - 3,00 ML CuAl8Ni6 8,50 - 9,50 0,10 0,60 - 3,50 4,00 - 5,50 ML CuAl9Fe 8,50 - 11,00 0,10 ML CuMn13Al7 7,00 - 8,50 0,10 11,00 - 14,00 1,50 - 3,00 0,20 0,20 0,50 - 1,50 9,00 - 11,00 0,50 - 1,50 29,00 - 32,00 2,80 - 3,00 0,75 - 0,95 0,05 2,80 - 4,00 0,75 - 1,50 ML CuNi10Fe 0,03 ML CuNi30Fe ML CuSi28L ML CuSi3 ML CuSn ML CuSn6 0,02 0,01 0,01 0,01 Zn 0,20 0,20 0,10 0,02 0,15 0,10 0,20 Sn 0,05 0,20 Pb 0,20 0,02 0,02 0,02 0,02 0,02 0,02 0,01 0,02 0,10 - 0,50 0,10 - 0,50 0,05 0,50 - 1,00 0,01 0,10 5,50 - 8,00 0,02 Safety data sheets may be obtained from www.migal.co! For latest details regarding the content of this page see www.migal.co 14

Indicative tables Fields of application and usage of MIGAL.CO consumables for identical or similar base materials Aluminium alloys Recommendation for the selection of welding consumables for base materials from wrought and cast aluminium alloys can be found in DIN EN 1011-4. An extract from this standard, especially for MIGAL.CO consumables, can be found underneath. Broken down to the single base materials a material calculator can be found at www.migal.co. Table 1 - Group division of consumables Type MIG WELD designation Alloy designation Chemical designation Remarks Type 1 Type 4 Type 5 MA 1450 MA 1070 MA 4018 MA 4020 MA 4043 MA 4046 MA 4047 MA 5754 MA 5554 MA 5556 MA 5183 MA 5087 MA 5356 S Al 1450 S Al 1070 S Al 4018 S Al 4020 S Al 4043 A S Al 4046 S Al 4047 A S Al 5754 S Al 5554 S Al 5556 A S Al 5183 S Al 5087 S Al 5356 Al99,5Ti Al 99,7 AlSi7Mg AlSi3Mn1 AlSi5(A) AlSi10Mg AlSi12(A) AlMg3 AlMg2,7Mn AlMg5Mn1(A) AlMg4,5Mn0,7(A) AlMg4,5MnZr(A) AlMg5Cr(A) Ti reduces the formation of solidification cracks in the weld metal by means of corn fining. The Type 4 fillers oxidise during anodizing or by atmospherical influences and give a dark grey colour, whose intensity increases with increasing Si-content. Such fillers do not give a suitable colour adjustment to base materials from wrought alloys. These alloys are especially used to prevent solidification cracks in combination with high dilution and stiff clamping conditions. In case that high corrosion resistance and colour adjustment are considered decisive then the Mg content of the filler metal shall be equal to the base metal. In case that a high yield strength and tensile strength are considered decisive then a filler metal with a Mg content between 4,5% to 5% shall be used. Cr and Zr reduce the susceptibility to solidification cracking by means of corn fining. Zr reduces the risk of hot cracking. Remark: The Type numbers 1, 4 and 5 correspond with the first figure of the alloy designation. For latest details regarding the content of this page see www.migal.co 15

Indicative tables Table 2 - Selection of filler metals (The types of fillers are shown in table 1.) Selection of the filler metals within each box (The figures in this table relate to the type numbers in table 1) First line: Optimal physical properties Second line: Optimal corrosion resistance Third line: Optimal welding characteristic Base material A Al AlMn AlMg < 1 % a AlMg 3 % AlMg 5 % b AlMgSi c AlZnMg AlSiCu < 1 % e, f AlSiMg e AlSiCu e, f AlCu c Base material B 4 1 4 4 or 5 1 4 4 or 5 1 4 4 or 5 5d 4 or 5 5 5 5 4 - 4 4 4 4 5 5d 4 5 5 5 4 4 4 5 5d 4 5 5 5 4 or 5 4 or 5 4 or 5 5 4 5 5 5 4 4 4 4 4 4 4 4 4 g 5 4 5 5 5 4 4 4 4 4 4 4 4 4 g 5 4 5 5 5 4 4 4 4 4 4 4 4 4 g 5 5d 5 5 5 5 5 5 4 5 5 5 4 4 4 4 4 4 4 4 4 g 5 5 5 5 5 4 5 5 5 4 4 4 4 4 4 4 4 4 g 5 or 4 5 4 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 g g 4 Al AlMn AlMg < 1 % AlMg 3 % AlMg 5 % AlMgSi AlZnMg AlSiCu < 1 % AlSiMg AlSiCu AlCu Remark 1: In case that the base material alloys contain >= 2 % Mg and welding is done with filler metals of the type AlSi5 or AlSi12 (or when the base materials contain >= 2% Si and welding is done with filler metals of the AlMg5 type) then sufficient Mg2Si precipitations can be formed at the fusion line to give a brittle joint. These combinations are not recommended for dynamically or shock stressed structures. If the alloy combination can not be prevented then filler metals of the AlSi5 or AlMg5 type can be used. Remark 2: The base materials are listed according to their chemical composition without reference to cast or wrought materials. a By welding without a filler metal these alloys are prone to solidification cracking. Precautions can be taken by the use of clamping devices or by increasing the Mg content in the weld up to more than 3%. b At certain environment conditions i.e. operation temperature >= 65°C alloys with a Mg content of more than 3% may be prone to intercristalline corrosion and/or stress corrosion. The susceptibility increases with rising Mg content and/or cold hardening. The effect of weld metal dilution should be taken into consideration. c These alloys are not recommended for welding without filler metals, due to their susceptibility of cold cracking. d The resistance against intercristalline corrosion and stress corrosion of type 5 according to table 1 is increased when the Mg content does not exceed 3%. At environment conditions which may cause intercristalline corrosion and/or stress corrosion, the Mg content of the filler metal should be similar to the base material or not significantly higher. Accordingly this must be obeyed for welding of the base materials with the referring filler metals. e The Silicon content of the filler metals should be selected in a way that they match the cast alloy of the base material as good as possible. f In case of die-casting the cast alloys are not weldable due the high gas content. g Not recommended – not suitable for the base metal. For latest details regarding the content of this page see www.migal.co 16

Indicative tables Fields of application and usage of MIGAL.CO consumables for identical or similar base materials ML CuAl8 ML CuAl8Ni2 ML CuAl8Ni6 ML CuAl9Fe ML CuMn13Al7 ML CuSi3 ML CuSn ML CuSn6 Filler metal l suitable m suitable under certain conditions For latest details regarding the content of this page see www.migal.co Copper alloys Base metal 2.0040 / OF-Cu 2.0070 / SE-Cu 2.1030 / CuSn8 2.0920 / CuAl8 2.0076 / SW-Cu 2.0090 / SF-Cu 2.0205 / CuZn0,5 2.0220 / CuZn5 2.0916 / CuAl5 2.1522 / CuSi2Mn 2.1525 / CuSi3Mn 2.0928 / G-CuAl9 CuAl8Fe3 2.0460 / CuZn20Al 2.0230 / CuZn10 2.0240 / CuZn15 2.1016 / CuSn4 2.0975 / CuAl10Ni 2.0978 / CuAl11Ni6Fe5 2.0980 / CuAl11Ni CuAl9Fe4Ni1 2.0966 / CuAl10Ni5Fe4 2.1020 / CuSn6 l l l l l m m m m m l l l l l l l l l l l l l l l l m m m l l 17

Indicative tables Fields of application and usage of MIGAL.CO consumables for identical or similar base materials Stainless steel The following table gives typical selections of welding consumables and basic designations for wire electrodes and filler wire / rods. For exact designations, please refer to the product datasheets of the indvidual products. To address the welding job in question a number of factors have to be considered. The weld geometry and dilution, requirements for heat treatment in association with the welding process, service conditions and temperature, etc. These factors may dictate the choice of consumable beyond those recommended here. For guidance on other steels or combination of steels not covered in these tables, please contact us. Material number Material designation 1.4000 1.4001 1.4002 1.4003 1.4006 1.4008 1.4016 1.4021 1.4024 1.4027 1.4034 1.4057 1.4059 1.4113 1.4120 1.4120 1.4122 1.4122 1.4301 1.4303 1.4306 1.4308 1.4311 X6Cr13 X7Cr14 X6CrAl13 X2CrNi12 X12Cr13 GX8CrNi13 X6Cr17 X20Cr13 X15Cr13 GX20Cr14 X46Cr13 X17CrNi16-2 GX22CrNi17 X6CrMo17-1 X20CrMo13 GX20CrMo13 X39CrMo17-1 GX35CrMo17-1 X5CrNi18-10 X4CrNi18-12 X2CrNi19-11 GX5CrNi19-10 ASTM AISI UNS 403 429 405 410 CA 15 430 420 410 A 217 431 A 743 434 304 305 304L Service temperature up to °C 1.4316 19.9.LSi 1.4332 24.13.LSi 1.4370 18.8.Mn 1.4430 19.12.3.LSi 1.4462 22.8.3.L 1.4551 19.9.NbSi 1.4576 19.12.3.NbSi l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l m m m m m l l l l l X2CrNiN18-10 304LN For latest details regarding the content of this page see www.migal.co 18

Indicative tables Fields of application and usage of MIGAL.CO consumables for identical or similar base materials Table continued 1.4332 24.13.LSi 1.4370 18.8.Mn 1.4430 19.12.3.LSi 1.4462 22.8.3.L 1.4551 19.9.NbSi 1.4576 19.12.3.NbSi l l l l l l l l l l l l m m m m m l l l l3 l3 m m m m m m m m m l l l l 19 Material designation GX10CrNi18-8 ASTM AISI UNS Service temperature up to °C 1.4316 19.9.LSi l X5CrNiMo17-12-2 X2CrNiMo17-12-2 X2CrNiMoN17-11-2 GX5CrNiMo19-11-2 GX2CrNiMo19-11-2 X2CrNiMoN17-13-3 X2CrNiMo18-14-3 X3CrNiMo17-13-3 GX6CrNiMo18-12 X2CrNiMoN22-5-3 X6CrNiTi18-10 X6CrNiNb18-10 GX5CrNiNb19-11 X6CrNiMoTi17-12-2 S32304 316 316L 316L S31500 316LN 317L S31600 S31600 S31803 321 347 CF8C 316 Ti X6CrNiMoNb17-12-2 316 Cb GX5CrNiMoNb19-11-2 X10CrNiMoNb18-12 316 Cb m m m Material number 1.4312 1.4362 1.4401 1.4404 1.4406 1.4408 1.4409 1.4417 1.4429 1.4435 1.4436 1.4437 1.4462 1.4541 1.4550 1.4552 1.4571 1.4580 1.4581 1.4583 1.47102 1.4712 1.4713 1.4724 1.4825 1.4878 850 850 800 850 800 800 405 A297 Gr. CF20 321 m1 m1 m1 m1 m1 m1 l matching or similar alloyed filler metal m dissimilar or higher alloyed filler metal (service conditions must be approved) 1 Austenitic weld metal with higher ductility; application in sulphur-containing environment or similar-colour requirement demands the usage of similar alloyed welding consumables 2 weldability of base material is limited 3 for service temperatures up to 400°C For latest details regarding the content of this page see www.migal.co

Indicative tables Lengths of wires in meters ... ... for aluminium alloys at a specific weight of 2,7 g/cm3 Wire diameter [mm] Weight [g/m] 0,8 1,0 1,2 1,6 2,0 2,4 1,36 2,12 3,05 5,43 8,48 12,21 0,5 368 236 164 92 59 41 2 1.474 943 655 368 236 164 6 4.421 2.829 1.965 1.105 707 491 Spool weight [kg] 7 5.158 3.301 2.292 1.289 825 573 18 13.263 8.488 5.895 3.316 2.122 1.474 40 80 140 26.198 14.737 66.020 45.847 25.789 13.099 7.368 4.716 3.275 ... for copper alloys at a specific weight of 8,9 g/cm3 Wire diameter [mm] Weight [g/m] 0,8 1,0 1,2 1,6 2,0 2,4 4,47 6,99 10,07 17,89 27,96 40,26 3 671 429 298 168 107 75 Spool weight [kg] 5 1.118 715 497 279 179 124 15 3.353 2.146 1.490 838 537 373 200 28.612 19.870 11.177 ... for stainless steel wires at a specific weight of 7,8 g/cm3 Wire diameter [mm] Weight [g/m] 0,8 1,0 1,2 1,6 2,0 2,4 3,92 6,13 8,82 15,68 24,50 35,29 15 3.826 2.449 1.700 956 612 425 Spool weight [kg] 150 38.258 24.485 17.004 9.565 6.121 4.251 300 76.517 48.971 34.007 19.129 12.243 8.502 ... for nickel alloys at a specific weight of 8,5 g/cm3 Spool weight [kg] Wire diameter [mm] Weight [g/m] 0,8 1,0 1,2 1,6 2,0 2,4 4,27 6,68 9,61 17,09 26,70 38,45 15 3.511 2.247 1.560 878 562 390 For latest details regarding the content of this page see www.migal.co 20

MA 1070 Al99,7 Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,20 Fe .......................................................................................................... < 0,25 Cu .......................................................................................................... < 0,04 Mn ......................................................................................................... < 0,03 Mg ......................................................................................................... < 0,03 Zn ........................................................................................................... < 0,04 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,03 Others .................................................................................................... < 0,03 Al ..................................................................................................... min. 99,70 EN ISO 18273 .................................................................... S Al 1070 (Al99,7) Material No. .......................................................................................... 3.0259 JIS Z3232 ............................................................................................... A1070 See page 15. Welding of pure aluminium requires special precaution due to the narrow melting range in order to prevent hotcracking and porosity. Consider the technological application reference. Electrical conductivity [S*m/mm2] ........................................................... 34-36 Heat conductivity at 20°C [W/(m*K) ................................................... 210-230 Linear heat extension coefficient (20-100°C) [1/K] ............................ 23,5*10-6 0,2 % yield strength Rp0,2 [MPa] ................................................................... 20 Tensile strength Rm [MPa] ........................................................................... 65 Elongation A5 (L0=5d0) [%] ........................................................................... 35 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-Drum / 80 kg .................................................... 2 Drums = 160 kg (pallet) Jumbo-Drum / 140 kg .............................................. 2 Drums = 280 kg (pallet) JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 24

MA 1450 Al99,5Ti Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,25 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,05 Mn ......................................................................................................... < 0,05 Mg ......................................................................................................... < 0,05 Zn ........................................................................................................... < 0,07 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,10-0,20 Others .................................................................................................... < 0,03 Al ..................................................................................................... min. 99,50 EN ISO 18273 ................................................................. S Al 1450 (Al99,5Ti) Material No. .......................................................................................... 3.0805 See page 15. Welding of pure aluminium requires special precaution due to the narrow melting range in order to prevent hotcracking and porosity. Grain refinement in the weld metal resulting from the addition of Ti. Consider the technological application reference. Electrical conductivity [S*m/mm2] ......................................................... min. 35 Heat conductivity at 20°C [W/(m*K) ................................................... 210-230 Linear heat extension coefficient (20-100°C) [1/K] ............................ 23,5*10-6 0,2 % yield strength Rp0,2 [MPa] ................................................................... 20 Tensile strength Rm [MPa] ........................................................................... 65 Elongation A5 (L0=5d0) [%] ........................................................................... 35 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF 1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-Drum / 80 kg .................................................... 2 Drums = 160 kg (pallet) Jumbo-Drum / 140 kg .............................................. 2 Drums = 280 kg (pallet) JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 25

MA 2319 AlCu6MnZrTi Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,20 Fe .......................................................................................................... < 0,30 Cu ..................................................................................................... 5,80-6,80 Mn .................................................................................................... 0,20-0,40 Mg ......................................................................................................... < 0,02 V ....................................................................................................... 0,05-0,15 Zn ........................................................................................................... < 0,10 Zr ...................................................................................................... 0,10-0,25 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,10-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ......................................................... S Al 2319 (AlCu6MnZrTi) AWS A 5-10 ....................................................................................... ER 2319 See page 15. This alloy is mainly used in the air- and spacecraft industry. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 70 Tensile strength Rm [MPa] ......................................................................... 160 Elongation A5 (L0=5d0) [%] ........................................................................... 12 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 26

MA 4018 AlSi7Mg Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ...................................................................................................... 6,50-7,50 Fe .......................................................................................................... < 0,20 Cu .......................................................................................................... < 0,05 Mn ......................................................................................................... < 0,10 Mg .................................................................................................... 0,50-0,80 Zn ........................................................................................................... < 0,10 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,10-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ................................................................. S Al 4018 (AlSi7Mg) Werkstoff Nr. ......................................................................................... 3.2371 See page 15. Welding of sand and permanent mould castings. The physical properties can be improved by heat treatment. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................. F: 80, T6: 250 Tensile strength Rm [MPa] ....................................................... F: 140, T6: 310 Elongation A5 (L0=5d0) [%] ............................................................... F: 2, T6: 4 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ..................................................................... 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-Drum / 80 kg .................................................... 2 Drums = 160 kg (pallet) Jumbo-Drum / 140 kg .............................................. 2 Drums = 280 kg (pallet) JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 27

MA 4020 AlSi3Mn Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ...................................................................................................... 2,50-3,50 Fe .......................................................................................................... < 0,20 Cu .......................................................................................................... < 0,03 Mn .................................................................................................... 0,80-1,20 Mg ............................................................................................................ 0,01 Zr ............................................................................................................ < 0,01 Be ...................................................................................................... < 0,0003 Ti .......................................................................................................... < 0,005 Others .................................................................................................... < 0,02 Others total ............................................................................................ < 0,10 EN ISO 18273 ............................................................... S Al 4020 (AlSi3Mn1) See page 15. Welding of body in white parts especially exterior shells. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 50 Tensile strength Rm [MPa] ......................................................................... 120 Elongation A5 (L0=5d0) [%] ........................................................................... 25 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-drum / 80 kg ..................................................... 2 drums = 160 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 28

MA 4043 AlSi5 Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings Si ...................................................................................................... 4,50-5,50 Fe .......................................................................................................... < 0,60 Cu .......................................................................................................... < 0,30 Mn ......................................................................................................... < 0,15 Mg ......................................................................................................... < 0,20 Zn ........................................................................................................... < 0,10 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ............................................................... S Al 4043A (AlSi5(A)) Material No. .......................................................................................... 3.2245 AWS A 5-10 ...................................................................................... ER 4043 JIS Z3232 ............................................................................................. A4043 See page 15. This alloy is particularly used to prevent solidification cracks in connection with high dilution and clamp conditions. Anodizing gives dark gray colours and is not recommended. The weld pool is very fluid. Consider the technological applica- tion reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 40 Tensile strength Rm [MPa] ......................................................................... 120 Elongation A5 (L0=5d0) [%] ............................................................................. 8 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ DB, VdTÜV MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-drum / 80 kg ..................................................... 2 drums = 160 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 29

MA 4046 AlSi10Mg Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si .................................................................................................... 9,00-11,00 Fe .......................................................................................................... < 0,50 Cu .......................................................................................................... < 0,03 Mn ......................................................................................................... < 0,40 Mg .................................................................................................... 0,20-0,50 Zn ........................................................................................................... < 0,10 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ............................................................... S Al 4046 (AlSi10Mg) Material No. .......................................................................................... 3.2382 See page 15. Welding of sand and permanent mould castings. The physical properties can be improved by heat treatment. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 70 Tensile strength Rm [MPa] ......................................................................... 140 Elongation A5 (L0=5d0) [%] ............................................................................. 4 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ..................................................................... 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-drum / 80 kg ..................................................... 2 drums = 160 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 30

MA 4047 AlSi12 Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si .................................................................................................. 11,00-13,00 Fe .......................................................................................................... < 0,60 Cu .......................................................................................................... < 0,30 Mn ......................................................................................................... < 0,15 Mg ......................................................................................................... < 0,15 Zn ........................................................................................................... < 0,20 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ............................................................. S Al 4047A (AlSi12(A)) Material No. .......................................................................................... 3.2585 AWS A 5-10 ....................................................................................... ER 4047 JIS Z3232 ............................................................................................. A4047 See page 15. This alloy is particularly used to prevent solidification cracks in connection with high dilution and clamp conditions. Anodizing gives dark gray colours and is not recommended. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 60 Tensile strength Rm [MPa] ......................................................................... 130 Elongation A5 (L0=5d0) [%] ............................................................................. 5 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-drum / 80 kg ..................................................... 2 drums = 160 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 31

MA 5087 AlMg4,5MnZr Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,25 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,05 Mn .................................................................................................... 0,70-1,10 Mg .................................................................................................... 4,50-5,20 Cr ...................................................................................................... 0,05-0,25 Zn ........................................................................................................... < 0,25 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Zr ...................................................................................................... 0,10-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 .................................................... S Al 5087 (AlMg4,5MnZr(A)) Material No. .......................................................................................... 3.3546 See page 15. Zirconium micro alloyed. The weld is not susceptible to hot cracking. Particularly advantageous for complicated weldments involving clamp conditions. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................. 140 Tensile strength Rm [MPa] ......................................................................... 285 Elongation A5 (L0=5d0) [%] ........................................................................... 18 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ VdTÜV, DB, DNV-GL, Bureau Veritas, Lloyds Register, ABS MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 32

MA 5183 AlMg4,5Mn0,7 Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,40 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,10 Mn .................................................................................................... 0,50-1,00 Mg .................................................................................................... 4,30-5,20 Cr ...................................................................................................... 0,05-0,25 Zn ........................................................................................................... < 0,25 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ................................................... S Al 5183 (AlMg4,5Mn0,7(A)) Material No. .......................................................................................... 3.3548 AWS A 5-10 ....................................................................................... ER 5183 JIS Z3232 ............................................................................................. A5183 See page 15. Seawater resistant weld metal. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................. 130 Tensile strength Rm [MPa] ......................................................................... 275 Elongation A5 (L0=5d0) [%] ........................................................................... 18 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ VdTÜV, DB, DNV-GL, Bureau Veritas, Lloyds Register, ABS MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 33

MA 5356 AlMg5Cr Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,25 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,10 Mn .................................................................................................... 0,05-0,20 Mg .................................................................................................... 4,50-5,50 Cr ...................................................................................................... 0,05-0,20 Zn ........................................................................................................... < 0,10 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,06-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ............................................................ S Al 5356 (AlMg5Cr(A)) Material No. .......................................................................................... 3.3556 AWS A 5-10 ...................................................................................... ER 5356 JIS Z3232 ............................................................................................. A5356 See page 15. The weld metal is sea water resistant. Suitable for anodizing when matching colours are required. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................. 120 Tensile strength Rm [MPa] ......................................................................... 250 Elongation A5 (L0=5d0) [%] ........................................................................... 18 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ VdTÜV, DB, DNV-GL, Bureau Veritas, Lloyds Register, ABS MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 34

MA 5554 AlMg2,7Mn Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,25 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,10 Mn .................................................................................................... 0,50-1,00 Mg .................................................................................................... 2,40-3,00 Cr ...................................................................................................... 0,05-0,20 Zn ........................................................................................................... < 0,25 Be ...................................................................................................... < 0,0003 Ti ...................................................................................................... 0,05-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ............................................................ S Al 5554 (AlMg2,7Mn) Material No. .......................................................................................... 3.3538 AWS A 5-10 ....................................................................................... ER 5554 JIS Z3232 ............................................................................................. A5554 See page 15. This alloy was developed for applications at high temperatures and for resistance against intergranular corrosion. Joining of the base metal 5454 with alloys of the 6000 range is possible. The weld metal is sea water resistant. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................. 100 Tensile strength Rm [MPa] ......................................................................... 215 Elongation A5 (L0=5d0) [%] ........................................................................... 18 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 35

MA 5556 AlMg5Mn Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,25 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,10 Mn .................................................................................................... 0,60-1,00 Mg .................................................................................................... 5,00-5,50 Cr ...................................................................................................... 0,05-0,20 Zn ........................................................................................................... < 0,20 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,05-0,20 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 ...................................................... S Al 5556A (AlMg5Mn1(A)) AWS A 5-10 ...................................................................................... ER 5556 See page 15. This alloy has the highest strength. The weld metal is sea water resistant. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................. 145 Tensile strength Rm [MPa] ......................................................................... 290 Elongation A5 (L0=5d0) [%] ........................................................................... 17 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 36

MA 5754 AlMg3 Rod/Wire electrode for Aluminium Typical composition in % Classification Base materials Remarks Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings Si ........................................................................................................... < 0,40 Fe .......................................................................................................... < 0,40 Cu .......................................................................................................... < 0,10 Mn ......................................................................................................... < 0,50 Mg .................................................................................................... 2,60-3,60 Cr ........................................................................................................... < 0,30 Zn ........................................................................................................... < 0,20 Be ...................................................................................................... < 0,0003 Ti ............................................................................................................ < 0,15 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 EN ISO 18273 .................................................................... S Al 5754 (AlMg3) Material No. .......................................................................................... 3.3536 See page 15. The weld metal is sea water resistant. Suitable for anodizing when matching colours are required. Consider the technological application reference. 0,2 % yield strength Rp0,2 [MPa] ................................................................... 80 Tensile strength Rm [MPa] ......................................................................... 190 Elongation A5 (L0=5d0) [%] ........................................................................... 20 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ TÜV, DB MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Jumbo-drum / 140 kg ................................................ 2 drums = 280 kg (pallet JumboXL-Drum / 240 kg ............................................ 1 Drum = 240 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 37

MA 6063 AlMg0,7SiTiB Rod/Wire electrode for Aluminium Typical composition in % Remarks Macro section: Base material AW-6082, 5 mm, filler wire MA-6063 1,2 mm Fine-grain structure due to TiB particles Si ...................................................................................................... 0,20-0,60 Fe .......................................................................................................... < 0,35 Cu .......................................................................................................... < 0,10 Mn ......................................................................................................... < 0,10 Mg .................................................................................................... 0,45-0,90 Cr ........................................................................................................... < 0,10 Zn ........................................................................................................... < 0,10 Be ...................................................................................................... < 0,0003 Ti ....................................................................................................... 0,20-0,30 B ........................................................................................................ 0,04-0,06 Others .................................................................................................... < 0,05 Others total ............................................................................................ < 0,15 When selecting a filler metal for joint welding, a similar alloy is usually chosen. This applies to steels as well as to non-ferrous metals. Burn-off of alloying elements, especially in processes with droplet transfer through the arc, is prevented by a somewhat higher proportion of such alloying elements. For aluminium alloys of the 6000 group (AlMgSi), this principle has been deviated from for decades. Although this group of alloys is widely used (bumpers, car bodies in automotive construction and for large profiles in rail vehicle construction), there has been no filler metal similar to this type until now. The reason for this is the high hot cracking tendency of aluminium alloys with a maximum cracking tendency at alloy contents of 1.2 % magnesium and about 0.75 % silicon. These are also roughly the alloy ranges of aluminium alloys of the 6000 group. For example, it is not possible to weld these alloys with the TIG process without adding an additive, because hot cracks always form. As a way out, it was previously only possible to increase the magnesium or silicon content of the weld by using additives of the 4000 or 5000 group with a content of approx. 5 % of Mg or Si to such an extent that the area at risk of hot cracking is avoided. This compromise naturally entails various advantages and disadvantages. A way out of this dilemma was shown in the dissertation by Dipl.-Ing. Philipp Schempp, TU-Berlin 2013, entitled „Grain refinement in aluminium GTA welds“. It describes how the formation of hot cracks in aluminium alloys can be reliably prevented by the addition of Ti5B1. These nanoparticles serve as heterogeneous solidification nuclei during the cooling of the melt and lead to a very significant reduction in grain size. This simultaneously prevents the formation of hot cracks. For latest details regarding the content of this page see www.migal.co 38

MA 6063 AlMg0,7SiTiB Rod/Wire electrode for Aluminium Remarks Comparison of the properties of different welding consumables for 6xxx base materials MIGAL.CO has now succeeded in making commercially available a first filler metal of the 6000 group with a Ti5B1 content of approx. 0.30%. This MA-6063 is available both as MIG wire electrode and as TIG rod. It can be used for joint welding as well as for additive manufacturing (WAAM). The advantages of this filler metal are impressively shown in the table, in comparison to the previously used filler metals 4043 and 5183. A very important feature is the possibility of increasing the strength by means of a subsequent heat treatment. This makes it possible to achieve a yield strength of 200-260 MPa, with good elongation values of 6-12% at the same time. The weldability (seam geometry, penetration depth, black precipitation) is also considerably improved compared to the AlMg alloy. The penetration profile of MA-6063 is almost identical to that of 4043 (AlSi5), which is very advantageous for many applications. 4043 5183 6063 Penetration Seam width Seam height Seam cross section 5,16 mm 13,42 mm 2,91 mm 27,07 mm2 2,68 mm 10,85 mm 3,29 mm 4,61 mm 11,60 mm 3,12 mm 26,46 mm2 26,54 mm2 4043 5183 6063 Black deposit Penetration depth Ductility Weld geometry Strength Hot cracking Heat conductivity Electr. conductivity Painting/Coating + + - + - + • • Not specified - - + - + - - - - + + + + • (as welded)/+ (T6) + + + + For latest details regarding the content of this page see www.migal.co 39

MA 6063 AlMg0,7SiTiB Rod/Wire electrode for Aluminium Physical properties of pure weld metal (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings 0,2 % yield strength Rp0,2 [MPa] ........................................ F: 80; T6: 200 - 260 Tensile strength Rm [MPa] .............................................. F: 150; T6: 250 - 280 Elongation A5 (L0=5d0) [%] ...................................................... F: 15; T6: 6 - 12 Test temperature [°C] .................................................................................. 20 PA, PB, PC, PD, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, WIG ~ MIG-wires [mm] ....................................................... 0,8; 1,0; 1,2; 1,6; 2,0; 2,4 TIG-rods [mm] ......................................................... 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spools .................................................................................... Packaging units S 100 / 0,5 kg ............................................................. 20 spools = 10 kg (box) S 200 / 2 kg .................................................................... 4 spools = 8 kg (box) S 300 / 6 kg ........................................................... 56 spools = 336 kg (pallet) B 300 / BS 300 / 7 kg ............................................ 56 spools = 392 kg (pallet) B 400 / 18 kg ......................................................... 28 spools = 504 kg (pallet) B 400 / 40 kg ......................................................... 15 spools = 600 kg (pallet) Eco-drum / 80 kg ..................................................... 2 drums = 160 kg (pallet) Jumbo-drum / 140 kg .............................................. 2 drums = 280 kg (pallet) Tube / 2,5 kg / Length 1.000 mm ........................ 225 tubes = 562,5 kg (pallet) Box / 5 kg / Length 1.000 mm ............................... 120 boxes = 600 kg (pallet) Box / 10 kg / Length 1.000 mm ............................... 60 boxes = 600 kg (pallet) For latest details regarding the content of this page see www.migal.co 40

Application reference Application reference to gas shielded arc welding of aluminium The use of aluminium and its alloys increases continuously all over the world. In the field of mobility an over proportional increase and further substitution of steel in particular, but not only, will occur in a near future. Increasing cost of energy make lightweight design more economical than ever. As a consequence, constructors switch from steel to aluminium and new manufacturers immediately start with aluminium. As production processes and applied terminology offen differ only slightly from steel, basic mistakes are commonly made and lead to expensive rework, reject and delay. As a matter of fact, some properties of aluminium are just opposite to steel and knowledge about these is essential for safe manufacturing. Physical properties of chemically clean aluminium (compared to iron) Properties Atomic weight Crystal lattice Density Elasticity Expansion coefficient Rp0,2 Tensile strength Rm Specific heat Heat of fusion Melting temperature Heat conductivity Electrical conductivity Oxides Melting temperature of oxides Density of oxides Unit [g/Mol] [g/cm3] [Gpa] [1/K] [MPa] [MPa/] [J/kg•K] [J/g] [°C] [W/m•K] [m/Ω•mm2] [°C] [g/cm3] Table: Physical properties of aluminium compared to iron Al Fe 26,98 cubically face-centred 2,70 55,84 cubically body-centred 7,87 67 24 • 10-6 ≈ 10 ≈ 50 ≈ 890 ≈ 390 660 235 38 Al2O3 2050 3,89 210 12 • 10-6 ≈ 100 ≈ 200 ≈ 460 ≈ 272 1536 75 ≈ 10 FeO / Fe2O3 / Fe3O4 1400 / 1455 / 1600 5,7 / 5,24 / ≈ 5,0 Relation ≈ 1 against 2 ≈ 1 against 3 ≈ 1 against 3 ≈ 2 against 1 ≈ 1 against 10 ≈ 1 against 4 ≈ 2 against 1 ≈ 1,5 against 1 ≈ 1 against 2,5 ≈ 3 against 1 ≈ 4 against 1 Fe similar to metal; Al three times as much Iron oxides are lighter than metal; Al oxides are heavier Effects of the differences between the physical properties of steel to aluminium on fusion welding The differences in density, modulus of elasticity and strength are hardly relevant for welding but most certainly for the design of structures. The high electrical conductivity of aluminium may lead to arc striking problems and the high thermal conductivity to a lack of fusion at the beginning of the weld and to forward moving welding heat. These aspects are discussed in this article. The high heat conductivity may also lead to overheating of fixtures and to dimensional deviations, which require a more stable For latest details regarding the content of this page see www.migal.co 41

Application reference design, and probably additional cooling of such devices. In general high heat conductivity and a high coefficient of expansion give more deviation than compared to steel and must be considered in design and in the construction of welding fixtures. Special attention has to be paid to the oxide layer and to the solubility of hydrogen. Oxide layer When exposed to the atmosphere, aluminium immediately forms an oxide layer, which basically consists of amorphous Al2O3 in two partial layers on top of each other, namely • a nearly pore free base- or barrier layer of amorphous aluminium oxide and • a porous and hydrated cover layer with low crystalline contents of Al-hydroxides and bayerite. Figure: Schematic structure of a natural oxide layer The thickness of the oxide layer increases with time, temperature and availability of oxygen. Even though the oxide layer is very tight, has a melting temperature of 2300° C and protects the aluminium surface from further corrosion, it can also be porous and pick up humidity. The surface condition of aluminium influences MIG and TIG welding in the following aspects: • The arc stability (a stable arc requires the presence of aluminium oxide) • The geometry of the arc focal point • The voltage drop in the arc and therefore the arc length • The geometry of the weld • The quality of the weld • The reproducibility of the process in particular with automatic welding Due to the extremely small thickness within few nanometres of the oxide layer, it is hardly measurable under practical For latest details regarding the content of this page see www.migal.co 42

Application reference conditions. Hence, the only remaining possibility to obtain a defined oxide layer is to remove the old layer completely by chemical processes (pickling) and by storing under controlled conditions (environment and time). Further remarkable is the fact that the density of aluminium oxide in comparison to the metal itself is higher. With iron (steel) the oxides have a lower weight than the metal and therefore float on the surface of the molten pool. With aluminium the oxide sinks into the molten metal and may cause oxide inclusions. Solubility of hydrogen Amongst all gases only hydrogen can be solved in aluminium. Compared to the solubility of gases in iron alloys, however, the quantity is rather low. The solubility of hydrogen in aluminium depends on the content of alloys and on the temperature. The solved quantity furthermore depends on the availability of hydrogen, which is usually given as the partial pressure and indicated in millilitres of the solved gas per 100 grams of metal. (1013 mbar and 0° C, 1ppm = 1.1124 ml/100 g). As the solubility of hydrogen in aluminium suddenly decreases at a temperature of approximately 600° C during cooling, it often comes to porosity caused by frozen gas bubbles. With pure aluminium the tendency to porosity is most serious, whereas it is lower with alloys. This is due to a smaller lap in the solubility of hydrogen. These circumstances lead to the fact that the presence of porosity with MIG welding of aluminium is nearly unavoidable. Pores have negative implications on the static and dynamic strength of welded joints and can be disturbing anyway. Machining the surfaces opens pores, which don’t look nice and may reduce the adhesion of paint. Inspectors have trouble to determine the level of acceptable porosity and both manufacturers and customers consider it as just poor work. Figure: Solubility of hydrogen in aluminium and iron The basic solution to this problem is to keep the level of available hydrogen as low as possible. Generally, a hydrogen content of approximately 0.2 to 0.3 ml/100 g is considered to be the maximum permitted level in order to get low porosity. This value is quite frequently exceeded under practical conditions. Sources of hydrogen are base material, filler material, shielding gas and atmosphere. Clean storage and manufacturing conditions, preparation of the surfaces and prevention of all other sources of hydrogen is the most important rule. For latest details regarding the content of this page see www.migal.co 43

Application reference Surface treatment prior to welding Due to the above mentioned circumstances, the surface treatment of base metals and filler wires plays a much bigger role than for instance with steel. The question if cleaning prior to welding is necessary can only be answered in one way: If the target is low porosity, high strength and constant welding joints, then thorough cleaning according to tested, fixed and reproducible processes is necessary. We have put together some basic rules for storage, cleaning, joint preparation and welding. Storage and handling Base materials Sheets and profiles are to be stored vertically and with sufficient distance in order to get air circulation and to prevent contact points to each other. The storage areas must be covered and preferably heated whereas the temperature should be constant. Controlled humidity would be a positive option. Filler materials Heated storage premises with constant temperature and if possible controlled humidity as well is of great importance. Prior to welding the filler metals should be stored in the same environment as the base materials without opening the boxes in order to get the same temperature. Protection against dust and any other pollution must be ensured at any time. Condensation The influence of atmospheric humidity and temperature may alter the conditions of fabrication during different seasons significantly. Just like humidity condenses on a glass of beer, this can happen on aluminium surfaces as well. The difference of temperature between air and metal and the humidity are the responsible parameters. The following table shows the dew points at different temperature differences and humidity in some examples. At www.migal.co a dew point calculator can be found. (Tair – Tmetal)° Relative humidity (Tair – Tmetal)° Relative humidity °C 0 1 2 3 4 5* 6 7 8 9 10 11 % 100 93 87 81 75 70* 66 61 57 53 50 48 °C 12 13 14 15 16 18 20 22 24 26 28 30 % 44 41 38 36 34 30 26 23 21 18 16 14 * Example: At a relative humidity of 70 %, water condenses on a metal surface with a temperature difference of 5° C only. Condensation must be avoided in any case. Table: Condensation of water depending on the temperature difference between metal and air For latest details regarding the content of this page see www.migal.co 44

Application reference Joint preparation Plasma cutting Attention must be paid to an utmost focused arc and the lowest possible heat input. Especially with alloys of the 2XXX, 6XXX and 7XXX groups cracking may occur in the heat affected zone and machining of the cutting edge of up to 3 mm and more may be required. Alloys of the groups 1XXX, 3XXX and 5XXX can usually be welded without any post treatment. Machining Turning, milling or other metal-cutting processes are most suitable. Lubricants or cooling liquids must not be used, however, and the tools need to have sharp edges to prevent smearing of the metal. Particularly suitable are milling rings and weld root opener from MIGAL.CO, for more information see www.migal.co/milling-substitutes-grinding For sawing and grinding only products recommended by their manufacturers shall be used. For brushing, take care to use stainless steel brushes to prevent inclusions of carbon steel into the base material. The bristle wire diameter of the brush should be between 0.1 and 1.25 mm for the softer aluminium alloys and between 0.25 and 0.4 mm for the harder alloys. If the wire is too thin it often bends at its ends and therefore is no longer able to remove the impurities. It rather gives a smearing effect. If the wire is too thick it leads to flutes in the material. Similar considerations are to be taken with shot blasting. Compressed air tools should exhaust to the back in order to prevent contamination with oil. Chemical cleaning The cleaning processes should be applied short before welding. Possible cleaning methods are pickling in alkaline solutions and the application of hydrocarbon solvents (alcohol, acetone). Despite high costs, pickling is preferable. Solvents are prohibited in many cases for reasons of work safety as solvent residuals may produce gases and fumes, which may be harmful to health. Gas Metal Arc Welding of aluminium General Information MIG (Metal Inert Gas) welding with a gas metal arc in shielded atmosphere is the most commonly used welding process for aluminium. Beside this process, there is TIG (Tungsten Inert Gas) welding with a tungsten arc in shielding atmosphere employed for thin aluminium sheet constructions where the metal has a thickness below 2 mm. However, the evolution of generators with pulsed power supply also permits the welding of thin sheets. In the MIG welding process, the wire is used as the electrode and at the same time as the consumable. Throughout the wire consumption, the wire is automatically unwound down to the welding handle. Gas metal arc welding is done with direct current (electrode positive) and ensures the pickling and fusion of the wire. The parts to be welded are bound to a negative pole. In the TIG welding process, the electric arc is produced between a tungsten electrode and the part to be welded. The filler metal fed by hand feeds the melt. Gas tungsten arc welds are made with alternating current. Both processes, MIG and TIG welding, are covered by the sign MSG (Metal Shielding Gas). MIG welding is easily automated (robot welding) which is not as easy with Tig welding. Due to this fact and the generally higher deposit rate of Mig welding, it will show an increasing significance in the future. For latest details regarding the content of this page see www.migal.co 45

Application reference Filler metals The selection of the proper filler metal can be made with the table in this catalogue or the material calculator at www. migal.co. These aids cannot consider all constructional and metallurgical characteristics and the conditions of the base metal. Due to this reason separate investigations and trials are required before production in many cases. The quality and the stability of the process are in an immediate relation with the quality of the filler metal. MIG welding Filler metals from MIGAL.CO have an outstanding purity and enjoy a special surface treatment. With Mig welding, the filler wire is the electrode at the same time. The wire is fed from the spool though a wire feed system into a hose pack and finally through the contact tip by means of an automated system. The welding current is given to the electrode only short before the arc. The gliding characteristics and the purity of the surface are essential for trouble free wire feeding. MIGAL.CO wires are optimised for this purpose and provide a stable and safe arc ignition as well as low friction in the liners. A favourable side effect of the surface purity is the low formation of welding fumes, which occurs substantially by evaporation of surface impurities. Welds made with wires from MIGAL.CO show lowest porosity and highest strength. The reduced formation of welding fumes was proved by investigations of the Institute for occupational health in St. Augustin, Germany, with wires of the alloy AlSi5 Ø 1.2 mm in comparison to other commercially available products. to The wire feeder unit must be equipped according the manufacturers specifications. This concerns the shape of wire feed rolls, the use of plastic or Teflon liners and the choice of contact tips. Figure: Comparison of wire electrodes regarding the formation of welding fumes In opposite to steel wires, the inner diameter of the contact tip bore must be larger. For instance, it has been proved that a bore diameter of 1.6 mm is suitable for a 1.2 mm wire diameter. It is most important to prevent the wire from rubbing and getting scratches from any metal part on its way from the spool to the electric arc and to ensure its surface remains undamaged. Furthermore, it has to be considered that pure aluminium and aluminium-silicon alloys are softer than aluminium-magnesium alloys and that the liner should not exceed 3 m. With aluminium-magnesium alloys a length of 4 m should be possible. With mechanised or robotic welding processes a hose pack length of 1.5 to 2 m should not be exceeded and in the full interest of a trouble free welding process, a pulled wire feeding system (wire drive in the welding torch) or combined systems (push-pull) are recommended. For latest details regarding the content of this page see www.migal.co 46

Application reference Wire feeding Wire feed systems for GMAW-welding machines were initially developed to transport steel wires as well as most other design criteria has been derived from steel welding. Steel wires generally have good gliding characteristics and high stiffness. Neither is true for aluminium and this is particularly difficult for the feeding of AlSi5 and pure aluminium wires. In no case, aluminium wire should be pulled through a liner as this leads to a self-amplifying braking effect. While it is hardly necessary to pull the wire through a liner when using 7 kg (B300 or S300) spools, this is quite often the case with bulk wire systems. In order to overcome this problem, push-push wire feed systems have been developed within the last 5 years. With such systems, either the spool itself is driven and the wire is directly put into the wire feeder or the wire is directly pulled out from a drum. Both are done with an extremely short and straight liner. The wire feeder, which comes right after the wire container pushes the wire into the liner. A second wire feeder is situated immediately before the welding torch and controls the wire feed speed needed for the welding process. This one feeds the wire through the last few centimetres until the contact tip. For the uncoiling of B-400 40 kg spools, special uncoiling systems are required while this is not necessary with Eco-drums and Jumbo-drums. An as-short-as-possible connection of the drum to the wire-feeder is essential (see picture). For longer connections between the bulk pack and the wire feeder we recommend our Rolliner. For a complete product line regarding the connection of bulk wire packs to wire-feeders refer to our separate catalogue „Wire transport“. Arc ignition Aluminium has a much higher electrical conductivity than steel. Due to this, it is much more difficult to heat the wire during short-circuit by Ohm’s law (I2*R) to ionise the shielding gas and to strike the arc. Additionally, the surface is covered with a hard and insulating aluminium oxide layer, which needs to be broken before short-circuit. This arc-striking problem could be partially overcome with conventional power sources with specially designed choke coils only. Due to the advance of electronic power sources, it has become possible to increase the ignition current sufficiently fast and to reach the process parameters quickly afterwards. For some years arc ignition is possible by means of a retractable wire feeder. With this system the wire is fed slowly to the work piece until short-circuit occurs. Then the wire is retracted a few millimetres and a low-power arc strikes. Successively the arc is quickly brought to the proper process parameters. This provides the opportunity of a spatter free ignition within a short and precise time frame. This way of arc ignition is limited to a wire feeder in immediate proximity of the contact tip in order to move the wire as accurate as possible. This may lead to a heavier and bulkier torch with disadvantages with semi-automatic and automatic applications. Only recent robotic systems can provide such a feature. There the robot and not the wire feeder do the retracting movement. For latest details regarding the content of this page see www.migal.co 47

Application reference Insufficient melting of the base metal at start and end crater at the end of the weld Due to the high heat conductivity of aluminium, it is difficult to create enough heat to melt the base metal right after arc ignition. Afterwards, the heat flow in the work piece is faster than the welding speed and the conditions at the end of the weld are unfavourable for a proper end-crater fill. Current control programs have been integrated to the welding power sources by the manufacturers in which higher arc power is provided at start and lower power at the end of the weld. This definitely leads to an improvement, however, lack of fusion, porosity and end crater cracks are not completely prevented. Higher arc power is always linked with a higher wire quantity (wire feed speed) and lower wire quantity at the end crater with MIG welding. Exactly the opposite would be required. If possible, the following steps should be taken: • Use of run-in and run-out plates • Beginning and end of weld on the base metal • Preheating • Well cooled welding fixtures Black deposit on and beside the weld With many applications (pallets for the chemical and food industry, ladder, scaffoldings) the black deposit is rather disturbing. Simple brushing removes it but requires additional operations that can often be done only manually at areas of limited access. Figure: Current program with increased start current and reduced end current Figure: EDS analysis of black deposit For latest details regarding the content of this page see www.migal.co 48

Application reference The deposit results from evaporation and following fallout of magnesium oxide. Magnesium is an alloying element of aluminium that substantially increases its strength and cannot be left out in most cases. Magnesium oxide is usually known in white colour. An EDS-analysis eliminates any doubt of the deposit being or not MgO that is known to show grey, yellow, brown or black colours beside its white form of existence. The following possibilities exist to prevent MgO formation: • Use of wire electrodes with low or no Mg content (AlMg3, AlSi5) • Optimised pulse parameters for the lowest possible formation of metal vapour • Avoid poor accessibility and resulting unfavourable torch positions • Sufficient shielding gas protection to keep the intake of oxygen as low as possible Special attention with gas shielded arc welding MIG welding Wire scratching at metallic edges Figure: Poorly adjusted wire feed system It must be guaranteed that the wire does not scratch over hard or metallic edges during its way from the spool to the contact tip and thereby gets damaged. Critical points are shown in the following drawings. Guiding tubes and inlet nozzles close to the feeding rolls are frequently improperly adjusted, have a too small diameter or have a bur. The same is true for contact tips, which are not suitable for soft wires in many cases. The bore diameter of contact tips for aluminium must be approximately 0.2 mm larger than for steel. Contact tips for steel have a bore diameter, which is usually 0.15-0.2 mm larger than the wire diameter, which means that tips for aluminium need to be 0.35-0.4 mm larger in diameter than the wire itself. Figure: Wire rub-off at contact tip Unsuitable wire feed rolls Rolls for aluminium and copper wires must be specially designed for aluminium by their manufacturer. A so-called semi-round groove or a similar groove shape is common. The picture shows frequent mistakes in connection with wire feed rolls. The pressure force of the rolls to each other must be as low as possible. It should not be increased when sudden wire feed problems occur but the reason for the problems needs to be investigated and removed. Figure: Unsuitable wire-feed-rolls For latest details regarding the content of this page see www.migal.co 49

Application reference Humidity and porous gas hoses The reason for porosity caused by hydrogen often appears to be traceable to the state of the gas hoses. It happens that gas and water hoses get mixed up and water gets into the gas hoses. In general these hoses should be changed completely after such an incident, as a full dry-out is not possible. Another reason for humidity is porous or leaking hose materials. ... specific molar current of component i ... hose permeability ... hose wall thickness ... partial pressure of component i According to Fick’s law, even seemingly dense materials are diffusible to matter (gases) if the partial pressure of the components is lower inside than outside. Humidity in the atmosphere diffuses through a hose wall if dry shielding gas is inside. Counter measures are a low permeability of hose material, short hoses and a greater wall thickness. Contamination The wire feed systems and especially all parts in touch with the wire, need to be kept as clean as possible. Usage of lubricants and anti-spatter spray must be avoided. The wire spools need to be covered at any time, thus protected from dust and humidity. Friction in the wire feed system Aluminium has poor gliding characteristics in general. Still, it needs to be fed through several meters of liner. Special attention must be paid to the liner material. With opened clamping levers of the wire feed rolls, it must be possible to push the wire with two fingers using medium force through the entire wire feed system. A good source of information is provided by modern power sources, which measure the electrical current into the wire feed motor. This should be close to the idle value and frequently observed. Arc too long Adjusting a long arc often leads to absorption of large quantities of atmosphere into the arc. This results in porosity and oxide inclusions. Thus, the welding parameters need to be optimised for an as short as possible arc. This requires much experience and sometimes demand assistance form the manufacturer of the power source. TIG welding During TIG welding, always make sure broken TIG cartons are closed and protected against moisture and dust. Take out only the quantity of rods necessary for the coming work. The rod can be cleaned with fine steel wool directly before welding. The rods should not be fed by a bare hand but clean gloves should be worn. To prevent excessive oxidation, leave the end of the rod in the shield gas flux of the torch until it has cooled down sufficiently. The above mentioned rules concerning moisture and leaky gas hoses are the same for TIG welding. Preheating and inter-pass temperatures Preheating can be done for the following reasons: • to reduce humidity before welding, i.e. welding on site • to remove irregularities at arc start • to provide heat adjustment when welding different thicknesses • to reduce the effect of cooling when welding thick plates For latest details regarding the content of this page see www.migal.co 50

Application reference The time of preheating should be as short as possible to prevent unfavourable effects. A too high preheat temperature may influence the strength of the welded joint in a negative way. By using argon-helium mixtures or pure helium as shielding gas the preheat temperature may be reduced or completely omitted. Base metal Not hardening alloys (1xxx, 3xxx, 5xxx, AlSi-cast, AlMg-cast) Hardenable alloys (6xxx, AlSiMg-cast, AlSiCu-cast) 7xxx Maximum preheat temperature [°C] 120 Maximum inter-pass temperature [°C] 120 120 100 100 80 The inter-pass temperature should be controlled for the following reasons: • to prevent a reduction of the physical properties from overheating • to reduce the size of the soft zone in the heat affected zone • to reduce precipitation in the heat affected zone, i.e. by superannuation It is recommended that the temperature at the beginning of each successive weld does not exceed the values shown in the above table. Anodizing Anodizing may lead to a discoloration of the weld and its heat affected zone in comparison to the base material. Silicon leads to grey or black welds and manganese to a slightly yellow colour. Due to this, only the alloys AlMg3, AlMg5 and the pure aluminium Al99.7 and Al99.5Ti are suitable for anodizing. The choice of the wire alloy should match the base material as much as possible. In case of colour critical applications, each batch of filler wire should be tested prior to welding. Correct storage Our filler metals have to be stored at temperatures well above the dew point any time. This can be maintained safely in a heated room at a temperature above 15° Celsius and a relative humidity below 50%. In case that this is not possible special packagings may be used. Storage at very high temperature (> 25° Celsius) shall be avoided as well, due to the fact that the lubricant on the wire may volatilize too early. When material is taken from the storage always choose the product with the oldest manufacturing date (FIFO)! Filler metals that are not fully consumed have to be packed prior to storage. Obviously damaged or wet packages of filler metals can be used only after approval from a qualified person (manufacturer, welding supervisor). Drying of wet welding wires or rods is not possible. A maximum duration of storage cannot be specified in general. In doubt a qualification by welding tests must be performed. For latest details regarding the content of this page see www.migal.co 51

Application reference Common welding defects and how to avoid them Defect Porosity Oxide inclusions Cracking Tungsten inclusions Copper inclusions Main reasons Contaminated filler wire. Humidity on the surface of the filler wire. Contaminated base material. Humidity on the surface of the base material. Unsuitable welding positions. Degassing time too short. Contaminated shielding gas, due to leaking cooling water or gas supply systems. Contaminated shielding gas due to diffusion of humidity. Unsuitable hose material. Non-laminar gas flow due to too high or too low gas flow or air draft. Arc voltage too high. Torch angle too small. Formation of oxides in the arc or in the weld pool by intake of Oxygen due to insufficient gas flow. Insufficient cleaning of the welding area and/or the preceding layers. Excess of oxygen in the preheating flame. Unsuitable treatment of the rods with TIG-welding. Solidification characteristic of the weld pool. Inner tensions. Remelting of components with a low melting range, which precipitate at grain boundaries in the heat affected zone. Tungsten inclusions from excessive current or from touching the weld pool. Copper inclusions with MIG-welding due to overheating. Uptake of Copper from the backup plate. Prevention and counter measurements Improve the cleanliness of the filler wire and the environment. Welding above dew-point. Cleaning and drying of the welding area, ie. Preheating. Make sure that the base material is at room temperature before welding. Use welding positions PA, PB, PF if possible. Increase heat-input and/or preheating. Modify joint preparation. Remove leaks. Use gases complying to EN 439. Use suitable hose materials, replace old and porous hoses and keep hose length as short as possible. Optimize shielding gas quantity. Prevent air drafts. Optimize arc voltage. Use proper torch angle. See porosity. Optimize gas flow quantity. Prevent air drafts. Make sure that the welding area and preceding layers are cleaned. Optimize flame. Do not retract the rod end from the shielding gas. Select the filler wire for optimized weldability. Make endcrater on run-out plates or use a crater fill program. Use welding sequences which reduce tension and distortion. Reduce heat input and inter-pass temperature. Reduce susceptibility of cracks by using a single-pass technique. Reduce inner tensions. Select suitable filler wires (ie. 4xxx-series). Reduce current or select a larger diameter. Do not touch the weld pool with the electrode tip. Select a torch and a tip suitable for the amperage. Replace the Copper backing plate. If necessary use backup made from stainless steel, aluminium or ceramics. For latest details regarding the content of this page see www.migal.co 52

ML CuAl8 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ...................................................................................................... 6,00-8,50 Si ........................................................................................................... < 0,20 Mn ......................................................................................................... < 0,50 Zn .......................................................................................................... < 0,20 Pb .......................................................................................................... < 0,02 Others total ............................................................................................ < 0,40 ISO 24373 ......................................................................... S Cu 6100 (CuAl7) DIN 1733 ......................................................................................... SG-CuAl8 Material No. .......................................................................................... 2.0921 BS 2901 part 3 ........................................................................................ C 28 AWS A 5.7 ................................................................................... ER Cu Al-A1 CuAl5; CuAl8; CuAl9; CuZn20Al Filler metal for joining and surfacing of Al-bronze, brass, steel- and cast-iron, as well as for MIG-brazing of carbonsteel with and without coating. Suitable for joining of steel to copper. The weld metal is resistant to corrosion, wear and brackish water. Electrical conductivity [S*m/mm2] .................................................................. 8 Density [kg/dm3] ......................................................................................... 7,7 Solidus-Temperature [°C] ........................................................................ 1030 Liquidus-Temperature [°C] ....................................................................... 1040 Tensile strength Rm [MPa] ................................................................ 390 - 450 Elongation A5 (L0=5d0) [%] ........................................................................... 45 Hardness [HB] ........................................................................................... 140 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 200 / 5 kg ................................................................................................. n/a S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / 3 kg ................................................................................................ n/a B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 54

ML CuAl8Ni2 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Al ...................................................................................................... 7,00-9,50 Si ........................................................................................................... < 0,20 Mn .................................................................................................... 0,50-2,50 Ni (incl. Co) ....................................................................................... 0,50-3,00 Zn .......................................................................................................... < 0,20 Pb .......................................................................................................... < 0,02 Fe ..................................................................................................... 0,50-2,50 Others total ............................................................................................ < 0,40 ISO 24373 ....................................................... S Cu 6327 (CuAl8Ni2Fe2Mn2) DIN 1733 .................................................................................... SG-CuAl8Ni2 Material No. .......................................................................................... 2.0922 BS 2901 part 3 ........................................................................................ C 29 CuAl10Ni; CuAl11Ni; Copper-aluminium-nickel alloys in general Filler metal for Cu-Al-Ni-materials and for joining steel to Cu-Al-alloys. Surfacing of Al-bronzes and aluminium coated steels. Can be used for cast- iron in mechanical engineering, shipbuilding and chemical industry. Excellent sea water resistance (i.e. surfacing of ship‘s propellors). MIG pulse welding is recommended for multi-pass surfacing welds on steel. Electrical conductivity [S*m/mm2] .................................................................. 5 Density [kg/dm3] ......................................................................................... 7,5 Solidus-Temperature [°C] ........................................................................ 1030 Liquidus-Temperature [°C] ....................................................................... 1050 Tensile strength Rm [MPa] .................................................................. 430-540 Elongation A5 (L0=5d0) [%] ........................................................................... 30 Hardness [HB] .................................................................................... 130-150 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+ MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 Spools .................................................................................... Packaging units B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) For latest details regarding the content of this page see www.migal.co 55

ML CuAl8Ni6 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Al ...................................................................................................... 8,50-9,50 Si ........................................................................................................... < 0,10 Mn .................................................................................................... 0,60-3,50 Ni (incl. Co) ....................................................................................... 4,00-5,50 Zn ........................................................................................................... < 0,10 Pb .......................................................................................................... < 0,02 Fe ..................................................................................................... 3,00-5,00 Others total ............................................................................................ < 0,50 ISO 24373 ....................................................... S Cu 6328 (CuAl9Ni5Fe3Mn2) DIN 1733 .................................................................................... SG-CuAl8Ni6 Material No. .......................................................................................... 2.0923 BS 2901 part 3 ................................................................................... C 26 Ni AWS A 5.7 ...................................................................................... ER CuNiAl CuAl11Ni6Fe5; CuAl10Ni5Fe4; Copper-aluminium-nickel alloys in general Filler metal for Cu-Al-Ni-materials and for castings and forged parts from nickel- aluminium bronzes. Surfacing of Al-bronzes and aluminium coated steels, and complex bronzes. Excellent sea water resistance (i.e. surfacing of ship‘s propellors). High wear and abrasion resistance. Suitable for bearings, valves, turbines, pumps, etc. Electrical conductivity [S*m/mm2] .................................................................. 4 Density [kg/dm3] ......................................................................................... 7,5 Solidus-Temperature [°C] ........................................................................ 1015 Liquidus-Temperature [°C] ....................................................................... 1045 Tensile strength Rm [MPa] .................................................................. 450-560 Elongation A5 (L0=5d0) [%] ........................................................................... 10 Hardness [HB] .................................................................................... 150-170 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+ MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 Spools .................................................................................... Packaging units B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) For latest details regarding the content of this page see www.migal.co 56

ML CuAl9Fe Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al .................................................................................................. 8,50 - 11,00 Si ........................................................................................................... < 0,10 Zn .......................................................................................................... < 0,02 Pb .......................................................................................................... < 0,02 Fe .......................................................................................................... < 1,50 Others total ............................................................................................ < 0,50 ISO 24373 ................................................................. S Cu 6180 (CuAl10Fe1) DIN 1733 ................................................................................ SG-Cu Al 10 Fe Material No. .......................................................................................... 2.0937 BS 2901 Part 3 ......................................................................................... C 13 AWS A 5.7 ................................................................................. ER CuAl – A2 CuAl8Fe3 Filler wire for joining and surfacing of base metals with similar composition, manganese-silicon-bronzes and some copper-nickel-alloys. Suitable for joining of steel to copper. The weld metal is sea water resistant. Very well suitable for flame spraying. Electrical conductivity [S*m/mm2] .................................................................. 8 Density [kg/dm3] ......................................................................................... 7,7 Solidus-Temperature [°C] ........................................................................ 1030 Liquidus-Temperature [°C] ....................................................................... 1040 Tensile strength Rm [MPa] ................................................................ 390 - 500 Elongation A5 (L0=5d0) [%] ........................................................................... 35 Hardness [HB] .................................................................................. 140 - 160 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 57

ML CuMn13Al7 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ...................................................................................................... 7,00-8,50 Si ........................................................................................................... < 0,10 Mn ................................................................................................ 11,00-14,00 Ni (einschl. Co) ................................................................................. 1,50-3,00 Zn ........................................................................................................... < 0,15 Pb .......................................................................................................... < 0,02 Fe ..................................................................................................... 2,00-4,00 Others total ............................................................................................ < 0,50 ISO 24373 ..................................................... S Cu 6338 (CuMn13Al8Fe3Ni2) DIN 1733 ................................................................................ SG-CuMn13Al7 Material No. .......................................................................................... 2.1367 BS 2901 part 3 ........................................................................................ C 22 AWS A 5.7 ................................................................................. ER CuMnNiAl Seawater resistant CuAl-alloys without zinc of high hardness and strength. ML CuMn13Al7 is a manganese-nickel-aluminium bronze for sea water resistant joint welds, particularly with erosion, corrosion and cavitation. Suitable for surfacing of Cu-alloys, carbon-manganese steels and cast-iron. Electrical conductivity [S*m/mm2] ............................................................... 3-5 Density [kg/dm3] ......................................................................................... 7,4 Solidus-Temperature [°C] .......................................................................... 945 Liquidus-Temperature [°C] ......................................................................... 985 Tensile strength Rm [MPa] .................................................................. 800-900 Elongation A5 (L0=5d0) [%] ........................................................................... 10 Hardness [HB] .................................................................................... 180-240 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG ~ MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 58

ML CuNi10Fe Rod/Wire electrode for Copper Typical composition in % Classification Base materials Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Ni .................................................................................................... 9,00-11,00 Fe ..................................................................................................... 0,50-2,00 C ............................................................................................................ < 0,03 Mn .................................................................................................... 0,50-1,50 Si ............................................................................................................ < 0,20 Ti ....................................................................................................... 0,20-0,50 Al ........................................................................................................... < 0,03 S ............................................................................................................ < 0,02 P .......................................................................................................... < 0,007 Pb .......................................................................................................... < 0,02 Others total ............................................................................................ < 0,40 ISO 24373 ....................................................................... S Cu 7061 (CuNi10) DIN 1733 ................................................................................... SG-CuNi10Fe Material No. .......................................................................................... 2.0873 BS 2901 part 3 ........................................................................................ C 16 Particularly suitable for highly stressed corrosion resistant weld surfacing on cast iron and on unalloyed and low-alloyed steel, seawater resistant CuZn alloys. Appropriate to joining/surfacing on Cu-Ni material. Especially recommended for plant engineering. Electrical conductivity [S*m/mm2] .................................................................. 5 Therm. conductivity [W/m K] ....................................................................... 45 Density [kg/dm3] ......................................................................................... 8,9 Melting temperature [°C] ........................................................................ 1.150 Tensile strength Rm [MPa] ......................................................................... 300 Elongation A5 (L0=5d0) [%] ............................................................................ 40 Modulus of elasticity [MPa] ................................................................. 126.000 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spools .................................................................................... Packaging units B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Box 5 kg .............................................................................. Length 1.000 mm For latest details regarding the content of this page see www.migal.co 59

ML CuNi30Fe Rod/Wire electrode for Copper Typical composition in % Classification Base materials Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Ni .................................................................................................. 29,00-32,00 Fe ..................................................................................................... 0,40-1,00 C ............................................................................................................ < 0,05 Mn .................................................................................................... 0,50-1,50 Si ............................................................................................................ < 0,20 Ti ....................................................................................................... 0,20-0,50 S .......................................................................................................... < 0,015 P ............................................................................................................ < 0,02 Pb .......................................................................................................... < 0,02 Others total ............................................................................................ < 0,50 ISO 24373 ......................................................... S Cu 7158 (CuNi30Mn1FeTi) DIN 1733 ................................................................................... SG-CuNi30Fe Material No. .......................................................................................... 2.0837 AWS A 5.7 ......................................................................................... ER CuNi BS 2901 part 3 ........................................................................................ C 18 Particularly suitable for high stressed corrosion resistant weld surfacing on cast iron and on unalloyed and low-alloyed steel as well as seawater resistant CuZn alloys. Suitable for welding on CuNi materials. Particularly recommended for the plant engineering. Electrical conductivity [S*m/mm2] .................................................................. 2 Therm. conductivity [W/m K] ....................................................................... 30 Density [kg/dm3] ......................................................................................... 8,9 Melting temperature [°C] ........................................................................ 1.210 Tensile strength Rm [MPa] ......................................................................... 400 Elongation A5 (L0=5d0) [%] ............................................................................. 35 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spools .................................................................................... Packaging units B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Box 5 kg .............................................................................. Length 1.000 mm For latest details regarding the content of this page see www.migal.co 60

ML CuSi28L Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ........................................................................................................... < 0,02 Si ...................................................................................................... 2,80-3,00 Mn .................................................................................................... 0,75-0,95 Sn .......................................................................................................... < 0,05 Zn ........................................................................................................... < 0,10 Pb .......................................................................................................... < 0,01 Fe .......................................................................................................... < 0,10 Ni ........................................................................................................... < 0,05 P ............................................................................................................ < 0,05 Others total ............................................................................................ < 0,50 ISO 24373 .................................................................. S Cu 6560 (CuSi3Mn1) DIN 1733 ......................................................................................... SG-CuSi3 Material No. .......................................................................................... 2.1461 BS 2901 part 3 .......................................................................................... C 9 AWS A 5.7 ...................................................................................... ER CuSi-A CuZn5; CuZn10; CuZn15; CuSi2Mn; CuSi3Mn Modified CuSi3, especially for Laserbrazing and MIG-brazing in the automotive industry. Electrical conductivity [S*m/mm2] ............................................................... 3-4 Density [kg/dm3] ......................................................................................... 8,5 Solidus-Temperature [°C] .......................................................................... 910 Liquidus-Temperature [°C] ....................................................................... 1025 Tensile strength Rm [MPa] .................................................................. 330-370 Elongation A5 (L0=5d0) [%] ........................................................................... 40 Hardness [HB] ........................................................................................ 80-90 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG =- MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 200 / 5 kg ................................................................................................. n/a S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / 3 kg ................................................................................................ n/a B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 61

ML CuSi3 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ........................................................................................................... < 0,02 Si ...................................................................................................... 2,80-4,00 Mn .................................................................................................... 0,50-1,50 Sn .......................................................................................................... < 0,20 Zn .......................................................................................................... < 0,40 Pb .......................................................................................................... < 0,02 Fe .......................................................................................................... < 0,50 P ............................................................................................................ < 0,05 Others total ............................................................................................ < 0,50 ISO 24373 .................................................................. S Cu 6560 (CuSi3Mn1) DIN 1733 ......................................................................................... SG-CuSi3 Material No. .......................................................................................... 2.1461 BS 2901 Part 3 ........................................................................................... C 9 AWS A 5.7 .................................................................................... ER CuSi – A CuZn5; CuZn10; CuZn15; CuSi2Mn; CuSi3Mn Filler wire for joining copper, copper-silicon and copper-zinc alloys. Suitable for joining of steel to copper and for surfacing of steel. High temperature and corrosion resistance. Very commonly used for galvanized steel. Electrical conductivity [S*m/mm2] ............................................................... 3-4 Density [kg/dm3] ......................................................................................... 8,5 Solidus-Temperature [°C] .......................................................................... 910 Liquidus-Temperature [°C] ....................................................................... 1025 Tensile strength Rm [MPa] ................................................................ 330 - 370 Elongation A5 (L0=5d0) [%] ........................................................................... 40 Hardness [HB] ...................................................................................... 80 - 90 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG - MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 200 / 5 kg ................................................................................................. n/a S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / 3 kg ................................................................................................ n/a B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 62

ML CuSn Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ........................................................................................................... < 0,01 Si ...................................................................................................... 0,10-0,40 Mn .................................................................................................... 0,10-0,40 Ni (einschl. Co) ...................................................................................... < 0,10 Sn ...................................................................................................... 0,50-1,00 Pb .......................................................................................................... < 0,01 Fe .......................................................................................................... < 0,03 P .......................................................................................................... < 0,015 Others total ............................................................................................ < 0,20 ISO 24373 .............................................................. S Cu 1898A (CuSn1MnSi) DIN 1733 .......................................................................................... SG-CuSn Material No. .......................................................................................... 2.1006 BS 2901 part 3 .......................................................................................... C 7 AWS A 5.7 ............................................................................................. ER Cu OF-Cu; SE-Cu; SW-Cu; SF-Cu; CuZn0,5 Filler wire for joining of high-duty copper materials. Excellent weldability. High quality welds without porosity for applications in construction and for pressure vessels. Electrical conductivity [S*m/mm2] ........................................................... 15-20 Density [kg/dm3] ......................................................................................... 8,9 Solidus-Temperature [°C] ........................................................................ 1020 Liquidus-Temperature [°C] ....................................................................... 1050 Tensile strength Rm [MPa] .................................................................. 210-245 Hardness [HB] ........................................................................................ 60-80 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG - MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / 3 kg ................................................................................................ n/a B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 63

ML CuSn6 Rod/Wire electrode for Copper Typical composition in % Classification Base materials Remarks Physical properties (Approx. values) Welding position Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Al ........................................................................................................... < 0,01 Zn .......................................................................................................... < 0,10 Sn ..................................................................................................... 4,00-7,00 Pb .......................................................................................................... < 0,02 Fe .......................................................................................................... < 0,10 P ....................................................................................................... 0,01-0,40 Others total ............................................................................................ < 0,20 ISO 24373 ................................................................... S Cu 5180A (CuSn6P) DIN 1733 ........................................................................................ SG-CuSn6 Material No. .......................................................................................... 2.1022 BS 2901 Part 3 ......................................................................................... C 11 AWS A 5.7 .................................................................................. ER CuSn – A CuSn4; CuSn6; CuSn8 Filler wire for joining and surfacing of bronzes. Tough and pore-free weld metal with a controlled content of phosphor. Electrical conductivity [S*m/mm2] .................................................................. 9 Density [kg/dm3] ......................................................................................... 8,7 Solidus-Temperature [°C] .......................................................................... 910 Liquidus-Temperature [°C] ....................................................................... 1040 Tensile strength Rm [MPa] ................................................................ 320 - 360 Elongation A5 (L0=5d0) [%] ........................................................................... 25 Hardness [HB] ...................................................................................... 80 - 90 PA, PB, PC, PE, PF I1, I2, I3 (Argon, Helium or Argon/Helium-mixtures) MIG =+, TIG - MIG-wires [mm] ................................................ 0,8; 1,0; 1,2; 1,6; 2,0; 2,4; 3,2 TIG-rods [mm] ................................................................ 1,6; 2,0; 2,4; 3,2; 4,0 Spools .................................................................................... Packaging units S 300 / 15 kg ......................................................... 25 spools = 375 kg (pallet) B 300 / BS 300 / 15 kg .......................................... 25 spools = 375 kg (pallet) Eco-drum / 200 kg ................................................... 2 drums = 400 kg (pallet) Box 10 kg ............................................................................ Length 1.000 mm For latest details regarding the content of this page see www.migal.co 64

Application reference Arc brazing General Increasing demands for the reduction of damages lead to the use of coated steels in many industrial fields. Among the many possibilities to protect steel against corrosion zinc plays a major role due to its favourable corrosion resistance and its low price. Protection against corrosion by a zinc coating can be done by hot-galvanizing of already finished parts or work pieces. In many cases and with complicated constructions this is not possible because of distortion. Another possibility is to use already finished – pre zinc-coated – sheets or profiles for welding. Such materials can be coated by either an electrolytic or a hot-galvanizing process. The thickness of the zinc coating lies between 1 and 20μm depending on the method of manufacturing. Large quantities of zinc coated thin sheets are used in the automotive industry, for buildings, ventilation and air-conditioning systems, household appliances, and furniture. Not only because of its ability to form a cover layer as a barrier which needs to corrode first before the steel corrodes zinc has reached a major position as corrosion protection because of its cathodic protection ability. If the protecting zinc coating is damaged then the surrounding zinc provides the cathodic protection even of the nearby uncoated steel. This protection is effective for a distance of 1-2 mm of uncoated surfaces. Due to the cathodic protection not only the uncoated cutting edges are protected, but also micro cracks from cold-forming and the surrounding of welds where zinc has been evaporated during welding. Equally subcutaneous corrosion can be avoided initiating from cutting edges. Arc brazing of zinc-coated steels Zinc has a melting point of approximately 420° Celsius and evaporates at 906° Celsius. This nature is unfavourable to any welding process, because evaporation of zinc starts before the melting point of steel being the base material is reached. This is the reason why it is more suitable for galvanized steel when less heat is introduced, respectively the base material does not get to its melting point at all. An alternative to welding of coated sheets is the use of filler wires based on copper also known as bronzes. Commonly known are wires with copper-silicon- (ML CuSi3) and copper-aluminium-alloys (ML CuAl8). The following advantages are provided by these wires: • no corrosion of the brazing • minimal spatter • low burn-off of coating • low heat input • simple post-treatment of the seam • cathodical protection of the base material in the immediate area of the joint Such bronze wires have a relatively low melting point due to the high content of copper (approx. 1.000 to 1.080° Celsius depending on the alloy). The base material does not get molten which means the joining principle is more brazing than welding. With arc brazing fluxes are usually not required. For latest details regarding the content of this page see www.migal.co 65

Application reference Classification of arc brazing processes Arc brazing can be classified into GMA and GTA processes. The principle is largely identical to GMAW-welding respectively to plasma welding with filler wires. Brazing Brazing by electric current Brazing by beam Brazing by gas discharge Brazing by gas Brazing by liquid Arc brazing Gas Metal Arc brazing Gas Tungsten Arc brazing MAG brazing MIG brazing TIG brazing (Tungsten-)Plasma brazing Figure: Classification of brazing processes GMA brazing The difference between GMA brazing to Gas Metal Arc Welding lies in the use of filler metals based on copper alloys instead of steel. This process is mainly used in the short- or pulsed arc mode in virtually all positions. A separate joint preparation is usually not necessary. Short-arc process The short-arc process provides GMA brazing with low heat input. At low arc power the droplet transfer occurs during the short-circuit phase (short-arc process). Pulsed arc process The pulsed arc technology provides a well controllable droplet transfer with few short-circuits and a good gap-bridging characteristic for brazing overlap joints. Generally the pulsed arc process gives flatter seams than the short-arc process. Because the evaporation of the coating may lead to arc instabilities it is recommended to use a short arc length. With Argon as shielding gas a low spatter process can be obtained at optimized parameters. To keep the heat input as low as possible a low base current is required. For latest details regarding the content of this page see www.migal.co 66

Application reference Special requirements to the brazing equipment GMA brazing requires special precautions on the power source. In order to keep the evaporation of zinc as low as possible, brazing is done at low arc power. Therefore, the power source needs to have a control range which goes to low levels of arc power. At the same time arc stability must be provided. A low base current together with a fast reacting arc-control to obtain a short arc length is required. Depending on each combination of filler metal and shielding gas GMA brazing requires a special pulse shape. Generally seen most available power sources on the market give good brazing characteristics. It might be necessary, however, to obtain an optimized arc characteristic from its manufacturer. The filler wires used are softer than wires for steel welding, and require higher demands on the wire-feed units. Similar to aluminium- or flux-cored wires wire- drive systems need to be equipped with semi-grooved wire feed rolls. The wire feed motor should be controlled to provide constant feeding speed. Hose packs must be equipped with plastic or Teflon liners. In case that hose pack lengths of more than 3 m for semiautomatic or more than 1.5 m for automatic brazing are necessary an extra wire-feed motor at the torch is required. For automatic brazing it is useful to use water cooled torches. Figure: Schematics of GMA brazing Technological remarks An additional important influence on the seam quality for GMA brazing is the torch angle and torch guidance. With a pushing arc angle the forerunning arc preheats the zinc coating as much that it may evaporate immediately before the arc down to a small rest. The heat energy of the molten metal droplet from the filler wire evaporates the, until then, remaining coating. Because the quantity of the remaining zinc coating in the still molten brazing alloy is rather low the remaining time until solidification is long enough for degassing. For latest details regarding the content of this page see www.migal.co 67

With manual TIG brazing the brazing alloy is usually fed into the arc similar to autogenous brazing with a rod. With automatic TIG brazing the copper alloys are wires like for MIG welding, or so-called cold wires. Usually a continuous arc is applied. Flat- and vertical down positions should be preferred. Special requirements to the brazing equipment All commonly available TIG-DC power sources can be used. Pulsed arc machines are not necessary. For most applications currents of 20-150 A are sufficient. For automatic welding a cold wire feeder is required. Application reference TIG brazing Figure: Schematics of TIG brazing Plasma brazing With plasma brazing either pulsed or continuous arc currents can be applied. Flat- and vertical-down positions are recommended. In opposite to GMA brazing the filler wire is fed into the arc without any current into the focused arc. The deposit of the filler wire is therefore (nearly) independent from the heat input. This makes the seam geometry variable within large boundaries. Plasma brazing with current on the wire is called plasma hotwire brazing. This variant differs basically only in the additional power provided by another current through the wire. The increased temperature of the filler wire can be used to increase the brazing speed and reduces distortion. For latest details regarding the content of this page see www.migal.co Figure: Schematics of plasma brazing 68

Application reference Special requirements to the brazing equipment For both, standard and pulse mode, power sources with a dropping characteristic are required. The power source is equipped with an ignition device (high-frequency) for a touchless striking of the arc. The high-frequency unit usually strikes the arc between the electrode and the plasma nozzle or between the electrode and the work piece. Manual applications usually work in a current range from 5-75 A. Mechanized or robotic applications may need up to 250 A. Plasma torches are usually water cooled to carry off the process heat and to provide production adequate service life. The wire is fed from external without a current. Due to the separation of wire feed and arc power it is for instance possible to do repair jobs by remelting without wire. Materials for arc brazing Base materials The arc brazing processes are generally used for joining of uncoated or coated steel fine sheets in a thickness range of up to 3.0 mm. With higher tensile strength of the steel sheets it must be considered that the strength of the brazing alloy is usually lower than the strength of the base metal. A speciality is brazing of different base materials i.e. of copper alloys with steel. These joints show two different characteristics, brazing on the steel side and welding on the copper side. Even stainless steel can be joined with arc brazing. In particular the low heat input can be of great advantage with long seams and thin materials, because distortion of the work pieces is greatly reduced. Due to a higher susceptibility for soldering cracks it needs to be tested in every single case. The improved gap-bridging capability is responsible for a higher tolerance on work piece dimensions. ML CuAl8 is the recommended filler wire. The colour difference between base material and filler wire must be obeyed. Surface coatings and preparation Sheets with a coating thickness of up to 15 μm can generally be used without any problems. In case that i.e. hot-galvanized work pieces with greater thicknesses are used additional investigations may be required. For base metals covered with aluminium also aluminium containing brazing alloys shall be used. Additional organic coatings may need specially adapted parameters. In order to obtain a metallurgical interaction between the base material and the wetting liquid braze the border area should be clean and pure metal. Dirt, grease, residuals from machining, wax, adhesives or oil may reduce the joint quality (porosity, lack of fusion etc.) and shall be removed by either chemical and/or mechanical surface treatment processes. Consumables and auxiliary materials Brazing consumables For arc brazing mainly the two alloys ML CuSi3 and ML CuAl8 are used as wires or rods. With MIG brazing a wire diameter of 1.0 mm is commonly used. Traditionally for Germany the ML CuSi3 is applied, whilst in other countries the alloy ML CuAl8 is used for similar applications. ML CuAl8 is also used for brazing of stainless steel and for joints in the furniture industry where the optical look of the seam surface is essential. For latest details regarding the content of this page see www.migal.co 69

Application reference MIG WELD consumables are optimized for GMA brazing. The wires have an ideal hardness and provide the best gliding characteristic. Shielding gases For arc brazing usually argon or Ar-mixes with additions of CO2 or O2 are used. Together with filler metals containing Si or Sn low active additions of CO2 or O2 may be of advantage. These gases stabilize the arc, reduce porosity, however, increase the heat input into the workpiece. N2 additions stabilize the arc and give a wider seam, however, may produce considerable amounts of porosity. H2 additions increase the speed of brazing, but may also lead to porosity. In order to optimize the shielding gas composition to the brazing job it is recommended to use the experiences from gas manufacturers. Joint designs Butt design Fillet design Overlap design Overlap design on shouldered sheet Lateral face design Flanged-butt design Corner design Occupational health Suitable fume extraction devices are required for semiautomatic brazing jobs and if necessary torches with integrated fume collection should be used. In case that seams need to be ground off the maximal permitted values for fine dust must be obeyed. Suitable dust extraction devices have to be installed in such areas. Due to occupational health and economic production a formation of zink oxide flakes (white deposit on the work piece or floating particles) must be avoided by reduction of the heat input. For latest details regarding the content of this page see www.migal.co 70

Application reference Laser beam brazing At high scale production in the automotive industry laser beam brazing is used in addition to MIG brazing. The laser being the source of heat melts the filler wire and similar to the arc a brazing result is obtained. Suitable joint designs are also flanged-butt and fillets. The process provides very high travel speeds of up to several meters/minute at a very low heat input. Distortion is rather low. In the automotive industry so- called “Grade A” joints can be made which do not need any finish after brazing and are used in visible areas of the car body. For a further increase of the process speed it can be extended to laser hotwire brazing by an additional current on the filler wire. Figure: Schematics of laser brazing For latest details regarding the content of this page see www.migal.co 71

Stainless Steel Stainless welding consumables by MIGAL.CO - better than the standard MIGAL.CO also supplies highest quality stainless filler metals. The high quality can be seen at first glance. The consistent silvery shine shows the smooth surface and the high constancy of manufacturing. Experienced technicians in our R&D department continuously develop the products and processes, in order to ensure that our customers can achieve best welding results and highest productivity. Use our Know-how Our experience and the practical know-how are at your disposal, in order to solve your welding tasks and to increase your productivity. Selection of filler metal The choice of welding consumables is crucial to the result of the welding operation. It must give the required weld properties and ensure a crack-free weld. The key factor in the choice is, of course, the parent metal, but the welding method can also influence the selection of filler metal. For surfacing, the welding parameters have to be considered as well. Balanced composition The composition of the welding consumable normally corresponds to that of the parent metal. For example, parent metal 304L (18 % Cr, 8 % Ni) is welded with a 308L filler metal (19 % Cr, 9 % Ni). In general, the contents of the main alloying elements - Cr, Ni and Mo - are higher in the welding consumable than in the parent metal in order to compensate for segregation in the weld metal. Impurity levels, however, are lower in the consumable than in the parent metal in order to reduce the risk of hot cracking, and to obtain the best arc stability, fluidity and wetting properties. In standard austenitic welding consumables - 308L, 316L, 347 - hot cracking can in practice be eliminated by a chemical composition, which gives a ferritic solidification. A ferrite content in the consumable of about 10 % (10FN) is usually sufficient, unless dilution from the parent metal is excessive. For latest details regarding the content of this page see www.migal.co 74

Stainless Steel Variants of one consumable For most standard grades there are two versions available; one with normal and one with high silicon content. The chemical compositions have been adapted to suit the welding method. The high silicon versions are recommended for MIG welding, because they give the best arc stability and smooth welds. In TIG and plasma-arc welding, the high silicon filler metals are not as advantageous as in MIG welding. Nonetheless, they are still preferred by many users. Thus we decided to have the LSi variants on stock. Simplified stock holding For stock holding reasons, many fabricators use one consumable grade to weld several different parent metals. Molybdenum has been shown to give only positive effects, except in highly concentrated, hot nitric acid environments. Therefore, 316L consumables can normally be used for both 316/316L and 304/304L parent metals. The simpler stock holding and the elimination of the risk of mixed material fully compensates for the potentially higher price for 316L consumables compared to 308L. Delivery forms Eco-Drum Wire diameter 0,8; 1,0; 1,2; 1,6 mm Outside diameter of drum 500 mm Height without decoiling hood 820 mm Height with decoiling hood 1080 mm Net weight 250 kg Basket spool BS 300 Wire diameter 0,8; 1,0; 1,2; 1,6 mm Net weight 15 kg, precision layer wound Highly environmentally compatible: empty rims can be treated as metal scrap. Rods Diameter 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 mm Length 1000 mm Net weight 5 kg, paper carton box Each rod marked for identification. For latest details regarding the content of this page see www.migal.co 75

1.4316 ML 19.9 LSi Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ............................................................................................................ ≤ 0,025 Si ................................................................................................................ 0,90 Mn .............................................................................................................. 1,80 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................... 20 Ni ................................................................................................................ 10,5 Mo ............................................................................................................. ≤ 0,5 Co .............................................................................................................. ≤ 0,2 Cu .............................................................................................................. ≤ 0,2 N ................................................................................................................. 0,06 DIN EN ISO 14343-A/G ...................................................................... 19 9 L Si Materialnumber ...................................................................................... 1.4316 AWS ER ................................................................................................. 308LSi Joining of stainless Cr-Ni steels, stabilised or non-stabilised, e.g. 304, 304L, 321 and 247, for service temperatures up to 350° C. Also for stainless Cr steels with max. 19 % Cr. Cryogenic applications down to -269° C, depending on welding process. Good resistance to general and, owing to the low C content, intergranular corrosion. Yield strength Rp0,2 [MPa] ........................................... 390 (20°C); 290 (400°C) Tensile strength Rm [MPa] .......................................... 600 (20°C); 440 (400°C) Elongation A [%] ............................................................. 42 (20°C); 24 (400°C) Reduction of area [%] .................................................................................... 60 Notched impact strength V [J] ..................................... 120 (20°C); 50 (-196°C) Hardness [Vickers] ...................................................................................... 160 Ferrite number from standard analysis DeLong ............................................11 Heat conductivity at temperature ° Celsius ........................ 20 | 100 | 300 | 500 Heat conductivity [W/m °C] ....................................................... 15 | 16 | 19 | 21 Thermal expansion per °C, from 20°C - 400°C ....................................18 x 10-6 Density [g/cm3] ............................................................................................. 7,9 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV, DB MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 76

1.4332 ML 23.12 LSi Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ............................................................................................................ ≤ 0,025 Si ................................................................................................................ 0,90 Mn .............................................................................................................. 1,80 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................ 23,5 Ni ................................................................................................................ 13,5 Mo ............................................................................................................. ≤ 0,4 N ................................................................................................................. 0,10 DIN EN ISO 14343-A/G .................................................................... 23 12 L Si Materialnumber ...................................................................................... 1.4332 AWS ER ................................................................................................. 309LSi Joining of stainless Cr-Ni steels of the 309 type, wrought or cast. Also for stainless Cr steels, e.g. in the automotive industry. The corrosion resistance is similar to that of the respective parent metal. Yield strength Rp0,2 [MPa] ............................................................................ 400 Tensile strength Rm [MPa] ........................................................................... 600 Elongation A [%] ............................................................................................ 35 Reduction of area [%] .................................................................................... 55 Notched impact strength V [J] ..................................................................... 140 Hardness [Vickers] ...................................................................................... 200 Ferrite number from standard analysis DeLong ........................................... 10 Heat conductivity at temperature ° Celsius ........................ 20 | 100 | 300 | 500 Heat conductivity [W/m °C] ....................................................... 14 | 15 | 17 | 19 Thermal expansion per °C, from 20°C - 400°C ....................................18 x 10-6 Density [g/cm3] ............................................................................................. 7,9 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] ........................................... 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0; 5,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 77

1.4337 ML 29.9 Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C .............................................................................................................. ≤ 0,10 Si ................................................................................................................ 0,40 Mn .............................................................................................................. 1,80 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................ 30,5 Ni .................................................................................................................. 9,2 Mo ............................................................................................................. ≤ 0,3 Cu .............................................................................................................. ≤ 0,3 DIN EN ISO 14343-A/G .............................................................................. 29.9 Materialnumber ...................................................................................... 1.4337 AWS ER ...................................................................................................... 312 Suitable for joining or cladding identical or similar steels or steel castings. Tough joints of un- and low-alloyed structural steels with higher strength, as well as Manganese steels and CrNiMn steels, between different materials, i. e. between stainless or heatresistant and un-/low-alloyed steels and steel castings. Good resitsnace against wet corrosion up to 300° Celsius. Additionally high resistance against hotcracking and good toughness at high yield strength. Yield strength Rp0,2 [MPa] ............................................................................ 500 Tensile strength Rm [MPa] ........................................................................... 750 Elongation A [%] ............................................................................................ 20 Notched impact strength V [J] ....................................................................... 25 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 WIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, WIG =- none MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 78

1.4370 ML 18.8 Mn Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ................................................................................................................. 0,08 Si ................................................................................................................ 0,90 Mn ................................................................................................................ 7,0 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................... 18 Ni ..................................................................................................................... 8 Mo ............................................................................................................. ≤ 0,5 Co .............................................................................................................. ≤ 0,5 Cu .............................................................................................................. ≤ 0,1 N ................................................................................................................. 0,06 DIN EN ISO 14343-A/G ........................................................................ 18 8 Mn Materialnumber ...................................................................................... 1.4370 AWS ER ...................................................................................................... 307 Joining of work-hardenable steels, armour plates, stainless austenitic Mn steels and free-machining steels, e.g. in the automotive industry. Overlay welding of carbon and low alloyed steels. The corrosion resistance is similar to that of the respective parent metal. Yield strength Rp0,2 [MPa] ............................................................................ 460 Tensile strength Rm [MPa] ........................................................................... 650 Elongation A [%] ............................................................................................ 41 Reduction of area [%] .................................................................................... 61 Notched impact strength V [J] ..................................................................... 140 Hardness [Vickers] ...................................................................................... 200 Heat conductivity at temperature ° Celsius ........................ 20 | 100 | 300 | 500 Heat conductivity [W/m °C] ....................................................... 15 | 16 | 18 | 20 Thermal expansion per °C, from 20°C - 400°C ....................................18 x 10-6 Density [g/cm3] ............................................................................................. 7,8 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 79

1.4430 ML 19.12.3 LSi Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ............................................................................................................ ≤ 0,025 Si ................................................................................................................ 0,90 Mn ................................................................................................................ 1,8 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................ 18,5 Ni ................................................................................................................... 12 Mo ................................................................................................................ 2,6 Co .............................................................................................................. ≤ 0,2 Cu .............................................................................................................. ≤ 0,2 N ................................................................................................................. 0,06 DIN EN ISO 14343-A/G ................................................................... 19 12 3 LSi Materialnumber ...................................................................................... 1.4430 AWS ER ................................................................................................. 316LSi Joining of stainless Cr-Ni-Mo and Cr-Ni steels, stabilised or non-stabilised, e. g. 316, 316L and 316Ti as well as 304, 304L, 321 and 347, for service temperatures up to 400° C. Also for stainless Cr steels with max 19 % Cr. Good resistance to general and, owing to low C content, intergranular corrosion. The Mo content gives good resistance also to pitting. Yield strength Rp0,2 [MPa] ........................................... 400 (20°C); 290 (400°C) Tensile strength Rm [MPa] .......................................... 610 (20°C); 440 (400°C) Elongation A [%] ............................................................. 37 (20°C); 29 (400°C) Reduction of area [%] .................................................................................... 68 Notched impact strength V [J] ..................................... 130 (20°C); 50 (-196°C) Hardness [Vickers] ...................................................................................... 160 Heat conductivity at temperature ° Celsius ........................ 20 | 100 | 300 | 500 Heat conductivity [W/m °C] ....................................................... 15 | 16 | 19 | 21 Thermal expansion per °C, from 20°C - 400°C ....................................18 x 10-6 Density [g/cm3] ............................................................................................. 7,9 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV, DB MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 80

1.4462 ML 22.9.3 NL Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ............................................................................................................ ≤ 0,020 Si ................................................................................................................ 0,50 Mn ................................................................................................................ 1,6 P ............................................................................................................ ≤ 0,020 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................... 23 Ni ..................................................................................................................... 9 Mo ................................................................................................................ 3,2 N ................................................................................................................. 0,16 DIN EN ISO 14343-A/G .....................................................................22 9 3 N L Materialnumber ...................................................................................... 1.4462 AWS ER .................................................................................................... 2209 Joining of duplex stainless steels i. e. 1.4417, 1.4462 und 1.4362 Very good resistance to intergranular corrosion and pitting. Good resistance to stress corrosion cracking, especially in environments containing H2S and chlorides. Yield strength Rp0,2 [MPa] ........................................... 600 (20°C); 420 (300°C) Tensile strength Rm [MPa] .......................................... 750 (20°C); 600 (300°C) Elongation A [%] ............................................................. 25 (20°C); 20 (300°C) Notched impact strength V [J] ..................................... 130 (20°C); 50 (-196°C) Hardness [Vickers] ...................................................................................... 240 Heat conductivity [W/m °C] ............................................................................ 16 Thermal expansion per °C, from 20°C - 400°C .................................14,5 x 10-6 Density [g/cm3] ............................................................................................. 7,9 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 81

1.4576 ML 19.12.3 NbSi Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ................................................................................................................. 0,04 Si ................................................................................................................ 0,90 Mn ................................................................................................................ 1,2 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................ 18,5 Ni ................................................................................................................ 12,5 Mo ................................................................................................................ 2,6 Nb ..................................................................................................≥ 12xC ≤ 0,6 Co .............................................................................................................. ≤ 0,2 Cu .............................................................................................................. ≤ 0,2 N ............................................................................................................... 0,065 DIN EN ISO 14343-A/G .................................................................19 12 3 NbSi Materialnumber ...................................................................................... 1.4576 AWS ER ................................................................................................... 318Si Joining of stainless Cr-Ni-Mo and Cr-Ni steels, stabilised or non-stabilised, e. g. 316, 316L and 316Ti as well as 304, 304L, 321 and 347, for service temperatures up to 400° C. Good resistance to general and, owing to Nb content, low intergranular corrosion. The Mo content gives good resistance also to pitting. Yield strength Rp0,2 [MPa] ........................................... 400 (20°C); 390 (400°C) Tensile strength Rm [MPa] .......................................... 610 (20°C); 540 (400°C) Elongation A [%] ............................................................. 35 (20°C); 30 (400°C) Reduction of area [%] .................................................................................... 60 Notched impact strength V [J] ..................................... 110 (20°C); 40 (-196°C) Hardness [Vickers] ...................................................................................... 160 Heat conductivity at temperature ° Celsius ........................ 20 | 100 | 300 | 500 Heat conductivity [W/m °C] ....................................................... 15 | 16 | 21 | 23 Thermal expansion per °C, from 20°C - 400°C ....................................18 x 10-6 Density [g/cm3] ............................................................................................. 8,0 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- TÜV MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 82

1.4842 ML 25.20 Stainless steel welding wires/rods Typical composition in % Classification Base materials Resistance against corrosion Physical properties at 20° C (Approx. values) Shielding gas Polarity Approvals Dimensions Ø Wire packagings Rod packagings C ................................................................................................................. 0,12 Si ................................................................................................................ 0,40 Mn .............................................................................................................. 1,80 P ............................................................................................................ ≤ 0,025 S ............................................................................................................ ≤ 0,015 Cr ................................................................................................................ 26,0 Ni ................................................................................................................ 20,7 Mo ............................................................................................................. ≤ 0,5 Cu .............................................................................................................. ≤ 0,4 DIN EN ISO 14343-A/G ............................................................................ 25.20 Materialnumber ...................................................................................... 1.4842 AWS ER ...................................................................................................... 310 Claddings and joints on identical/similar heatresistant steels/steel castings. Scale resisting up to 1.150° Celsius. Yield strength Rp0,2 [MPa] ............................................................................ 320 Tensile strength Rm [MPa] ........................................................................... 550 Elongation A [%] ............................................................................................ 25 Notched impact strength V [J] ....................................................................... 80 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 WIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, WIG =- none MIG-wires [mm] ..................................................................... 0,8; 1,0; 1,2; 1,6 TIG-rods [mm] .................................................. 1,0; 1,2; 1,6; 2,0; 2,4; 3,2; 4,0 Spool types: BS 300 / 15 kg; Drum / 250 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 83

Application reference Recommendation of shielding gases for stainless steel welding Protecting the weld The primary tasks of a shielding gas are to protect the molten pool from the influence of the atmosphere, i. e. from oxidation and nitrogen absorption, and to stabilise the electric arc. The choice of gas can also influence the characteristics of the arc. MIG welding Besides the development of welding machines, the use of shielding gases contributes to increased efficiency in the MIG method. This has led to greater usage of MIG welding. The basic gas for MIG welding is inert - argon (Ar) or helium (He), or a mixture of both. However, small additions of oxygen (O2) or carbon dioxide (CO2) can further stabilise the arc, improve the fluidity and also improve the quality of the weld deposit. For stainless steels there are also gases available containing small amounts of hydrogen (H2). TIG and plasma welding The normal gas for TIG welding is argon or helium, or a mixture. In some cases nitrogen (N2) and/or hydrogen (H2) is added in order to achieve special properties. For instance, an addition of hydrogen can be used for many conventional stainless steels to increase productivity. Alternatively, if nitrogen is added, the weld deposit properties can be improved. Oxidising additions are not used because they destroy the tungsten electrode. Gas MIG welding Ar He Ar + He Ar + (1-3) % O2 Ar + (1-3) % CO2 d) Ar + 30 % He + (1-3) % O2 Ar + 30 % He + (1-3) % CO2 d) Ar + 30 % He + (1-2) % N2 Austenitic Duplex Ferritic High-alloy austenitic Super duplex Nickel alloys Parent metal m m m l b) l e) l f) l f) m m m l b) l e) l f) l f) m m m l b) l e) l f) l f) l l l l l l l c) l c) l c) l c) l g) l a) l a) l a) l b) l e) l f) l f) l For latest details regarding the content of this page see www.migal.co 84

Application reference Gas TIG welding Ar He Ar + He Ar + (2-5) % H2 Ar + (1-2) % N2 Ar + 30 % He + (1-2) % N2 l suitable m suitable under certain conditions Austenitic Duplex Ferritic High-alloy austenitic Super duplex Nickel alloys Parent metal l l l l i) l l l l l l l l l l l l i) l l l l l l l h) l i) a) Ar preferably in pulsed MIG welding. b) Higher fluidity of the molten pool than with Ar. c) Except for 22.12.HT and 27.31.4LCu where Ar is preferred. d) Not to be used in spray-arc welding where extra low carbon is required. e) Higher fluidity of the molten pool than with Ar. Better short-arc welding properties than with Ar + (1-3)% CO2. f) Higher fluidity of the molten pool than with Ar. Better short-arc welding properties than with Ar + (1-3)% CO2. g) For nitrogen alloyed grades. h) Ar + 30 % He improves flow compared with Ar. i) Preferably for automatic welding. High welding speed. Risk of porosity in multi-run welds. Root protection The perfect welding result, without impairment of corrosion resistance and mechanical properties, can only be obtained when using a backing gas with very low oxygen content. For best results, a maximum 20 ppm O2 at the root side can be tolerated. This can be achieved with a purging set-up and can be controlled with a modern oxygen meter. Pure argon is by far the most common gas for root protection of stainless steels. Formiergas (90 % N2 + 10 % H2) is an excellent alternative for conventional austenitic steels. The gas contains an active component, H2, which brings down the oxygen level in the weld area. Nitrogen can be used for duplex steels in order to avoid nitrogen loss in the weld metal. Tips for tack welding Tack welds should not be thinner than specified for the root weld and should be subject to the same quality requirements for welding as are also applicable for the root weld. The length of the tack weld should not be less than four times the thickness of the thicker of the parts to be joined. For workpiece thicknesses over 50 mm or for high-tensile materials consideration should be given to increasing the length and thickness of tack welds. This may also include a two-pass weld. Attention should also be paid to the use of lower-tensile filler metals when welding higher-alloy steels. For latest details regarding the content of this page see www.migal.co 85

Application reference For joints that are supposed to be welded using automated or fully-mechanised processes, it is necessary to include the conditions for fabricating the tack welds in the welding procedure. If a tack weld is to be included in a welded joint, then the shape and quality of the tack should be suitable for incorporation into the final weld. It should be fabricated by qualified welders. The tack welds should be free from cracks and prior to final welding should be cleaned thoroughly. Tack welds that exhibit cracks should be grooved out. However, crater cracks may also be removed by grinding. All tack welds that are not to be included in the final weld should be removed. Any necessary aids that are temporarily attached for the construction or assembly of parts with fillet welds should be designed so that they can easily be removed again. The surface of the component must carefully be ground smooth again if the aid is removed by cutting or chiselling. It is possible to demonstrate by means of a dye penetrant test that the metal is not cracked in the area of the temporary weld. Schaeffler diagram - different base materials The Schaeffler diagram provides information on the welding properties of the various types of microstructure, as a function of what alloying elements they contain. Chromium equivalent is calculated using the weight percentage of ferrite stabilising elements and Nickel equivalent is calculated using the weight percentage of austenite stabilising elements. By entering the Ni- equivalent over the Cr-equivalent for stainless steel into a diagram according to Schaeffler one is able to find the content of martensite, austenite and ferrite in the resulting microstructure. Calculation After entering the range of the standard analysis and the actual analysis the Ni-equivalent and the Cr-equivalent are calculated and shown in a diagram. An online calculator tool is available at www.migal.co. 3 different versions of the Schaeffler diagram are available: a) for joining two different base materials with filler metal (see example below) b) for joining two different base materials without filler metal c) for the presentation of the actual analysis and the range of the standard analysis of a certain material For latest details regarding the content of this page see www.migal.co 86

Application reference The sample data can be overwritten and the red backgrounded fields show the results. Composition Base material 1 Base material 2 Weld metal Carbon C [%] Silicon Si [%] Manganese Mn [%] Chromium Cr [%] Molybdenum Mo [%] Nickel Ni [%] Niobium Nb [%] Titanium Ti [%] Chromium equivalent [%] Nickel equivalent [%] Dilution 0,04 0,50 0,50 17,0 1,10 0,00 0,00 0,00 0,02 0,50 1,00 17,50 2,25 12,50 0,00 0,00 0,02 0,80 1,00 19,00 2,70 12,00 0,00 0,00 25 [%] Compute Ni equivalent [%] Cr equivalent [%] De Long diagram for standard analysis The nickel and the chromium equivalent provide information about the amount of the various structures in stainless steels. Nickel and chromium are contained in such steels in considerable amounts. Nickel creates austenite and chromium creates ferrite. By entering the Ni-equivalent over the Cr-equivalent for stainless steel into a diagram according to De Long one is able to find the content of austenite and ferrite in the resulting microstructure. In opposite to the Schaeffler diagram nitrogen is taken into consideration with the nickel equivalent. This diagram permits a more precise evaluation of the ferrite content. Calculation After entering the range of the standard analysis and the actual analysis the Ni-equivalent and the Cr-equivalent are calculated and shown in a diagram. For latest details regarding the content of this page see www.migal.co 87

Application reference WRC-1992 diagram for range of standard analysis The WRC-1992 diagram provides information on the welding properties of the various types of microstructure, as a function of what alloying elements they contain. Chromium equivalent is calculated using the weight percentage of ferrite stabilising elements and Nickel equivalent is calculated using the weight percentage of austenite stabilising elements. By entering the Ni-equivalent over the Cr-equivalent for stainless steel into a diagram according to WRC one is able to find the content of austenite and ferrite in the resulting microstructure. The WRC diagram is today accepted as an improved version of the Schaeffler or the De Long diagram. Calculation After entering the range of the standard analysis and the actual analysis the Ni-equivalent and the Cr-equivalent are calculated and shown in a diagram. For latest details regarding the content of this page see www.migal.co 88

NiCr20Nb Welding wires/rods for Nickel alloys Typical composition in % Classification Application Base materials Physical properties at 20° C (Approx. values) Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Ni ......................................................................................................... ≥ 67,00 Cr .................................................................................................. 18,00-22,00 Fe .......................................................................................................... ≤ 3,00 C ............................................................................................................ ≤ 0,05 Mn .................................................................................................... 2,50-3,50 Si ............................................................................................................ ≤ 0,50 Cu .......................................................................................................... ≤ 0,50 Ti ............................................................................................................ ≤ 0,75 Nb .......................................................................................................... ≤ 3,00 S .......................................................................................................... ≤ 0,015 EN ISO 18274 ....................................................... S Ni 6082 (NiCr20Mn3Nb) DIN 1736 ................................................................................. SG - NiCr20Nb Material No. .......................................................................................... 2.4806 AWS A 5.14 ..................................................................................... ER NiCr-3 BS 2901 .................................................................................................. NA 35 Solid nickel chrome wire electrode suitable for welding nickel alloys and joining austenitic to ferritic steels subjected to ambient temperatures exceeding 300°C and joining dissimilar materials. The weld metal is scale-resisting up to 1000°C and good toughness down to -196° C. Suitable for Austenite-Ferrite joints up to 550° C. Dissimilar joints: Ni-Base with Austenite / Ni-Base with Ferrite / Austenite with Ferrite up to 550° C 2.4630 NiCr20Ti; 2.4631 NiCr21TiAl; 2.4669 NiCr15Fe7TiAl; 2.4816 NiCr15Fe 2.4817 LC-NiCr15Fe; 2.4851 NiCr23Fe; 2.4867 NiCr60 15; 2.4869 NiCr80 20 2.4870 NiCr 10; 2.4951 NiCr20Ti; 1.5637 12 Ni 14; 1.5662 X8Ni9; 1.5680 12Ni19 1.6900 X12CrNI18 9; 1.6901 GX8CrNi18 10; 1.6903 X10CrNiTi18 10 1.6906 X5CrNi18 10 Tensile strength Rm [MPa] ......................................................................... 800 Specific electr. Resistance [Ohm mm2/m] ................................................ 1,10 Density [g/cm3] ........................................................................................... 8,3 Melting point [°C] .................................................................................... 1.400 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spool type BS 300 / 15 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 90

NiCr21Mo9Nb Welding wires/rods for Nickel alloys Typical composition in % Classification Application Base materials Physical properties at 20° C (Approx. values) Shielding gas Polarity Dimensions Ø Wire packagings Ni ......................................................................................................... ≥ 60,00 Cr .................................................................................................. 20,00-23,00 Fe .......................................................................................................... ≤ 5,00 C ............................................................................................................ ≤ 0,10 Mn ............................................................................................................ 0,50 Si ............................................................................................................ ≤ 0,50 Cu .......................................................................................................... ≤ 0,50 Ti ............................................................................................................ ≤ 0,40 Al ........................................................................................................... ≤ 0,40 Mo .................................................................................................. 8,00-10,00 Nb ..................................................................................................... 3,15-4,15 S .......................................................................................................... ≤ 0,015 P ............................................................................................................ ≤ 0,02 Co .......................................................................................................... ≤ 1,00 EN ISO 18274 ....................................................... S Ni 6625 (NiCr22Mo9Nb) DIN 1736 .......................................................................... SG - NiCr21Mo9Nb Material No. .......................................................................................... 2.4831 AWS A 5.14 ................................................................................ ER NiCrMo-3 Nickel base wire electrode for welding nickel alloys and cold tough nickel steels, joining dissimilar steels and welding joints between austenitic and ferritic metals. Operating temperature -196° C bis +550° C. Dissimilar joints: Ni-Base with Austenite / Ni-Base with Ferrite / Austenite with Ferrite up to 550° C 1.4558 X2NiCrAlTi32-20; 2.4631 NiCr20TiAl; 2.4605 NiCr23Mo16Al 2.4618 NiCr22Mo6Cu; 2.4619 NiCr22Mo7Cu; 2.4630 NiCr20Ti 2.4641 NiCr21Mo6Cu; 2.4660 NiCr20CuMo; 2.4951 NiCr; 2.4816 NiCr15Fe 2.4817 LC-NiCu15Fe; 2.4851 NiCr23Fe; 2.4856 NiCr22Mo9Nb; 2.4858 NiCr21Mo 1.4951 X6CrNi25-20; 1.5662 X8Ni9; 1.5680 X12Ni5; 1.5681 GX10Ni5 1.6907 X3CrNiN18-10; 1.6967 X3CrNiMoN18-4; 1.4876 X10NiCrAlTi32-20 1.4959 X8NiCrAlTi32-21; Alloy 800, 800HT Tensile strength Rm [MPa] ......................................................................... 800 Specific electr. Resistance [Ohm mm2/m] ................................................ 1,28 Density [g/cm3] ........................................................................................... 8,4 Melting point [°C] .................................................................................... 1.350 Thermal conductivity [W/m K] ..................................................................... 9,8 Thermal expansion 20 - 100 °C [1/K] ................................................... 13*10-6 Modulus of elasticity [N/mm2] ............................................................. 200.000 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spool type BS 300 / 15 kg Box 5 kg / Length 1.000 mm Rod packagings For latest details regarding the content of this page see www.migal.co 91

NiCu30MnTi Welding wires/rods for Nickel alloys Typical composition in % Classification Application Base materials Physical properties at 20° C (Approx. values) Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Ni ......................................................................................................... ≥ 62,00 Fe ..................................................................................................... 0,50-2,50 C ............................................................................................................ ≤ 0,15 Mn .................................................................................................... 2,00-4,00 Si ............................................................................................................ ≤ 1,00 Cu ................................................................................................. 28,00-34,00 Ti ....................................................................................................... 1,50-3,50 Al ........................................................................................................... ≤ 1,00 Nb .......................................................................................................... ≤ 0,50 S .......................................................................................................... ≤ 0,015 P ............................................................................................................ ≤ 0,02 EN ISO 18274 ........................................................ S Ni 4060 (NiCu30Mn3Ti) DIN 1736 ............................................................................. SG - NiCu30MnTi Material No. .......................................................................................... 2.4377 AWS A 5.14 .................................................................................... ER NiCu-7 BS 2901 .................................................................................................. NA 33 Solid Nickel copper welding wire electrode suitable for joinig nickel copper alloys and copper to steel, claddings and buffer layers. 2.4360 NiCu 30 Fe; 2.4361 LC-NiCu 30 Fe; 2.4365 G-NiCu Nb; 2.4375 NiCu 30 Al Tensile strength Rm [MPa] ......................................................................... 550 Yield strength Rp0,2 [MPa] ............................................................................ 250 Elongation A200 [%] ...................................................................................... 35 Hardness [HV] ............................................................................................. 135 Specific electr. Resistance [Ohm mm2/m] ................................................ 0,62 Density [g/cm3] ........................................................................................... 8,5 Melting point [°C] .................................................................................... 1.330 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spool type BS 300 / 15 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 92

NiFe2 Welding wires/rods for Nickel alloys Typical composition in % Classification Application Physical properties at 20° C (Approx. values) Shielding gas Polarity Dimensions Ø Wire packagings Ni ......................................................................................................... ≥ 53,00 Fe ............................................................................................................. Rest C ............................................................................................................ ≤ 0,20 Mn .................................................................................................... 1,00-4,00 Si ............................................................................................................ ≤ 0,30 Cu .......................................................................................................... ≤ 2,50 Ti ....................................................................................................... 0,20-0,50 Al ........................................................................................................... ≤ 0,20 S ............................................................................................................ ≤ 0,02 P ............................................................................................................ ≤ 0,02 DIN 8573 ....................................................................................... SG - NiFe2 AWS A 5.14 ................................................................................... ER NiFe-Cl This alloy is particularly suited for welding of ferritic and austenitic nodular Cast iron as well as for joining it with non-alloy and high-alloy steel, copper and nickel alloys. Buildups on grey Cast iron qualities are also possible. Special applications are construction welding of ductile centrifugal casting tubes, such as joggles and flange joints, fittings, pumps, and for corrosion resistant claddings. The deposit is tough, crack resistant and easily machinable with cutting tools. Tensile strength Rm [MPa] ......................................................................... 800 Specific electr. Resistance [Ohm mm2/m] .................................................. 0,4 Density [g/cm3] ........................................................................................... 8,4 Melting point [°C] .................................................................................... 1.440 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 MIG =+ MIG-Drahtelektroden [mm] ........................................................... 1,0; 1,2; 1,6 Spool type BS 300 / 15 kg For latest details regarding the content of this page see www.migal.co 93

NiTi4 Welding wires/rods for Nickel alloys Typical composition in % Classification Application Base materials Physical properties at 20° C (Approx. values) Shielding gas Polarity Dimensions Ø Wire packagings Rod packagings Ni ......................................................................................................... ≥ 93,00 Fe .......................................................................................................... ≤ 0,70 C ............................................................................................................ ≤ 0,05 Mn ............................................................................................................ 0,80 Si ............................................................................................................ ≤ 0,80 Cu .......................................................................................................... ≤ 0,20 Ti ............................................................................................................ ≤ 4,00 Al ........................................................................................................... ≤ 1,00 S ............................................................................................................ ≤ 0,01 EN ISO 18274 ...................................................................... S Ni 2061 (NiTi3) DIN 1736 ......................................................................................... SG - NiTi4 Material No. .......................................................................................... 2.4155 AWS A 5.14 ......................................................................................... ER Ni-1 BS 2901 .................................................................................................. NA 32 Solid wire electrode suitable for welding pure nickel and nickel alloys as well as joints between these materials and steel, cast steel, copper claddings and buffer layers. 2.4056; 2.4062; 2.4066 Nickel 200; Nickel 201; Nickel 99 Tensile strength Rm [MPa] ......................................................................... 550 Yield strength Rp0,2 [MPa] ............................................................................ 250 Elongation A200 [%] ...................................................................................... 35 Hardness [HV] ............................................................................................. 135 Specific electr. Resistance [Ohm mm2/m] ................................................ 0,29 Density [g/cm3] ........................................................................................... 8,7 Melting point [°C] .................................................................................... 1.430 MIG: Ar+1-3% O2, Ar+1-3% CO2, Ar+He+O2, Ar+He+CO2, Ar+He+CO2+H2 TIG: Ar, He, Ar+He, Ar+2-5% H2 MIG =+, TIG =- MIG-wires [mm] ............................................................................ 1,0; 1,2; 1,6 TIG-rods [mm] .............................................................................. 1,6; 2,0; 2,4 Spool type BS 300 / 15 kg Box 5 kg / Length 1.000 mm For latest details regarding the content of this page see www.migal.co 94

Contents The Company .................................................................................................................................................................... 3 Robot quality - constant products ................................................................................................................................ 3 MIGAL.CO Quality ............................................................................................................................................................. 4 Tolerance of diameter and surface purity .................................................................................................................... 4 Twist-free wires ............................................................................................................................................................ 4 Quality control...................................................................................................................................................................5-7 Residual analysis - precision in surface coating .......................................................................................................... 5 Welding robot and digital image radiography .............................................................................................................. 6 Spectral analysis, tensile test and coefficient of friction .............................................................................................. 6 Standard vacuum packaging of MIGAL.CO welding wire ............................................................................................ 7 The Centre of Technology ................................................................................................................................................. 8 The Internet .................................................................................................................................................................. 9-10 E-Commerce ................................................................................................................................................................ 9 Certificates ................................................................................................................................................................... 9 Shoplist ........................................................................................................................................................................ 9 Metal supplements .................................................................................................................................................... 10 Spools and Packaging ................................................................................................................................................ 11-13 Overview Spools and TIG welding rods ..................................................................................................................... 11 Eco-Drum ................................................................................................................................................................... 12 Jumbo-Drum and JumboXL-Drum ............................................................................................................................. 12 Physical design of the welding system when using drums ........................................................................................ 13 Indicative tables .......................................................................................................................................................... 14-21 Chemical compositions .............................................................................................................................................. 14 Fields of application and usage of MIGAL.CO consumables for identical or similar base materials (Al) ............. 15-16 Fields of application and usage of MIGAL.CO consumables for identical or similar base materials (Cu) ................. 17 Fields of application and usage of MIGAL.CO consumables for identical or similar base materials (CrNi) ......... 18-19 Lengths of wires ......................................................................................................................................................... 20 Approvals ................................................................................................................................................................... 21 Rods/Wire electrodes for Aluminium Alloys ................................................................................................................ 23-40 MA 1070 • Al 99,7 ...................................................................................................................................................... 24 MA 1450 • Al 99,5Ti .................................................................................................................................................... 25 MA 2319 • AlCu6MnZrTi ............................................................................................................................................. 26 MA 4018 • AlSi7Mg .................................................................................................................................................... 27 MA 4020 • AlSi3Mn .................................................................................................................................................... 28 MA 4043 • AlSi5 ......................................................................................................................................................... 29 MA 4046 • AlSi10Mg .................................................................................................................................................. 30 MA 4047 • AlSi12 ....................................................................................................................................................... 31 MA 5087 • AlMg4,5MnZr ............................................................................................................................................ 32 MA 5183 • AlMg4,5Mn0,7 .......................................................................................................................................... 33 MA 5356 • AlMg5Cr .................................................................................................................................................... 34 For latest details regarding the content of this page see www.migal.co 95

Contents MA 5554 • AlMg2,7Mn ............................................................................................................................................... 35 MA 5556 • AlMg5Mn .................................................................................................................................................. 36 MA 5754 • AlMg3 ....................................................................................................................................................... 37 MA 6063 • AlMg0,7SiTiB ....................................................................................................................................... 38-40 Application reference for Aluminium Alloys ................................................................................................................. 41-52 Physical properties of chemically clean aluminium (compared to iron) ..................................................................... 41 Effects of the differences between the physical properties of steel to aluminium on fusion welding ...................................... 41 Oxide layer ................................................................................................................................................................. 42 Solubility of hydrogen ................................................................................................................................................ 43 Surface treatment prior to welding ............................................................................................................................. 44 Storage and handling ................................................................................................................................................. 44 Base materials ..................................................................................................................................................... 44 Filler materials ...................................................................................................................................................... 44 Condensation ............................................................................................................................................................. 44 Joint preparation ........................................................................................................................................................ 45 Plasma cutting ...................................................................................................................................................... 45 Machining ............................................................................................................................................................. 45 Chemical cleaning ................................................................................................................................................ 45 Gas Metal Arc Welding of Aluminium .................................................................................................................... 45-49 General Information ............................................................................................................................................. 45 Filler metals .......................................................................................................................................................... 46 MIG welding ......................................................................................................................................................... 46 Wire feeding ......................................................................................................................................................... 47 Arc ignition ........................................................................................................................................................... 47 Insufficient melting of the base metal at start and end crater at the end of the weld ........................................ 48 Black deposit on and beside the weld .................................................................................................................. 48 Special attention with gas shielded arc welding ................................................................................................... 49-50 MIG welding ......................................................................................................................................................... 49 Wire scratching at metallic edges ........................................................................................................................ 49 Unsuitable wire feed rolls ..................................................................................................................................... 49 Humidity and porous gas hoses ........................................................................................................................... 50 Contamination ...................................................................................................................................................... 50 Friction in the wire feed system ............................................................................................................................ 50 Arc too long .......................................................................................................................................................... 50 TIG welding .......................................................................................................................................................... 50 Preheating and inter-pass temperatures ................................................................................................................... 50 Anodizing ................................................................................................................................................................... 51 Correct storage .......................................................................................................................................................... 51 Common welding defects and how to avoid them ..................................................................................................... 52 For latest details regarding the content of this page see www.migal.co 96

Contents Rods/Wire electrodes for Copper Alloys ..................................................................................................................... 53-64 ML CuAl8 ................................................................................................................................................................... 54 ML CuAl8Ni2 .............................................................................................................................................................. 55 ML CuAl8Ni6 .............................................................................................................................................................. 56 ML CuAl9Fe ............................................................................................................................................................... 57 ML CuMn13Al7 .......................................................................................................................................................... 58 ML CuNi10Fe ............................................................................................................................................................. 59 ML CuNi30Fe ............................................................................................................................................................. 60 ML CuSi28L ............................................................................................................................................................... 61 ML CuSi3 ................................................................................................................................................................... 62 ML CuSn .................................................................................................................................................................... 63 ML CuSn6 .................................................................................................................................................................. 64 Application reference for Copper Alloys ..................................................................................................................... 65-71 Arc brazing ................................................................................................................................................................. 65 General ................................................................................................................................................................ 65 Arc brazing of zinc-coated steels ......................................................................................................................... 65 Classification of arc brazing processes ..................................................................................................................... 66 GMA brazing .............................................................................................................................................................. 66 Short-arc process ................................................................................................................................................. 66 Pulsed arc process ............................................................................................................................................... 66 Special requirements to the brazing equipment ................................................................................................... 67 Technological remarks ......................................................................................................................................... 67 TIG brazing ................................................................................................................................................................ 68 Special requirements to the brazing equipment ................................................................................................... 68 Plasma brazing .......................................................................................................................................................... 68 Special requirements to the brazing equipment ................................................................................................... 69 Materials for arc brazing ............................................................................................................................................ 69 Base materials ..................................................................................................................................................... 69 Surface coatings and preparation ........................................................................................................................ 69 Consumables and and auxiliary materials ........................................................................................................... 69 Brazing consumables ........................................................................................................................................... 69 Shielding gases .................................................................................................................................................... 70 Joint designs .............................................................................................................................................................. 70 Occupational health ................................................................................................................................................... 70 Laser beam brazing ................................................................................................................................................... 71 For latest details regarding the content of this page see www.migal.co 97

Stainless steel welding wires/rods .............................................................................................................................. 73-83 Stainless welding consumables by MIGAL.CO - better than the standard ...................................................................... 74 R&D, Know-How ........................................................................................................................................................ 74 Selection of filler metal .................................................................................................................................................... 74 Balanced composition ................................................................................................................................................ 74 Variants of one and the same consumable ................................................................................................................ 75 Simplified stock holding ............................................................................................................................................. 75 Delivery forms .................................................................................................................................................................. 75 1.4316 • 19.9.LSi ....................................................................................................................................................... 76 1.4332 • 24.13.LSi ..................................................................................................................................................... 77 1.4337 • ML 29.9 ........................................................................................................................................................ 78 1.4370 • 18.8.Mn ........................................................................................................................................................ 79 1.4430 • 19.12.3.LSi .................................................................................................................................................. 80 1.4462 • 22.8.3.L ........................................................................................................................................................ 81 1.4576 • 19.12.3.NbSi ................................................................................................................................................ 82 1.4842 • ML 25.20 ...................................................................................................................................................... 83 Application reference for stainless steel welding ........................................................................................................ 84-88 Recommendation of shielding gases for stainless steel welding ............................................................................... 84 Protecting the weld ............................................................................................................................................... 84 MIG welding ......................................................................................................................................................... 84 TIG and Plasma welding ..................................................................................................................................... 84 Root protection .......................................................................................................................................................... 85 Tips for tack welding .................................................................................................................................................. 85 Schaeffler diagram - different base materials ............................................................................................................ 86 De Long diagram for standard analysis ..................................................................................................................... 87 WRC-1992 diagram for range of standard analysis ................................................................................................... 88 Rods/Wire electrodes for Nickel Alloys ....................................................................................................................... 89-94 NiCr20Nb ................................................................................................................................................................... 90 NiCr21Mo9Nb ............................................................................................................................................................ 91 NiCu30MnTi ............................................................................................................................................................... 92 NiFe2 ......................................................................................................................................................................... 93 NiTi4 ........................................................................................................................................................................... 94 Contents ..................................................................................................................................................................... 95-98 For latest details regarding the content of this page see www.migal.co 98