Metrode Products Limited

Newsletter
Summer 2009

In this issue -

Essen 2009 Reviews

Offshore, oil & gas and LNG
Power generation
Petrochemical
Nickel base alloys

New faces in the technical department

Sports section

New literature

NAG makes a return

Quality news

Supercore update

History section

Metrode around the world

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 1

A Lincoln Electric Company

Essen 2009 - 14-19th September

Metrode will be continuing a story S32750, S32760 and S32550). Metrode has a long and well
that started back in 1981 and will established track record of supplying welding consumables
be exhibiting at Essen 2009. For to projects worldwide.
the first time we will be joining
Lincoln Electric on their stand in
Hall 6.
The Metrode section of the stand
will highlight how integration
within the Lincoln organization
has strengthened our already
high worldwide market profile, whilst maintaining Metrodes
unique position in the supply of high performance/integrity
alloyed welding consumables.
We will be highlighting Metrodes range of welding
consumables in the following industries: -
Lean duplex, Duplex, Superduplex, Zeron 100, 2507
Duplex and superduplex stainless steels have become firmly
established for a number of applications in the offshore
sector because of their excellent combination of strength
and corrosion resistance. Standard duplex is 22%Cr (eg.
UNS S31803 and S32205) and superduplex is 25%Cr with a
Offshore, Oil & Gas & LNG
pitting resistance equivalent number (PREN) 40 (eg. UNS

New Duplex LNG

Electrode
A new product has been introduced into the standard
duplex consumable range.
The Supermet 2205AR electrode is designed for general
fabrication applications where optimum operability is
required. The electrode is classified to AWS E2209-17 and
has excellent arc characteristics and slag release. The
existing products: Supermet 2205, Ultramet 2205
(E2209-16) and 2205XKS (E2209-15) will continue to be
made.
The general areas of application for each product can be
summarised as follows:
Supermet 2205 - Has an existing customer base
mainly in the foundry industry where it is used for
repairing castings. 308LCF, 316LCF
Ultramet 2205 - Rutile all-positional electrode for
general fabrication made on a matching core wire. The Controlled Ferrite (CF) electrodes were originally
designed over 15 years ago to satisfy the requirements of
Supermet 2205AR - Rutile electrode with optimised Mobil/Ralph M Parsons for the SAGE (Scottish Area Gas
operability. Evacuation) project terminal at St Fergus in Scotland. Over
2205XKS - Basic coated electrode made on a matching the last few years the range has been expanded to include
core wire. Preferred electrode for offshore applications consumables for all the major welding processes including
and for other projects where the best impact flux cored wires. The full range has been used on the
properties are required. recently opened LNG terminals in the UK at Isle of Grain and
South Hook.

1 Metrode Products Limited 2009 Newsletter

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 2

A Lincoln Electric Company

Power Generation Production Improvement

The production improvements that can be achieved by using
an all position flux cored wire compared to traditional MMA
electrodes are obvious. Twice the weld deposition rate of
MMA electrodes and up to four times the productivity can be
achieved by using flux cored wire. This while maintaining
full control over the weld pool in ASME 5G/6G welding
position.

P11, P22, CrMoV, P91, E911, P92, T23, T24

Part of a range
Metrode offer a range of flux and metal cored wires for Cr-
Mo base materials:
Metrode has been a major supplier to the power generating
industry in the UK for many years, but over recent years the Base Material Type1 Trade Name
growth in expanding export markets, in particular China and 1Cr- Mo P/T11-12 R Cormet 1
India preceded by a strong presence in the USA, has been 2Cr-1Mo P/T 21 -22 R Cormet 2
nothing short of spectacular. Low C-2Cr-1Mo P/T 21 -22 R Cormet 2L
1Cr-1Mo-V R Cormet 1V
P91 & P92 MMA Electrodes 5Cr-1Mo P5 R Cormet 5
9Cr-1Mo P9 R Cormet 9
There have been a number of specifications that require the
use of fully matching core wires for the latest generation 9Cr-1Mo-V-Nb P/T/F91 M Cormet M91

CrMo alloys. In response to these requirements for specific 9Cr-1Mo-V-Nb P/T/F91 R Supercore F91
markets Metrode manufacture their Chromet 9MVN+ 9Cr-1Mo-1W-Nb-V-N E911 M Cormet 10MW
(P91) and Chromet 92 (P92) electrodes on fully matching 9Cr-1W-Mo-V-Nb-N P/T/F92 R Supercore F92
core wires. 1 : R=rutile core M=metal cored
The Chromet 9MVN+ (P91) electrode is being extensively
used in the Indian market and the Chromet 92 is being used
Conclusion:
worldwide although currently the major market is China. Metrode continues to develop and introduce new flux cored
T24 CrMo wires for advanced creep resisting materials, leading the
industry, the commercial use of Supercore F92 is evidence
Metrode has expanded the range of CrMo alloys of this. Supercore F92 offers substantial productivity benefits
manufactured with the introduction of the 24CrMoV wire to the fabricators welding P92 while maintaining quality and
(TIG and sub-arc) for the welding of T24. This alloy is integrity.
currently used, predominantly in tube form for the
manufacture of waterwalls in boilers. The TIG wire would be More details can be found in our P92 Technical Profile
used for joining tubes to themselves and the sub-arc process available on www.metrode.com
is used for joining the tubes to the interconnecting fins. Metrode has been strong in the Petrochemical and Refinery
Ready for the future with Supercore F92 industries for many years and has an extensive range of
consumables for many applications.
Metrodes Supercore F92 flux cored wire - firmly established
in the Power generation Market
Petrochemical
There is continuing effort to increase the energy conversion
efficiency of fossil-fired power plants, for which enhanced
creep resisting steels are essential to withstand more
advanced steam conditions. Steel X10CrWMoVNb9-2 is
currently applied in Ultra Supercritical (USC) fossil fuel power
generation plants and is expected to take part of the market
that is currently covered by gradeX10CrMoVNb9-1.

Leading the way

Metrode Products Ltd. was the first to introduce an all-
position rutile flux cored wire for F91. To date Supercore F91
is still the benchmark and close to 200 metric tonnes has
been successfully used by fabricators and contractors.
Now Metrode is again leading the way in providing
production improving welding consumables for the power
generation industry. Supercore F92 has recently been used
in large quantities in projects in the U.S.A. after going
300H, 347H, 16.8.2, 316H, 800, HP40Nb, 35.45.Nb
through an extensive validation program.

Metrode Products Limited 2009 Newsletter 2

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 3
A Lincoln Electric Company
300H high carbon stainless steel consumables
Metrode has a long history of supplying high carbon
stainless steel consumables such as 308H, 347H, 316H and
16-8-2. Various papers have been presented over the years
describing the design philosophy adopted to ensure
optimum high temperature properties and metallurgical
stability; the most recent presentation was by Graham
Holloway at a Seminar in Jubail, Kingdom of Saudi Arabia
organised by Tarek Nasser Al-Akeel Co. Ltd.
The seminar presentation covered the controls required to
optimise consumables for high temperature service; ranging
from the necessity to control ferrite content to the effects of
bismuth and niobium on creep strength. Emphasis was
placed on the excellent properties of the 16-8-2 weld metals
which have found widespread use for welding 300H base
Nickel Base Alloys
182, 625, C276, 59, C22, 617, 690, 400, B2
3 Metrode Products Limited 2009 Newsletter
materials particularly in refinery Cat Crackers. Metrodes
range of 16-8-2 consumables covers all processes:
TIG ER16.8.2
MMA Supermet 16.8.2
E16.8.2-15
Sub-arc ER16.8.2 + SS300
FCAW Supercore 16.8.2 & Supercore 16.8.2.P
As a whole, nickel-base consumables have a very wide range
of applications. They can be roughly divided into those with
compositions matching specific parent materials, usually for
corrosion resistance, and those with compositions unique to
weld metal specifications some of which have specialised
uses and others more general purpose applications. The
Metrode range of consumables has been the subject of
extensive development over recent years.
As always we will have a strong team on the stand to answer
your technical questions so please make a point to come
along and visit us. Look for us on the Lincoln stand in Hall
6 and you will get a warm welcome.
SCHWEISSEN & SCHNEIDEN is the most important event in
the world of welding. The world market and global know-
how, the decision-makers from companies and the top
people in science only come together at this leading fair.
Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 4

A Lincoln Electric Company

Technical Team News R&D and Technical support

Metrodes research & development team consists of a
selected group of highly-trained and experienced
development specialists. The team has always been
dedicated to the design of high quality welding
consumables for new alloys and the improvement of
existing products to meet the current and future needs
of the fabrication industry.
Metrode has always had good reputation for technical
support and to help maintain this advantage Metrode is
continually moving forward. The technical support team
is led by Graham Holloway, who has been with Metrode
for nearly 15 years and he is assisted by Miroslav Fabian
who has now been with Metrode for 2 years. The
technical support team has now been strengthened by
the addition of Dr Raghvendra Srivastava (known as
Raghav). Raghav recently completed his PhD at
Cambridge and is a valuable addition to the Metrode
team.

Pavlina Hromadova has joined Metrode R&D team as a

development chemist. Pavlina holds a masters degree in
chemistry and her appointment will strengthen the team
and has already started producing a valuable contribution
to Metrodes continuous increasing product range for
alloyed welding consumables.

Sports News The Best in the business

Earlier this year, we were asked to sponsor the story continues
the new kit of the under-7 football team of
Abbey Rangers, based in Chertsey, within
two miles of the Metrode factory. Two
members of staff have children in the
team. The addition of the logo made all
the difference apparently - they won their
next two games, 3-0 and 6-1!

The next edition of the Metrode Technical Handbook is

reaching the final stages of production and will be launched
at the Essen show in September. A new edition of the
product summary will also be launched as a sister
publication.

Metrode Products Limited 2009 Newsletter 4

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 5
A Lincoln Electric Company
Quality News
Metrode originally developed a quality system back in the
1970s. It was the first welding consumables manufacturer
to gain the newly introduced BS5750 pts. 1 and 2 in 1985.
The company did not rest on its laurels and Quality is
continually monitored and improvements are implemented.
Currently the company is working towards an environmental
health and safety quality system that will encompass ISO
14001 (environment) and ISO 18001 (health & safety). We
are hoping to implement this during 2010. We have recently
been awarded the latest certificate of approvals from LRQA
(ISO 9001:2008)and TV NORD
Stainless steel flux cored wires
Pressure on fabricators to reduce costs and increase
competitiveness is a fact of 21st century life;
Supercore flux cored wires wires can provide that
competitive edge.
Supercore combines the productivity of continuous GMAW
(MIG) with the operability and bead appearance of rutile
SMAW (MMA) electrodes, and this alone would justify the
decision to switch to Supercore.
But many additional benefits - such as low cost introduction,
ease of use, excellent weld appearance and radiographic
quality have all contributed to its success.
5 Metrode Products Limited 2009 Newsletter
Four main factors will influence your decision to use
Supercore: -
Minimal Capital Outlay
Supercore uses standard GMAW equipment and Argon/CO2
or CO2 shielding gas, all of which are readily available,
making investment in additional equipment or gases
unnecessary.
Increased Productivity
Twice the weld deposition rate of SMAW electrodes and
approximately four times the productivity can be achieved.
Reliable Weld Quality
Metrodes research and development of the Supercore range
has focussed on combining all that is best in SMAW quality
with GMAW productivity. High quality weld profiles and
surface finish, good penetration, high radiographic quality
and virtually spatter-free welding, are all consistently and
reliably achievable.
Economics
The productivity gains possible with Supercore reduce the
cost of fabrication, with inevitable beneficial effects upon
the bottom line.
Interested?
Supercore flux cored wires are an integral part of the
Metrode range of alloyed welding consumables
manufactured at Chertsey in the UK in a recently
commissioned dedicated production facility.
We have a full range of technical documentation to support
the range, much of which is available on the Metrode
website at -
www.metrode.com
Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 6

A Lincoln Electric Company

A moment in history excerpt from article

to be published in Stainless Steel World
Metrode was founded in 1963, 26 years before Stainless Steel range that includes consumables for the power generation,
World (SSW) was established, and has seen a number of offshore and oil & gas industries.
significant milestones during SSWs existence. The Company
The evolution of the company can be seen by looking at the
was the vision of Bill Marshall and with the financial support
original site in Weybridge, the new premises in Chertsey
of Jim Morton, Metrode started manufacturing electrodes in
(1970) and the Chertsey factory as it looks in 2009. Although
what at first sight appeared to be a detached house, in
there have been significant changes over the 46-year period,
Weybridge Surrey.
there are some constants: the early records show a product
called 17.8.2.RCF being made in the 1960s, and the same
electrode (with some tweaks) is still being made in 2009.
Looking at the early records there are many consumables
whose origins can be traced back to the 1960s and 1970s.
In 2003 a key milestone in Metrodes history occurred, the 40th
anniversary of the founding of the company. Staff, past and
present, gathered to celebrate Metrodes 40th anniversary with
an evening boat cruise along the Thames being the centrepiece
of the celebrations. Not everything went according to plan
because of amplifier problems the music was of a more
personal (unplugged!) one-to-one nature than anticipated but
this just added to the sense of occasion.
In October 2006 Metrode saw another major milestone in its
evolution when the company was acquired by Lincoln Electric.
Metrodes original factory, Weybridge, Surrey Metrode maintains its individualistic and highly specialist
approach to the niche alloyed consumable market but, with
The detached house in Weybridge gave way to factory the backing of the worlds largest welding company, has
premises in 1970, when Metrode relocated to its present site accelerated its growth well beyond the expectations of the
in Chertsey, Surrey UK. founders, Bill Marshall and Jim Morton. This ongoing success
story is one that can no doubt be told in more detail in SSWs
The two founding fathers were both followed into the
silver jubilee issue in 2014.
business by their sons, Adam Marshall and Alex Morton. Adam
succeeded his father in developing a depth and breadth of
technical expertise which is legendary in the welding industry.
He retired in 2008 after 42 years with the Company. Alex
Morton steered the Company to the successful integration into
Sellafield Limited
the Lincoln Electric Group and himself took early retirement
when that came to fruition in 2006.
A number of other renowned metallurgists and welding
specialists have helped to shape Metrodes success over the
years, significantly Dr Tad Boniszewski and Dr Chris Farrar.
When Metrode was started, its aim was to produce specialist
electrodes in small quantities for niche applications and alloys.
This philosophy still exists today even though the size of the
undertaking has increased. Metrode is now a major player in
the alloyed arc welding consumables market with a product

Metrode is currently manufacturing the largest quantities

of Nitric Acid Grade (NAG) stainless steel consumables
made since the 1980s. The consumables were first used
used in the manufacture of the THORP (Thermal Oxide
Reprocessing Plant)
Metrode has a long history of supplying consumables to
Sellafield Ltd (previously BNFL) and the successful
manufacturing expertise they have acquired made them
the first choice for the manufacture of consumables for
this critical application.

Metrode Products Limited 2009 Newsletter 6

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 7

A Lincoln Electric Company

EuroJoin 2009 - Venice The 3rd Conference on

Advanced Materials and Welding
for USC Power Plant China
The conference was dedicated
to advanced materials for ultra
super critical (USC) power plant
and involved the major Chinese
steel makers for special alloys,
boiler and turbine fabricators
and electric power engineering
companies. It is held once every
two years and the 3rd conference was held in Tianjin, China,
24-27 July. Some 300 delegates from the Chinese power
Metrode continued to promote its expertise in the power generation industry attended the 3 day conference. As one
generation industry with a paper on P92 welding of the major welding consumable suppliers to the Chinese
consumables at the seventh EuroJoin Conference held in power generation industry, Metrode participated in this
Venice. P92 is one of a growing range of creep resisting important event for the second consecutive time. Dr Zhuyao
CrMo alloys that are being used in the latest design of ultra Zhang, Metrode R&D Director, was invited by the organising
super critical (USC) power plant. committee to present a key-note speech to the conference.
Metrode offers a full range of consumables for P92: The subject that Dr Zhang presented was 617 type nickel
base filler metals for welding Super 304H and HR3C
TIG /GTAW 9CrWV
austenitic stainless steels. With superior mechanical
MMA/SMAW Chromet 92 properties and high temperature microstructural stability,
617 type filler metal offers an ideal solution for joining Super
FCAW Supercore F92
304H and HR3C steels which are now widely used in
SAW 9CrWV wire + LA492 flux Superheater and Reheater tubes of USC power plant. The
latest test data indicate that Metrodes 61-70 TIG/GTAW 617
weld metal produces satisfactory creep performance that
Obituary matches the base materials.

Dr J C M Farrar HonFWeldI
We mentioned above that Chris
Farrar was one of the people
New 309LMo all
who shaped the way Metrode is
today. You could probably
narrow the field down and say
positional FCW
that without Chris we would
have been a very different
company and may not be sitting
Supercore 309MoP
in such a strong position in the Adding to the existing down-hand wire, Supercore
welding industry today. 309Mo (E309LMoT0-1/4), Metrode has recently
In his chosen profession he demonstrated a lifetime introduced a new grade of 309LMo all positional flux
commitment to welding and fabrication on a global cored wire, Supercore 309MoP (E309LMoT1-1/4).
scale: in research, in welding manufacture, in his This completed Metrodes austenitic flux cored wire
contribution to the development of welding range. The wire offers satisfactory operability in all-
consumables and, in his later years, through his welding positions and can be used with either Ar-CO2
reputation as an international consultant, Chris was one mixed gas or 100%CO2.
of the most well-known, liked and respected people in
the welding community world-wide. The 309Mo range also includes: -

To his friends and colleagues he will be remembered for MMA

many qualities; he was able to combine business and Supermet 309Mo AWS E309LMo-17
technical excellence whilst, at the same time, being
inspirational, approachable, sympathetic and humorous. Ultramet B309Mo AWS E309LMo-15
His premature passing earlier this year following a four
Vertamet 309Mo AWS E309LMo-17
year long battle against a debilitating illness, is a great
sadness to all those who knew him. He is survived by his TIG/MIG/SAW
wife, Averil, two married sons and four grand children.
Metrode ER309Mo BS EN 23 12 2 L

7 Metrode Products Limited 2009 Newsletter

Metrode NL Aug09:MetrodeAug09 25/8/09 12:34 Page 8
The 14th Beijing Essen Welding & Cutting Fair
The 14th Beijing Essen Welding & Cutting Fair was held in
Shanghai, 2-5 June 2009. Benefiting from Chinas steady
and vigorous economic growth, this exhibition has now
become one of the top two international welding shows in
the world. Metrode again attended the show that attracted
manufacturers, sellers and buyers from the welding industry
with a total entry of 62,486 from 73 countries. From the 4
day show, little indication was seen of the effect of the
economic situation which is currently troubling the world.
Instead, confidence was clearly visible everywhere with both
exhibitors and visitors from the industry.
The Metrode stand, with a new stylish design, reflected our
success in China and firm commitment to the Chinese market.
We were very pleased to meet again with many of Metrodes
existing customers as well as many new friends. As ever, the
Metrode stand proved very popular with visitors and at most
times it was one of the busiest spots in the show!
Cormet 2 flux cored wire
Drax Power Station UK has a generating capacity of 3,960
megawatts, the highest in Western Europe and meets about
7% of the UKs electrical power demand. It is the cleanest
and one of the most efficient coal-fired power stations in
the UK. Most recently Cormet 2 was used during the
fabrication of replacement main steam manifold branch
sections.
If you want further information on any of the
consumables in this newsletter, please contact us on
the numbers below or visit our website at
www.metrode.com
Metrode Products Limited 2009 Newsletter
A Lincoln Electric Company
The final dressing of the stand before opening
The Metrode team (left to right) Zhang Chongwen, Yan
Ye, Frederic Lobinger, Han Min, Stephanie, He Ziyuan,
Peter Frost, Dr.Zhuyao Zhang
IIW Conference & Assembly
in Singapore July 2009
Dr Zhuyao Zhang presented a paper on lean duplex
stainless steel welding consumables in Singapore. Metrode
has introduced two lean duplex stainless steel consumables
into its product range: a MMA electrode Ultramet 2304 and
an all-positional flux cored wire, Supercore 2304P.
The lean duplex stainless steels have generated interest
because they provide a good combination of strength
(comapared to standard duplex) and corrosion resistance
(comparable to 316L) combined with
potential cost savings.
If you are interested in welding lean
duplex stainless steel please contact
Metrode for additional information.
If you are coming to Essen, we look forward
to seeing you there!
Metrode Products Limited
Hanworth Lane, Chertsey, Surrey, KT16 9LL, UK
Tel: +44(0)1932 566721
Fax: +44(0)1932 565168
Emails: sales@metrode.com
tech@metrode.com
A Lincoln Electric Company
info@metrode.com
Or visit the website at www.metrode.com
8