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BÖHLER AM 500-UP / Marathon 204

General Welding Consumables · Welding Consumables

Class-certified type (DNV register) · technical data sheet not yet verified​​⁠​⁠⁠⁠⁠⁠⁠‌​‍‍⁠‌‍‍​‍

BÖHLER AM 500-UP / Marathon 204 by voestalpine Böhler Welding Germany GmbH. DNV TA certificate TAW00005B1.

Inspection

Inspector Detail

Common issues

  • Moisture pickup in the flux causing porosity, hydrogen cracking risk or poor bead appearance if stored or handled incorrectly
  • Wire rust or surface contamination from damp storage, leading to weld defects and feed problems
  • Wrong wire/flux combination used for the parent material or procedure, giving off-spec mechanical properties
  • Flux not recovered and re-screened correctly, mixing in slag or foreign material and causing porosity
  • Undried flux used after prolonged air exposure from an opened, not resealed, container

Inspection checklist

  • Check wire and flux batch/certificate against the approved Welding Procedure Specification (WPS) for the job
  • Confirm flux has been stored/dried per the manufacturer's data sheet before use (redry log)
  • Visual check of wire surface for rust, dirt or drawing lubricant residue before loading
  • Verify the wire/flux combination matches the classification required by the WPS and class-approved procedure
  • Check open containers are resealed and flux recovery/screening system is functioning (no slag carry-over)
  • Confirm welder qualification covers the process (SAW) and this consumable combination

Service intervals

Flux redrying before use (if exposed to air)per manufacturer's data sheet, typically a few hours at the specified temperature
Wire/flux stock rotationuse oldest certified batch first; recheck condition if stored beyond the manufacturer's shelf guidance

Typical intervals for this design class, not the manufacturer’s figures for your model. The manufacturer’s manual is binding.

Critical spares

  • Matching wire spool/coil of the same classification and diameter
  • Matching flux of the same classification, stored and dried per the data sheet
  • Contact tips and feed rolls sized for the wire diameter in use

Safety

  • Fumes from submerged arc welding are largely trapped under the flux, but flux handling and slag grinding generate dust - use appropriate respiratory protection
  • Arc flash and burn risk at process start/stop when flux coverage is incomplete
  • Store flux in a dry, ventilated area away from ignition sources; hot slag is a burn and fire risk on deck or in tanks

Class survey

For class-approved repairs, the surveyor checks that the wire/flux combination and welder qualifications match an approved WPS referencing this consumable's Type Approval (DNV TA, cert. TAW00005B1), and that welding procedure and consumable certificates are traceable to the work performed.

Classification

DNV type approval

Listed in the DNV Approval Finder at the time we recorded it. The certificate is issued by DNV, not by us; check its current status at DNV.

CertificateTAW00005B1
Open the certificate at DNV
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