Hi
Have you RT'ed any of the joints? I ask because we have had a similar problem, but we were getting porosity when welding in the overhead position with SDSS FCAW wire. (During PQR qualification tests.) When I did some research, I found that porosity in the OH position is typical of these fillers. Does pass code acceptable limits though, but still more than makes me comefortable. I notice that you mention using a 90/10 mix. The specs generally call for a 20 - 25% CO2. Apparently if the CO2 percentage gets below 15%, it can lead to problems, so you may want to look at that. Some other issues that we had while using the wire:
1) We were using a fancy Miller power source, and the welder had it set on the GMAW setting. On this setting, the power source does unexpected wave shaping, that appears to not be beneficial for FCAW. Make sure you have the power source on the FCAW setting.
2) The flux appears to be very fluid, running down the filler wire and causing an unstable arc. Try to get the arc as far to the front of the puddle as possible, and travel faster. This may leave a "ropey" bead, but this can be countered by a rapid but small "weave" motion.
3) Make sure your wire stick-out is as per manufacturer's recomendations.
Keep in mind that to get the right properties from the SDSS, you need to have a very low heat input. With higher heat inputs you will not be able to pass the required impact and corrosion tests normally required when welding these materials.
Hope this helps.
Regards
Niekie
MRWeldSoCal,
Back in 2011 we had to qualify a number of Duplex and Super Duplex procedures. One was a S32507 to C.S using E309LMO T1-1/4 0.045. 75%-25% We had to x-ray and perform to ASTM A923 A,B, and C. I had the same issue. Could not get it to look very good. The finished weld did not look that great. I welded this up using an SA 250D Lincoln. (CC only) I have never showed this picture before, just out of sheer embarrassment. Now that I have seen yours, I’m not so embarrassed. Just kidding. :) I think what you are seeing in the as welded condition if about right.
Jim