I can't thank you guys enough for all the help on this particular problem. I appreciate the knowledge and willingness to help here on the AWS forum. This is the place to get these technical questions answered for sure. To try and answer some of the replies, (and as I can remember everyone's posts) is sounds like we are on the right track indeed with our pre and post heat as well as interpass temp. We will in fact begin our test pieces to be sent out for destructive testing at 400-450* F pre-heat and 700* F interpass using .045 ER70S-6 and see what happens in a bend and tensile test. Again, I will report back our findings there when we get results (few weeks). The Design Engineer did the thermal conductivity ratings of various materials and settled on KWool as the best solution, needing approx 2" thick of it to be sufficient. I have not used Kwool specifically but have used similar products in the past. As for heat induction, we are still looking into that but still feel that will be the best solution. It does, however, have some challenges when it comes to wrapping the product in the heating cables but we will get that resolved.
As for the filler material(s), all out WPS' are with solid wire (for GMAW) and this is what our company prefers over other fillers. We do have E7018 and the associated WPS' but will be choosing a solid wire for this application. I cannot argue some of the points presented as far as the low hydrogen content of flux and the efficiency of metal core but since our bosses don't care for the smoke and clean up, along with the fact that there is only one of these we will ever do, there would be no need to perform a WPS with another filler. I am working on WPS' with dual shield for A36 just to have when we need them though. I am trying to show them the advantages of other fillers as opposed to sticking with just ER70S-6 for most applications. Another reason the 70 series wire was selected is the A572 is a 50ksi material thus the 70 series wire exceeds the strength requirements. If you truly feel this is the incorrect filler I will be open to discussing that further.
And last, for the moment, Henry, on the Welding Tips and Tricks Forum you mentioned you can only see items 1 and 2. If you click on the picture it will expand it so you can see the whole image you can see here.
![red :red:](/f2/epx.png)
![lol :lol:](/f2/epx.png)
![lol :lol:](/f2/epx.png)
I appreciate you sharing the link and pics here with everyone. I wanted to do the same but didn't get to it.
Now on to getting the testing of the 4140 to A572 Gr B done and see what happens there. Again, I say thank you to everyone who has contributes thus far and will be sharing this link with everyone involved, especially as it is updated.
-Jonathan