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CONSUMABLES
Welding consumables are the electrodes, wires, fluxes and gases. Each consumable is critical in respect to
specification/supplier, condition and treatment (if any).
Helium:
Nitrogen:
provides a smooth arc at low arc voltage with dc-ve also gives cleaning action with ac for
light alloys.
In addition of hydrogen, provides a high arc voltage and gives deeper penetration also
increase speed on stainless steel.
less than argon therefore high flow rate (2~2.5 times) required to achieve same
effectiveness with argon. Produces high arc voltage and heat suitable for thick section. More
cost expensive than argon.
inert gas in the room but becomes active with oxygen therefore unsuitable for majority of
material but gives good result on the copper. More cost effectiveness than argon or helium.
Provides a gas shield to protect the weld pool and arc from atmospheric oxygen and nitrogen.
Provides a slag, which gives additional shielding to the weld pool and assists in manipulation during
the welding.
Improves the physical properties of the arc (arc initiation and stability)
Introduces weld metal alloys such as iron powder, de-oxidant etc.
Improves metallurgical properties to lowering oxygen and nitrogen levels.
Increasing deposition factors and over all efficiency
14.3.1
14.3.2
RUTILE
CELLULOSIC
Page 1 of 9
Section 14
Welding Consumables
14.3.3
BASIC
High limestone and fluorspar content to produce weld metal with low hydrogen content )< 5ml /
100mg of weld metal)
Limestone has good stability and produces carbon dioxide gas shield.
May be bake up to 500C approximately or depending on the manufacturer.
Ability to weld low alloy, high & medium tensile strength with high sulphur content without any
cracking, also reduce the possibility of the hydrogen induced cracking in the weld metal and heataffected zone, but dependant upon the properly dried.
Need higher degree of skill and must be used vertical up technique.
Productive and expensive
Constituents; limestone (calcium carbonate) gas former, CO2 secondary ionizer, fluorspar slag
former, sodium/potassium silicate main ionizer
.
Page 2 of 9
Section 14
Welding Consumables
70
Covered Electrode
Tensile Strength (ksi)
Welding Position
Flux Covering & Electrical Characteristics
AWS A 5.5 ALLOYED ELECTRODES
70
8 D3
Covered Electrode
Tensile Strength (ksi)
Welding Position
Flux Covering & Electrical Characteristics
Alloy Content (1.5% Mn 0.5% Mo)
STRENGTH
Tensile X 1000 PSI
POSITIONAL CAPABILITIES
Symbol
1
2
3
Welding Position
All position
Horizontal & Flat
Flat only
Symbol
0
1
2
3
4
5
6
8
Coating Type
Cellulosic
Cellulosic
Rutile
Rutile
Rutile + Iron Powder
Basic
Basic
Basic + Iron Powder
COVERING
ELECTRICAL CHARACTERISTICS
Classification
E 6010
E 6011
E 6012
E 6013
E 6020
E 6027
E 7014
E 7015
E 7016
E 7018
E 7024
E 7027
E 2028
Page 3 of 9
DC
AC
Positive
Negative
Section 14
Welding Consumables
A 5.17 F 6 A 2 EM12K
SAW Welding Flux
Heat Treatment Conditions
Chemical Composition of Wire Electrode
A 5.18 ER 70 S 6
Designate an Electrode Rod (ER) or only an Electrode (E)
Solid (S) or Composite (C)
Page 4 of 9
Section 14
Welding Consumables
E 46 3 1Ni B 5 4 H5
Strength (Yield, UTS & Elongation)
Alloying Composition
Weld Metal recovery and Type of Current
Low Hydrogen Potential
STRENGTH
Symbol
35
38
42
46
50
Elongation min. %
22
20
20
20
18
IMPACT PROPERTIES
Impact Energy Charpy V Temp C for 47 J min
No requirements
+ 20
0
- 20
- 30
- 40
- 50
- 60
Symbol
Z
A
0
2
3
4
5
6
ALLOYING COMPOSITION
Symbol
COVERING
Symbol
A
B
C
R
RR
RC
RA
RB
Coating Type
Acid
Basic
Cellulosic
Rutile
Rutile (Thick Coated)
Rutile Cellulosic
Rutile - Acid
Rutile - Basic
Metal Recovery %
< 105
< 105
> 105 < 125
> 105 < 125
> 125 < 160
> 125 < 160
> 160
> 160
Type of Current
AC + DC
DC
AC + DC
DC
AC + DC
DC
AC + DC
DC
POSITIONAL CAPABILITIES
Symbol
1
2
3
4
5
Welding Position
All position
All position, except vertical down
Flat butt weld, flat fillet weld, horizontal - vertical fillet weld
Flat butt weld, flat fillet weld
Vertical down and positions according to symbol 3
Page 6 of 9
Section 14
Welding Consumables
EN 440 - G 46 3 M G3Si1
Weld deposit produced by Gas Shielded Metal Arc
Welding
Impact Properties
Type of Wire Electrode
EN 756 - S 46 3 AB S2
Wire Electrode and / or Wire / Flux Combination
Impact Properties
Chemical Composition of Wire Electrode
Page 7 of 9
Section 14
Welding Consumables
Electrode
Strength (Yield, UTS & Elongation)
Impact Properties (47 Joules @ 0 C)
Chemical Composition (2.0% Mn)
Covering (Cellulosic)
E 50 4 2 Ni B 2 1 H5
E
50
4
2Ni
B
2
1
H5
-
Electrode
Strength (Yield, UTS & Elongation)
Impact Properties (47 Joules @ -40 C)
Chemical Composition (1.4 Mn, 1.8 2.6 Ni)
Covering (Basic)
Weld Metal recovery & Type of Current
Position
Hydrogen Content
E 42 2 R 1 3 H15
E
42
2
No Symbol
R
1
3
H15
-
Electrode
Strength (Yield, UTS & Elongation)
Impact Properties (47 Joules @ -20 C)
Chemical Composition (2.0% Mn)
Covering (Rutile)
Weld Metal recovery & Type of Current
Position
Hydrogen Content
Question No 2:
Which, if any of the following types of electrode require baking?
E 38 0 C
E 50 4 2Ni B 2 1 H5
E 42 2 R 1 3 H15
Solution:
E 38 0 C
E 50 4 2Ni B 2 1 H5
E 42 2 R 1 3 H15
Question No 3:
What is meant by S.T.C. (STC)
Solution:
S
Strength
T
Toughness
C
Covering
Page 8 of 9
Section 14
Welding Consumables
Question No 4:
Which, of the following AWS classified electrodes have Cellulosic coating?
E 6010
E 7016
E 7012
E 6011
E 6013
E 7018
E 9010 - G
Solution:
E 6010
E 7016
E 7012
E 6011
E 6013
E 7018
E 9010 G
Page 9 of 9
Cellulosic
Basic
Rutile (Wrong value for UTS)
Cellulosic
Rutile
Basic
Cellulosic (Classified to AWS A5.5)
Section 14
Welding Consumables