SELECTION OF WELDING CONSUMABLES

1.0 INTRODUCTION:
The term Welding Consumables refers to the filler metals employed in different forms in
various welding processes. The selection of most appropriate welding consumables is of
paramount importance to achieve good weldments most economically and selection involves
study of metallurgy of base material, service conditions as also ready availability of
consumables.
Globalization and rapid Industrialization has brought about major changes in design and
selection of base materials for fabrication. The emphasis is mainly in cost reduction by using
improved base materials. The advancement in welding technology has made it possible to
meet this challenge by developing new consumables to meet specific requirements.
Advances made by consumable manufacturer in terms of product and process are needed to
be understood by fabricator to achieve quality-welded product at minimum cost.
2.0 CRITERIA FOR SELECTION:
For a given specific application, the filler metal selection with compatible process is to be
done taking following factors into consideration.
2.1. METALLURGICAL

Base Materials
Mechanical Properties
Chemical composition
Corrosion requirements
Physical properties
Soundness & Structural Stability
Heat treatment

2.2. MECHANICAL

Thickness of Material
Dimension & No. of components

2.3. PROCESS

Available forms of consumables

Adaptability for the job
Welding process selected

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2.1.1 BASE MATERIAL:
The single important factor determining the selection of filler metal and process is, base
material specification being joined. The base materials are classified as per ASTM
specification.
In general the base metals are broadly classified as Carbon Steel, LAS, SS and High Alloy
Steels. In addition there are other steels for low temperature application, Q & T Steels etc.,
for specific application.
Even though consumable selection steps are same for various materials, in this presentation
consumable selection for CS & SS are highlighted.
2.1.2 MECHNICAL PROPERTIES:
Mechanical property of weld metal basically covers the aspect of
(i)
Soundness
(ii)
Strength
(iii)
Toughness
The welding consumable should be so designed, so as to be compatible metallurgically with
base material and produce sound weld to give radiographic quality deposits.
As the weld metal has a cast structure as compared to the rolled structure of the base metal
and weld zone is likely to contain defects like porosity and slag, the weld metal tensile
strength is required to be higher than base material or atleast equal to it.
The Weld metal should also have adequate toughness at given design temperature taking in
to account fabrication practices.
2.1.3CHEMICAL COMPOSITION:
The Weld Metal chemistry in general matches the composition of base metal for similar
metal joining. In case of dissimilar base metals are being welded, the selection care should
be taken to see that diluted weld metal will not result information of brittle inter metallic of
weld metal chemistry is based on diluted weld metal compatibility.
2.1.4 CORROSION PROPERTIES:
The Weld Metal corrosion properties are to be equal or superior to that of base metal. This
is to avoid preferential attacks on the weld joint.
2.1.5 PHYSICAL PROPERTIES:
The Physical properties of weld metal should be compatible with that of the base metal.
These include properties like the thermal expansion co-efficient, thermal and electrical
conductivities, magnetic permeability etc.
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2.1.6 SOUNDNESS AND STRUCTURAL STABILITY:
The Weld Metal should be capable of resisting some amount of dilution of the base metal
without forming a crack sensitive weld metal and the weld micro structure should be stable
under the expected service conditions.
2.1.7 HEAT TREATMENT:
The Consumables selected for joining should be capable of giving the desired test results in
as welded condition as well as heat-treated condition. When heat treatment is not specified
in design/code, it is very essential to identify various heat-treatment stages during
fabrication and ensure that consumable selected does meet these requirements. The general
heat-treatment cycles encountered during fabrication are normalizing and stress relieving.
2.2.1 THICKNESS OF MATERIAL:
For selection of proper consumable and process, thickness of material plays a vital role.
The selection of semi-automatic and automatic process comes into picture only if base
metal thickness normally exceeds 10mm and joint configurations are adaptable for
automation.
2.2.2 DIMENSION & NO. OF COMPONENTS:
While thickness in principle decide the selection of process, the dimension of job and
number of components to be welded also play an important role. In case of heavy subassembles even though length of the joint may be too small for automation, if the operation
is repetitive in nature, the same can be considered for automation. The automation not only
reduces the cost but also improves the quality of jobs.
2.3.1 AVAILABLE FORMS OF CONSUMABLES:
As you will all agree, this is single most important factor for selection of process. Once the
technical details are worked out and suitable consumable specifications are identified, it is
essential to find out whether consumables are readily available for SMAW, GMAW, FCAW
&/or SAW before process selection could be started. At present, thanks to technological
development, in general for all common materials SMAW, SAW & FCAW consumables are
readily available.
2.3.2 ADAPTABILTY FOR THE JOB:
Before finalization of the type of consumable to be used, it is essential to study whether the
job is being done in the work shop, site or sub-contractors premises, so as to ascertain
availability of suitable equipment and also take into consideration environmental condition.
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3.0 CONSUMABLE SELECTION:
The Welding consumables for welding of CS, LAS & SS are selected based on guidelines
provided in ASME II C. The relevant specification for the same are indicated here below:
SFA 5.1
Carbon Steel Electrodes for Shielded Metal Arc Welding
SFA 5.4
Stainless Steel Electrodes for Shielded Metal Arc Welding
SFA 5.5
Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
SFA 5.9
Bare Stainless Steel Welding Electrodes and Rods
SFA 5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.18 Carbon Steel Electrodes and Rods for Gas Shielding Arc Welding
SFA 5.20 Carbon Steel Electrodes for Flux Cored Arc Welding
SFA 5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux
Cored Rods for Gas Tungsten Arc Welding
SFA 5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding
SFA 5.29 Low Alloy Electrodes for Flux Cored Arc Welding
SFA 5.01 Filler Metal Procurement Guidelines
3.1 CONSUMABLE SELECTION FOR CS:
Suggested welding consumables for welding CS are indicated in Table I. For welding of
Carbon the additional metallurgical factors to be taken into consideration are discussed here
below:
(i)
BASE MATERIAL: As per ASTM specification
(ii)

MECHNICAL PROPERTIES: For achieving mechanical properties with regard to

strength, there are not many problems as matching consumables are readily available.
Wherever toughness requirements are specified for weld metal, particularly for low
temperature application, it is essential to keep in view variable like specification of
electrodes used, heat input, inter-pass temperature, position of welding heat treatment
and specify higher impact acceptance value than required for the job.

(iii)

CHEMICAL COMPOSITION: In most cases, the consumables selected are of

matching composition with lower percentage of carbon and higher percentage of
manganese to compensate the strength. The Silicon percentage is so controlled as to
achieve full de-oxidation without seriously affecting the ductility.

(iv)

CORROSION REQUIREMENTS: For CS material, this requirement is not

generally applicable. However, for specific cases like weathering steel, atmospheric
corrosion tests may be specified which has to be taken into account and weld metal
should meet the same.

(v)

PHYSICAL PROPERTIES: As matching consumables are used, the physical

properties match quite well.

(vi)

SOUNDNESS & STRUCTURAL STABILITY: For CS consumable, no

metallurgical transformation takes place at operation temperature. Hence, this
requirement does not pose any serious problems at operating temperature provided
the weldment is sound at room temperature.

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(vii)

HEAT TREATMENT: This is a critical area that requires study of fabrication

sequence. Even though heat treatment may not be called for many CS applications,
the components like Dished End Blanks, Petal Dished End Assembly may undergo
normalizing treatment due to process requirement. If matching consumable is used,
there may be drastic reduction in the strength values of the weld. Also in case of
components having toughness requirements specified, the heat treatment cycle may
alter the values.
Hence, the consumable selected has to be duly tested for operational heat treatment
cycles whether final heat treatment cycle is involved or not. Table II highlights the
properties of consumables with typical HT cycles. Also typical case study of
fabrication of Dished End brings to fore the problems involved.

3.2 CONSUMABLE SELECTION FOR SS:

Table III indicates the selection of consumables for austenetic SS. In addition for welding of
SS the metallurgical factors to be considered are as indicated below.
(i)

BASE MATERIAL: As per ASTM specification

(ii)

MECHNICAL PROPERTIES: In general, for welding of SS matching composition

consumables are used. Hence, the strength properties are easily achieved.
Whenever SS is selected for cryogenic service say 196 deg C application, special
emphasis on selection of consumable is to be considered vis--vis micro fissuring. It
is true for sensitive corrosion applications also.

(iii)

CHEMICAL COMPOSITION: In most cases matching composition consumables

are selected.

(iv)

CORROSION REQUIREMENT: For SS application, the corrosion requirement

becomes the most important factor. For many applications, control of delta ferrite in
the weld becomes critical to achieve the desired corrosion rates. Even though the
control of delta ferrite to near zero percentage gives excellent corrosion results, this
in turn results in micro fissuring of welds. Hence, such consumables are not
particularly suitable for restraint joint welding. The solution lies in selecting suitable
consumables having excellent crack resistance behavior and also controlled ferrite.
This is possible by selecting consumables by subjecting them to Thomas Schaeffler
crack resistivity test in addition to standard corrosion test.

(v)

PHYSICAL PROPERTIES: As matching consumable are used no appreciable

change is noticed.
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(vi)

SOUNDNESS & STRUCTURAL STABILITY: For SS consumables used for

application below 450 deg C there is no metallurgical transformation and stable
structure is guaranteed. However, whenever operating temperature is in the range of
530 deg C 750 deg C carbide precipitation occurs along the grain boundaries and
corrosion resistance is drastically reduced in HAZ area. This leads to typical failure
known Knife Edge Attack and subsequent failure. Their failure can be minimized
with use of either extra low carbon consumable or by using stabilized grade
depending on specific application.

(vii)

HEAT TREATMENT: SS fabricated components are not normally subjected to

Heat-treatment operations, except solution annealing treatment which only improves
corrosion properties without impairing mechanical properties.

3.3 SELECTION OF PROCESS: The process selection of course is based on availability of

suitable consumables in addition to taking into consideration thickness of components,
dimensions, number of components also adaptability of the process for the job.
We will now look at various process options available such as SMAW, SAW, GMAW &
FCAW Advantages & Limitation of each of above.
3.3.1

SHIELDED METAL ARC WELDING (SMAW):

Advantages:
a)
b)
c)
d)

Variety of electrodes with different features

Most versatile in use-all-position joints/joints with limited access
Suitable for most alloys
Equipment simple, inexpensive & portable

Disadvantages:
a) Finite length
b) High dependence on welder skill
c) Not amenable to automation

3.3.2

SUBMERGED ARC WELDING (SAW):

Advantages:
a)
b)
c)
d)

Highest deposition rate

Most suited for automation
Consumables can be contomised
Lowest operator fatigue

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Disadvantages:
a)
b)
c)
d)
3.3.3

Not versatile no positional capability

Generally not used for thin sections
Joint fitup very critical
Arc not visible. Hence joint or seam tracking may be necessary

GAS METAL ARC WELDING (GMAW):

Advantages:
a)
b)
c)
d)

Continuous electrode
Higher current possible
Minimal post-weld cleaning required
Highly amenable to automation

Disadvantages:
a) Equipment more complex and costlier their SMAW
b) Welder skill dependence still high, especially for out-of-position welding
c) Not amenable to customization
3.3.4

FLUX CORED ARC WELDING (FCAW):

Advantages:
a)
b)
c)
d)
e)

High productivity of continuous wire welding

Metallurgical benefits of flux
Higher current density than solid wires
Versatile use-all-positional, wide thickness range
Visible arc easy to use

Disadvantages:
a)
b)

Equipment more complex and costlier than SMAW, same as GMAW

FCAW wires more expensive on weight basis but compensated by higher
productivity

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As for welding of CS/LAS & SS in most cases as all the process consumable are
readily available, the process limitation is finally dictated by following criteria.
SMAW

SAW

GMAWFCAW

Dep. Rates

Geo. Symmetry

Positional welds

Field joints

Difficult field joints

Code: (1) Very Good (2) Good (3) Satisfactory (4) Low
3.5 COST OF WELD METAL:
Another important factors to be considered by welding engineer in selecting appropriate
welding consumable is cost of weld deposition.
The cost of weld metal consists of following factors.
i)
ii)
iii)
iv)
v)
vi)

Consumable Cost
Gas cost for GMAW & FCAW
Flux cost for SAW
Power cost
Labour and Overhead
Rework cost

It is well-established fact that cost of labour and overhead will decide the economic level of
operation. Hence reduction in fabrication cost is possible only with increase in productivity.
The fig 1 indicates the productivity of various processes and table IV indicates typical cost
calculation for SMAW & FCAW processes.
From this it is clear that even though unit cost of consumable is high, the deposited weld
metal cost is lower beyond particular labour and over head cost. This factor becomes prime
importance while selecting process for fabrication using available consumables.
4.0 TYPICAL CASE STUDIES
Keeping in view selection of consumables as per guideline given in ASME Sec IIC &
establishing procedure as per Sec IX, some of typical industrial applications where failure
occurred are highlighted here below with analysis of likely cause.
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4.1 MANUFACTURING OF CS D.E

Description: Formation of DE can be done by one of the following methods.
a)
b)
c)

Petal construction
Hot forming
Spinning

Problem: In petal construction, the weld metal does not undergo any heat-treatment. In case
of hot forming even though normalizing cycle is known, many a times blank made with weld
is not specified in drawing. In case of spinning the fabricator may use intermediate
normalizing for ease of forming.
Hence, in case of Hot forming with welded blank / spinning the weld may undergo
normalizing operation which is not planned.
Analysis: Considering C.S of 515 Gr 70 as base material & E 7018 or E 71T-1 as welding
consumable, the UTS drop of 50-70 N/mm2 is common with normalizing operation. Hence,
the UTS of weld metal will drop to 470 N/mm2-, which is below acceptable level and results
in a failure.
Solution: It is recommended to use E708-A1 or E70-TA1 as welding consumable which does
not show any significant drop in UTS with normalizing heat treatment also.
4.2 316 LF WITH NIL FERRITE
Description: 316 LF consumables with Nil ferrite for butt welds and overlays for used
reactor application.
Problem: These types of consumables were required to be used for fabrication of urea
reactor. During qualification of consumable, no problems were encountered and corrosion
results were excellent.
However, on actual job condition, particularly on C-seams & Nozzle to Shell joints serious
micro fissuring problems were encountered.
Analysis: Even though problem was controlled by grinding of all crater points, still micro
fissuring were noticed at regular interval which shattered confidence of fabricator.
After detailed study, an additional Thomas Schaeffler crack sensivity test was introduced
for evaluation of consumables. The consumables, which gave satisfactory results in this test,
were found to give excellent weld performance or actual job also.
Solution: Use modified 316 LF with crack sensitivity test qualified consumables.

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5.0 CONCLUSION:
1. Even though Selection of Welding Consumables are based on guidelines specified in
ASME Sec II C and procedures have to be established as per ASME Sec IX, in actual
fabrication, the need to consider metallurgical factors affecting the weldment have to be given
due recognition.
2. The process of welding is dictated by availability of suitable consumables. When available,
due importance is to be given for productivity.
3. Whenever weld contour and location makes SAW process not easily adaptable, FCAW plays
an important role as most adaptable process without unduly sacrificing productivity.
4. Quality and Productivity being main tools for minimizing fabrication cost, the
adaptability of processes like SAW & FCAW are to be fully explored and utilized.

TABLE I
SUGGESTED CONSUMABLES FOR WELDING
CARBON STEEL FOR STRUCTURES
Welding process
ASTM Steel
A 242
A 441
A 572 Grade 42
A 588 (4 in and under)
A515 GR 60/70
A 572 Grade 60,65
A 633 Grade E
A 515 GR 70

Shielded
Metal arc
E 7015
E 7016
E 7018
E 7028
E 8015-XX
E 8016-XX
E8018-XX

submerged
arc

Gas metal
arc

F7XX-EXXX

ER 70S-X

F8XX-EXXXb

ER80S-XXb

flux covered
arc
E7XT-1
E7XT-4,5,6,7 or 8
E7XT-11
E7XT-G
E8XTX-XXb

TABLE II
PROPERTIES OF CONSUMABLES WITH TYPICAL
HEAT TREATMENT CYCLE

Sl. No

Technical Condition UTS

N/mm2

Consumable
Type
As Welded

SR

Normalized

1.

E 7018

530

525

480

2.

E 7018 A1

540

535

530

3.

E 8018

550

540

500

TABLE III
SUGGESTED CONSUMABLE FOR
AUSTENITIC STAINLESS STEEL
Recommended filler materials for austenitic stainless steels
Base Metal
GMAW/GTAW
Wrought Cast
SMAW
PAW, SAW
AISI
ACI
AWS A 5.4
AWS A 5.9
201
E 209
ER 209
202
E 219
ER 219
E 308
ER 308
301
302
CF-20
E 308
ER 308
304
CF-8
308
304L

CF-3

303

FCAW
AWS A 5.22
E 308T-X
E 308T-X

E 308L
E 347

ER 308L
ER 347

E 308LT-X
E347T-X

E 312

ER 312

E312T-X

309

CH-20

E 309

ER 309

E 309T-X

310
314

CK-20

E 310

ER 310

E 310T-X

316

CF-8M

E 316

ER 316

E 316T-X

316L

CF-3M

E 316L

ER 316L

E 316LT-X

317

E 317

ER 317

E 317T-X

321

E 347

ER 321

E 321T-X

347

E 347

ER 347

E 347T-X

TABLE IV
WELD METAL COST FORMULAS
1. LABOR & OVERHEAD

= LABOR & OVERHEAD COST /HR

DEPOSITION X
RATE (KG/HR)

2. ELECTRODE

OPERATING
FACTOR

= ELECTRODE COST/KG
DEPOSITION EFFICIENCY

3. GAS

= GAS FLOW RATE X GAS COST

(LITRE/MIN)
PER LITRE
DEPOSITION RATE (KG/HR)

4. FLUX

FLUX COST/KG X 1.4

DEPOSITION EFFICIENCY

5. POWER

COST/KWH X VOLTS X AMPS

1000 X DEPOSITION RATE

TOTAL COST PER KG OF

DEPOSITED WELD METAL =

SUM OF 1 5 ABOVE