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WELDING CONSUMABLES.
FILLER RODS or FILLER WIRES:
Consumables added separately to the weld pool.
ELECTRODES:
Consumables which are part of the welding circuit, providing one end of the arc.
WELDING CONSUMABLES
All those things used up in the production of a weld Though generally, we refer to those elements that are used in a specific welding process i.e:
WELDING CONSUMABLES
welding fluxes (SAW) TIG/PAW rods
cored wire
SAW strips
Courtesy of ESAB AB
COVERED ELECTRODES.
THREE GENERIC TYPES OF ELECTRODE COVERING:
Type of coverings
Rutile covering: are based on titanium oxide
easy to strike arc, less spatter, easy to remove slag, excellent for positional welding
produce finely rippled regular welds; also concave fillet welds increase fatigue life! can be dried needs a reasonable proportion of combined water to keep the covering intact if moisture is driven off, the binding of the flux will suffer hydrogen content is 25-30 ml/100 g of weld metal
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Type of coverings
Cellulosic covering: flour and wood pulp are common constituents weld metal has a very high hydrogen content resultant slag layer is thin
Type of coverings
Basic covering: contain calcium compounds like calcium fluoride and calcium carbonate a.k.a. lime-coated basic refers to the chemical behaviour of the flux can contain iron powder increased efficiency (but less slag poor positional capabilities!) have the lowest level of hydrogen (less than 5 ml/100 g of weld metal) needs baking to perform correctly (at approximately 350C for 2,5 hours; see also manufacturer recommendations!) after baking, maintain at minimum 120C to prevent moisture pick-up cannot be rebaked indefinitely!
World Centre for Materials Joining Technology
Weld
Electrode efficiency
up to 180% for iron powder electrodes
Flux Covering Weld Metal Recovery and Current Type Welding Position
Hydrogen Content
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CONSUMABLES .
QUESTIONS ?
E - Electrode 42 Strength, Yield, UTS, Elongation. 2 Impact Properties. (47 joules @ -20C) No symbol Chemical composition.(2.0Mn) R Covering Rutile 1 Weld metal recovery & type of current 3 Position
E 42 2 R 1 3 H15
E 50 4 2Ni B 2 1 H5 Basic Will require baking E 42 2 R 1 3 H15 Rutile Keep dry but no baking
World Centre for Materials Joining Technology
E 7018
E 8016 -D3
Alloy Content
1.5%Mn/0.5%Mo
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AWS Question 1.
Which of the following AWS classified electrodes have cellulose coatings? E6010 E7016 E7012 E6011 E6013 E7018 E9010 - G
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Standard number
EN 756 - S 46 3 AB S2
Wire electrode and/or wire/flux combination Impact properties Chemical composition of wire electrode
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SAW Fluxes
Agglomerated
SAW Fluxes
Fused
CONSUMABLES .
QUESTIONS ?
Fused fluxes are normally not hygroscopic but particles can hold surface moisture so only drying
Agglomerated fluxes contain chemically bonded water. Similar treatment as basic electrodes
If flux is too fine it will pack and not feed properly. It cannot be recycled indefinitely
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Standard number
EN 440 - G 46 3 M G3Si1
Weld deposit produced by gas shielded metal arc welding Impact properties Type of wire electrode
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Radius
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Gases
supplied in cylinders
BS EN 10204-Type of documents
Non-specific inspection documents Type 2.1 Name: Declaration of compliance with the order Content: statement of compliance with the order (doesnt include test results!) Who validate it - the manufacturer
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Type 2.2
Name: Test report Content: statement of compliance with the order (include test results!) Who validate it - the manufacturer
BS EN 10204-Type of documents
Specific inspection documents
Type 3.1
Type 3.2
Name: Inspection certificate 3.1 Content: statement of compliance with the order (include specific test results!) Who validate it - the manufacturer inspection (independent of manufacturing department!)
Name: Inspection certificate 3.2 Content: statement of compliance with the order (include specific test results!) Who validate it - the manufacturer inspection (independent of manufacturing department!) + purchasers/official designated authorised inspector
Quality assurance
filler material must be stored in an area with controlled temperature and humidity
poor handling and incorrect stacking may damage coatings, rendering the electrodes unusable
there should be an issue and return policy for welding consumables (system procedure) control systems for electrode treatment must be checked and calibrated; those operations must be recorded filler material suppliers must be approved before purchasing any material
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fused fluxes are normally not hygroscopic but particles can hold surface moisture only drying
agglomerated fluxes contain chemically bonded water similar treatment as basic electrodes for high quality, agglomerated fluxes can be recycled with new flux added if flux is too fine it will pack and not feed properly cannot be recycled indefinitely
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plastic spool
wire spool
coil
wires must be kept clean and free from oil and dust flux cored wires does not require baking or drying
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Courtesy of ESAB AB
Cast diameter improves the contact force and define the contact point; usually 4001200 mm
Rutile electrodes
Inspection of consumables
Why? How?
Non-specific inspection carried out by the manufacturer in accordance with its own procedures the products inspected are NOT necessarily the products supplied!
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To assess whether the products are in compliance with the requirements of the order or not see BS EN 10204 Specific inspection carried out before delivery in accordance to product specification inspection is performed on the products to be supplied or on test units of which the products supplied are part
Moisture pick-up
Type of coverings
Acid covering: contains large quantities of iron oxide - need deoxidants to preserve mechanical properties of the weld deposit (especially toughness!) the slag cannot remove impurities from the weld pool susceptible to solidification cracking! high in hydrogen susceptible to cold cracking! produces flat and smooth welds, with deep penetration fast freezing/easy to detach slag used for positional welding does not require backing or drying limited use due to poor mechanical properties!
Copyright 2005, TWI Ltd