wee ee bw eee ee eee Module 6 Electrodes and Consumables PART OF THE GCIL CERTIFICATE PROGRAMS ea FOR INDUSTRIAL LEARNIN | Copyright 2001 The CWB GroupGooderham Centre for Industrial Learning 3.0 Flux and Metal Cored Wires Types of Flux Cored Wires Shielding Gases . : : Seen Self Shielded Electrodes. eee Standards and Specifications for Flux and Metal Cored Arc Welding Electrodes te Chemical Requirements Mechanical Properties a Description of the Flux Cored Arc Welding Electrode Classifications Description of the Metal Cored Arc Welding Electrode Classifications Optional Supplemental Designators ...... Low Alloy Flux and Metal Cored Electrodes . 4.0 Submerged Arc Welding Consumables ... Submerged Arc Wires ........ Fluxes for Submerged Arc Welding Chemical Actions of Fluxes Oxygen Transfer : ‘Specification of Submerged Arc Welding Consumables. Classification of Submerged Arc Welding Consumables Examples of SAW Flux/Electrode Classifications Choices of Fluxes .... : Crushed Slags .. : ‘A4 Diffusible Hydrogen. . Low Allloy Steel Electrodes for SAW 5.0 Tungsten Electrodes ............. eee 6.0 Aluminum and Aluminum Alloy Electrode: General . Shielded Metal Arc Welding Gas Shielded Arc Welding Processes . ‘Selection and Use of Electrodes .. 7.0 Stainless and Heat Resisting Steel Electrodes .. Hae Classification Systems for Stainless Steel Electrodes - 102 au Chemical Composition wo Recommended Reading . 407 n List of CSA Standards Covering Consumables for Welding nator oe List of AWS Filler Metal Related Documents .......... e pet 108 as ; Guides and Exercises 2.0.02. oe eee c cee eeee eee eesseeneee seen eeneseee 109 ' ‘Test and Answer Sheets . 17 aGooderham Centre for Industrial Learning MODULE 6 ELECTRODES AND CONSUMABLES TABLE OF CONTENTS Terma and Definilonstes ce tniinsn senna ennnniec re tinii 3 1.0 Covered Electrodes . Core Wire .. Flux Coating . Manufacture of Electrodes 2.0 Functions of Electrode Coatings . Functions of the Slag Specific Materials in Electrode Coatings Classification of SMAW Electrodes ...... 15 Classification System for Covered Electrades for Carbon and Low Alloy Steels .... we : 16 Characteristics of Covered lectrodes. eerie .22 Specific Electrode Types 22 Summary of Electrode Characteristics . - 30 Example of Electrode Selection . +32 Principles of Electrode Selection 32 Detrimental Action of Moisture and 133 Storage of Arc Welding Electrodes . £38 Moisture Resistant Electrodes .. 138 Low Alloy Steel Arc Welding Electrodes 138 Moisture and Hydrogen Tests . 143 Solid Electrodes and Rods for Welding 47 Cast and Helix 249 Solid Carbon Steel Filler Metals for Gas Shielded Arc. Welding .49 Specific Electrode Types . 152 Welding Conditions and Shielding . 53 Mode of Metal Transfer Tensile Properties of As-Welded Deposits Impact Properties of As-Welded Deposits . i Revised: 08/2002dia Gooderham Centre for industrial Learning 3.0 Flux and Metal Cored Wires . Types of Flux Cored Wires . Shielding Gases . Self Shielded Electrodes ‘Standards and Specifications for Flux and Metal Cored Arc Welding Electrodes Chemical Requirements Mechanical Properties . Description of the Flux Cored Are Welding Electrode Classifications . Desoription of the Metal Cored Arc Welding Electrode Classifications Optional Supplemental Designators . .... Low Alloy Flux and Metal Cored Electrodes 4.0 Submerged Arc Welding Consumables .76 Submerged Arc Wires... 76 Fluxes for Submerged Arc Welding . 77 Chemical Actions of Fluxes 79 Oxygen Transfer at Specification of Submerged Are Welding Consumables. Classification of Submerged Arc Welding Consumables . Examples of SAW FluwElectrode Classifications . Choices of Fluxes Crushed Slags . . AA Diffusible Hydrogen Low Alloy Steel Electrodes for SAW . 5.0 Tungsten Electrodes ..... ©... 2.12 92 6.0 Aluminum and Aluminum Alloy Electrodes, General ............5 Shielded Metal Arc Welding Gas Shielded Arc Welding Propess Selection and Use of Electrodes... 7.0 Stainless and Heat Resisting Steel Electrodes .... Classification Systems for Stainless Stee! Electrodes Chemical Composition .............---- Recommended Reading List of CSA Standards Covering Consumables for Welding List of AWS Filler Metal Related Documents ...... Guides and Exercises . Test and Answer Sheets ‘ Caaaanannaanaaananno tain 74 7 AagatannnonnannnaanananaganSI aaa eae Gooderham Centre for Industrial Learning combined oxygen L ) ~ | Terms and Definitions ) 7 ) absorbed sucked up or in and retain. d ) admixture the act or state of being mingled or mixed. ) ) adsorbed the result of being drawn in. Where a gas, vapour or dissolved matter is ) assimilated by the surface of a solid y ) agglomerate to make or form into a rounded mass. ) ) alkaline having a pH greater than 7 d ) ampere a unit of electrical current. ? ) austenite solution of one or more elements in face centered cubic iron. The solute ) is generally considered to be carbon. ) ) austenitic a metal whose dominant structure is austenite. ) basic electrode @ consumable whose coating contains large amounts of calcium ) carbonate. These electrodes are intended to produce weld deposits of ) controlled or low hydrogen content. ) ) composite Any of the multi-component filler metals available in various forms such ) electrode as; stranded wires, covered tubular cores and covered wires. d ) conduction the transmission or conveying of something through a medium. In arc ) welding we experience conduction of heat and electricity. > ) curing preserved or finished by a chemical or physical process ) ‘ ) deformation to alter the shape of by pressure or stress. ) ) density the mass per unit volume of a substance, under specified standard ) conditions of pressure and temperature ) ) deoxidizing an action element or compound which is intended to remove chemicallyGooderham Centre for Industrial Learning deoxidization diffuse dilution diffusible hydrogen dissociate ductility elongation embrittlement energy ferrite freezing range friable fusible to remove oxygen from. In welding, elements are added to filler metals to promote the removal of oxygen absorbed by the liquid during the during the welding process. to spread out. Diffusion is the act of gradual mixing of two or more ‘substances. a change in the chemical composition of the weld deposit from the composition of the filler metal due to admixture of base metal or previous weld metal. hydrogen which can spread out in a steel. Considered to be single atoms when absorbed by the weld pool and the cause of cold cracking and embrittlement of carbon and low alloy steels once single hydrogen atoms recombine after cooling. to separate. Dissociation is the chemical process where a change in physical condition causes molecules to separate into smaller groups, single atoms or ions. the ability of a material to become permanently deformed without failure. the act of lengthening or extending a loss of ductility. the work that a physical system is capable of doing in changing from its actual state to a specified reference state. In steel; a solid solution of carbon in body-centered cubic iron. There are two ferrite regions on the iron-iron carbide equilibrium diagram, separated by an austenite area. The upper ferrite is referred to as ‘delta ‘delta ferrite’ and the lower is referred to as ‘alpha ferrite’. a range of temperatures over which a liquid becomes a solid easily crumbled; brittle capable of being melted by heating eee ee ete etetaeGooderham Centre for Industrial Learning ~peP ee ee ee eee ae fusion boundary hygroscopic inorganic ionization grain hardness heat affected zone killed steel martensite microstructure oxidation potential parameter penetration plastic deformation the junction between metal which has been melted and the unmelted base metal. capable of readily absorbing moisture from the atmosphere substances or compounds not containing carbon having electrons either removed or added to a neutral atom or molecular compound An individual crystal in a polycrystalline metal or alloy. in metals; resistance of a metal to plastic deformation usually by indentation. In some ways a measure of the material's ability to flow without fracturing. that portion of the base metal which has not been melted but whose mechanical properties or microstructure have been altered by the heat of welding. a steel which has been deoxidized while liquid through additions of strong oxide forming elements a phase of steel formed by transformation of austenite below the usual transformation temperature range, achieved by rapid cooling. Its appearance is needle like crystals which are a supersaturated solution of carbon in iron the structure of polished and etched metals as revealed by a microscope at a magnification greater than 10 diameters. @ measure (in volts) of the driving influence of a metal or compound to form an oxide avariable a non-standard term for joint penetration or root penetration deformation that does or will remain permanent after removal of the joad which caused it.Gooderham Centre for Industrial Learning preheat rimmed steel saturate semi-killed steel ‘solute solubility ‘solution ‘supersaturated surface tension toughness viscosity volt voltage welding procedure to heat beforehand. In welding, preheat is often described as the minimum temperature of the material at any time before commencement of welding an ingot cast steel product which has not been deoxidized to soak, imbue or impregnate thoroughly. an ingot cast steel which has had some of its excess oxygen removed by the addition of small amounts of deoxidizing agents the component of either a liquid or solid that is present to a lesser or minor extent the amount of one substance which can be dissolved in a given amount of another substance the state of being dissolved to saturate a solution beyond the point normal under a given temperature. In steels, a martensitic structure is considered to be supersaturated body centered cubic iron carbon (excess carbon). a property of liquids resulting from unbalanced attractive forces between molecules at or near their surfaces the ability of a material to resist the growth of a crack the degree to which a liquid resists flow under an applied force A unit of electrical potential or electromotive force equal to the difference of electrical potential between two points on a conductor carrying a constant current of one ampere when the power dissipated is one watt. é the electromotive force or potential difference expressed in volts Arecipe for creating a welded connection. A document providing details of relevant variables for a specific application to assure repeatable results by qualified personnel.Gooderham Centre for Industrial Learning ‘The purpose of this module is to acquaint the student with the major types of electrodes and consumables available and their characteristics. Completion of this module should provide the student with a knowledge of: 1. The major electrodes covered in various CSA and AWS standards. 2. The main groupings of electrodes. 2 The function of SMAW electrode coatings. 4. Materials used in coatings. a . Requirements of various standards. 6. Operating characteristics of electrodes. ~N Solid, flux cored and metal cored wires. 8. Submerged arc wires and fluxes. 9. Low alloy and stainless steel electrodes. 10. Other consumables for welding dn most welding operations, additional “filler metal is added to the joint to complete the weld. In consumable electrode electric arc welding, this comes from the melting of the electrode itself which may be a covered electrode, or a continuously fed wire or tube filled with various compounds. In non-consumable electrode welding, or oxy-fuel-gas welding, the filler metal is added as a separate rod. The electrode may also introduce other materials such as fluxes, deoxidants and alloy elements which can have an affect on the welding operation. Electrodes can therefore be complex. A wide range of operating characteristigs and weld metal properties may be achieved using different electrodes. As a result of this, many specifications have been written by the Canadian Standards Association (CSA), the American Welding Society (AWS), the International Organization for Standards (ISO), and other organizations covering a wide range of filler materials. The most important of these will be discussed in this module.Gooderham Centre for Industrial Learning 1.0 Covered Electrodes The shielded metal arc welding (SMAW) process using covered electrodes (also known as coated or stick electrodes) is the most versatile process, and is still widely used. The electrode comprises a core wire which is coated with a layer of flux materials and other ingredients which provide the specific operating characteristics and properties. Covered electrodes have a long history of development starting from the original bare electrodes, progressing to the lightly dipped electrodes having a thin layer of lime, to the asbestos wrapped electrodes, and finally to the modem electrode with a relatively thick and complex coating. The main features of the covered electrode are shown in Figure 1.1. The heat of the arc melts both the core wire and the coating. (The latter, in some electrodes, melts at a slower rate, thus forming a collar around the arc and allowing the electrode to be dragged on the work piece.) The molten slag separates from the molten metal and solidifies as a hard layer on the surface of the weld. The weld metal is protected from contamination from the air by gases from the flux and/or by the molten slag in contact with the metal. core wire solldified slag -coating weld pool protective atmosphere _- are column molten slag PeMtmulac) Figure 1.1 - Covered Electrode (SMAW)ante wwe ew ewe wee Gooderham Centre for Industrial Learning 1.1 Core Wire In the past, the core wire was made from rimmed steel. However, with the advent of continuous casting, it became cheaper to make killed hot rolled steel rod, and rimmed steel became difficult to obtain in large quantities. As a result, most electrodes now have a core of con-cast or killed steel. Any alloying elements are generally added through the flux, except in the higher alloyed stainless and heat resisting steels. (Even here, the analysis of the core wire is often quite different from that of the final weld. For this reason, it is definitely not recommended that core wires stripped of their coating be used as filler rods in GTAW or similar processes.) Electrode core wires for carbon and low alloy steels are typically low in carbon (<0.10%), manganese (0.25 ~ 0.60%), silicon (0.10 - 0.35%), sulphur (<0.02%) and phosphorus (<0.02%). 1.2 Flux Coating The flux coating consists of various minerals, chemicals and alloy materials which provide arc stability and shielding of the molten weld metal, and also control the mechanical properties, chemical analysis and metallurgical properties of the weld metal. It is this flux covering that determines the properties, or classification, of the electrode. A “binder’, usually sodium and/or potassium silicate, is added to the dry mix of minerals and alloys to form a paste which can be extruded onto the core wire. 1.3 Manufacture of Covered Electrodes The various steps in the manufacture of coated electrodes are shown in the block diagram in Figure 1.3, although there may be some variation. (Examples: Identification may be stamped on the electrodes before baking. Electrodes may be stabilized, or “air dried” before baking.) The coating is applied by an extrusion process which squeezes a paste of the coating mixture around the core wire to form a concentric covering (Figure 1.2). Concentricity is extremely important to the handling of the electrode. If the coating is extruded off center, the arc will be deflected to the side where the coating is electrode thinnest and most easily burned off. Asimplified core wire diagram of the extrusion process is shown in Figure 1.4. Electrodes are usually produced in standard lengths, the most popular being 350mm (14") and 450mm (18"), and diameters from 2.4mm (3/32") to 6.0mm (1/4"), although other sizes are available. The diameter refers to the core wire, not the overall electrode diameter. equal Figure 1.2: Electrode coating must be Concentricert Me Gooderham Centre for Industrial Learning COATING CORE WIRE Formula proportion weighed Hot rolled to about 9.5mm (3/8") diameter Dry mixed Drawn to final diameter Binder added and wet mixed Straightened Slug prepared (if required) Cut to length Uniform concentric coating extruded onto core wire Coating removed from contact and holder ends Electrode dried in oven at suitable temperature Electrode stamped with identification Packaged for shipments Fig. 1.3: Steps in The Manufacture of Covered Electrodes The thickness of the coating depends on the type of electrode. Lightly coated electrodes have about, 10 to 20 percent electrode weight in the coating. Medium coated electrodes comprise about 20 to 35 percent electrode weight in the coating and iron powder is usually an important constituent have a high iron powder content. This contributes to a high deposition rate and these are | | Heavily coated electrodes may have up to 55 percent electrode weight in the coating and | | popular electrodes for production welding in the flat position. y ’ } Be rotenone ees ee essere Bay nGooderham Centre for Industrial Learning Re eee eee eee a ae coating in bare core wire paste form fi feeding tube covered electrode. Figure 1.4: Extrusion of Covered Electrodes 1.4 Functions of Electrode Coatings The coating on the electrode may perform a wide variety of functions depending on the composition. The primary function is the protection of the molten metal from contamination by the air through the formation of shielding gases and a molten slag. Several other functions may be important depending on the type of electrode and application. Among the more important functions include: * Protect the molten metal by gas and slag formation + _ Influence the arc characteristics such as striking, ionization, stability, arc force, side arcing + Influence bead shape + Ald slag removal * Influence penetration ‘ + Add alloying elements to the weld metal + Increase deposition rate + Controt chemical and mechanical properties of the weld metal + Control the hydrogen introduced into the weld metal + Influence the ease of manufacture such as extrudability 11Gooderham Centre for Industrial Learning 1.5 Functions of the Slag The chief function of the molten slag that is formed from the flux coating is to protect the liquid weld metal from contamination from the air. It does this by forming a physical gaseous shield or barrier, and also by reacting chemically to reduce the gas content of the weld metal. Fluxes are carefully formulated to give what the designer believes is the best combination of slag viscosity, surface tension, freezing range, etc to promote “wetting” of the surface of the base material and molten weld metal, to hold and shape the weld metal as it freezes, and to control the strength and toughness of the final weld metal. As individual designers will have differing views on what “optimum conditions” mean, electrodes from different manufacturers will have different characteristics. The handling characteristics of the same designation electrode produced by different manufacturers will be totally different. Thus, we may have one electrode giving (for example) better impact properties than another of the same classification, but possibly at the expense of ease of welding. Certain electrodes will sacrifice some “welder appeal” in order to create superior mechanical properties. The main functions of the slag may be summarized as follows: * To protect the weld metal from contamination + To reduce the amount of oxygen and other impuri * To control the bead shape and smoothness 1.6 Specific Materials in Electrode Coatings Having seen the functions of electrode coatings, it is of interest to examine the functions of specific ingredients. The materials used include various organic materials, minerals, chemical compounds, clays and ferro-alloys. Among the more important materials used are the following. Cellulose This may be a product of wood pulp, or cotton. Sugar, flour and starches may also also be used. Such materials can disintegrate in the arc to form large volumes of carbon dioxide and water vapour which provide a protective gas shield to the weld weld metal. The penetration characteristics of the electrode are increased Calcium Calcium carbonate (found as limestone, calcite or marble) is an important Carbonate ingredient in basic, low hydrogen electrodes. It breaks down in the arc to produce produce carbon dioxide, which shields the weld metal and lowers the hydrogen content of the arc atmosphere. Lime helps the resulting slag maintain low sulphur and oxygen levels sulphur and oxygen levels in the weld metal, giving sound deposits with good mechanical properties. 12 7Gooderham Centre for Industrial Learning Fluorspar Fluorspar (or fluorite) is the natural form of calcium fluoride and is used to control the fluidity of the slag, and allow gases to escape. It is widely used in low hydrogen electrodes where it also helps to maintain a low gas content in the weld metal. Rutile Minerals, such as rutile and ilmenite, which contain high concentrations of titania, help to make the arc stable and form a fluid, quick freezing slag. This increases welder appeal, and results in a fine, smooth finish to the weld, (Note: Titania is the common name often given to titanium dioxide, TiO,,) Potassium A number of different potassium compounds such as potassium feldspar and Compounds potassium titanate may be used in electrode coatings. Potassium aids in ionization and therefore helps to stabilize the arc and promote arc ignition. It is often used in electrodes intended to operate on alternating current. Ferro-alloys Where additional alloys or deoxidizing agents are required, these are offen added in the form of ferro-alloys. The common additions are ferromanganese and ferrosilicon, both of which act as deoxidants in the weld metal. Manganese, and silicon, recovered in the weld metal, can improve the mechanical properties of the weld deposit. ‘Sodium Also known as water glass, this is a liquid binder which, when mixed with the dry Silicate minerals and ferro-alloys of the flux, forms a paste that facilitates extrusion of the flux around the core wire. It also affects the fiuidity of the slag, and has an are stabilizing effect. Some, or all, of the sodium can be replaced with Potassium, which can further stabilize the arc, allowing operation on ac current. Iron Oxide Iron oxide in the form of ores, such as magnetite and hematite, is included in some electrode coatings principally as a slag former. Iron Powder In some electrode coatings, iron powder may be added, sometimes up to 50% or more of the flux mass. The main purpose is to increase the deposition rate of the electrode since the iron powder melts and adds to the weld metal. It may may also influence the bead appearance, and can aid in the formation of a cup at the electrode tip that allows a “drag” technique to be used.Gooderham Centre for Industrial Learning Functions Primary Secondary Gaseous Protection Arc Force Calcium Carbonate Gaseous Protection Fluxing Agent Fluorspar Slag Formation Fluxing Agent Dolomite Gaseous Protection Fluxing Agent Rutile (Titanium Dioxide) "| Slag Formation Are Stabilization Potassium Titanate ‘Are Stabilization ‘Slag Formation Feldspar ‘Slag Formation ‘Arc Stabilization Mica Extrusion Aid ‘Arc Stabilization Clay Extrusion Aid Slag Formation Silica Slag Formation - Manganese Oxide Sleg Formation Alloying Iron Oxide Slag Formation - Iron Powder Increases Deposition Rate | Drag” Technique Ferrosilicon Deoxidation Attoying (Si) Ferromanganese Alloying (Mn) Deoxidation Sodium Silicate Binder Fluxing Agent Potassium Siticate __| Are Stabilization Binder Table 1.1: Summary of Main Functions of Electrode Coating Constituents The effects of some of the major flux ingredients are summarized in Table 1.1. Most coatings would employ about six to twelve different ingredients. However, one or two of them always dominate, and this allows an electrode to be characterized by the principal ingredients in the coating, e.g. cellulose type or rutile type. As a result, classification of SMAW electrodes is on the basis of the main ingredient(s) in the flux coating. (This does not apply to all welding processes.) 14 Ree eer eeaeeeed a ate a eeoere ee ate ete, y ) ) ) ) ) ) ) ) ) ) ) a ) ) ) ) ) Gooderham Centre for Industrial Learning 1.7 Classification of SMAW Electrodes The large number of electrodes available, and the wide range of operating characteristics and properties that can be achieved, initially resulted in much confusion in the welding industry. For this reason, standards organizations and societies in many countries have issued standards and specifications for welding electrodes. In Canada, the CSA Standard W48-01 is issued by the Canadian Standards Association (CSA), while in the USA, the AWS AS series of specifications is issued by the American Welding Society (AWS). The Canadian standard is similar to, but not necessarily the same as, the AWS specifications. Other U.S. organizations such as the ‘American Society of Mechanical Engineers (ASME) adopt the AWS system. The AWS system is in US customary units, whereas the CSA Standards are in Sl (Metric) units. At the time of writing, the AWS is revising its specifications to include metric versions, some already being available. For example, the specifications for SAW carbon steel welding electrodes and fluxes is available as AWS A5.17 (US customary units) and AWS A5.17M (St metric units). Welding Process Filler Metal tsimenes fice ceca ‘Shielded Metal Arc Bee = era Welding (SMAW) | Covered electrode ABA for Carbon Steels 'SMAW for SWAW for, | Covered electrode ABA 'SMAW for Low Covered electrode ASS Aloy Steels Gas Metal Arc Welding (GMAW) | Ree A518 for Carbon Steels \ Gas Tungsten Arc Solid wie rod Welding (GTAW) A518 Welding (STAW) | (usualy in cut lengths) Flux Cored Are Fluxccored wire Welding (FCAW) | electrode (on cols, 5.20 for Carbon Steels | ete.) Submerged Arc Welding (SAW) ony ASAT for Carbon Steels ; “These standards cover the consumable electrodes. For the Tungsten, nor-consumable dlectrode, see AWS A5.12 Table 1.2: Specifications and Standards for Mild Stee! Electrodes 7 15Gooderham Centre for Industrial Learning ‘Table 1.2 shows the consumables covered by the CSA Standard W48-01, and the equivalent AWS specifications. The CSA standard and a complete list of the AWS specifications are shown at the end of this module. The CSA and AWS classification systems for carbon steels and low alloy steel covered electrodes are established according to: 4. weld deposit strength (MPa, psi) 2. type of coating (rutile, cellulosic, basic) 3. position of welding (flat and horizontal only, all positions) 4, type of current (DC+, DC-, AC) The standards describe the various tests that have to be carried out and list the requirements that must be met if the electrode is to be considered as meeting the requirements of a certain classification. Usually, a standard allows an electrode to be designated under one classification only, although there are some exceptions. Each classification has a code number and this number must be imprinted on each electrode near the grip end so that it is properly identified. Proper identification is of great importance since the use of an incorrect electrode could be extremely dangerous. The student should be clear on the differences between the CSA standard and AWS specifications. The CSA Standard W48-01 uses the “Systeme International” (Sl) metric measuring system, and is designed to be administered by a third party certification agency. The AWS AS series uses U.S. customary measuring units (although, as mentioned earlier, they are now also issuing alternate SI metric specifications) but they are designed for application by the manufacturer. Thus, a statement on the label that an electrode meets AWS AS.1 classification E6011 does not necessarily mean that the manufacturer has performed tests in the recent past. However, a statement that the electrode is certified by Canadian Welding Bureau (CWB) to CSA W48-01, E4311, means that CWB has witnessed tests on that electrode, as required by CSA W48-01, and has Issued a document of certification that certifies the electrode meets all the requirements of that classification. This can be an extremely useful quality control tool for fabricators. ‘The CSA standard identifies regular periodic retesting of the manufacturers’ electrodes to ensure that they continue to meet the requirements of their designation. 4.8 Classification System for Covered Electrodes for Carbon and Low Alloy Steels The system used by CSA and AWS standards for classification of carbon steel SMAW electrodes comprises the letter E (denoting an electric arc electrode) followed by four or more digits. For low alloy electrodes, this is followed by a designator defining the chemical analysis of the weld deposit. ‘ 16vps Ve VV mee reer uur U UUs e emu U UE pe | Gooderham Centre for Industrial Learning For CSA W48-01, the first two digits denote the minimum tensile strength of the deposited weld metal in the as-welded condition in units of megaPascals (MPa) divided by 10. In the AWS A5.1 US customary units version, the first two digits denote the minimum tensile strength in A5.1 in ksi (i.e., thousands of pounds per square inch). For example, in W48-01 the symbol E4918 indicates an electrode with a minimum tensile strength of 490 megaPascals, whilst US customary units version, an E7018 indicates that the electrode has a minimum tensile strength of 70 ksi or 70,000 psi (pounds per square inch). (Note: Tthe CSA W48 Technical Committes on Welding Electrodes adopted the European system in March 2001. AWS is also considering the European System which uses just two digits to denote strength. Consequently the former £48018 designation has become an E4918, In the new designation the 9 is enother adjustment fo the Europen System). The third digit (i.e. the one following the strength group), gives information on the welding positions in which the electrode may be satisfactorily operated, 1 =all positions, except vertical down* 2 = flat and horizontal fillets 3 = flat only (no longer used by CSA or AWS) * These are the specified (or required) welding positions for the operation of the electrode. A particular electrode ‘may also be capable of welding in the vertical down position. ‘The welding positions are given the following abbreviations: F = flat position H_ =horizontal V-U = vertical (vertical, upwards progression) OH = overhead V-D = vertical (vertical, downwards progression) The final digit, in combination with the positional digit just described, signifies the type of coating ‘on the electrode and the type of electrical current that the electrode is designed for, as follows: EXX10 = cellulose, sodium (de electrode positive) EXX11 = cellulose, potassium (ac or dc electrode positive) EXX12 = titanla, sodium (ac or de electrode negative) EXX43 = titania, potassium (ac or de either polarity) EXX14 = titanla, Iron powder (ac or de either polarity) EXX45 = basic, sodium (de electrode positive) ' 7Gooderham Centre for Industrial Learning EXX16 = basic, potassium (ac or de electrode positive) EXX18 = basic, Iron powder (ac or dc electrode positive) EXX22 = Iron oxide (ac or de elther polarity) EXX24 = titania, high iron powder (ac or de either polarity) EXX27 = iron oxide, high Iron powder (ac or dc elther polarity) EXX28 = basic, high Iron powder (ac or dc electrode positive) EXX48 = basic, iron powder (ac or de alther polarity) The above (where “XX” symbolizes any character allowed by the standard - (For example 49 would mean 490 MPa) gives a condensed description of each of the CSA classifications for carbon steel arc welding electrodes. Let us consider some examples from CSA W48-01 (AWS AS. 1) for covered elctrodes for carbon steels. 4. £4948 (E7018) This designates an electrode with a minimum tensile strength for as-deposited weld metal of 490 MPa (70,000 psi or 70 ksi) and a minimum elongation of 22%. The weld has a maximum level of diffusible hydrogen of 16m/100g deposited weld metal. It is designed for welding in all positions except vertical down, (although it may be capable of welding in the V-D position) and has a basic coating with iron power added. It can be used with ac or de electrode positive. 2. £4310 (E6010) This describes an electrode with a minimum tensile strength of 410 MPA (60 ksi) and a mi elongation of 22%. It can be used in the F, H, OH and V-U positions (and may be usable in the V-D position also), and has a cellulose coating. It can be used on dc, electrode positive, but is not designed for ac welding. The complete list of mild steel electrodes classified under the AWS and CSA systems is shown in Table 1.3, Table 1.4 summarizes tha chemical requirements and Table 1.5 the mechanical property requirements.Gooderham Centre for Industrial Learning > Classification 2 > or ‘Type of Coating Wolding Current was-01 AeA Positions 5 E4310 | “BBO | Cellulose, sodium FW, 0, | acep 2 E4910 ~ | Cottulose, sodium F,WU,0,H | doep 2? E4311 E6011 | Cellulose, potassium F,VU,0,H | acordcep 2 E4911 — | Cellulose, potassium F,VU,0,H | acordcep 3 £4312 | 6012 | Titania, sodium F,VU,0,H | acordcen 2 E4912 ~ | Titania, sodium F,Vu,0,H | acordcen 2 4313 £6013 | Titania, potassium F,VU,0,H | ac, doep or doen 7 £4913 ~ | Titania, potassium F,VU,0,H | ac, dosp ot doen 3 £4914 | E7014 | Titania, iron powder F,VU,0,H | ac, doep or doen 2 £4915 | 7015 | Basic, sodium F.VU,0,H | deep ? E4018" E7018" | Basic, potassium F,VU,0,H | acordoep 2 £4322" | 6022" | Basia ron powder F,VU,0,H | acordeep 3 4922 ~ | tron oxide, tania, potassium | F,VU,0,H | ac, doep or deen, 2 E4924" E7024" | Iron oxide ‘ac, deep or deen i, 4327 £6027 | Iron oxide ‘ac, deep or doen 5 4927 + | Titania, high iron powder ac, deep or doen. 5 £4327 | £8027 | Iron oxide, high iron powder 2, deep or deen. 2 4927 ~ | tron oxide, high iron powder 1c, deep or deen. 2 4928 €7028 | Basic, high iron powder ‘ac or deep 2 cxoa | crom | sus rpc oe da orden 2 H-F = Horizontal-filet welds only ac = altemating current 2 ‘VD = Vertical: Progression downwards doep = direct current, electrode positive 2 © = Overhead doen = direct current, electrode negative 2 = Horizontal ¢ 2 |? Notes: 2 (1) The specific code should be consulted regarding welding current and the position 2 in which tests must be undertaken. 2 (2) Includes E4918-1 and E7018-1 3 {) Intended for single pass welding only 3 (4) Includes E4924-1 and 7024-1 2 Table 1.3: CSA W48-01-M and AWS A5.1 Carbon Steal Covered x Are Welding Electrodes i 5 ‘ 19 2 2 |Gooderham Centre for Industrial Learning “Chemical Composition as per CSA W48-01 Maximum Porcont oy im ew | er | Me] Vv 02 | 120 ns. | 030 | 020 | 030 | 008 NS. os | 1.25 0.095 | 0.30 | 0.20 | 030 | 008 1.50 0.18 | 1.60 | 0.75 | 0.035 | 0.035 0.30 | 008 175 os | 1.60 0.30 | 0.08 | 475__| Notes: N.S. means Not Specified The chemistries indicated are those of CSA W48-01. The equivalent AWS classifications might be different. Table 1.4: CSA W48-01 Carbon Stee! Covered Arc Welding Electrodes chemical requirements (deposited metal).’ a ’ a a ’ a , ) ’ a 1 ’ ? ? z , } ’ ) ? ) ’ ) ) ’ ’ ’ ; ? ’ ’ Gooderham Centre for Industrial Learning Tensile _Strength’ 490-650 400 22 27@-30 Notes: (1) (2) 3) (4) 6) Single values shown are minimum. For those steels which do not exhibit a definite yield point, the 0.2% offset value shall apply. Transverse tensile and bend tests required. (Single pass electrode) For £4918-1, impact values shall be 27) @ 45°C For £4924-1, impact values shall be 27) @ -20°C SA W48-01 Mechanical Property Requirements of Carbon Stee! Covered Arc Welding Electrodes 21Gooderham Centre for Industrial Learning 1.9 Characteristics of Covered Electrodes In this section, the characteristics of individual electrodes will be described in more detail Covered electrodes can be divided roughly into four groups depending on the dominant component of the flux as shown in Table 1.6. ‘System ‘ype Wa8-01 ‘AS. Cellulosic EXXi0 EXX10 as | EXO | EXxt4 Rutile (Titania) Iron Oxide Basic Note: (1) Contains iron powder. (2) Not listed any more in the CSA W48-01 Standard (not an A5.1 classification either) Table 1.6: Four Groups of Covered Electrodes 410 Specific Electrode Types 4.10.1 4310 and £4910 - Cellulosic Electrodes of this type are used on de current, electrode positive (reverse polarity) only. The fiux coating is high in cellulose and is usually white or grey in appearance, although some manufacturers use dyes to give their electrode a distinctive colour. High cellulosic content is designed to produce large volumes of gases such as carbon dioxide, carbon monoxide, hydrogen and water vapour which effectively protect the molten metal passing across the arc. The combination of coating constituents causes considerable liberation of heat in the base metal (negative pole) with resultant deep penetration. Care must be taken to ensure that the operational procedure is correct because the deeply penetrating arc can give rise to undercutting with careless handling of the electrode.PULL UQMULUUUUUUU LUE UU UU UU UU ULE e eee Oppel Gooderham Centre for Industrial Learning Because of its high organic content, the stag volume is low and in many cases it does not cover the weld deposit completely. The slag is fast-freezing and for this reason it is ideal for welding in the vertical and overhead positions. Being porous, light and friable, itis easily removed. Its effect on bead formation is only slight and the bead is comparatively rough. The core wire melts before the coating and a cup (frequently up to 1/16" deep) is formed at the end of the rod enabling the operator to hold the rod very close to the work without it sticking. Holding the electrode close gives added protection against oxidation and decreases spatter loss. Although any increase in arc length or excessive current causes high spatter loss in this type, many operators find a “whipping” technique useful when welding in the vertical-up position. The soundness of metal deposited is of very high order. Porosity is usually negligible and the ductility is high, usually ranging from 22 to 30 percent. Until the development of the basic type electrode, the EXX10 produced the soundest and most ductile deposit in the vertical and overhead positions. This electrode has long been considered to have a high degree of tolerance for detrimental factors, such as poor storage and faulty manipulation. Because of its good quality metal and deep penetration, the E4310 is favoured for much work where a high standard is required. It is particularly popular in welding pipelines, storage tanks and in ship building. It is particularly good for the joining of square groove butt joints where 100 percent penetration is required and for welding galvanized material. Although of high penetrating characteristics, it may be usefully employed where fit-up varies due to its fast freezing nature. Also, because of its penetrating properties, it is often used to ensure deep fusion and high quality in the first and most critical run, while other electrodes are employed for subsequent runs. The electrodes are made in all of the standard diameters, 2.5 to 6.0 mm (3/32" to 1/4"), generally in 350 mm (14 inch) lengths only, although some larger sizes are made in 450 mm (18 inch) lengths. Deterioration of the coating due to heating of the core wire may occur during welding. Cellulose decomposes at temperatures as low as 180°F, and it is unwise to use high current densities with this type. Moisture also plays an important part in the coating, and care should be taken to prevent either absorption or loss of moisture through unfavourable storage conditions. Excess moisture results in arc instability and increases spatter loss, while excessively low moisture reduces penetration and causes pinholes and blistered craters. Cellulosic electrodes unfortunately produce weld metal with an inherently high hydrogen content. This is a limiting factor when welding high strength steels. Common practice when combining cellulosic and basic electrodes for pipe welds for example; is to weld the “hot pass” or second pass with a low hydrogen electrode immediately after the root is complete. The second pass reheats the root bead and drives off the trapped hydrogen before it causes a cracking problem.Gooderham Centre for Industrial Learning 1.10.2 £4311 and £4911 - Cellulosic Alternating current welding power sources created demand for an electrode having all the good qualities of the EXX10 electrode and yet capable of being used with the AC transformer. Combining these requirements is almost an impossibility because ingredients which aid one characteristic generally oppose another. However, electrodes which meet code requirements have been developed by making a slight compromise, mainly in the matter of depth of penetration. ‘The cellulosic content is usually lower and easily ionized materials, such as potassium feldspar, are added to increase arc stability at low open circuit voltage and low welding currents. Spatter with the E011 electrode is generally finer and readily removed. When used on AC the arc can be recognized as being somewhat noisier than an EXX10 and DC, electrode positive (CEP). The electrodes are used on work similar to that indicated for EXX10 and, as stated above, the characteristics are very close to this type. Usually, ductility, tensile strength and yield strength are higher than those obtained with EXX10 electrodes. 4.10.3 £4312 and £4912 - Rutile Commonty known as the general purpose electrode, almost every welder will have used this type. Usually tan or light brown in colour, it is made in all diameters up to 7.0 mm (5/16") and in lengths varying from 225 to 450 mm (9" to 18"), depending on the diameter. Originally developed for use on direct current electrode negative (DCEN), most electrodes can also be satisfactorily operated on AC. Rutile (also known chemically as titania) is the main coating constituent with clays, silica, feldspar, etc. being added to aid extrusion, arc stability and slag characteristics. The cellulose content is quite low, protection for the molten metal being afforded by the shield of molten slag. The slag is usually rather heavy, bluish black in colour and very fast freezing, making the electrode easy to use in all positions. It is fairly easy to remove, although it tends to cling to the upper edge of horizontal fillet welds, and is a little harder to remove when deposited in a fiat filet. These slag characteristics produce single pass fillets which are slightly convex, the edges of the bead being sharply defined. The bead is smooth and bright with fine ripples and ends in a shallow dense crater. Penetration is decidedly lower than either E4310 or £4311, but this factor enables it to be used on joints where “fit-up” is poor and deep-penetrating electrodes would tend to bum through. For this reason it is good for the welding of sheets and light-gauge material. Undercutting is rare. 24vps Sep Ra Ra re LL | Gooderham Centre for Industrial Learning Itis used to advantage for welding low-alloy steels and those of relatively high carbon since the admixture with the parent metal, or what is called ‘pickup’, is low due to little penetration. Consequently, the effect of carbon or other hardening alloys is reduced. (The heat affected zone must, however, be considered!) The lower heat input of this electrode reduces distortion to a minimum. The electrode is quite easy to handle in any position, has a fairly high burning speed combined with low spatter, and is very economical. A cup is rarely formed in this rutile type and there is a slight tendency to sticking if the arc is too short. Decomposition of the coating (away from the are) during welding is rare even at high current densities. Unfortunately the mechanical properties of the weld metal are the poorest displayed by any coated electrode. Porosity is quite common, particularly in the root of fillet welds, and codes Fequire an elongation of only 17 percent, although this is often substantially exceeded. These mechanical properties and the lack of deep penetration prevent it being used with confidence on weldments and structures where fatigue stresses are anticipated. It is excellent for building up mild steel shaffs, fabrication of sheet metal, tacking, general repair work, etc. ‘At-one time it accounted for a large percentage of electrodes used, but heavily covered electrodes, with their higher deposition rates and excellent mechanical properties, have replaced ait to. great extent. 1.10.4 £4313 and £4913 - Rutile Usé of this type of electrode steadily increased with the spread of AC welding. The coating is similar to, but usually thicker than, that on the E4312 electrode and may be tan or brown in colour, often with a reddish hue. Because of the relatively high cellulosic content of this rutile is present in larger proportions in order to produce steady operation when the in the reverse polarity phase of the alternating cycle. lonization of the arc atmosphere, to facilitate easy striking and maintenance of.the arc under all conditions, is achieved by additions of potassium-bearing compounds such as potassium titanate and potassium feldspar. The electrode can be held very close to the work, spatter loss is very low and the metal flows smoothly across the arc in any position. The slag produced is slightly heavier and slower freezing than the 4312 type, but it is still satisfactory for all-position welding. Slag removal is almost perfect, in many cases peeling itself from the weld deposit. Beads are flat, shiny and evenly rippled, having straight, clearly defined edges. {In depth of penetration, most mechanical properties, and uses, this type is almost identical with the £4312 electrode. Ductility is somewhat improved by the higher cellulose content, althoughI Gooderham Centre for Industrial Learning most codes require a minimum of only 17 percent as for £4312. High current densities are not t recommended because of coating decomposition. Root porosity in fillet welds made with this type of electrode is virtually eliminated, and it is well suited for single-pass welding. Weld metal is usually freer of slag-oxide inclusions than E4312 and E4912 and slag removal is somewhat better for the smalll sizes, 1.6, 2.0 and 2.5 mm (1/16", 5/64, and 3/32”). 1.10.5 £4914- Rutile This electrode is essentially of the E4312 or £4313 type with the addition of approximately 30 percent iron powder to the coating. The amount of coating, and the percentage of iron powder init, is usually less than that of an £4924 electrode. E4914 is not quite as fast as £4924 in the flat position, but is faster than E4313. Slag removal is usually better, arc characteristics are smoother, and less sticking occurs with the small sizes than with similar sizes of £4313. The bead appearance is improved and the deposition rate is higher than E4313, but it is not as high as obtained with an £4924 electrode. The amount and character of the slag permits the £4914 electrode to be used in all position welding and it is therefore more versatile than the E4924 electrode. The E4914 electrode is suitable for welding mild and low alloy steels. Penetration is approximately the same as E4312, which is advantageous when welding over gaps due to poor fit-up. Currents are higher than for £4312 and £4313 due to the Iron powder content of the coating. q 4.10.6 £4924-Rutile The £4924 classification electrode has a covering with fluxing ingredients similar to £4312 and £4313, together with a high percentage of iron powder. As a rule, the coverings on E4924 electrodes are very heavy, amounting to as much as, and sometimes even more than, 50 percent of the total electrode weight. Due to the thick covering and deep arc cup produced, the £4924 electrodes are used more extensively with the covering in contact with the parts being welded, i.e., with a “drag” technique. This consists of keeping the electrode covering in contact with the workpiece (both legs of filet welds) at all times, which makes for expeptionally easy handling. However, sometimes an open arc technique is preferable in groove welding. The £4924 electrode is well suited for fillet welds in mild steel. The welds are slightly concave in profile, with a very smooth surface and extremely fine ripples approaching the appearance of machine-made welds. The electrode is characterized by a smooth quiet arc, very low spatter and low penetration and can be used at high travel speeds. This electrode operates with AC or DC, either polarity. Although most generally used on mild steel, the E4924 electrode also produces satisfactory welds on many low-alloy, medium and high-carbon steels. 4 ' 26? Gooderham Centre for Industrial Learning ttt neeneenenaneaitententntannnnennteinnneene At one time, the amount of iron powder in the coating was so high that it became conductive. As a result, it was often possible to strike the arc through the coating, especially when the electrode was hot. However, development work has allowed manufacturers to produce insulated coatings which prevent side arcing, but preserve the restrike characteristic. Everything stated above for E4924 applies equally to E4924-1. It must be noted, and omphasized, that the E4924-1 electrode is an £4924 with enhanced impact (toughness) properties. The “-1” is not part of the classification, but is a designator indicating that this electrode has, In tasts specified In CSA W48-01 (and AWS AS.1 for the E7024-1) demonstrated minimum impact strength of 27 J at -20°C. It is still an E4924 electrode. 4.10.7 £4320 and E4920 - Iron Oxide The E4320 electrode Is rarely encountered these days, and is no longer listed in GSA W48-01 or AWS A5.1. It is described here to inform the student should he/she encounter this type in some application. It is limited by the volume and nature of its slag for use in two positions only, horizontal fillet and flat. The electrode operates well on direct or alternating current, deen being preferred because it produces a flatter bead contour. Generally referred to as mineral coated, this electrode has a heavy coating usually black or red ln colour, depending on which iron oxide predominates in the coating. Other materials include Manganese oxides and siliceous materials. This produces a voluminous slag, which provides a mechanical shield of moiten slag to guard against oxidation in the arc. Ferromanganese is used as the main deoxidant and sodium silicate is the binder. When solid, the slag is usually shiny black and extremely porous. This porosity makes it very friable and easily removable. During solidification of the weld, its fluid nature and wetting power influences the freezing weld metal by forming a concave bead, whose edges are ideally flared into the plate. In depositing horizontal fillets at high amperages there is a tendency to undercut the vertical plate, but this can be overcome by careful electrode manipulation. Penetration with this class is good and can be increased by the use of high amperages. The coating will withstand exceptionally high temperatures without deterioration. The weld metal has excellent mechanical properties with elongation in 2 inches up to 30%. Porosity is negligible and most joints fabricated with £4320 are perfect under X-ray examination. PU Vg Yee eEUUUU UU UU UU mu UU YUU UU UU UU - ro Before the advent of the iron powder electrode, EXX20 was in wide use for heavy weldments such as machine bases, centre sills on raiWway cars, pressure vessels etc. However, the increased deposition rate of the iron powder electrodes, together with the high quality obtainable has resulted in a steady decrease in the relative importance of this type. |Gooderham Centre for Industrial Learning 4.10.8 £4327 and E4927 (Iron Oxide) ‘The £27 classification has a covering similar to that found in £4320 electrodes together with a high percentage of iron powder. The coverings, as with E4924, are very heavy, amounting to approximately 60 percent of the total electrode weight. A deep arc cup is formed allowing Use erin “drag” technique for filet welds, although the open arc technique is sometimes used in groove welding. The EXX27 electrode is designed to produce satisfactory fillet or groove welds in the flat position with AC or DC, either polarity, and will produce flat or slightly concave horizontal fillet welds with either AC or DC, electrode negative. This electrode has @ spray type of metal transfer and deposits at high speeds. Penetration is Tsium and spatter loss Is very low. The covering on this type produces a heavy slag, oneycombed on the under side, which covers the weld deposit and is quite fable and easy to Tomeve, particulary in deep groove joints. Consequently, because of the wash-in of the weld ronal eomnbined with the ease of slag removal, X-ray quality welds are readily made in deep groove joints in very heavy sections. Welds produced with the EXX27 electrode have a flat, to slightly concave profile with a smooth, fine. even ripple and with a good metal wash up the sides of the joint. The weld metal possesses sReatlent radiographic quality. Current ranges for the various diameters are high since @ Considerable portion of the electrical energy passing though the electrode is used to melt the iron powder in the coating. ‘The EXX27 electrode has had wide usage in the pressure vessel and structural field but, a8 with Other electrodes, there has been a tendency for it to be replaced by the low-hydrogen, iron powder types such as the £4928. 4.10.9 £4915 and E4916 - (Basic) The recognition thatthe presence of hydrogen in the weld metal was a prime cause-of cracking Tarts the development, about 50 years ago, of electrodes that controlled the levels of weld metal hydrogen. This allowed carbon and alloy steels to be welded without cracking, offen without the eed of preheating. It also reduced problems in welding sulphur bearing steels, and produced tad metals of improved toughness. By using only minerals with very low moisture contents, the flac coating does not have the same hydrogen potential as other electrode, classifications, During wolding, this coating breaks down, producing carbon dioxide gas. The amourt of hydrogen in the arc atmosphere is minimal. (The effect of hydragen on cracking in welds is, discussed briefly below. Amore in depth discussion is given in Module 10.) ‘These electrodes, and also the EXXX8 types, have coatings containing relatively large amounts of calcium and magnesium carbonates. This gives them the generic name of Basic electrodes, but they are also known as low hydrogen electrodes. £4915 and E4916 electrodes require 28 Ee eeeas eee sae ewe Gooderham Centre for Industrial Learning different handling from other types because the arc is somewhat hesitant. High current densities are required for suitable operation. A short arc length must be maintained for optimum weld properties, and whipping techniques are not recommended. Penetration is medium and there is little tendency to undercutting. In the vertical position, the slag is rather fluid and heavy, and the maximum diameter recommended for this position is 4.0mm (6/32 inch). A smooth, evenly rippled bead is produced in all positions, spatter loss is low but the slag is not very easily removed. A deep arc cup is formed allowing a ‘drag technique’ to be used in some applications. E4915 is designed for DC electrode positive welding, whereas the E4916 contains potassium compounds promoting ionization and allowing AC to be used. 1.10.10 £4918 - (Basic) Although still used, the E4915 and £4916 have been largely superseded by the £4918 type. This has a basic covering with the addition of iron powder and its higher deposition rate and ease of handling make it the preferred electrode for many applications. The coating of this electrode is slightly thicker than that of the £4915 and £4916 type. The iron powder in the coating usually amounts to between 25 and 40 percent of the coating weight. The thinner coating on £4915 and E4916 allows their use for root passes in narrow joints of higher strength, more hydrogen sensitive materials where a cellulosic root pass would present the danger of cracking. It can be used with DC electrode positive and AC but the highest speeds are obtained with DC. It is designed for the same applications as the E4915 and E4916 electrodes. In common with all basic electrodes a short arc should be maintained at all times. In addition to its use for mild steel, the E4918 electrode is well suited for fillet welds in high- strength, high-carbon or alloy steels. The fillet welds made in the horizontal and flat position are slightly convex in profile, with a smooth or finely rippled surface. The electrode is characterized by a smooth quiet arc, very low spatter, low penetration and can be used at high travel speeds. Everything that has been stated above for £4918 also applies to £4918-1. It must be noted, and emphasized, that the “1” only indicates that this electrode has enhanced impact properties when compared to the general £4918 classified electrodes. It Is still an E4918 electrode. 4.10.11 £4928 - (Basic) The £4928 electrode is in many respects very much like the E4918. The E4928 differs from the £4918 in the following respects: 29—_————— Gooderham Centre for Industrial Learning 1. The £4918 is an all-position electrode, where the E4928 is suitable for horizontal fillet and flat position welding only filet and flat position welding only. 2. The coating of the E4928 electrode contains more iron powder (about 50%) than the E4918. As a result, the coating can amount to approximately half the total weight of the electrode. This allows a higher deposition rate thant he E4918 for any given size of electrode. . The £4928 has a spray type of transfer, the 4918 transfer is globular. |. The ratio of the weight of the weld metal to the weight of the core wire consumed is about 4.05 minimum for the E4918 and about 1.30 minimum for the £4928. (This is often referred to -particularly by the Europeans- as the “efficiency” of the electrode.) 5. The weld metal toughness of the £4918 is usually better than that of the E4928. BO 1.10.12 £4948 - (Basic) ‘The £4948 electrode is very similar to the £4918 types, but is designed specifically for welding in the vertical down position. (Although it may be usable in other positions.) The amount of iron powder is less than for the £4918 classification, but is typically higher than levels found in the E4916 types. 4.11 Summary of Covered Electrode Characteristics The characteristics of the various electrodes described in detail in the preceding sections are ‘summarized in Tables 1.7, 1.8, and 1.9. Following W48-01, the S.|. (metric) designation is used but the tables apply equaily well to the equivalent electrodes using US Customary units. For ‘example the comments for EXX18 electrodes apply to W48-01 electrodes such as E4918, and also to A5.1 such as E7018. iron oxide, silica, manganese oxide feldspar, clay, mica, carbonates, sodium Boar silicate, ferro-manganese, ferrosilicon EXX00, EXX10, EXX11 | Cellulose, rutile, carbonates, slates utile, 7 clay, lose, silicates, pore.eois [tion otis, te rule, iron powder, feldspar, carbonates, EXK14, EXX24 cellulose, ferromanganese EXx18, EXX28, EXX48 | fluorspar, carbonates, iron powder*, EXX15*, EXX16* ferromanganese, ferrosilicon, silicates “EXX15 abd EXX16 do not contain significant amounts of iron powder. Table 1.7: Principal Ingredients in Electrode Coatings 7 30 Sobor toi iera POSGooderham Centre for Industrial Learning : 0 t0 10% 10 t0 20% 20t040% | 40to 60% : EXx00 EXK48 EXXi4 Exx22 EXxto Eis EXx24 EXXt1 Exx27 EXX12 EXX28 Exx13 EXX15 EXX16 Classification | Deposition | Penetration | _Soundness Ductility Exx00 4 10 6 6 Exx10 4 10 6 6 Exxtt 4 a 6 7 EXx12 5 6 3 4 EXX13 5 5 5 5 EXxt4 6 6 7 6 EXX15 4 7 8 10 EXX16 4 7 10 10 ExxI8 6 7 8 10 Exxa4 10 4 8 5 exer 10 8 8 10 Exxza 8 7 8 10 Pua 5 z 8 9 Note: The figures are not measured quantities but are used to give an approximate indication of perormance on a scale of {to 10. The actuel electrode Performance wil depend on many factors such as welding conditions and ski! ofthe welder. ‘The electrode forruation and method of manufacture can also affect the comparative level Table 1.9: Comparable Performance of Electrodes Classifications caGooderham Centre for Industrial Learning 1.12 An Example of Electrode Selection In order to select an electrode, the job for which it is being chosen must be carefully considered, and at lease five or six of the most essential characteristics listed. ‘As an example of such consideration, take the fabrication of a heavy excavator frame or base of 0.25 to 0.30% carbon steel plate. Although perhaps unusual in a shop where such work is performed, it can be assumed that no positioning equipment is installed and therefore an all-position electrode must be used. Also, only AC power supplies are available. From the nature of the job and anticipated service it can also be assumed that. 4. The frame will be subject to fatigue and alternating stresses and therefore sound weld metal of high impact and ductility values will be highly desirable. 2. Since the plate is fairly high in carbon, an electrode producing low hydrogen deposits and of low or medium penetration would be best. 3. Good fit-up may be anticipated. 4. Astraight-to-concave fillet contour will be best for fatigue performance. 5. Good bead appearance is of course desirable but not really important. 6. Low electrode cost is desirable but is a relatively insignificant part of the total cost of such a fabrication. The correct performing consumable offsets any minor premium with labour savings. Since an electrode high in impact toughness is desirable, this would lead to selecting an E4918, £4916, or E4311. Minor cost factors would favour both E4312 and £4313 about equally. Both would have a smoother bead than E4311 and between the two, E4313 would have the better finish and contour. However, in a job of this nature, weld qualities of impact toughness, ductility and soundness must be given preference and the choice will fall on type £4916 or £4918. 1.13 Principles of Covered Electrode Selection When selecting an SMAW electrode, to keep the following principles in mind: 1. If a deep groove is to be filled or a heavy fillet weld made, these should, wherever possible, be arranged for welding in the flat position. Economy would dictate the use of 7 32 a Lak. arr eeee reece areca feast tert:Gooderham Centre for Industrial Learning ) I ere eee ene eater an iron powder electrode with its higher deposition rate, which would lead to the choice of £4327, £4924 or £4928, Design requirements would rule as to whether or not the E49 series was needed and questions of preheat and type of steel would determine if it were necessary or desirable to have low hydrogen weld metal, with the choice then pointing to E4928. ny . If high production on light-gauge metal is sought, an electrode which can carry high currents and move at fast speeds while still retaining satisfactory bead size and shape would give the best answer. This would be an application for £4312. In the automotive industry this electrode has been used for lap welds at 25 mm/sec (80 inches per minute) inches per minute) welded with as much as 1.2 m (48") of joint with one electrode. 3. Vertical and overhead welding and horizontal butt welding require that the metal stay in position by solidifying rapidly. All the EXX1X electrodes are designed for this, with E4310 the first choice unless low-hydrogen weld is called for, when E4916 or E4918 would be chosen. 4. When the steel is high in sulphur, carbon or phosphorus, or is thick enough to cause rapid quenching, or is of low-alloy composition, the best assurance of crack-free welds will ‘come from the use of low-hydrogen electrodes. These would be E4916, 4918 or 4928 if there were no necessity to match the plate composition. Otherwise, one of the compatible low-alloy electrodes would be the choice. 1.14 Detrimental Action of Moisture and Hydrogen from Electrode Coatings Moisture, contained in the flux ingredients, is a component of all electrode coatings, and should be maintained within certain limits. This is not always easy since some coatings absorb moisture in varying degrees, depending on the atmospheric conditions. If a coating takes up excessive moisture, it can be dried, but some electrodes fail to function properly if they are too dry. The coating of an excessively damp electrode will have a tendency to ‘pop’ or explode. Often a ‘swelling will be observed just above the arc. Also, if the electrode is short circuited, permitting the welding current to pass through it for a short period, moisture may be driven off as a vapour. This should be done only as a test for moisture and not as a means of drying. Moisture will have a tendency to produce porosity in the weld, but more important, it can break down into hydrogen gas and this can be seriously detrimental to a weld. Hydrogen in the weld, when associated with stress (always present in the as-welded state) can result in microscopic fissures capable of developing into cracks. See Figure 1.5. The big danger is that these cracks can go undetected until the weldment is put into service. Failure in service can result in severe financial losses, and even loss of life. 33Gooderham Centre for Industrial Learning rere Figure 1.5 : An Example of Weld Area Cracking due to Hydrogen This is the reason for the popularity of basic, or low hydrogen, electrodes, and is also why it is of the utmost importance that the coatings of basic electrodes be kept dry. Considerable research has been undertaken on the effects of hydrogen which can be partly ‘explained as follows. Hydrogen from the electrode coating, and other sources, is absorbed by the molten metal during the welding process. The solubility of hydrogen in iron diminishes as the temperature of the molten weld metal decreases, and then drops abruptly at the freezing point. The absorbed hydrogen will be partly released as the metal solidifies, but some remains in the solid metal. At temperatures just below the melting point, the steel transforms to an austenitic structure which can hold a certain amount of hydrogen. The solubility keeps decreasing slowly until the point at which the steel changes from austenitic to ferritic structure. At this point, the solubility decreases to almost nothing, and the hydrogen must find a way to escape. It does this by trying to diffuse to the surface of the weldment. The thicker the metal from which the gas is to be released and the lower the temperature, the longer the diffusion process will take. If the metal to be welded is very thick, a large quantity of hydrogen will be retained. The amount of remaining hydrogen increases for two reasons:reer uti ees ec re Gooderham Centre for Industrial Learning 1. Increasing material thickness increases the distance hydrogen must travel to the surface, in the diffusion process. 2, The rapid cooling caused by the thickness of metal reduces the rate at which the hydrogen can diffuse. This retention of hydrogen encourages cracking both in the weld metal and the heat affected zone of the parent metal. This subject is dealt with more fully later in this module. Welding with conventional types of electrodes with non-basic coatings may be expected to lead to the absorption of relatively large amounts of hydrogen. 1.15 Storage of Arc Welding Electrodes To obtain the best possible results from arc welding electrodes, it is essential that they be stored under suitable conditions. This is particularly so in the case of basic electrodes, which are more hygroscopic than other types, i.e. they readily pick up moisture. Electrodes are manufactured so that the proper level of moisture, consistent with the covering type and the electrode strength classification, is in the coverings. These electrodes are then packaged in a container designed to provide the protection appropriate to the type of covering involved. Under proper storage conditions, electrodes can be maintained for many months. However, if the electrodes are exposed to high moisture conditions, the coverings can absorb excessive moisture. This can happen when the original containers are damaged, or if the electrodes are improperly stored. If there is a possibility that the electrodes may have picked up excessive moisture, they can be restored by rebaking as indicated in Table 1.10. Basic (E4915 and £4916) and basic-irgn powder (E4918, £4928 and £4948) electrodes are the most critical types for moisture absorption. Rebaking may well be required when basic electrodes are believed to have been exposed to the atmosphere. When a container is opened, the electrodes should be placed in a storage oven (Figure 1.6). (CSA Standard W59 recommends storage at 120°C). These types of inorganic covered electrodes are designed and developed to contain the very minimum of moisture in their coverings, consistent with handling and use, and should be handled with care. Welders should take only sufficient electrodes for use in a four hour period under normal circumstances - even less if the ambient temperature and the relative humidity are high. This care should be extended particularly to field welding where the danger of moisture absorption is greatly increased. Small portable containers are effective in keeping electrodes dry in field conditions (Figure 1.7). Any basic electrodes which are ‘ 35Gooderham Centre for Industrial Learning exposed to the atmosphere for periods longer than four hours should be rebaked, or discarded. Many manufacturers supply their electrodes in small packages so that only a few electrodes are exposed at one time. £4310 and E4311 electrodes should not be rebaked because the coverings for these types are designed to have moisture levels of 3 to 7 percent and excessive drying may substantially affect their operation. "A holding oven containing basic electrodes should not contain anything else, -even other types of electrode. ‘Store rooms for electrodes should have a controlled humidity of less than 50% (relative humidity) by using a dehumidifier and sealing the room. Smaller quantities of electrodes may be stored in unheated containers that use silica gel or other material to maintain a dry atmosphere. 2 3 3Gooderham Centre for Industrial Learning {stool __ ‘All submerged are fluxes Note: Discard rusty electrodes _ Consult manufacturer CSA Wa8-01 ‘Ambient Air Storage Rebakingy Filler Matorial_ oe . Tomperature (°C) Temperature (°C) Carbon Stee! EXX10; EXX11 20 to 70% re, Humidity ~ Not required ~~ | Consult manufact EXX12; EXX13 “10 to +#30°C. thr, @ 135415 EXX14; EXX22 150% max. relative 10-25 above EXx24; EXX27 humidity ambient between 2 hr @ 230 and 1 h EXX15; EXX16 @ 430 EXX18; EXX28 Not recommended 120 to 150 (Consult manufacturer) EOOCXE Not recommended 12010 150 1 hr @ 340-400 Not recommended 120 to 150 Consult manufacturer coe (1) Manufacturer should be consulted for exact drying conditions because of difference in coating materials. Generally, if the electrode coating flakes after drying, it has been dried at too high a temperature. if porosity is evident, moisture levels may still be too high, indicating that drying temperature was too low. (2) Unusually high ambient méisture levels may necessitate use of holding ovens. Table 1.10: ‘Storage and Rebaking of Filler Metals (After opening package) 0 aGooderham Centre for Industrial Learning Figure 1.6 - Electrode Storage Oven Figure 1.7 - Portable Electrode Storage Oven 41.16 Moisture Resistant Electrodes Recent developments in basic electrode design have resulted in electrodes which resist, to ¢ prying degrees, moisture pick-up when exposed to the atmosphere. High extrusion pressures nd careful selection of binding agents produce an extremely dense flux coating, with a hard *skin". Such moisture resistant electrodes are designated by the use of an ‘R” suffix in AWS AS.1, as in E7018-R. Under normal exposure conditions, up to about 30°C and 80% relative humidity, moisture pick-up is small, and confined to the surface of the electrode. Also, flux ingredients are chosen that do not form a chemical bond with water. Any moisture adsorbed is merely attached to the surface. During welding, the electrical heating of the electrode can drive off much of this surface adsorbed water before it reaches the arc. However, more deeply absorbed water cannot reach the surface in time and would likely be absorbed, in part, into the weld deposit. Unfortunately, at time of writing, there is no definitive test that can prove that an electrode meets all the requirements of the “R" designator. Round robin tests between laboratories have shown that tests within a laboratory are reproducible. However, the figures obtained at different laboratories may not agree. This is because the levels of moisture being measured are extremely low, and small variations in laboratory procedures can produce quite different results. In addition, the precise control of exposure temperature and relative humidity over the hours required by AWS AS.1 is very difficult, and can give results that vary from one laboratory to another. This makes third party certification of moisture resistant electrodes practically impossible. For these reasons, User standards such as CSA WS59 have not recognized moisture resistant electrodes. If a Fabricator plans to use such electrodes, reference should be made to {fre Authority having jurisdiction. ‘ 38Gooderham Centre for industrial Learning 1.17 Low Alloy Steel Arc Welding Electrodes All the electrodes described in the preceding sections produce, essentially, carbon steel weld deposits (although the manganese and silicon content may, for some electrode types, exceed the normally considered levels for a carbon steel). Weld metal of higher strength may be obtained by using low alloy steel electrodes. Requirements for these types of consumables are covered by CSA Standard W48-01 and AWS Specification A5.5. The alloy elements are usually introduced through the flux, as ferro-alloys, although there are some manufacturers who add ‘some or all alloys through the core wire, There ate differences between the American and Canadian standards, but the electrode classifications are essentially the same. CSA W48-01 and AWS AS.1 require testing of carbon steel electrodes to be carried out in the as-welded condition. Many low alloy steel electrodes give weld metal that is quite brittle in the as-welded condition. As a result, many classifications for low alloy stee! electrodes in CSA W48-01 and AWS A5.5-96 require the mechanical testing to be carried out in the post weld heat treated (PWHT) condition. Users wishing to take advantage of higher strength, better impact properties, or even improved corrosion resistance, should also consider the heat treatment requirements necessary to ensure that the properties of the final welds meet the requirements. Itis sometimes impractical (and expensive) to heat treat the finished structure! Tables 1.11 and 4.12 summarize the types of low alloy steel electrodes covered in the CSA and AWS standards. Increased strength may be obtained in a variety of ways and the chemical composition of different welds of the same strength level may not be the same. It Is extremely important that attention be given to the suffix of the low alloy steel electrode classification. In fact, the ‘suffix is an essential part of the electrode classification. The user must ensure that ALL of the requirements of the electrode classification are understood. It could be disastrous if an E5518- B3 was used where an E5518-C3 was specified. The former is intended for use in structures that must resist high temperature creep, and require PWHT at 690°C. The latter is designed to give high impact properties in the as welded condition. There is no such thing as an “E5518”. The suffix is required to properly define the classification. When making the weld deposit for the purpose of testing the electrodes to the appropriate standard, the preheat, interpass temperature, and stress relief time and temperature are specified. These may be different for the various classifications. These testing temperatures (particularly those of preheat) may not necessarily be the same as those used on the job for the same electrode. 39 eee @Gooderham Centre for Industrial Learning O CSA Standard W48-01 Type | Classification | Capable of Producing of Covering ‘AWS — | Satisfactory Welds In Positions Shown ae ‘E70 Series Minimum jtrength of Deposited Metal in Strese-Relleved Condition, 70,000 pal DD: High celiuiose, sodium EAQ1OX — ETO10-X OHH de electrode positive 0! High colluiose, potassium E4Q1tX — ETOILX OHH 1c or dc electrode positive i Basle, sodium E4915-X — E7018-X OH, H de electrode postive iy Basle, potassium E4016X — E7O16-X OHH ‘ac or dc electrode positive 1} lc, lron powder | E401 X__E7018-X J, OH, H ‘ac or de electrode positive oo E40 Series ini Tana Siro eta, 80 505k = } High cellulose, sodium ES51O-X EB010-X FV, OH, H ‘dc electrode positive oO High cellulose, potassium E6511-X — E8011-X FV, OH, H ac oF de electrode positive Oy High tania, potassium E5513X — E8013-X F.V,OH.H ac or de either polarity ot Basic, sodium ES515X EB015-X F,V.OH.H dc electrode postive Basic, potassium E5516-X — E8016-X FV, OH. H ‘ac or de electrode positive O: Basic, iron powder E5518-X__E8018-X F Oo £00 Serles-Minirwum Tensile et High ceitulose, E6210X— EQOI0-X or High cellulose, potassium E6211-X — E9011-X ac of de electrode positive ie] High tania, potas: E6213 — EB013-X ac or dc either polarty ra) Basle, sodium E6215-X — EDO1S-X ‘de electrode positive *y Basic, potassium E6216X — EB0I6-X ac or de electrode positive ; | Basic, ron powder E6218-X ___| acorde electrode posi YD 1 ; (Yih coliuiose, sodiur ‘e eiectrode positive ) {high cettutose, potassium 6911-X — E10011-X 8c or de electrode positive } High tania, potassium E6813X — E10019-X ‘ac or do either polarty Batic, sodium E6915-X — E10015-X de electrode positive ) Basic, potassium E6916-X —E10016-X ‘ac oF dc electrode positive 7 Basic, on pow E10018.X ac or dc electrode positive ) dc pos ) EV6IGX — E11016-X 1c or de electrode positive 7 E7618X__£11016-X ac or de electrode positive i EHD Series Minima Tenia Sirenge Tot af 4: ‘Basie, sodium EB315-X de electrode postive y Basic, potassium E8316-X 8¢ oF de electrode postive Basic, iron powder 1c oF de electrode postive ae D ‘ o a Table 1.11 - Low Alloy Steel Arc Welding Electrodes ) D De > ) a ) ) ) ie ‘ a 40 7 2 )Gooderham Centre for Industrial Learning oe 080 0a] G03 | O40 03 980, 0.03 | o03 | 040 O48 090 8.03 | aos | 080 012 2.90, 003 | 003 | 080 tH 9.90. 003 | 003 | 080 part i cee 305 ‘300 ‘ea | 008" | 1.00 io 50] 0.08, cr 003 | 003 | 080 10010150 esi: |o0swar2 | 000 93 | 003 | oso 4010055, Essiest — Jocswor2 | 000 03 | 003 | 080 040100. essee2 — |ooswor | 090 0.03 | 003 | o60 1.0010 150, essise2 | cosieotz | 090 03 | 003 | 080 110016 1.50 esstssa. | 005 0.00 0.03 | 003 | +00 20010250 essteast | 008 800 003 | 003 | 080 2001620 621509 | o0ste012 | 090 0.03 | 003 | 1.00 20010250 | ogo 1.20 esiees —|aosear | oso 0.03 | a03 | 080 20010280 | oso. +20 ceziees —|ooswor | ogo 0.03 | a03 | 080 200250 | oso 120 essrsea | 005 090 0.03 | 003 | 1.00 17610225 | 040085 } essees | oarwors | osot0o70 | 009 | 003 | 0200080 o4oivaso | 10010425 | 005 0.0 5515.0, | oosor0 | 100 0.03 | 003 | 080 04 |401080 | o4sto08s eseiese’ | coste0t0 | 100 003 | 003 | 090 049 |40080 | oastoaes ) fesse | asswose | +00 003 | 003 | oso 040 |40w80 | oasteaes esersoa, aos [100 fogs Jom Jam [awe Jenme0 | easwoss O essieset” | 00s 00 008 | 003 | 080 040 }eomso | oasieaes essiepst | 00s 100 003 | 003 | oso 040 [eowso | casieass essis67 | aoswor0 | 1.00 2.03 | 003 | os0 o40 |s0105 | 4510005 Essieo7 | ooswo.t0 | 100 003 | 003 | 080 040 |sow105 | cas i0088 essiesr —fooswor0 | 100 003 | 003 | oso 040 fsowis | casieaes essiser | 005 100 2.03 | 003 | os0 040 [800105 | o4sto005 esis | 005 00 03 | 003 | oso 040 [800105 | casieoes essissn | 005, +00 03 | 00s | 080 040 |sowi0s | casie08s essiss | o0steos0 | 100 0.03 | 003 | 090 040 [800105 | oast0120 essiess — |a0steo%0 | 100 008 | 003 | O80 040 [sowi0s | casi 120 essiees — | o0steo%0 | 100 03 | 003 | 080 040 | sowi05 | caste 120 essisoe | 005 100 0.03 | 003 | 090 049 |soi105 | 08510120 7 essieest | 00s +00 003 | 003 | 080 oa |eowis | asst6120 ‘ Essieeat | 00s 100 203 | 09s | 090 040 |eDW10s | 088te120 essisect | oosteats | 125 cot foo: | 020 100 | 800105 10120 | 01810030 | 025 esses! | ooswors | 128 cot foo: | 030 400 [800105 | 085120 | o1sw030 | 026 essieeo" | oosweors | 125 aot foo | 030 too [80108 | 085120 | ox6t0030 | 025 Table 1.11: Low Alloy Steel Arc Welding Electrodes tad AtGooderham Centre for Industrial Learning 2000275 20000275 20010275 20010275 2000275 30010375 3000375, 3.000375, 30010375 30010378 osowss0| os 03s | a0s. Bao iio | O48 03 | 808 13010200 144016200 eta | oa 040 tetao | 003 04016 065 0175 | 003 | 003 | 960 09 | 020045 wetts | 903 | 00s | 080 090 | 02816046 102.00 060 om | 07510045 0200 280 000 | 02510045 162.00 30 c at aim 010 038 esi 940 02610050, Eriem O10 02610050 asia 10 0300055, estemt |] 010 essienw? | 010 04010085 eao10Ps ox | 120 0.09 980 Ess10-P1 020 | 120 03 | 003 } 080 4100 030 exorew ‘x2 | o4otoo70 | 0.028 | 0025 | 04010070 | 020%0049 | 0.150020 008 | o30w080 E5510W o42 | esotosao | 00s | 003 |o3swa80 | 0401080 | 04510070 23010075, Notes: (1) Single values are maximum, unless specified otherwise. (2) The suffix (At, B3, C2, etc.) designates the chemical composition, and is an essential part of the electrode classification. (3) Nb 0.03 - 0.10; N 0.02 - 0.07; Al 0.04 max. (4) The letters "XX" used in the classification designations in this table stand for the various strength levels in MPa/t0 (6) In order to meet the alloy requirements of the g group, the weld deposit must have the minimum of only one of the specified elements as indicated. (6) Al 0.05 max. Note: The chemical requirements for AWS A5.5-96 are similar to CSA Standard W48-01 Table 1.12 - Chemical Requirements for CSA W48-01 Electrodes 42 mb = i a tooss a ts ) D Rett arenes rae» ) ) ) y ) d ) ) , , ’ , ’ ) ’ ) Sere reel eloee } Gooderham Centre for Industrial Learning Yoon nineteen tin 4.18 Moisture and Hydrogen Tests It was pointed out earlier that electrodes with a basic coating are designed to produce a weld deposit with a low hydrogen content. If the moisture level of these electrodes is too high, they will not be capable of producing low hydrogen levels. This applies equally to the controlled hydrogen electrodes of the FCAW process. As a result, some countries have adopted standards to specify low hydrogen levels and the test methods to measure them In the Sections of CSA Standard W48-01describing the requirements for carbon and low alloy steel SMAW electrodes, a diffusible hydrogen test is mandatory for the basic classifications, and an optional test is available in the section relating to FCAW electrode requirements for manufacturers who wish to classify their FCAW electrodes as hydrogen controlled. In the AWS. specifications for carbon and low alloy steel SMAW electrodes (A5.1 and A5.5), a moisture test ig required. However, AWS Specifications for most processes dealing with these steels provide an optional test for diffusible hydrogen. Percentage moisture in an electrode flux is not a good measure of the amount of diffusible hydrogen to be expected in a weld deposit. As mentioned in the discussion on Storage of Arc Welding Electrodes, above, the form in which the moisture is adsorbed on the surface, or absorbed deep into the flux materials, can have a strong effect on hydrogen content in the weld. The parameters used in making the weld (especially FCAW), and even the atmospheric moisture can affect the results, Figure 1.8 shows a typical welding fixture to hold the test piece during welding. An alternate method, which eliminates the dangers inherent in using mercury (Hg), is Gas Chromatography. In both test methods, a weld bead is deposited on a small plate held in a copper clamp, and then immediately quenched in water. It is then placed in a tube containing mercury, (see Figure 1.9 for a typical example) or in an enclosed capsule for Gas Chromatography. The time between depositing the weld, and containing it, is carefully controlled. The tubes, or capsules, are held for a specified time under closely controlled conditions so that the hydrogen can diffuse out. The amount of hydrogen evolved is measured and the hydrogen content of the weld metal is calculated : AWS A4.3 Standard Procedures for the Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic and Ferritic Stee! Weld Metal Produced by Arc Welding covers both the mercury and the Gas Chromatographic methods. Also recognized in Canada is the ISO 3690 Determination of Hydrogen in Deposited Weld Metal Arising from the Use of Covered Electrodes for Welding Mild and Low Alloy Steels, which is for the mercury method only. Although the amount of moisture in differerit electrode coatings may not be an accurate measure of the effective diffusible hydrogen in the weld metal, it can be a very effective quality control parameter for a particular electrode. Electrode manufacturers can measure moisture levels quite rapidly, compared to diffusible hydrogen determination, and use them extensively in ensuring that the electrode manufacturing process is operating correctly. 43 ( EeGooderham Centre for Industrial Learning oO a ; ( | { : vy 1) oy te Oo ot oD Figure 1.8: Typical Copper Fixture for Determining Diffusible Hydrogen : ‘In Weld Metal (from AWS A4.3) : (Photo courtesy of Lincoln Electric Co. of Canada) D 7 cy “) 1.8") | K Es d > o Y 260 ms Figure 1.9: Typical n) ory Eudlometer Tube and 4 Assembly for : ‘Standard Mercury : Displacement Method ) for Determination of ? Hydrogen in Weld oO Metal (from AWS 4,3) 9 > 160 mm uo (6.3") at > d ) , te) - ' d bal d )TT rpm rr rr ree pr rere erreur SS | Gooderham Centre for Industrial Learning £4918, 21°C (E7018, 70°F). 60%RH. 8 © \ rehydrated from 0.04% — as-manufactured coating moisture Diffusible Hydrogen,mi/100g o 04 Coating Moisture, wt% Note: jeg aeons eaten ee as manufactured mois ‘moisture level is far more harmful than rehydrated Se gure 1. 7 Relation Between Moisture In a Typical Electrode Coating Weld Metal Hydrogen Content (From AWS A4.3) £4918(E7018), 0.04% Coating Moisture Diffusible Hydrogen, mi/400 gm ‘Atmospheric Moisture, mm Hg Partial Pressure of Water Vapour Figure 1.11: Approximate Effect of Atmospheric Molsture at Time of Welding ‘on Diffusible Hydrogen with a Very Dry Covered Electrode (from: AWS A4,3-93) ‘ 45: Gooderham Centre for Industrial Learning The approximate relationship between the moisture content and the level of diffusible hydrogen is shown in Figure 1.10, which also shows the more harmful effect of the humidity coming from the manufacturing process compared to the absorbed humidity. The reason for this relates to the manufactured humidity in an electrode being distributed evenly throughout the coating. Moisture absorbed by the coating after the electrode has been manufactured is generally close to the surface and may be eliminated from heating the electrode during the welding process. In Figure 1.11, the effect of the amount of moisture in the air at the time of welding is shown for a typical electrode. It must be understood that Figures 1.10 and 1.11 are for test results on a specific electrode. The results for a different electrode could be quite different. Nevertheless, it is obvious that basic electrodes should be kept dry if their low hydrogen. properties are to be maintained. ) Figure 1.12: Electrode handling container 1 oa to help reduce the rate of moisture pickup. (Not a substitute for heated storage) ) AGooderham Centre for Industrial Learning ) ’ 2.0 Solid Electrodes and Rods for Welding Hot Rolled Steel Rod Descale, Pickle Draw to Size Copper Plate Final Sizing Wind-on Spool, Package Figure 2.1: Sequence In the Manufacture of Wires for Welding Solid electrodes and rods are used in many welding processes. (It is an electrode when it actually carries the current. It is a rod when it does not carry the current, but is inserted into the weld poo! as a filler metal.) In contrast to the core of covered electrodes, solid wires are usually made from steel containing deliberate alloy additions. The general sequence for the manufacture of wires is shown in Figure 2,1. Most solid welding wires have a thin coating of copper, which may assist with current pick-up in the contact tube and prevent corrosion of the wire when stored. When these electrodes were first manufactured, the copper coating was used as a lubricant in the drawing process. Modem drawing lines do not need the help of copper. In fact, copper may actually cause trapping of other lubricants between the copper plating and the underlying steel. Welding personnel have become so used fo the copper coating that manufacturers add it at the final sizing stage for the sake of appearance. Non-copper coated wires are becoming more popular since the requirements of nuclear reactor construction made extra low copper electrodes necessary. Welding performed with non-copper coated electrodes demonstrated that the copper coating was not necessary for ‘good welds. In addition, some fears of the toxic effects of copper are supporting the increased use of non-copper coated electrodes. Solid wire electrodes and rods are available in a wide range of sizes and can be supplied in cut lengths, coils, spools or large drums, and pay-off packs. The sizes of wires, and the dimensions and weights of spools etc ., are specified in relevant specifications or standards. 47Gooderham Centre for Industrial Learning Figure 2.2: Wire Electrode Packaging Identification of the wire is most important and the outside of each package of certified electrodes must have at least the following information: * Classification and specification numbers + Suppliers’ name and trade designation + Electrode size and net welght * Lot, control, or heat number + Country of manufacture, + Astatemont that the electrode is certified by CWB Electrodes and wires may be tested in accordance with other designation systems such as AWS specifications and a statement of compliance by the manufacturer must appear on the outside of the package. (ie., ER70S-3 per AWS A5.18) Welding standards and codes often specify the qualification requirements for filler metals and must be checked to ensure these requirements are being met. ‘Gooderham Centre for Industrial Learning 2.1 Cast and Helix ‘An important aspect of coiled wires is the unrestrained shape the wire takes up after it comes off the coll. This can have an important effect on the welding operation, particularly in robotic applications, affecting arc wander or a misplaced weld bead. The cast is the diameter that a single loop of wire assumes when a length is cut from the coil and placed unrestrained on a flat surface. The helix is defined in the standards as the maximum distance from any point on the Wire to the flat surface when a single unrestrained loop fs placed on that surface. The helix for all coils larger than 4 inch spools should not exceed 1 inch (24 mm). Figure 2.3 illustrates the meaning of cast and helix. Helix Figure 2.3 2.2 Solid Carbon Steel Filler Metals for Gas Shielded Metal Arc Welding Wires for Gas Shielded Metal Arc Welding may be used as either an electrode (i.., forming part of the electrical circuit) as in Gas Metal Arc Welding (GMAW), o as a rod separately fed into the arc as in Gas Tungsten Arc Welding (GTAW). Although called carbon (or mild) steel, they do contain alloy elements which are used for deoxidation. These are mainly manganese and silicon but some wires may contain additional elements such as aluminum and titanium. Deoxidation is particularly important when carbon dioxide is. used as the shielding gas, since this gas has a relatively high oxidation potential, reacting with the motten steel to form iron oxides. The amount of deoxidation required also depends on the type of stee! being welded. More deoxidation Is tequired for welding rimmed steel, than for semi-killed and killed steels. Rimmed steels contain comparatively large amounts of oxygen, and as a result, can be prone to creating porosity when welded. The same is true when welding steel with rust or scale on it.Gooderham Centre for Industrial Learning { CSA Standard W48-01, and AWS Specification A5,18-93, cover solid mild steel filler metals for ) gas shielded arc welding. The meaning of the symbols used for classification is explained as follows: ER_49 s—x Ee Chemical Analysis of Wire Electrode Solid Wire Rod (for GTAW, PAW or OFW) 49 = minimum tensile strength in MPa/10 (which means 490 MPa as per 'W48-01) 70 = minimum tensile strength in ksi (AWS A5.18-93) Figure: 2.4 Note that the welding position Is not included In the classification as it Is with covered or ‘ > tubular electrodes. The ability to weld out-of-position is actually determined by the wire diameter, shielding gas and mode of metal transfer. The chemical requirements for these wires are summarized in Table 2.1. Minor differences between the AWS and CSA Standards are to be noted, but are not ‘significant in regard to the behaviour of the wires. The various classifications differ mainly in the level of deoxidizing elements contained in the wires.Gooderham Centre for Industrial Learning 0.4510 0.75 0651095 | 0.300080} 0,07 10 0.15 [0.07 t0 0.19 0.06 t0 0.15 . Single values shown are maximum, ‘Total copper content, including any coating, shall be 0.50% maximum. Sulphur is 0.035% maximum, and phosphorus is 0.025% maximum, AWS A5.18 silicon is 0.65 to 0.85. Mangenese may exceed the 2.00, provided carbon maximum levels are reduced 0.01% for each 0.05% increase in manganese. paene Table 2.4 CSA W48-01 and AWS AS5.18 Chemical Requirements for GMAW Electrodes and GTAW Rods 51{ i Gooderham Centre for Industrial Learning 2.3 Specific Electrode Types The main characteristics of the wires are as follows. 2.3.1 ER498-2 This classification covers muttiple deoxidized steel filler metals which contain nominal amounts of zirconium, titanium and aluminum in addition to the silicon and manganese content. These filler metals are capable of producing sound welds in semi-killed and rimmed steels, especially sing the short-circuiting mode of metal transfer, as well as in killed steels of various carbon levels. Because of the added deoxidants they can be used for welding steels that have a rusty or dirty surface, with a possible sacrifice of weld quality depending upon the degree of surface contamination. These filler metals can be used with CO,, argon-oxygen or argon-CO, shielding gases. Although the nominal amounts of titanium, zirconium and aluminum contribute to deoxidation of weld metal during welding of rimming and semikilled steels, the amounts remaining in the finished weld are generally too low to adversely affect impact levels. This is a triple deoxidized stee! electrode which is capable of making sound welds in rimmed and semi-killed steels even when some rusty conditions exist. Shielding gases permitted are carbon dioxide, argon and oxygen (1-5% 0,)and argon-CO, mixtures. 2.3.2 ER49S-3 ‘These filler metals are used for single-pass and multiple-pass welds, especially when welding killed and semi-killed steel. They can be used for out-of-position welding with small diameter electrodes using the short-circuiting type transfer with argon-O, or argon-CO, shielding gases. Carbon dioxide shielding gas will resutt in a greater loss of alloying elements than in the case of argon-oxygen (1-5%) or argon-CO, (5-25%) applications. This may resuit in some loss of tensile strength, especially if high heat inputs are used. 2.3.3 ER49S-4 These filler metals contain slightly more manganese and silicon than the ER49S-3 classification and produce a weld deposit of higher tensile strength. The primary use for these electrodes is for CO, shielded applications where a slightly longer arc or base metal conditions or both require more deoxidation than filler metals of the ER49S-3 classification provide. The ER49S-4 classification of electrodes is considered to be intermediate between the ER49S-3 & ER49S-6 types, combining some of the advantages of both classifications. 2.3.4 ER498-5 This classification covers filler metals which contain aluminum in addition to manganese and silicon as deoxidizers. These filer metals can be used when welding rimmed, killed or semi- Killed steels with CO, shielding gas and high welding currents. The relatively large amount of ‘ 52ARAL epeeeeeaaae at fet nasShota es pm eae eo ened c 0 len Gooderham Centre for industrial Learning aluminum assures the deposition of well deoxidized and sound weld metal. Because of the aluminum, they are not used for short-circuiting type transfer, or with argon rich shielding gases; thus limiting the use of this electrode to globular type transfer only. These filler metals can be used for welding steels that have a rusty or dirty surface with a possible sacrifice of weld quality, depending on the degree of surface contamination. 2.3.5 ER49S-6 Filler metals of this classification have the highest combination of manganese and silicon and will produce welds that will meet the highest impact property requirements of this Standard when using CO, shielding gas. They may be used with high currents when welding rimmed steels and may also be used to weld sheet metal where smooth weld beads are desired. They can be used for out-of-position welding using the short-circuiting mode of transfer. These filer metals can be used for welding steels that have a rusty or dirty surface with a possible sacrifice of weld quality, depending upon the degree of surface contamination. The high levels of manganese and silicon in the filer metal cause this classification to be Particularly liable to give welds of higher strength and lower ductility when used with shielding gases of low oxidation potential. A minimum oxygen potential shielding gas is usually needed to prevent excess hardness resulting from retained manganese in the deposit. 2.3.6 ER49S.7 ‘ These electrodes have higher manganese, but lower silicon, contents when compared to thé ER49S-6 classification. This provides slightly better wetting action and improved weld appearance and may permit higher welding speeds. They are generally recommended for use with argon-oxygen shielding gas, but are also usable with argon-CO, and CO, shielding. 2.3.7 ER49S-G This classification is for filler metals which do not meet all the requirements of any of the preceding classes. They are not required to meet any specific chemistry requirements and are not tested for impact values, but must meet all the other requirements of this Standard. The filler metal supplier should be consulted for the characteristics and intended use of these filler metals. 2.4 Welding Conditions and Shielding Gases In all cases, except the ER49S-G, the filler metal qualification test is performed with 100% CO, shielding gas. (The shielding for the "G” classification is not specified, and is by arrangement with the electrode manufacturer.) CSA W48-01 specifies the range of shielding gas composition qualified with each electrode classification, based on the amount of deoxidants in the wire. The qualified range of shielding gas composition is based upon a formula which establishes “Oxygen Equivalent’. The formula for calculating oxygen equivalent is: OE (%) = (%0,) + 0.5(%CO.) ' 53t Gooderham Centre for Industrial Learning For those electrode classifications with lower levels of Mn and Si, ER49S-2, ER49S-3 and ER49S-4, the Oxygen Equivalent (OE) shall be not less than 2.0%. For the electrodes having higher Mn and Si contents, ER49S-6 and ER49S-7, OE shall be not less than 4.0%. Shielding gases may contain up to 5% O, and 30% He. The chemical composition of the weld metal will vary with shielding gas used. The use of mixtures of argon with CO, andlor O,, with or without additions of helium, will increase the levels of manganese and silicon in the weld deposit as compared with CO, shielding. Increasing the amount of alloy elements in the weld metal may result in higher tensile and yield strengths and correspondingly lower elongations. It may also affect impact properties. Users are cautioned that shielding gases of low oxidation potential should be used only after consultation with the electrode manufacturer, and careful evaluation of the welding procedure since such gases may lead to tensile strengths higher than the maximum, and elongations below the minimum allowable in CSA W48-01. 2.5 Mode of Metal Transfer 2.8.1 General Gas metal arc welding can be divided into three categories based on the mode of metal transfer. These are known as spray, globular and short-circuiting transfer. Spray transfer occurs as a stream of fine droplets. In globular transfer, the drops are typically larger than the electrode diameter and more erratic transfer can result. Short-circuiting transfer, also known as dip transfer, deposits the weld metal by frequent short-circuiting of the electrode into the weld puddle. 2.6.2 Transition Point ‘Axial-spray transfer in argon-rich shielding gases is mainly related to the magnitude and polarity of the arc current and the electrical resistance heating of the electrode. The high droplet rate (ie. 250 droplets/sec or more) develops suddenly above a critical current level, commonly referred to as the transition current. Below this current, the metal is transferred in drops generally larger in diameter than the electrode at a rate from 10 to 20droplets/sec (globular transfer). The transition current is dependent to a great extent upon current density, electrical stick-out and electrode composition, as well as the shielding gas. (See Module 4) For 1.6 mm (1/16 in) diameter mild steel electrodes, with argon plus oxygen shielding, a transition current of 270 A (dcep) is common. Alternating current is not recommended. 2.8.3 Spray Transfer Spray transfer welding of carbon steels is most commonly done with argon plus oxygen in the range 2-5%, or argon plus CO, in the range 5-15%. A characteristic of spray transfer welding is the smooth arc plasma, with a distinctive “Humm’, through which hundreds of droplets per second are transferred axially from the electrode to the weld puddle. If the current is below the transition point for a given size of electrode, transfer tends to be globular and erratic 54 ‘ ‘ fGooderham Centre for Industrial Learning 2.5.4 Globular Transfer With 100% CO, as the shielding gas, the transition level is practically never exceeded and thus spray transfer is not obtained. At high current values, transfer will occur at rates of 30 to 70 globules/s. The globules are usually larger in diameter than the electrode. With a current near 275 Afor a 1.2 mm diameter electrode, or 350 A for a 1.6 mm size, relatively small welds can be obtained with deep penetration and high travel speeds. To minimize spatter, it is common practice to keep arc voltage low, which “buries” the arc below the work surface. At lower current levels stable transfer can be produced a rate of only a few droplets/second. This type of transfer produces smooth beads but only shallow penetration. Its use is commonly restricted to fill and capping passes of vertical welds. 2.5.5 Short-circuiting Transfer This mode of GMAW transfer is generally used with smaller diameter (0.8 - 1.2 mm) electrodes. Arc voltages and currents are lower than for spray transfer. The electrode feed rate is higher than the bum-off rate, and the electrode actually touches the surface of the work piece. The surge of current resulting from this short-circuit melts the electrode tip and re-establishes the arc, when the process starts again. The rate at which these short-cirouits occur can vary from 50 to 250 times per second, Metal transfers from electrode to work piece during the short circuit period. Little or no transfer occurs across the arc itself. Short-circuiting GMA welding of carbon steels is most commonly done with 100% CO, or argony CO, mixtures. Penetration is usually greater with the pure CO,, compared to A + CO, Use of argon containing 60 - 80% CO, can result in a higher short-circuiting rate with lower currents and voltages, which can be an advantage when welding thin sheet. 2.5.6 Pulsed - Spray Transfer In pulsed arc welding, the mode of transfer is generally spray, although the average current may be well below the transition current needed for spray. This is made possible by using a relatively low “back-ground” current with a pulses of high current superimposed on it. The background current is sufficient to maintain the arc, but cannot give the spray type transfer on its own. At the peaks of the pulses, transfer of weld metal droplets occurs in spray mode. The background current then maintains a stable arc while reshaping the electrode end in preparation for the next droplet detachment. (See Mouide 4). Typically, only one or two droplets will be “squeezed off” during each pulse of current. This mode permits out-of-position welding, but with the advantages of the deeper penetration and lower spatter levels usually associated with spray transfer.be woh Gooderham Centre for Industrial Learning 2.6 Tensile Properties of As-Welded Deposits The CSA W48-01 mechanical properties requirements for all classifications of solid carbon steel filler metals are as follows: Minimum yield “Elongation Strength 400 Mpa Table 2.2 AWS A5.18-93 requirements are similar but, being strictly a classification document rather than a certification standard, it does not have any restrictions on oxidation potential of the shielding gas, nor does it impose a maximum on the tensile strength of the weld metal. 2.7 Impact Properties of As-welded Deposits The only major difference between the CSA and AWS documents is that impact properties are defined in “Joules” at a Celsius temperature in the former, whilst the latter gives “foot-pounds” at Fahrenheit temperatures. No impact levels are specified for ER49S-5 or ER49S-G. For ER49S-3, the requirement is 27J @ -20°C (or 20f-Ib @ 0°F). For all others except ER70S-4, impact toughness must meet a minimum of 274 @ -30°C (20f-1b @ -20°F). The ER70S-4 under AWS A8.18 has no impact requirements. (It also has a slightly different chemical analysis range.)Gooderham Centre for Industrial Learning BhApS t) t 3.0 Flux- and Metal-Cored Wires it ( The flux-cored arc welding (FCAW) process employs wires comprising an outer metal sheath EG with a core containing fluxing and alloying components. Some wires are designed to be used +E with a shielding gas in a manner similar to gas metal arc welding, whereas others can be used c without any additional shielding gas. In a relatively recent innovation, wires have been « introduced which have cores comprising metal powders and only small additions of arc c stabilizers and fluxing ingredients. These are generally referred to as metal-cored, or composite, © wires. Certain cored wires can also be used with the submerged arc process, and these will be t discussed in a later section. In many cases, when reference is made to flux-cored arc welding OG electrodes, the term is (incorrectly) assumed to embrace both flux-cored and metal-cored © electrodes. However, although the distinction becomes blurred at high metal and low flux wr contents, this text will endeavour to maintain the correct distinction. a ¢ is : Tubular Flux or C Electrode Metal Powder 7 and Arc Bete Stabilizers C) G ee oO rO Molten Slag 16 , — oO 44 Base Metal tO (igisteatagg ge eee de asa bge ee eECEE At [a 1G LG ‘ ja Figure 3.1: FCAW/MCAW Process iO ro 1 1G Lo 1a ta 57Gooderham Centre for Industrial Learning Flux- and metal-cored wires are available as coils without supports, coils with supports, spools, or in drums and pay-off packs. Figure 3.2: FCAW Packaging ‘ t t ‘ Identification of the wire is most important and the outside of each package of 7) cetified electrodes will have at least the following information: ( + Classification and specification numbers + Suppliers’ name and trade designation t + Blectrode size and net weight + Lot, control, or heat number . Country of Manufacture , | : + Astatement that the electrode is certified by CWB i 1 Electrodes and wires may be tested in accordance with other designation systems such as AWS | specifications, and a statement of compliance by the manufacturer must appear on the outside of the package. (ie., E71T-9 per AWS A5.20) Welding standards and codes often specify the | i qualification requirements for filler metals and must be checked to ensure these requirements : are being met. | ! | The sequence of manufacture of flux- and metal-cored wires is summarized in Figure 3.3 and =). the fabrication method is illustrated in Figure 3.4. A steel strip is passed through a set of rolls ‘ 58 eee ee eee eee eee emerGooderham Centre for Industrial Learning ‘LAR SB: Which form it into a U shape. The flux is poured in, maintaining a careful steelflux ratio, and thd ) U closed up to make a tubular wire which is then drawn down to final size. Sometimes the wire receives a baking treatment during manufacture depending on the type of wire and flux formulation. The type of closure may vary and examples of various cross-sections are illustrated in Figure 3.5. The close-butt joint illustrated on the left is the type most often encountered now. Generally, cored wires are not copper coated because there is a seam along the wire. However, seamless wires are made by drawing down seamless tubes filled with flux, and these may be copper coated. Mild Steel Strip Core Ingredients Weigh and combine | Dry mix formula A ee : ee eee eee aaa eee Dox G © o | oO 40 Draw to size ho <6 | ia i Spool and package G a E a a Figure 3.3: Sequence of Manufacture of Flux Cored Wires oO oO a a a a a4 } G G - GGooderham Centre for Industrial Learning a O flux hopper strip reel #0” forming rolls flux poured at this point “U” closing rolls reel of formed electrode Fig. 3.4: Simplified Schematic of the Manufacture of Flux Cored Wires. Butt Folded Overlap i Fig. 3.5: Typical Cross-Section of Flux Cored Wires Cored wires are available in a range of diameters from more than 3.2mm (1/8 inch) to less than 0.8mm (0.030 inch). The 1.6mm (1/16 inch) may be the most widely used, although 1.2mm (0.045 inch) is also used in many applications. The availability of the very small diameters has allowed the use of flux cored wires in welding in the vertical and overhead positions. Bee) eee ae eee eee eeethe pote ect age 4 I - 7 1G G a a Gooderham Centre for Industrial Learning 3.4 Types of Flux Cored Wires As with covered electrodes, the operating characteristics and the resulting weld metal properties of flux: and metal-cored wires depend largely on the composition of the filling. They are broadly divided into two main classes, those intended for use with an external gas shield and those operating without a separate gas shield (self-shielding types). The self-shielded types can be very complex and contain elements to compensate for the effects of oxygen and nitrogen absorbed from the air, which can also affect the operating characteristics. 3.1.1 Gas Shielded Electrodes Within the gas shielded classifications, the available wires can be broadly grouped into three major categories: + Rut or titania, types + Lime, or basic, types * Metal cored types In Canada, CSA W48-01 covers in the same tables, the classification of both flux and metal cored electrodes. In the U.S., fiux cored and metal cored electrodes are separated. The flu cored electrodes are classified in AWS A5.20, while metal cored electrodes are included in the solid wire specification AWS A5,18. The two flux cored categories operate with very different welding characteristics. The rutile types operate on deep and generally give a smooth, spray type arc with little spatter. The weld bead is flat to slightly convex and the slag completely covers the bead. Out of position welding is often possible with smaller diameters. Rutile classifications are the E49XT-1, E49XT-2, E49XT-9 and E49XT-12. (Where the X indicates either 1 or 2.) The basic cored wires are more difficult to handle, and thus have lower “welder appeal’. They operate on either deep or deen, and are characterized by a globular type transfer, convex beads and a thin slag which may not fully cover the bead. They are not as easily used out of position, but some electrodes can give acceptable vertical and overhead welds with deen and small diameters. They typically give welds with superior impact properties, and have a high resistance to hot and cold cracking. The basic classification is E49XT-5. Metal-cored electrodes are somewhat similar to the rutile electrodes in operation, but exhibit some of the characteristics of solid wires. The arc is smooth, with low spatter, and the transfer is in the form of fine globules. With argon-CO, mixtures, a pure spray transfer can be obtained. The weld bead is flat to slightly convex, and slag volume is low, usually consisting of small islands. It should be noted that the definition of a metal cored wire differs between CSA an? 1 61\ } Gooderham Centre for Industrial Learning AWS. Metal cored electrodes, £491C-3, E492C-3, E491C-6 and E492C-6, have generally less than 5% by weight of non-metallic elements in the core. The classification defines positional capablility. AWS A5.18 defines E70C-3 and E70C-6 as “composite stranded or metal cored electrodes”, and does not have a positional designator. It is therefore important to realize that an E70C-6 may not also be an E491C-6, although an £491C-6 will always be an E70C-6. Always check to make sure that an AWS classified composite electrode is equivalent to the desired CSA metal cored classification. 3.2 Shielding Gases The choice of shielding gas to be used with a gas shielded flux- or metal-cored electrode is often as difficult as the selection of the electrode itself. Presenting a welding Supervisor or Engineer with the choice of 100% CO, or a mixture of argon with a percentage of CO;, with perhaps addition of O, and/or helium is always a good way to spoil a good night's sleep! ‘Some electrodes are designed for use with 100%CO,, and should not be used with less reactive shield gases without first consulting the manufacturer. Other wires are designed for use with (typically) argon + 25%CO,, Only the gases recommended by the electrode manufacturer should be used. A shield gas with a substantially lower oxidation potential than recommended could result in a considerably stronger weld deposit, with consequent danger of reduced toughness. A lower than recommended oxidation potential could result in welds that are not as strong as the design requirements. What are the advantages and disadvantages of the gas mixtures available? Most carbon steel gas shielded flux-cored electrodes are classified with 100%CO,. With the introduction of the *M" designator in AWS AS.20 and, more recently, in CSA W48-01 an increasing number are being classified with an argon + 20 to 25%CO, shielding. Asmall number of the “G" classifications are designed for use with gases other than these. CO, shielding gas is by far the cheapest, and is adequate for the majority of applications. The next gas in popularity in North America is the argon + 25%CO;. It has greater operator appeal and a smoother, spray-type arc, (not spray transfer as in GMAW), and is often used to weld out-of- position. ‘The deoxidants in the core have higher transfer efficiencies, often resulting in weld deposits with higher strength than those deposited with 100%CO, shielding. Higher CO, contents can give welding properties almost as good at a slightly lower cost, while lower CO, contents can give even higher operator appeal at greater cost. Generally speaking, CO, levels below 5% are not recommended. In the larger picture, the cost of shielding gas is greatly overshadowed by labour. The shielding medium which gives the best overall performance for the scope of a work cell or the company's welding applications, is the correct selection. For special applications, additions of O, and/or helium can be of advantage. The former gives ‘a more concentrated arc, while the latter gives a hotter arc. The potential deposition rate can be extremely high compared with more conventional shielding gases. However, the more 1 62 gee eee eae eset eeeDSB Gooderham Centre for Industrial Learning ‘complex tri- and quad-mixes are much more expensive, and the high levels of infra-red and ultra-violet radiation can diminish operator appeal. As a result, their advantages can often realized only in fully automated applications. Robotic applications are often ideally suited to the quad mixes, where the high deposition rates and travel speeds can be utilized without operator fatigue, and the disadvantages of high infra-red and ultra-violet radiation can be isolated. In addition, the low oxidation potential of many tri- and quad-mix gases may result in very high Tecovery levels for carbon and manganese, which in turn can lead to excessive tensile and yield strength levels, and correspondingly low elongation values (which increases risks of cold- cracking). 3.3 Self Shielded Electrodes The need for the flux to also provide protection of the arc from the effects of atmospheric contamination results in a much more complex slag system than is the case for gas shielded wires. As a result, the choice of self shielded classifications is much wider, but the damage that ‘may result from an unwise choice can be much greater. The gas shielded flux- and metal-cored wires can generally be divided into three main groups (acid, basic and metal cored), where the differences between members in each group are quite small. Welding professionals faced with selection of a self-shielded flux-cored wire, however, may find themselves faced with a bewildering number of classifications, each with its own narrow range of applications. The self- shielded electrode arc is much more open to atmosphere. The effects of oxygen and nitrogen in the weld pool can be disastrous if not counteracted. Luckily, oxygen is relatively easy to neutralize by the addition of deoxidizers. Unfortunately, nitrogen is not nearly so easy to fight, and the manner in which the electrode flux deals with it can have an enormous impact on thé deposition characteristics. Thus, it seems appropriate at this point to discuss methods of nitrogen control. Air enters the arc of self-shielded electrodes much more easily than is the case for other welding processes. In SMAW, the flux/metal ratio of the electrode can be almost whatever the electrode designer requires. (Thus the tendency in SMAW to increase deposition rates by adding iron powder to the covering.) For gas shielded FCAW, the atmosphere is pretty much excluded by ‘the flow of gas which blankets the arc area (under ideal conditions). For self-shielded FCAW, the flux/metal ratio is restricted by the electrode configuration. There just isn't the room available in the core to allow for a flux/metal ratio much higher than 35%. Thus the designer of a self- shielded FCAW electrode must be extremely careful in using the little space available to provide sufficient fluxing agents to deal with the large amounts of absorbed oxygen and nitrogen, while performing all the other tasks described at the beginning of this module. Awelding arc will always be contaminated by the atmosphere to some extent, In self-shielded FCAW, the contamination is maximized. Oxygen and nitrogen in the arc dissociate into atoms which can react with the molten metal as it crosses the arc. The molten weld poo! can contain large amounts of dissolved oxygen and nitrogen. Oxygen will react with iron and manganese to form oxides, which can be at least partially removed by fluxing agents. Nitrogen does not form iron nitrides to any significant extent, and so will come out of solution during solidification, and can result in gross porosity. ' 63—) Gooderham Centre for Industrial Learning The amount, and effects, of nitrogen (and oxygen) entering the weld pool can be controlled to some extent by: 1. adding certain materials to the core that generate vapours in the arc, thus reducing the amount of air that can enter the arc adding certain materials to the flux which inhibit the absorption of nitrogen, by either chemical reaction or by physically coating the droplets as they cross the arc (or both) altering the mode of transfer for metal across the arc. A fine, spray transfer consisting of a great many small droplets presents a large surface area for reaction to the arc atmosphere. Globular transfer, consisting of relatively few large droplets, presents a much lower reactive area for a given mass of weld metal adding arc stabilizers that allow a shorter, tighter arc stream, thus reducing the exposure time for each droplet : neutralizing the effect of nitrogen (and oxygen) by using nitride formers (oxide formers) such as aluminum and titanium use of complex configurations in the wire cross-section to protect at least a portion ‘of the metal component from direct exposure to the arc atmosphere. (This last method, although effective in reducing total nitrogen levels, has proven too costly to manufacture, and is now little used.) 3.4 Standards and Specifications for Flux- and Metal- Cored Arc Welding Electrodes In Canada, carbon steel flux- and metal-cored wires are covered by CSA Standard W48-01. AWS A5.18-93 classifies composite electrodes, while specification AWS A5.20-95 covers flux cored electrodes. The 1995 edition of AS.20, included certain innovations which have been included in the CSA Standard W48-01 published in 2001. (An obvious example is the use of the “M? designator which allows the qualification of some wires with the use of gas mixtures having 75% to 80% Argon the remaining being CO,). However, certain differences should be noted in the two systems: + In AWS AS.18, two symbols are used to denote minimum tensile strength (there is no positional designator), whilst in AWS A5.20 only one symbol is used (the second number is used as a positional designator). CSAW48-01 uses two digits as a strength designator, followed by a third to designate position. 64 eee aceC C CO Gooderham Centre for Industrial Learning aca ee { Figure 3.6 shows the meaning of the various designators used in classifying flux- and metal- cored arc welding electrodes. 3.5 Chemical Requirements The requirements for the chemical composition of the deposited weld metal are shown in Table 3.1. The requirements are very similar in both CSA and AWS. Although they are usually referred to as carbon steel electrodes, they do contain certain alloy elements, which are added to contro! performance, weld metal toughness and, in the self-shielded wires; oxygen and nitrogen. 3.6 Mechanical Properties: The requirements for the mechanical properties of the deposited weld metal (in the as-welded condition) are summarized in Tabla 3.2. The various classes of wire differ mainly in their requirements for toughness as measured by the Charpy V notch impact test. (The only major difference between CSA W48-01 and AWS 5.20 Is the use of 60 ksi and 70 ksi strength designators). E XX XT- XMJ-HZ E XX XC-XMI-HZ geetruyae none E tore —<—— eahenwosan Saeed os Sein ie eoenea a eee = ald ea Societe Soon, Seer oma {92s wed for lassen fe 100% CO, or Pat the ‘ ‘ect ie sa-onetec Usaity and parermance charactastcs Tenmcona C= mata oored Figure 3.6: Meaning of Symbols for Flux and Metal Cored WiresGooderham Centre for Industrial Learning CSA AWS. Mn, Mo” | v7 | AL [eaext-raay PPT) Eaaxt-sa) | E7xT-5(M) | 0.18 | 1.76 | 0.90 30 | 008 Ns, Easxt-op)_| E7xT-9(M)_ | ey ee pe eaxta | E7XT-4 : Eaaxts | E”XTS EAGXT-T | ETXT-T @ | 175 os | 03s | 18 E49XC-91M) EASXC-A(M) | E4axo-s, E4axc-08. Oy @) @) (4) ®) 6 a «®) [ Electrode Classification | € lent lens” in, Maximum % Z ETS, EaXT-13 EDXT-20M) Emxr-3 EXxT-10 Ent” smcsny, | ws 78 ETOC-Gix)" 00s | oss” | Ns. Eroc-ouy"| | __ ‘The amounts of these or any other elements shail be recorded if intentionally added. ‘This value shall be recorded. ‘Chemical content is not meaningful for single pass electrodes. The sum of all elements, other than Fe, shaill not exceed 5%. 0.12 for AWS A5.18 CU = 0.50 max, as per AWS A5.18 According to A5.20 the E7XT-6 classificatior udes both single pass electrodes and multipass electrodes. It is the same for the E70C-G classification as per AS.18. ‘The 2X" will be a “C" i the electrode has been tested with 100% CO. Pethe x" will be an “NF ifthe electrode was tested with 75 to 80% argon, balance COp. N.S. means “Not Specified”. Table 3.1: Chemical Analysis Requirements of Deposited Weld Metal {Flux and Metal Cored Electrodes) nnn Tenn nn nnnncnnnnenseeGooderham Centre for Industrial Learning L T nonaentes Tensile Strength en MPa kal E43xT-A13" 430 60 NS. 490 70 2 490 70 NS. 490 70 Ns. E49XT-4 490 70 2 E49xT-6(M) | ETXT-5(m) | 490 70 22 E4exts | E7XT-6 490 70 2 E4OXT-T ETXT-T 490 70 2 E4OXT-8 EMTS 490 70 2 E4xT-o@m) | E7XT-9(m) | 490 10 2 E4oxt-t0® | EPXT-10° 490 NS. Eaoxtt1 | EPXT-11 490 20 E49xT-144M) | E7XT-124M) | 490t0620 22 E49xT-14" | ETXT-14 480 NS, E4xTS | ERTS 480 2B Eaoxr.cs? |t 490 _NS. E49XC-3(0) 30K | 480 to 650 2 E49xC-6(M) | E70C-6(x)° | 490 to 650 2 E49XC-G E70c-Goo* 490 2 esoxc-gs’ [6 "| 430 NS. Notes: (1) Single values a maximum (2) Yield point and impact values are not meaningful for single pass electrodes. (3) As an option the J designator may be used as a suffix when the impact values are verified at 40°C (4) According to A5.20 the E7CT-G classification includes both single pass electrodes and multipass electrodes. It is the same for the E70C-G classification as per A5.18. (©) The *X" willbe a “C" if the electrode has been tested with 100% CO. The "X" will be an “M” ifthe electrode was tested with 75 to 80% argon, balance CO2. Table 3.2: Mechanical Properties Requirements (As-Welded All Weld Metals) 67Gooderham Centre for Industrial Learning 3.7 Description of the Flux Cored Arc Welding Electrode Classifications General 3.7.1 T-1 Electrode Electrodes of the E49XT-1 group are classified with CO, shielding gas in the CSA W48-01 Standard. However, gas mixtures of argon-CO, or argon-CO,-oxygen may also be used to improve usability, especially for out-of-position applications. Classification E48XT-M allows certification with a gas mixture having 75 to 80% Argon balance CO,. That classification allows the certification of the wire with various proportions of CO, vs Argon, or ternary gas mixtures as long as the manufacturer successfully passes the tests required by the Standards for those gas mixtures. (AWS A5.20 allows classification as an E7XT-1M using an Argon plus 20-25% CO;) The last comments apply to all flux cored and metal cored classifications which can have the designator “M’. Decreasing amounts of CO, in the argon-CO, mixture will result in higher Mn and Si contents in the deposit, with a probable increase in tensile strength. The impact properties may also change. Thus, the manufacturer should be consulted before using argon ges mixtures. T-1 electrodes are designed for single- and multiple-pass welding. The larger diameters (usually 2.0 mm and larger) are used for welding in the flat position and for horizontal fillets. The smaller diameters (usually 1.6 mm and smaller) may be suitable for welding in all positions. The T-1 electrodes are characterized by high deposition rates, fine globular transfer, low spatter loss, flat-to-convex bead configuration, and a moderate volume of slag that completely covers the weld bead. Most electrodes in this group have a rutile-based slag. Some electrodes in this classification require that joints be relatively clean and free from oil, excessive oxide, and scale in order that welds of radiographic quality can be obtained. 3.7.2 T-2 Electrode Electrodes of this classification are essentially T-1 electrodes with higher Mn and/or Si designed primarily for single-pass welding in the flat position and for horizontal fillets. The higher levels ‘of deoxidizers in these electrodes allow single-pass welding over scaled or rusted steel. Standards do not impose chemical composition requirements for single-pass electrodes since checking the undiluted deposit chemistly gives no reliable indication of composition of normal single-pass welds, The two-run technique (one pass fram each side on the butt joint) is ‘equivalent to the single-pass applications because of the similar weld metal dilution obtained. T- 2 electrodes, which use manganese as the principal deoxidizing element, may also give good mechanical properties in multiple-pass applications where the total number of passes is restricted, but the Mn content and tensile strength will be higher in these applications. T-2 electrodes can be used for welding material that has heavier mill scale, rust, or other foreign materials on its surface than can be tolerated by some electrodes of the T-1 classification and still produce welds of radiographic quality. The arc characteristics and deposition rates are similar to those of the T-1 electrodes. 68 eee gee eee Egewe be neal ccerancet Gooderham Centre for Industrial Learning 3.7.3 T-3 Electrode t Electrodes of the T-3 classification are used without externally applied gas shielding and are intended primarily for depositing single-pass welds at high travel speeds on light plate and gage- thickness base metals in the positions designated. Electrodes of this classification have a spray- type transfer and have a fluoride and rutile-type of slag system. Titanium is used to improve wetting and “fix” nitrogen. Additional amounts of silicon and aluminum may also be used as deoxidisers. The electrodes run on dcep, and the deposit has a relatively high hardenabilty. These electrodes are not recommended for welding thicker materials. 3.7.4 T-4 Electrode Electrodes of the T-4 classification are designed to be used with no extemal shielding gas, and may be used for single- or multiple-pass applications in the flat and horizontal positions. These electrodes are predominantly fluoride-bearing with special additions of deoxidisers such as aluminum. They operate on de, electrode positive, are characterized by a globular arc transfer, and produce convex beads with good slag removal. Typically, the necessary electrical extension (‘stickout’) is 60 to 80mm (2.5 to 3.75 in.), which results in very high deposition rates. One problem is the low penetration, making it difficult to reach the root of a fillet weld. Also, because of the relatively large globules of metal transferring across the arc, itis difficult for the welder to make a fillet weld smaller than 8mm (5/16 in.). Best suited for welding deep grooves and welds with poor fitup. This electrode should not be used where impact toughness is desired. 3.7.6 T-6 Electrodes { Electrodes of this classification are primarily designed to be used with CO, shielding for single- and multiple-pass welds in the flat and horizontal position. However, some recent additions in this classification can be used out-of-position. For best operation in out-of-position welding, some manufacturers recommend use of deen. These electrodes are characterized by a globular transfer, slightly convex bead contour, and a thin slag of the lime-fluoride (basic) system. Weld deposits produced by these electrodes have impact properties and crack resistance that is superior to those with rutile-base slags. These electrodes can also be used with argon-CO, mixtures, although it is recommended that users check with their suppliers before so doing. 3.7.6 T-6 Electrode These electrodes were a development of the T-4 types, and have some similarities. However, electrode extension of 25mm is more usual. T-6 electrodes are designed to be used with no external shielding gas for single- and multiple-pass welding. They operate on de, electrode positive, are particularly susceptible to the operator and weld settings, and are characterized by a low spatter and spray transfer. Penetration is better than the T-4, the weld bead is flat to ‘slightly convex and the slag is easily removed. Electrodes in this group have a basic oxide slag. Good impact toughness is possible with this classification.Gooderham Centre for Industrial Learning 3.7.7 T-7 Electrode Electrodes of the 1-7 classification are used without externally applied shielding gas and are intended for depositing single- and multiple-pass welds. They are predominantly fluoride- bearing with special additions of deoxidizers such as aluminum. They operate on dc, electrode negative, are characterized by small droplet transfer, and produce slightly convex weld beads with good slag removal. Electrode extension is lower than T-4 electrodes, but deposition rates are still relatively high. They have the advantage over T-4’s of higher travel speeds and higher penetration, but have similar (i.e. poor) impact values. 3.7.8 T-8 Electrode Electrodes of the T-8 classification are designed to be used with no external shielding gas for single- and multiple-pass welding, usually in all positions. They are predominantly fluoride- bearing with special additions of deoxidizers such as aluminum. They operate on de, electrode negative, and are characterized by small droplet transfer to produce very high quality weld metal. Good impact values are possible. 3.7.9 T-9 Electrode Electrodes of the E49XT-9 group are classified under CSA W48-01 with CO, shielding gas, but electrodes of the E49XT-9-M designation (as well as E7XT-9M classification in A5.20)allows classification with Argon + 20-25% CO,. However, other gas mixtures of argon-CO, or argon- CO,-0, are often used to improve usability, especially for out- of-position applications. It is recommended that the manufacturer be consulted before using a mixed gas. Decreasing amounts of CO, in the argon-CO, mixture will increase Mn and Si in the deposit thereby increasing tensile strength and possibly changing the impact strength. For this reason the manufacturer's recommendations should be followed. These electrodes are designed for single- and muttiple-pass welding. The larger diameters (usually 2.0 mm and larger) are used for welding in the fiat position and for horizontal filets, The smaller diameters (usually 1.6 mm and smaller) are often used for welding in all positions, The T-9 are similar in most respects to the T-1 types, but have improved impact toughness. 3.7.10 T-10 Electrode Electrodes of this classification are for lise with no externally applied shielding gas. They are intended for single-pass applications only, and should not be used for multipass welds. They operate on doen, and usually contain a high proportion of fluorides with additions of oxidizers such as aluminum. The slag fully covers the bead, and is easily removed. High travel speeds, which may exceed 2.0m/min. are possible, and they are especially suited to highly automated applications. 3.7.14 T-11 Electrode This self-shielded electrode classification is designed for single- and multipass welding. Electrodes contain large amounts of fluorides and deoxidizers such as aluminum, and often contain iron powder in the flux. As a result, they may have a relatively low slag volume. The slag ‘ 70Gooderham Centre for Industrial Learning is designed to freeze quickly, to allow out-ot-position welding with high operator appeal. This i$ achieved by using substitution of some of the calcium fluoride with barium fluoride, which can result in barium exceeding the threshold limit value (TLV), Thus, adequate ventilation is recommended. They operate on deen, with a short electrode extension, and transfer is in spray mode. Because of the fine spray transfer, nitrogen pick-up can be high, and this is counteracted by increasing aluminum levels. In turn, this requires carbon levels at the maximum level consistent with ductility requirements. Thus, these electrodes are sometimes restricted by the manufacturer to welding steels of 12mm (% in.) maximum thickness. 3.7.12 T-12 Electrode Electrodes of this classification are essentially T-1 types that have been modified to improve impact toughness without increasing the manganese and/or silicon content and therefore the tensile strength. Weld metal composition conforms to the A1 requirement in the ASME Code. In addition, they are designed to give weld-metal strength within a certain range, and so it is particularly important that the composition of the shielding gas be within the range recommended by the manufacturer. 3.7.13 T-13 Electrode This electrode classification is self shielded, and operates on dcen, and was developed to handle poor fit-up. The slag system allows operation in all positions, and it is primarily used for the root pass in circumferential pipe joints. Nitrogen fixing is by a combination of aluminum ai titanium, which allows better wetting than aluminum alone. Arc stabilizers allow very low ars. voltage, even down to short circuiting transfer, which allows bridging of poor fit-up. At higher voltages.and currents, T-13's have a smooth arc and low spatter, and can be used at high travel speeds. They are not recommended for multi-pass applications. Although it is referred to here as an E4317-13, there are some variations available that meet the E491T-13 classification. When welding in the vertical position, progression is usually downwards. 3.7.44 T-44 Electrode Electrodes of this classification are self shielded, and operate on dcen, and have high operator appeal. The slag system, consisting largely of barium and/or strontium compounds, allows high current densities, welding in all positions, and high travel speeds. When welding in the vertical position, progression is usually downwards. Slag coverage is light. They are most often used ‘on sheet metal up to 5 mm (3/16 in.) thick, and are capable of welding galvanized or aluminized steels. Because of potentially very high aluminum and carbon levels, which result in high tensile strength and low ductility, they are not recommended for multi-pass welding. 3.7.15 T-G Electrode The EXXXT-G classification is for new muttiple-pass electrodes that are not at present covered under any of the defined classifications. The multiple-pass properties can be anything covered by this Standard. The slag system, arc characteristics, weld appearance, and polarity are not defined.et Gooderham Centre for Industrial Learning 3.7.16 T-GS Electrode The EXXXT-GS classification is for new single-pass electrodes that are not covered at present ( under any other defined classifications. The single-pass properties can be anything covered by this Standard. The slag system, arc characteristics, weld appearance, and polarity are not defined. (Note: This classification is not included in AWS 5,20. It is included in the T-G classification.) EE 3.8 Description of the Metal Cored Arc Welding Electrode Classifications 3.8.1 C-3 Electrode These electrodes exhibit some of the characteristics of T-1 classifications, but also bear a resemblance to ER49S-3. In many cases, the addition of small quantities of arc stabilizers to the core makes the arc smoother and more stable, with tower spatter levels than ER49S-3. However, they are not normally recommended for use as rods with the GTAW process, nor are they generally suitable for use in the short circuiting mode. Metal transfer is in the form of fine globules. With Argon - CO, mixtures, a pure spray transfer is common. The weld bead is flat or slightly convex. Slag volume is low, and usually consists of small islands. With most electrodes, the joint must be relatively clean if good radiographic quality is required. 3.8.2 C-6 Electrode These electrodes are similar in many respects to the E49C-3 classification, but contain higher levels of deoxidants such as manganese and silicon. Mechanical properties are similar to E49XT-9 or ER49S-6. They can be used on weld joints which do not meet the same standards ( of cleanliness required for E49XC-3. Some electrodes operate best on 100% CO,, whilst others are designed for use with argon-rich shielding gases. It is advisable to consult the electrode manufacturer if a different gas from that recommended is contemplated. 3.8.3 C-G Electrode Metal cored electrodes can be manufactured to yield a wide range of weld metal compositions. + ACG classification has been added to allow approval of metal cored wires that may not meet + all of the requirements of either the C-3 or C-6 classifications. In general, arc action and weld appearance will be similar to other metal cored classifications, but this will not always be true. ‘ 3.8.4 C-GS Electrode This classification is for metal cored electrodes designed for single pass applications. They are not recommended for multi-pass applications. In some cases, they may be more tolerant of rust and mill scale. In general, arc action and weld appearance will be similar to other metal core classifications, but this may not always be true. (Note: This classification is not included in AWS A5.18. It is included in the C-G classification.) 72i . Gooderham Centre for Industrial Learning 7 7 ~~ Classification ~~ Single or { ‘ _CSA____ AWS _|__Multi-Pass a ( E4sxT-1—E7XT-4 | Mttiple Pass ( E49XT-1M E7XT-1M_—_| Multiple Pass c E49xXT-2E7XT-2__| Single Pass ree E49XT-2M —E7XT-2M_| Single Pass ee Hs E4927-3 E7OT-3 Single Pass c E4e2T-4 E70T-4 —_| Multiple Pass . E49XT-5 — ETXT-5_—_| Multiple co, doep{dcen) ie E49XT-5M —ETXT-5M 7 dcep(dcen) a E4927-6 70-6 —_| Multiple Pass None ‘dcep Cc iG 4027-7 E70T-7__| Multiple Pass None doen G E49XT-8 — E7XT-8 None deen E49XT-9 ETXT-9 Co, doen E49xT-9M — E7XT-OM : doen 4927-10 E70T-10 None doen E4OXT-11—E7XT-11. | Multiple Pass None deen E49XT-12E7XT-12_—_| Multiple Pass co, dcop E49XT-12M_E7XT-12M | Mutiple Pass : deep E43iT-43 E61T-13 | Single Pass None deen ‘ E4gtT-14 E71T-14 E49XT-G_E7XT-G E49XT- b _| Single Pas E4exC-3 E7OC-3C | Mutt ‘deer E49XC-3M E70C-3M Multiple Pass deep"? 4 B49XC-6 — E70C-6C Multiple Pass deep!” i E49XC-6M E7OC-6M deep!” ze E49XC-G_E70C-G a a ee E49XC-GS__b sii Wisse a a Notes: a = Not Specified LO b indicates that for AWS 5.18 E70C-G also covers single pass metal-cored (composite) ha electrodes, and for AWS A5.20 E7OT-G also covers single pass flux-cored (tubular) LO electrodes. LO (1) Not Specified in AWS A5.18 bo *75 to 80% argon balance CO. Other gas mixtures can be used if the required La tests are performed as per CSA W48-01 or, according to AWS A5.18, those mixes 7 are suggested by the manufacturer of the electrode. a Table 3.3: Welding Conditions and Shielding Gases a a a G oO ' 73 haGooderham Centre for Industrial Learning 2) Suffix Slag T-4 Rutile T-2 Rutile, extra metal powders: 1-3 Fluorspar, rut, silicon, aluminum T=4 Fluorspar, aluminum T-5 Lime, fluorides (basic) T-6 Basic compounds, rutile, aluminum: T-7 Fluorspar, aluminum 1-8 Basic compounds, aluminum T-9 Rutile : T-40 Fluorspar, aluminum T-1 Fluorspar, iron powder, aluminum 1-12 Rutile T.13 ‘Stabilizers, aluminum, titanium 1-14 Basic compounds, aluminum He T-G Not defined ) T-Gsi Not defined c-3 Metal powder C68 ‘Metal powder c-G Not defined i c-GS'__|Not defined Notes: t (1) CSA only i t | 3.9.1 Controlled Hydrogen Designators For flux- and metal-cored electrodes, the CSA Standard W4801 allows the use of a designator which could be H2, H4, H8, or H16. On application by the electrode manufacturer, the Canadian Welding Bureau can extend the certification of a flux-cored or metal-cored electrode to show that tests have proven the electrode capable of providing weld metal with a maximum level of Xml \ diffusible hydrogen per 100 grams deposited weld metal, (X can be 2, 4, 8 or 16) when tested Table 3.4: Usual Principal Ingredients of Flux Cored and Metal Cored Wires 3.9 Optional Supplemental Designators 14{G a ,a a Gooderham Centre for Industrial Learning according to AWS A4.3, Standard Methods for Determination of the Diffusible Hydrogen Content ) of Martensitic, Bainitic, and Ferritic Stee! Weld Metal Produced by Arc Welding. The AWSAS.18, AWS A5.28 and AWS AS5.29 allow the use of the optional designator HX. 3.9.2 Mixed gas Designator Since 2001, the CSA Standard W48-01 allows the use of the "M" designator which designates a flux or metal cored electrode certified with a gas mixture having 75 to 80% Argon, balance CO. Some electrodes can be classified as both (as example E491T-9 and E491T-9M). Previously the tests required for classifying many flux and metal cored electrodes had to be succeeded with 100% COp. In the past years, the electrode manufacturers have developed fiux and metal cored electrodes which would perform better with gas mixtures rich in Argon. The fact that some tests needed to be performed with CO, did not match the reality. The "M’ designator now being used has corrected the situation allowing tests with Argon rich gas mixtures only. 3.9.3 “J” Designator for Improved Toughness Properties Since 2001 the CSA Standard W48-01 allows the use of the “J” designator when Charpy-V notch tests are performed at -40°C, which is a temperature lower than the temperature specified for the standard classifications. 3.9.4 Example A flux cored electrode having the classification E491T-9MJ-H16 is an electrode tested with a gas mixture having 75 to 80% Argon, balance CO2. When tested as per CSA Standard W48-01 Standard, the electrode meets 27) at ~40°C and the requirement of 16 ml maximum of diffusible hydrogen per 100g of deposited weld metal.Gooderham Centre for Industrial Learning 3.40 Low-Alloy Flux- and Metal-Cored Electrodes CSA does not publish a standard for low-alloy flux-cored electrodes. The AWS A5.28; Specification for Low Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding covers solid fi and metal-cored (and other composite types such as stranded) electrodes and AWS A5.29, - Specification for Low Alloy Electrodes for Flux Cored Arc Welding. Classification is similar to that used in AWS A5.18 and AWS A5.20, with the addition of chemical analysis designators similar to those already described under tow alloy SMAW electrodes (CSA W48-01). Many self shielded low alloy electrodes have been designed for welding structural steels rather than the higher strength low alloy steels. Addition of alloying elements such as nickel have greatly improved impact strength and ductility in the weld metal, resulting in self shielded electrodes that meet, or even exceed, the levels normally expected only in gas shielded classifications. This has been particularly useful in field welding of structures subject to fatigue and/or impact loading. 76 a t £ ci ee eeGooderham Centre for Industrial Learning i) 4.0 Submerged Arc We Consumables ‘Two separate consumables are used in the Submerged Arc Welding (SAW) system; wire and flux. The wire is fed from a coil, and the flux, in the form of a granular material, is fed into the welding arc zone from a hopper. Some of the flux melts to produce a slag that covers the weld pool, while the unmelted flux may be recovered and used again. A diagram of the essentials of the submerged arc process is shown in Figure 4.1. Since the arc is surrounded or ‘submerged’ by the loose granular flux, itis not visible and this is an attractive feature of the process. Flux Feed Electrode Arc Cavity ——~ ‘Molten Flux Slag ——~ = Diraction of Welding Granular Flux Blanket Solidified ‘Weld Metal Base Metal x G Molten Weld Metal QO oO 7 { o Figure 4.1: Schematic of SAW Process 460 [OQ 44 Submerged Arc Wires tO i a Wires for SAW are made in the same way as that described for GMAW earlier, except they are Qa generally of a larger diameter. They are not usually as ‘hard’ as GMAW wires (ie. the tensile {a ‘strength is not as high), since they are not drawn down to the same extent. In most cases SAW yo wires are copper coated. Composite, or cored, wires may also be used for SAW, usually for high ine alloys and stainless steels, but also for low alloy structural and machinery steels. fa || © Aswith GMAW, the cast and helix is important in controlling the position of the tip of the wire as LO it emerges from the contact tip, but, again, the specifications do not set limits. SAW wires are 4 Oo available as coils without supports, coils with supports, spools or in drums and pay-off packs. Qa = 1G 0 ‘ 7 ha PQ ie |Gooderham Centre for Industrial Learning Identification of the wire is most important and the outside of each package of certified electrodes will have the following information: = Classification and specification numbers * Suppliers’ name and trade designation fe Electrode size and net weight . Lot, control, or heat number : Country of Manufacture + Asstatement that the contents are certified by CWB. Electrodes and wires may be tested in accordance with other designation systems such as AWS ‘specifications, and a statement of compliance by the manufacturer must appear on the outside of the package. (ie., F7A2-EM12K per AWS A5.17) Welding standards and codes often specify ‘the qualification requirements for filler metals and must be checked to ensure these requirements are being met. In addition a coil will have an identification tag attached to the coil and, if the wire is on a liner or drum, identification will be placed directly on the liner or drum. 4.2 Fluxes for Submerged Arc Welding The flux performs functions essentially the same as in SMA electrodes, the main one being the protection of the molten weld metal from the atmosphere. There are several important differences, however, and these should be noted. * SAW fluxes do not have to be designed to be extruded and, therefore, do not contain ingredients added to covered electrodes for this purpose. + SAW fluxes must be capable of handling a wide range of current. In some cases currents over 2000 amps are used in SAW. * SAW fluxes need not produce large quantities of gas to protect the arc as in MAW. Organic materials, such as cellulose, are not, therefore used in SAW fluxes. Fluxes are made from minerals comprising oxides of calcium, silicon, manganese and other elements. By careful design of the flux formulation, a wide range of properties may be obtained. The melting range of fluxes is below that of the weld metal so that molten slag can float out of the weld metal before it solidifies. Slags melt typically in the range 1100 - 1200°C. When the 78 ( Sec ce eee ee eee eneEt C c a. - +6 ‘ hehe rac uO Oo a Gooderham Centre for Industrial Learning ‘slag becomes solid, the shrinkage rate should exceed that of the steel so that the slag shrinks ) faster and peels off from the weld. A good flux, in a well designed groove, and with a careful choice of welding parameters, will form a slag that detaches by itself, leaving a completely clean weld without the need of chipping or grinding. If the parameters cause undercutting of the bead, the slag can be very difficult to remove. 4.2.1 Method for Making Fluxes There are two basic methods for making submerged arc fluxes. The first involves fusing the flux ingredients together then crushing to size. The second involves mixing the ingredients together with a binder, then baking. The latter process has variations depending on the baking temperature and is termed agglomerated or bonded. 4.2.1.1 Fused Fluxes Fused fluxes are made by dry mixing carefully proportioned quantities of silica sand, metal oxides, and a small amount of a halide salt, and melting them together at a temperature of 1500 - 1700°C in an electric furnace in which the current passes through the flux itself (which becomes ‘a conductor when molten). The molten flux is poured into water, or onto a chill plate. The product, when cooled, is ground and screened to a particle size range suitable for handling and welding. Fused fluxes may be sub-divided into alkaline earth metal silicates and silicates in. which manganese silicate is a major constituent. In some cases, the physical and chemical properties of the slag produced during welding may not be changed dramatically from the original flux. In such cases, it may be feasible to recover the slag and re-cycle it as a “new” flux. (This is termed “crushed slag”, and is discussed more fully later.) Fused fluxes are usually considered “neutral” (see Wall Neutrality Number, discussed below). ‘The advantages of fused fluxes are: + Auniform product with all particles of constant composition. + Fused fluxes do not usually absorb moisture. ‘ 4.2.1.2 Agglomerated and Bonded Fluxes: Agglomerated, or bonded, fluxes consist of intimate mixtures of finely divided oxides of two or more metals such as alkaline earth, manganese, aluminum, silicon, titanium, and zirconium, together with other materials such as deoxidants and halogen salts, bonded with a suitable binder and treated so that hard granules are formed. The physical and chemical properties may be changed quite dramatically during welding, so recycling as a crushed slag may not be feasible. They are made by mixing the ingredients together with a binder, such as sodium silicate, then heating in a kiln, The particles agglomerate to form small balls which are ' 79+ et Gooderham Centre for Industrial Learning then crushed to size. A temperature of 800 - 1000° C is used in the agglomeration process. Bonded fluxes are made by a similar process except that lower temperatures are used for curing. ‘A major advantage of this method of manufacture is that oxidizable materials such as ferro- silicon can be added to the flux, and will remain ‘active’ (i.e. not turn to oxide) after the baking treatment. Thus, deoxidizing elements and alloys can be included in the flux rather than the wire. ‘Agglomerated fluxes have a lower density than fused fluxes, and less flux is used in the welding operation. In a typical application the flux consumption for an agglomerated flux is approximately 20% less by weight than for a fused flux. Agglomerated fluxes may, or may not, be “neutral” (see Wall Neutrality Number, discussed below). 4.2.1.3 Mixed Fluxes: Mechanically mixed fluxes, within the context of CSA Standard W48-01, may be mechanical mixtures of two or more fused or bonded fluxes in varying proportions, or mechanical mixtures of finely divided minerals and metallic deoxidisers in proportions necessary for a desired performance. 4.3 Chemical Action of Fluxes Although the main purpose of a submerged arc flux is to protect the weld metal from the atmosphere, the flux itself may react chemically with the weld metal. The two most important consequences of this are: + The composition of the weld metal will not necessarily be the same as that of the wire. Some elements may increase in concentration, while others decrease. + The flux may transfer oxygen to the weld metal. The extent to which these effects occur depends on the type of flux. Those fluxes having litle effect on the composition being called ‘neutral’ in North American practice. European terminology is somewhat different. Fluxes transferring significant amounts of oxygen to the weld metal are termed ‘acidic’, while those transferring small amounts are termed ‘basic’. Itie most Important to recognize that the flux can influence the composition, because in so doing, it will also Influence the properties of the wold. For this reason, fluxes and wires must be selected as a combination, and the specifications treat them as such. 80 et Tec eeGooderham Centre for Industrial Learning r The elements which can change most In concentration are: + Elements such as manganese and silicon which may be prasent in the flux. ee oe + Readily oxidizable elements. 3 If the flux contains a large percentage of silica (Si0,), the silicon level of the weld metal may be well above that of the wire. Similarly, the chromium content of a stainless steel! deposit may be well below that of the wire, and careful selection of fluxes for stainless stee! welding is necessary to minimize this chromium loss. It was pointed out that one of the advantages of agglomerated, or bonded, fluxes was that they could contain ‘active’ deoxidants and alloys. These are useful, for example, in a fiux that is tolerant to rust and scale on the plate. The amount of these deoxidants transferred to the weld c t ( ( #¢ ¢ 70 metal will depend on how much flux is metted, and this in turn depends on the arc voltage. Some C fluxes, therefore, are sensitive to the welding parameters and in some cases they are only ie recommended for single pass welding. Figure 4.2 shows the effect of arc voltage on the weld c metal silicon content for two fluxes, one being an ‘active’ flux and the other ‘neutral. This graph C shows the effect of arc voltage on the amount of silicon transferred to the weld metal for two C fluxes. Both fluxes are of the bonded type, but one contains ‘active’ deoxidants where the other -) is “neutral. \ Gr G Qa ee oO 3 Active Flux 16 2 oO = 40 o fo = ,O = ize) c Lo 8 a | a Neutral Flux ho PS La ' i 20 24 28 32 36 40 i a | qa Figure 4.2: Effect of Are Voltage tt |— Gooderham Centre for Industrial Learning When selecting fluxes it is important to study the manufacturers’ recommendations to determine if there are any limitations in application, and whether special procedures are required to obtain the best results. 4.4 Oxygen Transfer ‘The amount of oxygen transferred from the flux depends on the types of oxides contained in the flux. At the high temperatures involved in welding; some of the oxides may break down to a limited extent and transfer oxygen to the weld metal. Silica (Si02) is one of the least stable oxides used in fluxes, and high contents of silica tend to result in high levels of transferred ‘oxygen. On the other hand, these components have many desirable characteristics, and the design of a flux will depend on the intended application and the desired properties. The main reason oxygen in the weld metal is important, is because it can affect the toughness of the weld metal. When the weld metal solidifies, the oxygen forms tiny round inclusions of oxides which are dispersed throughout the weld metal. They are very small (one millionth of a metre in diameter), but they can reduce the energy required to fracture the metal. Where improved toughness is required, fluxes have been developed that have reduced oxygen transfer. Special care should be exercised in the selection of submerged arc consumables whenever there is a toughness requirement, bearing in mind that many other requirements may also have to be met. 4.5 Specification of Submerged Arc Welding Consumables ‘Two separate consumables are used in submerged arc welding; the wire and the flux. Solid wires can be specified in terms of the chemical composition of the wire (as with other solid wires for gas shielded welding), but the flux is not specified separately. Instead, fluxes are specified in terms of the properties of the resulting weld metal when used in conjunction with a specified wire. The specification, therefore, refers to a flux/vire combination. The student will note also that for cémposite wires, chemical composition of the wire is meaningless, and thus the analysis of the weld metal, as a result of welding with a flux/wire combination, is specified. As a result, a composite wire may have (for example) an EC1 classification with one flux, but an ECG classification with another. 82 Aa ee seg cert esse eaeGooderham Centre for Industrial Learning ah oc 4.5.1 Specifications Submerged arc consumables are covered by CSA W48-01 for carbon steels. Canada does not have a standard for SAW low alloy steels. In the USA, AWS A5.17/A5.17M-1997 covers carbon steel consumables for SAW and AWS AS.23/A5.23M-1997 covers low alloy steels. (You will note that these two AWS Specifications are both US Customary -A5.17 and A5.23- and SI Metric - AS.17M and AS.23M) These are two of the few metric standards published so far by AWS. However, over the next few years, all AWS AS standards will be published in both US Customary and SI Metric versions.) 4.6 Classification of Submerged Arc Consumables In SAW, an electrode is used in conjunction with a flux that is added separately. Therefore, itis possible to use a particular electrode with several different fluxes, and it is self-evident that the Weld properties could be quite different for each combination. As a result, it has been necessary to devise a classification system that is in two parts, one for the electrode, and the other for the properties of the weld when the electrode is used with a certain flux. This gives rise to a classification, for CSA W48-01 such as E49A3-EL12K. The system is slightly different for AWS AS. 17/A5. 17M. In Figure 4.3, below, the meaning of the various designators is explained for CSA W48-01. Figure 4.4 illustrates the system for AWS A5.17/A5.17M Designates a Flux i ‘The first two digits indicate the minimum tonsile strength af the deposit in Incromanis of 10MPa, |e K moans a killed steel For solid electrodes, these one or two is Fecal the nominal carbon ‘composition of the weld deposit. a For solid electrodes, the weld metal wnen tested "A for“as- “L'indicates a low manganese (0.6% max) Mredod” and Por tne postonel hat Mt indicates & medium manganese (1.25% max) ‘treated condition. “Ht indicates a high manganese (2.25% mex) "C’ Indicates a composite (us in*C at which the Weld otal met the eqarorant of 20 minimum. AZ" Indicates thet impact tasting isnot required. AnS* indicates that the flelectrode combination fs suitable for single pass welding onty The ouch ct ndeates the temperature, Impact strength of Figure 4.3: CSA W48-01 Classification System for Submerged Arc Welding Consumables 83Gooderham Centre for Industrial Learning Example: In the example given earlier, F48A3-EM12K represents a specific flux in combination with an electrode having medium manganese content, nominally 0.12% carbon, and is silicon killed steel. The weld metal from this combination, in the as-welded condition, has @ minimum tensile strength of 480MPa and a minimum impact strength of 27J when tested at -30°C. F S XX X X- E X XX ie Olan a Fux 7 ryerogn cantar If present, indicates the flux is made It present, K means a thn shed ig, who rbot 9 to a blend of virgin fux. Omission of the *S" Indicates that the flux s virgin fax For soll electrodes, these one or ‘wo digit Ineate the nominal carbon ‘content of the wire, For composite For A5.17,a single digit indicates the elactrodes, indicates the chemical ‘ ‘strength of the weld metal in increments ‘0f 10,000 psi. For AS.17M, two digs ‘composiion of the weld deposit. Indicate the minimum tensiie strength of the deposit in Increments of 1OMPa. For asad aco “Lindicates a low manganese (0.6% max) “M" Indicalos a medium mangonese (1.25% max) "H"Indloates a high manganese (2.25% mex) Indicates a composite (uovally 8 matalicored. ‘elecroae. The next lator indlcates the condition of tha wold metal whon tasted ‘A’ for ‘as-welded" and P" forthe post-wold heat treated condton ‘The noxt digit indicates the temparature (in “F for Designates an Electrode Rennie rae i atone gt | erin ted tl nota berwaarent saat ame craig ana ean SRS RE ai tains Sikeeted ee Figure 4.4: AWS A5.17/A5.17M Classification Systems a for Submerged Arc Welding Consumables That the CSA and AWS systems are, similar is self-evident, but there are differences. The following is a brief summary: ‘The AWS AS Committee on Filler Metals and Allied Materials felt that it was necessary to identify a flux that was comprised wholly, or partially, of a crushed slag, and have done so by the introduction of the “S* designator following the *F" for flux. The CSA W48 iu Technical Committee on Welding Filler Metals, however, decided that, as the W48-01 Standard is a certification document certification document administered by a third party (the Canadian Welding Bureau), such a designator was not necessary. A certified fiuxlelectrodefiux/electrode combination of necessity would identify the source of raw materials. (See below for a more in-depth discussion on crushed slags). i 84Gooderham Centre for Industrial Learning a ancrc opti Saccecccccttecscc | 2. Use of a co-habitation approach by AWS, resulting in two specifications (AS.17 and A5.17M), allows classification in either US Customary units (ie. pounds and inches) or SI Metric units (.e. kilograms and metres). Under AWS A5.17, a °7” following the “F” designator (assuming the flux is not a crushed slag) indicates a weld metal having a minimum tensile strength of 70,000 psi (70 ksi). Under AWS AS.17M, the same flux/wire combination would probably carry the “48" designator, indicating the weld metal tensile strength was 480MPa minimum. As per CSA W48-01 the "49 designator will appear. This is because, in 2001, the W48 Technical Committee changed the strength levels from 480 MPa to 490 MPa to be in line with international standards. 3. The next designator, either an “A” or a “P" is identical in all three standards (W48.6, A5.17 and A5.17M). The former indicates a weld that has been tested with no heat treatment exceeding the interpass temperature specified in the standard, the latter indicates a weld tested in a heat treated condition, as specified by the relevant standard. s The last digit in the flux part of the classification indicates the temperature at which impact tests are carried out. For the A5.17 specification, the temperature is in degrees Fahrenheit, whilst for CSA W48-01 and AWS A5.17M, the temperature of test is quoted in degrees Celsius. For all three standards, a “Z” indicates a flux/electrode combination which has not been tested for impact strength. The difference between A5.17M and W48-01 in this instance is the use of the “S” designator by CSA to indicate a flux/wire combination that is Suitable for single-pass weld only. The W48 Technical Committee felt that, as impact testing on single-pass welds was meaningless for classification purposes, the designator could be used to differentiate between multi-pass flux/wire combinations that were not tested, and single-pass combinations. 5. The last part of the mandatory designators, covering the electrode, is identical for all three standards. 6. The introduction of a diffusible hydrogen designator for A5.17 and A5.17M gives users a measure of the amount of diffusible hydrogen to be expected from a given fluxwire combination. However, CSA felt that, given that the SAW process was inherently low hydrogen, such a designator in,a certification document would result only in unnecessary additional testing. Should the user require this kind of information, the manufacturer should be contacted The full chemical requirements for solid wires are shown in Table 4.1. The requirements for composite (metal cored or composite) wires are shown in Table 4.2. Chemical composition requirements for AWS A5.17 requirements are the similar, if not identical, as for CSA W48-01 85Gooderham Centre for Industrial Learning ‘Chemical Composition? Classification| si P s “Ti cr | 7 Low ae : Manganese EL8K O1 0.25 to 0. 0.10t00.25 0.030 0.030 NS. 0.35 EL12 004t00.14 0.351006 0.10 0.030 0.030 Ns 0.35 ‘Medium Be at Hee ‘Manganese Emtik —[0.07t00.19 1.00t04.54 06510089 0.025 0.030 Ns. 0.35 EM12 0.06 to 0.18 0.80 to 1. 0.10 0.030 0.030 NS. 0.35 Emt2« [0.050019 080t0125 0.100039 0.030 0.030 NS. 0.38 EM13K 0.06 to0.16 0.90 to 1. 0.35 to 0.78 0.030 0.030 NS. 0.35 EMiak —[0.06t00.19 0.901014 0.35t00.75 0.025 0.025 | o0st0017| 0.35 EM15K 024 08010129 0.100039 0.030 0.030 Ns. 0.35 High Be Beecseeceea Manganeso EHI0K — fo.07t00.19 1.201017 0.05t0025 0.025 0.025 Ns. 0.35 EHIK — [0.060019 14010489 08010119 0.030 0.030 Ns. 0.35 EHI2k [0.060019 1.501020 0.200069 0.025 0.025 Ns 0.35 EH 0.401002 17010224 0.10 0.030 0.030 NS 0.38 Notes: (1) Per cent mass. Single values are maxima. Total Cr + Ni + V + Ti (if not specified) 4 shall not exceed 0.50%. : (2) Copper limit includes any copper present in a coating which may be applied to the es electrode. Table 4.1: Chemical Composition Requirements for Solid SAW Electrodes CSA W48-01, Fluxes and Carbon Steel Electrodes for Submerged Are Welding ee Hel le 7 86 a ‘ t ‘ piesa aepeeereeek cattle t Gooderham Centre for Industrial Learning Chemical Composition ' Electrode 2 Classification a a fi | . Ge Ect 0.15 180 0.90 0.038 0.035 0.38 Eco? Ns. Ns. Ns. Ns. NS. Ns. Notes: (1) Percent mass. Single values are maxima, Total of Cr+ Ni+ Mo + V+ Ti shall not exceed 0.50%. (2) Copper limit includes any copper present in a coating which may be applied to the electrode. (3) For this electrode, there are no chemical requirements for the elements ‘marked N.S. with the exception that there shall be no intentional addition of Ni, Cr, Mo, Ti or V. Table 4.2: Chemical Composition Requirements of Weld Metal for Composite SAW Electrodes CSA W48-01, Fluxes and Carbon Steel Electrodes for Submerged Arc Welding 4.7 Examples of SAW Flux/Electrode Classifications Consider the following flux/electrode combination classifications for CSA W48-01, AWS A5.17- 97 and AWS A5.17M-97. We will give CSA W48 examples, and then show how AS AS5.17 and A5.17M classify the same combination. (Note: It should be remembered that classification to all three standards is not required. Amanufacturer can classify to one, two, or all three standards. Of course, classification to CSA W48-01 requires that CWB has witnessed the specified certification tests.) EXAMPLE 1: F49A3-EM12K This classification describes a flux/electrode combination giving a weld deposit having a minimum tensile strength of 490MPa in the as-welded condition (see table 4.3, below). Impact strength is a minimum of 27J at -30°C. The electrode is a medium manganese killed steel! with a nominal carbon level of 0.12% The classification system for A5.17M is identical except that the 49 is a 48. For A5.17, the classification would be F7A2-EM12K, where weld metal strength is 70,000 psi, and impact ‘strength is 20 ft-lbf at -20°F. (Note: Should the flux in this combination be a blend of 50% crushed slag and 50% virgin (unused) flux, the classification would be FS7A2-EM12K.) 87wok: Gooderham Centre for Industrial Learning EXAMPLE 2: F43PS-EH14 This classification describes a flux/electrode combination suitable for single-pass welds only, giving a weld having a minimum tensile strength of 430MPa in the heat treated condition. (The manufacturer would be consulted on the details of the heat treatment.) The electrode is a high manganese steel, which has not been silicon Killed, having a nominal carbon content of 0.14%. ‘As the AWS does not use the “S" designator for single pass combinations, the AWS A5.17M classification would be F43PZ-EH14, showing impact testing is not required. The AWS A5.17 classification would be F6PZ-EH14. EXAMPLE 3: F49AZ-EL8K This classification describes a flux/electrode combination suitable for multi-pass welds only, giving a weld having a minimum tensile strength of 490MPa in the as-welded condition. Impact testing is not required. The electrode is a low manganese, silicon killed steel, having a nominal carbon content of 0.08%. The AWS A5.17M classification would be F48AZ-EL8K, which could be either single-pass or multipass, The A5.17 classification would be F7AZ-EL8K. CAUTION: The mixing of designators from different standards is not permitted. If the tensile strength designator is 6 or 7 (for carbon steels), the standard being used is A5.17, and all the other designators must be in US Customary units. Similarly, if the test temperature for Charpy V-notch tests is in °C, whether the standard is W48-01 or AS.17M, all the other designators must be in SI Metric units. In the following Table 4.3, an attempt has been made to include classifications from all three (W48-01, A5.17 & A5.17M) standards. The result may be a little difficult to understand. Therefore, it may be convenient to explain some of the features beforehand. 1. For Charpy V-notch impact testing, the AWS ASB Sub-committee on Submerged Arc Welding felt that it was unneceséary to have US Customary classifications for -10°, -30°, and -70°F. Similarly, a classification for 0°, -70°, and -80°C was considered unnecessary. (CSA agreed for the metric classifications). The spaces left vacant by these non- classifications are marked N.A. (Not Applicable.) 2. As.explained earlier, the AWS specifications do not provide a classification specifically for single pass flux/electrode combinations. These are considered covered by the classifications for which impact testing is not specified. Thus, we have again marked these as N.A. for A5.17, and provide a footnote explaining the situation for A5.17M.len ae Gooderham Centre for Industrial Learning EE ; 3. As for the CSA W48-01 Standards and for the series of AWS AS standards, the % elongation is measured from a tensile specimen having a gage length four times the diameter. _ 4. As mentioned earlier, a metric classification is all metric, and a US Customary 4 classification is all US Customary. Mixing the units is not permitted in CSA Standard 48-01 or any other and AWS AS standard. esa WwasoT : AWS ASATM | 4 F43XS-BOO" at FASXZ-EXXX NAS FEXO-EXXX FA3X2-E0K | FEXZEXXX : FAax3 BOK [NAP 430 0 550 FABX4- BOK | FEXAEXXX F43X5-EXXX, | FEXS-EXXX F43X6-E00 | FOXE-EXXX ) NAS | F6XBEXxx i G Fa9xS, ce excGr A Faoxz-6000 | FrAZEXAK NAS Oo F49X2-E20008 | FIXZ-EXXX to FASXS-EXXX! | NAS FASKEEXI® | FIXGEXXK =a FAQXS-EXXK | FXSEXXK LO FAQX-EXXX | FIXB-EXXK ii NAS erxaexxx| a Notes: oO (1) Single values shown are gninim a (2) Not applicable to AS.17M ts (3) Not applicable to A5.17 (4) Not specified oy (5) Not applicable a (6) 48 instead of 49 for A5.17M (7) 480 instead of 480 for A5.17M : (8) Not applicable for W48-01, General note: 4:1 gage length /diameter ratio for the tensile tests a 0 Table 4.3: Mechanical Properties for CSA W48-01 and AWS A5.17 u a 7 89Ree Gooderham Centre for Industrial Learning 4.8 Choice of Fluxes Submerged Arc Welding fluxes are granular, fusible mineral compounds of various proportions and quantities, and are generally named by the method of manufacture, such as fused, agglomerated and mechanically mixed types. Each type has unique characteristics which affect the chemical composition and mechanical properties of the deposit. 4.8.1 Wall Neutrality Number The Wall Neutrality Number is a convenient measure of the comparative neutrality of a flux for use in welding carbon steels (it is not applicable to the welding of alloy steels). For a flux to be considered neutral, it should have a Wall Neutrality Number of 40 or less. The Wall Neutrality Number (N) can be determined as follows: (a) _ Using parameters similar to those indicated in the CSA W48-01, weld a pad consisting of a minimum of five layers. (b) Weld a second pad, using the same parameters, except for an arc voltage increased by 8 volts. (c) Analyze samples from each pad. (d) The Wall Neutrality Number depends on the change in silicon, regardless of whether it increases or decreases, and on the change in manganese, regardless of whether it increases or decreases. The Wall Neutrality Number is equal to 100(change in %Si + the change in %Mn). As can be seen, a totally neutral flux, by this measure, would have a Wall Neutrality Number of 0. Example: The test described shows an increase of 0.20% for both Mn and Si: N = 100 (0.20 + 0.20) = 40 4.8.2 Neutral Fluxes Neutral fluxes will not produce any significant change in the weld metal chemical analysis if the arc length, and therefore are voltage, is changed. This is of importance in multiple pass welding, particularly in deep groove welds. Neutral fluxes contain little or no deoxidizers and must rely on the electrode to provide deoxidation. Single pass welds with insufficient deoxidation on heavily oxidized base metal may be prone to porosity, centreline cracking, or both. Although the neutral fluxes maintain the chemical composition of the weld metal even when the voltage is changed, it is not always true that the chemical composition of the weld metal is the same as that of the original electrode. Some neutral fluxes decompose in the heat of the arc and release oxygen, resulting in a lower carbon value in the weld metal than is present in the electrode. Some neutral fluxes contain manganese silicate, which can decompose in the heat of 7 90Gooderham Centre for Industrial Learning A the arc to add manganese and silicon to the weld metal. Because no metallic manganese or silicon was added to these fluxes, the changes are fairly consistent, even when there are large changes in arc voltage. 4.8.3 Active Fluxes Active fluxes contain small amounts of metallic manganese and/or silicon. These deoxidisers are added to provide improved resistance to porosity and weld cracking caused by contaminants ‘on, or in, the base metai. The primary use of active fluxes is to make single pass welds, especially on oxidized base metal, although they are also used for certain applications involving low alloy base metals. Since active fluxes contain deoxidisers, weld metal composition will vary with changing arc voltage. For this Teason, tight control of arc voltage is often critical, especially for multi-pass applications. Some fluxes are more active than others. This means they offer more resistance to porosity due to base metal oxides, but may pose bigger problems when used in multiple pass welding. 4.9 Crushed Slags The slag formed during submerged arc welding may contain relatively large quantities of iron oxides absorbed during the welding process and may differ in other ways from the chemical composition of the unused (virgin) flux. Its composition is affected by the composition of the original flux, by the base metal and electrode composition, and by the welding parameters. It may also be affected by mill scale, rust, or other surface contaminants. Crushed submerged arc welding slag may be usable as a flux for submerged arc welding, but it cannot be considered to be the same as the original flux. In particular, the manufacturer of the original (virgin) flux will not generally accept responsibility for the recycled flux. It may be classified under the AWS and CSA SAW standards, but must be considered as a new, chemically different flux. If it is to be certified under CSA W48-01, it must be provided with its own unique marking, using the name of the manufacturer, so as not to be readily confused with the manufacturer of the original (virgin) flux. (The “manufacturer is defined below.) Flux generated in a “closed loop" system may be certified if it can be determined that the raw materials (slag) are of consistent composition, and that collection, handling, crushing, screening and packaging produces a flux that can be reasonably represented by a single random sample. closed loop system is defined as slag generated by one fabricator from a specific flux using a consistent welding procedure and is crushed for subsequent reuse by the same fabricator. it is considered manufactured by the fabricator, with the crushing company being considered as a ‘sub-contractor. It may, or may not, be mixed with a controlled portion of virgin flux. A change in the proportion of virgin flux would require re-certification 91Gooderham Centre for industrial Learning It is obvious that close control of the generation of the slag is required, if a consistent product is to be obtained. Any materials introduced from another procedure could alter the composition of the final crushed slag very dramatically. Addition of even a small amount of slag from a (say) calcium silicate based flux to the slag from a manganese silicate based flux would radically change the melting range, viscosity, surface tension and other factors in the crushed slag. The action of the slag on the molten weld pool would be unpredictable Flux generated without one or more of the “closed loop"controls may be certified on a batch basis. That is, each batch of crushed slag would be individually tested and certified. Such a crushed slag is considered to be manufactured by the crushing company. 4.10 A4__ Diffusible Hydrogen ‘Submerged arc welding is normally considered to be a low hydrogen process, provided care is taken to maintain the electrodes and fluxes in a clean and dry condition. Users who need a very low diffusible hydrogen content in the weld metal should consult the manufacturer. Testing for diffusible hydrogen in the “as-manufactured” condition does not give information of great value to the user, unless values of mi/100g, or less, are sought. The situation is very similar to the use of continuous, solid wire, electrodes used in the GMAW process. For this reason, an optional test has not been defined Users who wish to preserve the inherent controlled hydrogen level (i.e. less than 16 mi/100g weld metal) properties must take proper precautions to keep SAW consumables clean and dry. Heated flux storage ovens are one popular way of preventing moisture pickup by the flux. Users desiring low hydrogen (less than 8 ml/100g) and very low hydrogen (less than 4 mi/100g) levels, should consult the manufacturer. 4.11 Low-Alloy Steel Electrodes for SAW Bare low-alloy steel electrodes and fluxes for SAW are covered by AWS specification A5.23- 97. At present, there is no equivalent CSA standard for low alloy submerged arc consumables. As with carbon steel consumables, the solid electrodes are classified according to chemical composition, but wire/flux combinations are classified according to weld metal composition as well as mechanical properties. Many types of electrodes are listed in AWS A5.23-97 and these will not be discussed in detail here. Cored-type composite electrodes are allowed under the specification and are denoted by the letter "C” following the “E” for electrode, A group of letters and numbers is included to represent the weld metal composition, in the same manner used for 'SMAW and FCAW electrodes, and this may differ from the electrode composition depending on the type of flux being tested.Bie Voge Gooderham Centre for Industrial Learning ee erence aes Le { rl 7 C te GO C C ae c c ie 5.0 Tungsten Electrodes Tungsten electrodes are available with diameters ranging from 0.5 to 6.4 mm, and AWS Standard A5.12 makes provision for seven types of tungsten alloys for use as electrodes in the GTAW process. These alloys along with their AWS classification and application are shown in Table 5.1. AWS Colour |__Application Classification | Code tungsten [Pe AG & OC welding | _ W- 1% thorium oxide | _DCwelding | W_- 2% thorium oxide DC welding |W - 0.25% zirconium oxide ACwelding |W - 2% cerium oxide AC & DC welding W.- 1% lanthanum oxide _ DC welding ‘94.5% W, remainder specified | — Specified by |by manufacturer manufacturer _ | Grey _ Table 5.1: Tungsten alloys for GTAW Alloy Application AWS Classification Colour Code In general, alloyed tungsten electrodes have a higher current carrying capacity. At a given current density, alloy electrodes operate at a lower temperature than do pure tungsten electrodes. Aiso, the alloyed electrodes provide greater arc stability, easier arc starting and less weld metal contamination due to erosion of the tungsten electrode. The choice of the type and size pf tungsten electrode for an application depends on the ‘operating current and current type as shown in Table 5.2. 93i Gooderham Centre for Industrial Learning ‘AG Unbalanced ‘AC Balanced DCEN DCEP Wave Wave [ers | 0 ewe | ewex | ewe “| 7010150 | 101020 | s0t0100 | 70t0150 | 301080, | 1501250 | 151020 | 100t0 160 | 140t0236 | e0to.130 | 100 2500400 | 251040 | 150t0200 | 225t0.325 | 10010 180 | 1 | 400tos00 | 40065 | 2000275 | 300t0400 | 160 to 240 50010750 | §5t080 | 250t0 360 190 to 300 ‘[7s01© 1000 8010 125 | 325 t0.480 | 0010630 | 25010400 | s40t0 525 Table 5.2: Typical Current Ranges for Tungsten Electrodes of different Diameters Excessive current causes electrode erosion leading to contamination of the weld metal, and if the current is too low, the arc can wander erratically at the electrode tip. An electrode size should be chosen that will operate near to its maximum current carrying capacity without overheating. (The electrode should remain shiny after use.) ‘Aluminum is usually welded using alternating current. The electrode used can be pure tungsten oran alloyed type. The most common in use today are EWCe-2 or EWLa-1. In the past a EWZr- 1 was used with a tapered, balled end, Electrodes with thoria additions can split when used with AC. Since relatively high heat is developed at the electrode with AC, pointed electrodes will melt easily and an alloyed electrode will be needed. The end of a pure tungsten electrode will melt to a hemispherical shape before use and this can be achieved by striking an arc on a copper block using AC or DCEP polarity. The size of the hemisphere for alloyed electrodes should not exceed the electrode diameter as it may detach and at high current levels, will “spit” droplets of tungsten into to weld pool. With pure tungsten electrodes, a large ball at the electrode end is difficult to avoid with AC. Large balls also have a de-focussing effect on the arc, making it difficult to make sound fillet welds in aluminum. The retention of a smaller ball is promoted through the selection of a larger diameter electrode. (See Module 4).Gooderham Centre for Industrial Learning 6.0 Aluminum and Aluminum Alloy Electrodes There are no Canadian standards for aluminum and aluminum alloy filer materials, the AWS specifications are used. Presently, there are two documents available, AWS A5.3 Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding and AWS A5.10 Specification for Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods. Shielded Metal Arc Welding is still quite widely used in small shops for non-critical applications, and for repair work. However, it is not recommended for good quality welding. For applications requiring high quality weld deposits, one of the gas shielded processes is recommended. In both A5.3 and A5.10, the classification of electrodes and rods is based on chemical composition of the core material or filler metal, respectively. Table 6.1 gives the AWS classifications and the corresponding chemical analysis for manual metal arc welding electrodes, and Table 6.2 gives the same information for solid wire electrodes. In both cases, classification is based on the Aluminum Association alloy designations of the filler metal or core wire, as appropriate. (As in previous processes, the “E” stands for electrode. The "R", when used, stands for rod.) 6.1 General Aluminum alloys are light in weight, but can be as strong as steel. Aluminum has good impact resistance at very low temperatures, has a high resistance to many corrosive environments, and is not toxic. It is also an excelient conductor of heat and electricity, coming close to copper in these attributes, and it is non-magnetic. It is therefore very popular in many applications, and is limited in most cases only by its cost. 6.2 Shielded Metal Arc Welding Shielded metal arc welding of aluminum and its alloys has certain advantages over the gas shielded processes. Welding equipment is cheap and readily available, and portable. However, it is slower than GMAW, and the quality of the weld is inferior. The classification of welding electrodes for SMAW is covered by AWS AS5.3. Such electrodes have an active flux that combines with the aluminum oxide to form a slag. This slag is a potential ‘source of corrosion and must be completely removed after each pass. The electrode coating will deteriorate if exposed to a humid environment for any length of time, and electrodes must be stored in a dry, warm area. If they have been exposed, and if they have suffered no physical damage, they can often be restored by baking at 100 - 150°C. Welding is done with deep. 95Gooderham Centre for Industrial Learning AWS a = anc Classification _| (ica si Fo | cu | Be E1100 oes | 0.95 | 0.05t0.0.20 | 0.05 0.0008 a £3003 06 | 07 | 0.08t00.20 | 1.0t01.5 0.0008 4043 451060 | 08 0.30 0.05 0.0008 Notes: ‘a) Single values are maxima ) Other elements, not specified, shall be no more than 0.05. The sum of all other elements shall nat exceed 0.15. ¢) The sum of Si + Fe shall not exceed 0.95. Table 6.1: Chemical Composition Requirements for Aluminum and Aluminum Alloy SMAW Electrodes (Core Wire) i ‘ t ‘ ‘ fl ( i ‘SMA Welding is best done on material of 3.0mm or greater thickness. Aluminum is well known for its extremely high heat conductivity (close to copper). For this reason it is recommended that, when welding plate or complicated joint geometries, preheat be used to improve penetration, and to reduce porosity and distortion. Even relatively thin material will often benefit from preheat to reduce moisture and oils on the surface and slow the rate of heat flow from the weld. Maximum time/temperature guidelines for certain alloys must be considered. (See CSA W59.2) Single pass welds should be used wherever possible. If multipass welds are necessary, the slag must be thoroughly removed by chipping or rotary wire brushing between passes. After the weld has been completed, all residual slag must be removed by steam cleaning or hot water rinse. In some cases, a wash with 5% nitric acid followed by thorough rinsing in hot water may be necessary. Atest to ensure full slag removal can be made by swabbing with 5% silver nitrate. Any remaining slag will cause foaming. ee ‘ Interrupting the arc will often result in a hard coating of fused slag forming over the end of the electrode. This must be removed before restriking the arc. To summarize for SMA Welding, it is essential to ensure that: {a) the electrode is dry, os (b) the base material is clean and dry, He (c) the base material is preheated, and (d) slag is fully removed between passes and from the finished weld. i 96ae ea ann Gooderham Centre for Industrial Learning 7 Because these electrodes are almost never used in critical applications, certification by the Canadian Welding Bureau is not normally required. 6.3. Gas Shielded Arc Welding Processes Gas shielded arc welding (Gas Metal Arc Welding, Gas Tungsten Arc Welding, Pulse Arc Welding, etc) of aluminum and its alloys has many advantages over the shielded metal arc process, First, and most important, it gives the highest quality welds, capable of meeting any normally recognized radiographic standards. Second, it is faster than SMAWY, and with the right equipment can give a much better economic return. Third, there is no flux covering, and so slag removal is no longer a problem. However, it still requires careful preparation for welding, and the arc must be protected to prevent loss of gas shielding. The classification of bare filler materials for GMAW, GTAW, PAW, and other similar processes is covered by AWS AS.10. Classification, as in the case for SMAW electrodes, is based on the Aluminum Association alloy designations. Because of higher demand, a wider range of classifications is available (Table 6.2). A significant drawback of SMAW is; no SXXX series electrodes. Therefore many 5XXX base materials cannot be welded with the SMAW process. 7Gooderham Centre for Industrial Learning Jaws oe ae i [clasaitcation| 4 _[ cu_| w fm | on 9st | 0.05 0020 = = 06 | oos | oo | oor | ao = oot 020 | 020 | satoss |oz0t040| coz | = 0.10 10029 ersoe | 5055 | 020 | 10.018 | 010 | ossos| =| eraoie | 65075 020 | 010 fosoteass| - = raat | 651076 020 10 [oaswor| - = eras | 45060 | 08 | 030 | 005 | 00s penne eraar _[s1ow130| 08 | 030 | ors | oro | caus _[osww7| 08 | asw47 | o1s | ors = erseax | setae | o8 | 010 | 005 |oso%030 018 ERSIS 0.40 | 0.10 [osowr0| 430052 015 lensase | 026 0.10 |o0swo20) 451055 0,06 to 0.20 Jenssse 025 0.10 | osotor0 ° 0.05 to 0.20 [0.10 471055 0.05 9 020 0.05, oot | artose [ox 0.05 19 0.15 | 421050 |o2.0s0[0150035| 0.15 00 | rors | o10 oawoe| - 020 _| 651075 | 020 | 020 | 010 |o2swoas =| 01 | 020 | a5075 | 015 lossiooe | - =| o05 | 020 | 51075 | 020 o19 [oswor| - = [010 ]o04 020] 6.4 Notes: 2) Singla values are maxima 1b) Other elements, not spectiad, shall be no more than 0.05, The sum of all other elements shalinot exceed 0.15. {©} Beryl content shall not exceed 0,0008%, 1d) The sum of Si+ Fe shallot exceed 0.05%. {e) The sum of Si+ Fe shall not exceed 0.45%. 1) Berylium content shall be 0.04 to 0.07%, 49) Vanadium content shall be 0.05% max. Gallium content shal be 0.03% max fh) Vanadium content aha be 0.05 to 0.16%. Zirconium content shall be 0.10 to 0.25%. ‘ Table 6.2: Chemical Composition Requirements for Aluminum and Aluminum Alloy GMAW Electrodes (Filler Metal) Selection and Use of Electrodes The selection of the correct electrode classification is dependent primarily on the aluminum alloy(s) to be joined, and the service conditions for the finished weldment. Secondly the welding process to be used, the joint preparation and the finish or appearance of the part. Experience 98Gooderham Centre for industrial Learning , has shown that certain classifications are best suited for specific base metals. These are shown in the well known Table 6.3. (Reproduced from AWS A5.10-92.) The cleanliness of the surface of the filler metal is very important, it is even more important than the cleanliness of the base metal, Small diameter wires used in GMAW are fed into the weld pool at high speeds. It is useful to remember that it takes almost a metre of 1.2mm diameter wire to make one cubic centimetre of weld metal, and the surface area of that wire is more than 30 square centimetres! It doesn't take much surface contamination on the wire to add up to a lot of trouble in the weld. It is for this reason that the Canadian Welding Bureau certifies aluminum and aluminum alloy welding wires by testing for the ability to give radiographically clear welds when tested in accordance with AWS AS. 10. Having first decided to use a certified electrode, the user must carefully consider the following: a) The crack sensitivity of the material b) The required strength of the weld c) The required weld metal and heat affected zone ductility d) Service temperature e) Corrosion environment and resistance f) Colour match in service and/or after anodizing 6.4.1 Crack Sensitivity Heat treatable alloys are more complex and more sensitive to hot short cracking than others. Often, a dissimilar filler metal having a lower melting temperature range and a similar or lower strength is used. Maybe an ER4043 or ER4145. This allows the low melting point constituents in the HAZ to solidify before the weld metal, thus reducing the tendency to intergranular cracking. Higher silicon (4XXX geries), or higher magnesium (5XXX series), content are generally easier to weld, being less crack sensitive. (However, high silicon filler metals should NOT be used to weld high magnesium alloys, as magnesium silicide eutectics are formed which reduce ductility and increase crack sensitivity.) 6.4.2 Strength The required weld metal mechanical properties can often be met by several filler metal classifications. Table 6.3 gives some typical values. However, admixture with the base metal may result in somewhat different values.eh ese re Gooderham Centre for Industrial Learning Welding heat treatable alloys may restrict the selection. In most cases, the filler metal used is not heat treatable. However, in some cases -for example, when welding thin (10 mm or less) 6061-T6 with ER4043- dilution of the weld metal will often introduce sufficient magnesium, and thus magnesium silicide, to allow response to heat treatment. 6.4.3 Ductility The 1XXX and 5XXX filler metal classifications produce the most ductile welds, and are preferred when the finished weldment requires further work, as in straightening operations, or forming or spinning operations. 6.4.4 Service temperature If service temperatures in excess of 650C are expected, filler metals containing more than about 3% Mg (5183, 5356, 5556, and 5854) should be avoided, as they are sensitized to stress corrosion cracking. This includes lengthy post weld heat treatments. All aluminum alloys are suitable for cryogenic applications. 6.4.5 Corrosion resistance Some vessels may require the use of purer aluminum alloys, such as 1188, for certain corrosive environments. The magnesium alloys are generally very resistant to corrosive media (except for the stress corrosion cracking situation at elevated temperatures) when used with base materials of similar content. However, they may be subject to preferential attack when used to join the XXX, 3XXX, and 6XXX alloy types. 6.4.6 Colour match ‘A good colour match between weld metal and base metal is often desired for ornamental and architectural applications, particularly if anodizing or similar finishes are applied. In such applications, silicon alloys of aluminum, will show gray or even black, depending on the silicon content. Chromium in the alloy can cause a yellowish colouration, so a weld metal should be chosen to match the Cr content of the base metal. Copper and manganese may promote a slight darkening Electrode classification 1188 is often a good choice for colour match with 1XXX alloys, as well as 3003, 5005 and 5050. ER5356 is good for welding 5XXX alloys. i 100Gooderham Centre for Industrial LearningGooderham Centre for Industrial Learning Jong SrLYAa PUE LYOVUa ‘CPOE 001142 ‘GEL 1US Auo ‘BupjOn S86 jnyivo 204 “sessac01d Bujon 22e popronys S86 of Ade FRR) SHA Ul SuogePUoUMCOeY (4 ‘soyuoe airjesedk} Do}eye POUIEINS 4) Dapuaunuodal Ure YEUSUA PUE OSSEYA ‘OSESUS CS1SHA rejau sy 0 eo}04> op yu Aes 9,c9 JoH0 auyezodus} PauTENE YB #40 soUieYD o} ansoche (es 40 Ysa) IER UI UERLOUIUN SE ANS “SUOUPUED SOAS (e {€9 SHEL OF SION 102ak fl ( ‘ « Gooderham Centre for Industrial Learning 7.0 Stainless and Heat Resisting Steel Electrodes For covered stainless steel electrodes, we use CSA Standard W48-01. As there are no specific Canadian standards for bare solid electrodes or for flux cored electrodes for stainless steel, we use AWS A5.9 Specification for Bare Stainless Steel Electrodes and Rods and AWS A5.22 ‘Specification for Stainless Stee! Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding respectively. Shielded Metal Arc Welding is widely used for welding stainless and heat resistant steels, but the faster, more economical GMAW and FCAW processes have established themselves in many areas. Doubtless, they will expand into many more. In all three standards, the classification is based on alloy type. However, there are differences inherent in the process involved, which is described below. 7.1 Classification Systems for Stainless Steel Electrodes 7.1.1 Shielded Metal Arc Electrodes Electrodes for the stainless steels are primarily classified according to alloy type. The process is identified by use of certain designators. For SMAW electrodes, flux coating and operating characteristics are part of the classification. A typical classification could be where the "E*, as. TE type © sone —_| positions of usability alloy type usual, denotes an electrode. The alloy type is “308°, which in this case is a nominally 18% Chromium, 8% Nickel alloy (see Table 7.1 for the chemical compositions of alloys listed in CSA W48-01). The “1” indicates that the electrode can be used in all positions (although usually only progression upwards in the vertical position) and the “6” defines an acid (or rutile based) flux coating. Electrodes designed for use in the flat groove and horizontal fillet positions would use “2” for the positional indicator. An electrode with a basic flux would be indicated with a “5”, as in E308-15 or E308-25. A third flux type is defined with a “7”. This denotes an acid flux with a significant amount of silica, which makes the slag more fluid. 103Gooderham Centre for Industrial Learning 7.1.2 Solid Wire Electrodes For solid wire electrodes and rods, suitable for GMAW, GTAW, PAW and similar processes, the classification for the 308 type is simply: ER308 The ER indicates the solid wire is suitable for use both as an electrode and a filler rod. 7.1.3. Flux Cored Arc Welding Electrodes Classification for FCAW cored electrodes is a little more complicated. For the 308 alloy type, we might have E 308 “E” olectrode | alloy type The student will easily recognize the first four characters as indicating an electrode of alloy type 308. The “T” indicates a continuous tubular, or flux cored, wire, and the "1" indicates that the electrode is suitable for welding in all positions (although vertical position, downwards progression, is not necessarily possible). If welding is not possible in all positions, the designator would be a “0” to indicate flat groove and horizontal fillets only. The final character, afier the dash, indicates the gas shielding. A “1”, as in the example, denotes 100% CO, shielding gas. A*3” indicates that no gas shielding is required. A “4” is used for electrodes that use a 75 to 80% Argon, balance CO,, shielding gas. There is another possible gas shield designator, “5”, to indicate a pure argon shielding gas for those wires that can be used as a rod for GTAW. These are shown as (for example) R308T1-5. LE position of capability “T" continuous tubular of flux cored ‘ ‘ i t fi ‘ ‘ ‘teen Gooderham Centre for Industrial Learning Students may be curious about the absence of a "2" as a shield gas designator. In AWS A5.22- 80, and previous editions, the “2” was used to indicate a shielding gas of argon plus 2% O2. The AWS Committee responsible for stainless steel electrode specifications found that this shielding gas was not appropriate for flux cored arc welding of stainless steels, and so deleted it from the classification system. However, it was decided that using this designator in another context would cause unnecessary confusion for those still using the old versions of A5.22, and so its use was discontinued in the 1995 version of the specification. 7.2, Chemi Composition Chemical compositions for covered stainless steel electrodes are given in Table 7.1. The chemical analysis of equivalent solid wire electrodes for gas shielded arc processes are very similar, although a small addition is made for chromium and manganese to compensate for losses across the arc. The chemical analysis for FCAW electrode deposits are similar, if not identical, to those for SMAW. Complete tables of chemical analysis requirements for these processes are therefore not necessary here. However, an idea of comparative values for the different processes is given in Table 7.2 for alloy types 308L, 316L and 347. Amore extensive explanation of the welding of stainless steels is given in Module 22. 105Gooderham Centre for Industrial Learning 19010215) 0107 aatea7s | 100 | 004 | 003 120210 sowsi0| 08 =| osw2s | 100 sa000 = _|.05128 | 100 10| e010 1010210] 20.180 012 _|22010250| 200140 004 _|2200280| 06149 [1010710] 90% 110 003 z200250| 2040 03 |z20250| 1 003 72010250 | 120% 40| 0525 90810020 |7010200| 200228 | os =| 0025 29610045 |25.010280| 200228 | os 12 |250m20| 200225 | os | o7w10 | rowes _[ sows. 25010200| 20025 =| so2s 200320] 300108 098 _| 12910200) 510185 1o0_| 008 | 00s 904} 1710200 so0_| oo | 00s] oo _| 003 200140 004 | 17010200] 110% 140 ext | oor | s9010210[ 20.080 osie2s | oo | oo | 009 e220 |o1810025| 1401170] s30ws70| 08 = 03510045 | 16910 17.0 | 38010370 oct |ieowaro}sowno|! os | axcw | osw2s | 100 | oo | os 013 |se0t0210] 201190 |ossio0es| 07512 | oss | 1.00 oo me aos @ © © @ © o @ 3) Single values are maxima Copper is 0.7% maximum, unless otherwise specified. Carbon shall be reported to the nearest 0.01%, ‘Niobium i sometimes refered to as Cotumbian (Cb) ‘Nitorgen shal be 0.1 to 0.30 Copper shall be 3.0 f0 4.0 “Tungsten shall be 1.250 1.75 Copper shall be 3.25 to 4.0, Table 7,1: Chemical Composition Requirements for Chromium and Chromium-Nickel SMAW Electrodes 106Gooderham Centre for Industrial Learning maaan anh © cr Ni 120102101 9010110 | os | o5to25 4 = __ERIOBL. 18510220] 9010110 191025 |os0t0es | _— EQ08LT1-4 0.04 | 18010210 sots10 | 05t025 | 4 17010200 | 11.0140 | 201030 | 051025 4 . 16010200 | 11010140 | 201030 | 101028 |osooss| — FoAW 17010200 | 11010140 | 201030 | os25 | 1 a sMAW te0%0210| 90110 | 05 | 051025 1 8xCmin. ~ 101.0 max, R347 ‘omaw 1900215] sotto | 075 | 101025 | o0t065| exc min oe a 01.0 max. goats | FCAW 008 | 180t215| sowt10 | 05 | osm2s 1 8x min, - . _ 01.0 max, Notes: (2) Single values are maxima. (©) high version is available for many solid wires, to promote fluidity in the weld pool ‘Such alloys typically have 0.65 - 1.00% Si, and are identified with the suffix Si, as in ERSOBLSi Table 7.2: Comparison Chemical Composition Requirements for Covered (SMAW), Bare Wire (GMAW and Flux ored (FCAW) Electrodes for Selected Stainless Steels (Major Elements Only) 107Gooderham Centre for Industrial Learning Recommended Reading The CSA Standard W48-01 and the series of AWS AS Specifications contain much useful information, particularly in the Appendices, and are highly recommended. ‘The Welding Handbook, Volumes 1 through 4, published by the American Welding Society, is. also recommended for a more in-depth treatment. Each chapter contains a bibliography that can lead the student to the very latest information. These volumes are published every second year, approximately. CSA W48-01 Standard Covers the following welding consumables: Carbon Steel Covered Electrodes for Shielded Metal Arc Welding Chromium and Chromium-Nickel Steel Covered Electrodes for ‘Shielded Metal Arc Welding Low Alloy Stee! Covered Electrodes for Shielded Metal Arc Welding Solid Carbon Steel Filler Metals for Gas Shielded Arc Welding Carbon Steel Electrodes for Flux- and Metal-Cored Arc Welding Fluxes and carbon Steel Electrodes for Submerged Arc Welding Comment: The CSA Standard W48-01 published in March 2001 consolidates and supersedes the previous W48 series of Standards comprising W48.1 to W48.6. The new CSA Standard W48-01 contains several technical changes including those intended to harmonize with other regional and intemational standards. During preparation, close liason was maintained between the American Welding Society (AWS), the International Institute of Welding (IIW) and International Organization for Standardization (ISO), The Technical Committee was also in contact with other organizations, such as the European Committee for Standardization (CEN) and the Japan Welding Engineering Society (JWES). 108 t ‘ fi ti ‘ fl c ( r cGooderham Centre for Industrial Learning AWS Filler Metal Related Documents FMC AAD AB A501 ASA AS A583 54 ASS ASB AST ASB AS AS.10 AS. AS.A2 A513 AS.14 ASS ASB 8.17 A548 A819 5.20 A524 A522 A823 A524 A825 A526 A827 A528 5.30 A531 Filler Metal Comparison Charts Standard procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic Stee! Weld Metal ‘Standard Method for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferrtic Steel Weld Metal Produced by Arc Welding Filler Metal Procurement Guidelines ‘Specification for Carbon Stee! Covered Arc Welding Electrodes ‘Specification for Carbon and Low Alloy Stee! Rods for Oxy-Fuel Gas Welding ‘Specification for Aluminum and Aluminum Alloy Electrodes for Shielded Metal Are Welding ‘Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding ‘Specification for Low-Alloy Steei Electrodes for Shielded Metal Arc Welding ‘Specification for Covered Copper and Copper Alloy Arc Welding Electrodes ‘Specification for Copper and Copper Alloy Bare Welding Rods and Electrodes ‘Specification for Filler Metals for Brazing Specification for Bare Stainless Steel Welding Electrodes and Rods Specification for Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods ‘Specification for Nickel and Nickel-Alloy Welding Electrodes for Shielded Metal Arc Welding Specification for Tungsten Arc Welding Electrodes Specification for Solid Surfacing Welding Rods and Electrodes ‘Specification for Nickel and Nickel Alloy Bare Welding Electrodes and Rods Specification for Welding Rods and Covered Electrodes for Welding Cast Iron Specification for Titanium and Titanium Alloy Welding Electrodes and Rods Specification for Carbon Stee! Electrodes and Fluxes for ‘Submerged Arc Welding Specification for Carbon Stee! Filler Metals for Gas Shielded Arc Welding Specification for Magnesium Alloy Welding Rods and Bare Electrodes ‘Specification for Carbon Steel Electrodes for Flux Cored Arc Welding Specification for Composite Surfacing Welding Rods and Electrodes Specification for Flux-Cored Corrosion-Resisting Chromium and Chromium Nickel Stee! Electrodes Speotfication for Bare Low-Alloy Stee! Electrodes and Fluxes for Submerged ‘Arc Welding ‘Specification for Zirconium and Zirconium Alloy Welding Electrodes and Rods ‘Specification for Carbon and Low Alloy Steel Electrodes and Fluxes for Electrosiag Welding ‘Specification for Carbon and Low Alloy Stee! Electrodes for Electrogas Welding ‘Spectfication for Copper and Copper Alloy Gas Rods for Oxyfuel Gas Welding ‘Specification for Low Alloy Filler Metals for gas Shielded Arc Welding ‘Specification for Consumable Inserts ‘Specification for Welding Shielding Gases 109Gooderham Centre for Industrial Learning GUIDES AND EXERCISES MODULE 6 ELECTRODES AND CONSUMABLES To obtain maximum benefit from this module, we suggest that you follow this guide and complete the exercises as indicated. It is important that you work through the text methodically, studying each section thoroughly before moving on. The exercises are designed to give you an indication whether you have learned the material and can move on or whether you need to go back and study the section again. Do the exercises honestly. They will not help you unless you take them seriously. If you get a question wrong, go back through the text until you understand where you have gone wrong and know the correct answer. The length of time required to complete the module will vary from student to student. Find your own pace. Do not rush. Remember you are trying to teach yourself something, not win a race. Some people like to underline sections when they read a text. We suggest that you use caution when you do this. What you think is important first time you read it may be different after reading it three times. We suggest you read a section three times thoroughly before highlighting anything. The last exercise is designed to give you an indication of whether you are ready to take the GCIL closed book examination. The exercise questions are similar to the official examination. Do not take the examination until you feel you are ready and you may wish to study several Modules before taking the examination for each. If you have difficulty with this module, do not hesitate to ask for help by contacting the Gooderham Centre for industrial Learning at 905-542-2176. ‘ 110Gooderham Centre for Industrial Learning sh-h aoc Module 6 Electrodes and Consumables Guide 4 Carefully read Section 1 and answer the following questions: 1. Today, most mild steel electrodes have a wire core composed of: (a) rimmed stee! (b) semi-killed steel (c) fully killed steel (d) cold-rolled ste! 2. In medium coated electrodes, the percentage of the electrode weight derived from the coating is: (a) 10-25% (b) 20-35% (c) 25-40% (d) 25-55% 3. Which of the following is not a main function of slag? (a) _ to slow the critical cooling rate of the weld (b) to protect the weld metal from contamination (c) to reduce the amount of oxygen and other impurities in the weld (d) to control the bead shape and smoothness 4, Which of the following electrodes is to be used with DC, electrode positive current only? (a) £4313 (b) E4910 () £4918 (d) €4924 41