1S 814 : 2004 oredr aTTe Bee ag are aes & fy ong Hrd aie ards Arie gear geagts — Papa ( wor Greer ) Indian Standard COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL — SPECIFICATION (Sixth Revision ) ICS 25.160:20;77 080.20 © BIS 2004 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHT 110002 ‘September 2004 Price Group 9‘Welding General Sectional Committee, MTD 11 FOREWORD This Indian Standard (Sixth Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by the Welding Generat Sectional Committee had been approved by the Metallurgical Engineeting Division Council This standard was first published in 1957 and subsequently revised in 1963, 1967, 1970, 1974 and 1991. While reviewing the standard in the ight of experience gained during these years, the Committee decided to revise it to bring it in line with the present practices being followed by the Indian and overseas industry. In this revision, the following changes have been made: 2) Semibasic type of covering has been included 'b) Chemical analysis of basic and semibasic classification has been provided ©) Percentage elongation for ‘O" designating digit has been included, Tn the formulation ofthis standard due weightage has been given to international co-ordination among the standards, prevailing indifferent countries in addition to relating itt the practices in the field inthis country. This has been. met by deriving assistance from the following publications: 4) 1802560: 1973 Covered electrodes for manual are welding of mild stel and low alloy steel— Code of symbols for identification ') BS 639: 1986 Covered carbon and carbon manganese stel electrodes for manual metal arc welding ©) ANSVAWSA 5.1-1991 Covered carbon steel arc welding electrodes — Specification In reporting the results of'a test or analysis, made in accordance with this standard, if the final value, observed or calculated, is to be rounded off, it shall be done in accordance with IS 2: 1960 “Rules for rounding off numerical values (révised)”1S 814: 2004 Indian Standard COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL — SPECIFICATION (Sixth Revision ) 1 SCOPE 18 No Tile ‘This standard specifies the requirements for covered 1608: 1995 Mechanical testing of metals — carbon and carbon manganese steel electrodes for Tensile testing (second revision) carbon and carbon manganese steel, including 1757:1988 Method for charpy impact test hydrogen controlled electrodes for manual metal are (V-notch) for metallic materials ‘welding of mild and medium tensile steels including (second revision) structural steels, depositing weld metalhaving tensile — 1977: 1996 Low tensile structural steel (third strength not more than 610 MPa revision) Electrodes designed specifically for repair welding, 2002: 1992 _Steel plates for pressure vessels for often marketed in India 2s "low heat input” electrodes intermediate and high temperature are not covered inthis standard service including boilers (second revision) ni ectrodes are being used fairly widel ine ae es eu Way 38 Storr scan pups use ilmenite as an ingredient of the covering in our (fh revision) country also, Provision for a separate class for such 2879: 1998 Mild steel for metal are welding electrode may be considered ata later stage electrodes (third revision) NOTE — For weld metal with onlestength higher stan 3039: 1988 Structural steel for construction of 510.6 ference maybe made ofS 1395 hulls of ship (second revision) 2 REFERENCES 8500: 1991 Structural steel-—Micro-atloyed z ; {medium andhigh strength qualities) ‘The following standards contain provisions which = Specification (frst revision) through reference in this text constitute provision of : 7 this standard. tthe time of publication, the editions 1801986 Misshod fel. Hetermination. of indicated were valid. All standards are subject to Nace ude taetal fone ed revision and parties to agreements based on these “i rpraapabry electrodes in welding mild and low standards are encouraged to investigate the possibility alloy stels ‘of applying the most recent editions of the standards indiated below. 13043: 1991 Covered manual metal arc welding electrodes — Determination of ea ae efficiency, metal recovery and 812: 1957 Glossary oftermsrelating to welding deposition coefficient and cutting of metals 13851: 1993 Storage and redrying of covered 1182: 1983 Recommended practice for electrodes before use — radiographic examination of fusion Recommendations welded butt joints in steel plates 3 7pRMINOLOGY (second revision) 1387; 1993 General requirements forthe supply Fer the purpose ofthis standard, the definitions given ‘of metallurgical materials (second i" 18 812 and the following definitions shall apply revision) 3.1 Weld Slope — It is the angle formed between the 1395:1982 _Lowandmediumalloy steelcovered lines of the weld root and a horizontal reference plane electrodes for manual metal arc Slope may be measured cither clockwise or welding (third revision) anticlockwise and either above or below the horizontal 1599: 1985 Method for bend test (second Plane between O° and 90: revision) 32 Weld Rotation — The rotation of weld is the angleIs 814: 2004 formed between upper portion of vertical reference plane passing through the weld root and a point on the face of weld equidistant from both the edges of weld Rotation may be measured either clockwise or anticlockwise between 0° and 180° 33 Weld Position — The welding position is given by the combination of weld slope and weld rotation (ee 55.1) 4.SUPPLY OF MATERIALS Genetal requirements relating to the supply of covered electrodes for metal arc welding shall be as laid down in IS 1387 5 CLASSIFICATION 511 Coding Classification of electrodes shall be indicated by the coding system of letters and numerals as given in $ 1-tand $.1.2 to indicate the specified properties ot characteristics of the electrodes. SALA Main Coding 11 consists of the following letters and aumerals and shall be followed in the order stated: a) A prefix letter ‘E* shall indicate a covered electrode for manual metal arc welding, ‘manufactured by extrusion process; 'b) A letter indicates the type of covering (see $2); ©) first digit indicates ultimate tensile strength in combination with the yield stress of the weld metal deposited (see 53); 6) Second digit indicates percentage elongation in combination with the impact values ofthe weld metal deposited (see 54); ©) Third digit indicates welding position(s) in which the electrodes may be used (see 5.5) and; 4) Fourth digit indicates the current conditions in Which the electrode isto be used (see 5.6) 5.1.2 Additional Coding The folowing letters indicating th additional properties of the electrodes may be used, if required: 2) Letters HI, H2 and H3 indicating hydrogen controlted electrodes (see 8.7): b) Letters J, K and L indicating increased metal recovery, as effective electrode; “Efficiency (EE)’ as per IS 13043 in the following range (see 5:8) J = 110-129 percent; K = 130-149 percent; and L = 150 percent and above ©) Letter ‘X” indicating the radiographic quality (see 59) ~ Examples illustaing for establishing electrodes ing fom the intial test results have boon given in ‘annex A 5.2 Type of Covering Type of covering shall be indicated by the following letters: A. = Acid B ~ Basic C= Cellulosic R ~ Rut RR ~ Rutile, heavy coated SB ~ Semibasic NOTE — The charatevistes ofeach typeof he covering and ‘coating ratio ae deszrited in Annex 8 for guidance only, 53 Strength Characteristics The combination of uhimaze tensile strength and yield strength of the weld metal deposited shall be indicated by the digit 4 and 5 (see Table 1) Table 1 Designation of Strength Characteristics Designating Uiinate Teas Digit Strength MPa a) @ @ ‘4 10-540 330 5 510-610 400 5.4 Elongation and Impact Properties The combination of percentage elongation and impact Properties ofthe weld metal deposited forthe twotensile ranges (see Table 1) shail be as given in Table 2. 58 Welding Position The welding position or positions in which the electrode can be used as recommended by the manufacturer shall ‘be indicated by the appropriate designating digits as follows 8) All positions; b) All positions except vertical down; ©) Flat butt weld, flat fillet weld and horizontal’ vertical fillet weld; 4) Flat but weld and flat fillet welds ©) Vertical down, flat butt, flat fillet and horizontal and vertical fillet weld; and ) Any other position or combination of posi not classified above, 5.5.1 Welding positions in detail have been described in Amex C. ‘5.5.2. Wherean electrode is codedas suitable for verticaland overhead positions, it may be considered that sizes larger than 4 mm are not normally used for welding in these positions, 5.53 Anelectrode shall not be coded as suitable for a particular welding position unless itis possible to use it satisfactorily in the position to comply with test requirements of this standard, IS 814: 2004 ‘56 Welding Current and Voltage Conditions ‘The welding currentand open circuit voltage conditions on which the electrodes can be operated as recommended by the manufacturer shall be indicated by the appropriate designation digits as given in Table 3. Welding current and voltage conditions have been described in Annex D. ‘Table 2. Combination of Percentage Elongation and Impact Strength ‘(Clauses 5.4 and 8:3; and Table 9) Designating Digit Percentage Elongation on Timpact Strength Gauge Length 5.6518, Min IPC, Min o @ ® For Tensile Range 410-510 MPa ° 6 ‘No impact requirements ‘ ey aac 2 2 see 3 2m nyavc 4 ™ 27-30, For Tensile Range 510-610 MPa ° 6 [No impact requirements 1 8 TIC 2 is amor 3 20 aye ‘ » 2730 s 2» 27-40 6 20 2y46C NOTE — UG Is the cross-sectional area of test pice Table3 Welding Current and Voltage Conditions (Clause 5.6; and Table 10) Designatig Digit Direct Current Recommended “Alternating Current i Hlectrode Polarity? Open Cireuit Voltage Vain o @ o o + ‘Not recommended ' tor 30 2 - 0 3 + 0 ‘ tor n s - n 6 + n 1 tor cy 8 - 90 9 + 0 frequency ofthe sltemating curent i atsumed to be $0 or 60 Hz. The necessary open circuit voltage when elecrodes are wed on direct current is closely related t dynamic characteristics of the welding power source Consequently no Indication of the rminizwm open cieuit voltege for dret curent is given ° Positive polarity (+) Negative polarity)IS 814: 2004 5.7 Hydrogen Controlled Electrodes The letters HI, H2 and H3 shall be included in the classification as a suffix for those electrodes which will give diffusible hydrogen in ml/100 g when determined in accordance with IS 11802 as given below: HI = Upto 15 ml diffusible hydrogen 112 Up to 10 ml diffusible hydrogen H3 = Up to 5 ml diffusible hydrogen NOTE —For 83, slyoetin method shall not be wed 5.8 Increased Metal Recovery The letters J, K and L shall be included in the classification asa suffix for those electrodes which have appreciable quantities of metal powder in their coating and give increased metal recovery with respect to that of core wire melted in accordance with the range given in S.1.2(0) ‘The metal recovery shall be determined as effective electrode efficiency (FE as per the method given in Is 13043), 5.9 Radiographic Quality Electrodes ‘The letter “X’ shall be included in the classification as «suffix for those electrodes which deposit radiographic quality welds (see 9.6) 6 CORE WIRE FOR ELECTRODES The core wire used for the manufacture of electrodes shall conform to TS 2879 ‘7 DIMENSIONS AND TOLERANCES 7.41 Size and Length The size of an electrode shall be designated by the nominal diameter of the core wire expressed in millimetres. Sizes of electrode and corresponding lengths of electrodes shell be as given in Table 4 7.11 The tolerance on the specified diameter of core ‘wire shall be 0.05 mm. The tolerance on the specified length of electrode shall be 43 mm. 7.1.2 Sizes and lengths of electrode other than those mentioned in Table 4 may be supplied subject to ‘mutual agreement between the manufacturer and the purchaser. The tolerance in such cases shall be agreed. to between the manufacturer and the purchaser. 72 Bare Length 72.1 Contact End The contact end ofthe electrode shall be clean and free fiom coveriig for enabling it to be gripped by the clectrode's holder as specified belo Electrode Size ‘Bare Length Minimum Maximum mn mom mn 16t0315 5 30 4.01080 20 40 7.2.2 Are Siriking End The are striking end of the electrode shall be bare and permits easy striking of the arc. The distance from the arc end to the first point where the full cross-section of provails shall not exceed the following For all classifications —1/2 core wire diameter or 2.0mm, whichever isless Table 4 Sizes and Lengths of Electrode (Clauses 1.1 and 7.12) Sie Length © a 16 150.0200 6250, 20 200 oF 250 or 300 or 350 25 250 0¢ 300 or 350 ais 3500r480 40 350.0" 450 50 350 0r450 63 3500r450 80 35007450 7.3 Concentricity of Flux Covering with Core Wire---Tolerance The flux covering on the electrode shall be uniform ‘and concentric with the core wire. The tolerance for concentricity ofthe covering (see Fig. 1) shall be such that the maximum core pls one covering dimension shall not exceed the minimum core plus one covering, dimension by more than: 48) 5 percent of the mean of two dimensions for EBXXXX and ESBXXXX class electrodes, ) 4 percent of the mean of two dimensions for ERXXXX, ERRXXXX and EAXXXX class electrodes, and ©) 3 percent of the mean of two dimensions for ECXXXX class electrodes, 7.4 Core wire and coverings shall be free from defects which would interfere with the uniform welding performance of the electrode.ae WIRE “FLUX COVERING B Ad All dimensions in iimetres. Fig. 1 Peawissinir TOuRRANces For Fux Covering ‘A = maximum cote plus one covering cimoneion, and B= minimum core plus one covering dimension 5 Ate An8 ae x SS? tor EBXXXX and ESBXXXX class elactrodos ERXXXX, ERRXXOX and EANKXX class electrodes 8, AO, anes ox SS ECXXXX class olectrodes & TESTS FOR ELECTRODE PROPERTIES 8.1 General Slectrode shall be subjected to the following tests for assessing the mechanical properties of the deposited ‘weld metal and the usability of an electrode for a Is 814: 2004 particular welding postion: 8) Initial tests, ») Periodic tests, and ©) Quality contol tests, 8.1.1 An electrode suitable for oper: shall be tested on ac onac.orde 8.1.2 When an electrode of particular nominal size is ‘manufactured in more than one lengths, the electrode used for the tests shall be longest manufactured. 8.1.3 The parent metal used for test plates shall conform to the requirements specified in Annex E. 82 Chemical Analysis ‘The sample for analysis shall be taken from weld metal obtained withthe electrode, The result of the analysis, shall meet the requirements of Table 5. 83 Initial Tests These are qualifying or proving tests for each type or modified type of electrodes and shall comprise the following: a) All weld metal mechanical tests as given in Table 2 (see als0 9.1); 'b) Butt weld bend test (see 9.23; ©) Running performance test (for sizes up to and including 2.5 mma) (see 9.3); 4) Increased metal recovery tests for electrode claiming recovery 110 percent and above (see 9.4); ©) Diffusible hydrogen estimation test for hydrogen. controlled electrodes (see 9.5); and ) Radiographic quality test for radiographic (quality electrodes (see 9.6) 8.4 Periodic Check Tests ‘These comprise of the following tests selected from ‘Table 5 Chemical Composition — Requirements for Weld Metal (Clause 82) Chassineation ‘Weight, Percent, Mas ‘Combined Limit for as oe PAL LEE MatNieCrsstor¥ : sie Mo Me i: EAXXXX, Not specified EXO & ERX ea ERRXXXX eo EBXXXX 012 16 075 0035-0035 030 020 030k 195 ESBXNXX, Samo #8 EBXXXK1S 814: 2004 among the initial tests (see 8.2) and are meant to be repeated at intervals to provide evidence that the electrodes currently produced possess the properties proved inthe initial tests: 2) All weld metal mechanical tests for tensile or impact (see 9.1); and ') Running performance test (for sizes up to and including 2.5 mm) (see 9.3) Such tests shall be conducted at least once in a year. These tests shall not apply to the electrodes not ‘manufactured during the year. When production of a particular type of electrode after stoppage of production for more than six months is restored, the periodic tests, shall be conducted, 85 Quality Control Tests By means of suitable system of control, the ‘manufacturer shall satisty himself that the composition and quality ofall the electrodes currently produced are similar to those electrodes which were subjected to I tests. He shall ensure thatthe result of quality contol tests and date of manufacture of electrodes is ‘waced from the batch number ofthe relevant details, ot both Notes 1 For the purpose of his standard, a batch is defined as aot ot covered electrodes of any one siz and clasiiation produced tom eoaing dented bya dy mat oF more than {ne dry micofconoled ceria eomposiion and core wie identified by a heat number or controlled chemical samposion 2 Ideieation of lesrode core wie: 48) Solid core wire for manufacture of electrodes ‘denied by heat number shall consist of materi fom a single heat of met 18) Solid. core wire identfed by contled chem Composition rahe han by heat rmber, sal cos il cols fone armor ea fom which sales have Been ake for comical analysis. The ess of ‘hans must be within the composition Timi 8 specie in 2879 3 Hntiicaon of covering mi 1 A dy mii the quantity of dry coating ingredients of wet mixes in using & ®) Covering idemified by 2 dy mix shall consist of leeuode produced from a single dry mix of couting Ingredients 12) Covering identified by controlled eompesiton rather than by dry mix shall consist of one oc more dey mixes and hal be eubjctd osuicientest to assure hat Al dy mixes within the ltare equivalent These tests ‘Shall include chemial analysis of the weld metal, the results of which must fll widin the manufactres ‘acceptance Limits The identification of the test procedure and dhe test els shall be recorded 8.5.1 Themanufacturer on request shall make available to the approving and certifying authorities the records, rmaintainet for quality control, for ensuring that the ‘composition and quality ofa the electrodes currently ‘produced ate similar to those electrodes subjected to initial and periodic check tests 8.6 Ac ditional Tests Subject to agreement with the manufacturer, the purchaser may request for additional tests to be made ‘or catifcates tobe provided for each batch of electrodes supplied If so, the tests and batch definition shall be agreed between the manufacturer and the purchaser. 9 DETAIL OF TESTS 9.1 All Weld Metal Mechanical Tests for Tensileand Impact 911 Weld Assembly Two all weld test assemblies shall be prepared, one using 4.0 mm and the other using the highest size ‘manufactured in accordance with the method described in Annex F_If the highest size produced by any ‘manufacturer is 4.0 mm, then two weld test assemblies using 4,0 and 3.15 mm size respectively shall be prepared, [NOTE — In case 3.15 mm isthe highest size manufactured, only one weld test assembly shall be prepared with ths size 9.1.2 All Weld Tensile Tests ‘Two all weld tensile test specimens, one from each of the assemblies as given in 9.1.1, shalt be prepared and tested in accordance with the method described in ‘Annex F, The ultimate tensile strength and yield stress shall comply with the values given in Table 6. When particular ductile properties are claimed or specified, the minimum percentage elongation shall comply with the appropriate value given in Table 6. [NOTE —Theall weld tens tstis for ual contol purpose only. Ts not intended to imply thet values obtained inal ‘weld tet should be used for design purposes, 9.1.3 All Weld Impact Tests Five charpy V-notch impact test specimens shall be ‘machined from the same test assembly and tested in accordance with the method described in Annex F at the temperature specified in Table 6 and shall comply with the values given in Table 6 at specified temperature. The results of the impact test from five test specimens shall be assessed as specified in 91.3.1, 91.32 and 9.1.33. 9.13.1 When computing the average values of the impact properties from the set of five specimens, the lowest value and the highest value obtained shall be disregarded. 9.1.32 For classification EXXIXX, EXX2XX and EXX3XX, two of the three remaining values shall be sreater than the specified 47 joules; one of the three ‘Values may be lower but shall not be less than 41 joules