SHRI G.

S INSTITUTE OF TECHNOLOGY AND SCIENCE

WELDING ELECTRODES

GUIDED BY :- PRESENTED BY :-
Mr. SHAILENDRA PUROHIT ANKUR PATNI
Mr.AJAY SHEKHAR BHARULAL AHIR
JUGAL KISHOR PATIDAR
SATISH BANSIYA
 D&H PROFILE
 D&H Sécheron Electrodes Pvt. Ltd, a
privately owned company, is in the
welding industry field since 1966.
 D&H Sécheron Electrodes Pvt. Ltd is
specialized in the manufacturing of
Welding Consumables such as Welding
Electrodes, MIG Welding Wires, Flux Cored
Wires and Gas Welding Rods. Through
their sales network, they cover a record
70% of the local market .
 WHAT IS ELECTRODE

The electrode may be defined as “it is metal of

which the sole purpose to carry the current and
sustain the electric arc between its tip and base
metal as well as in some cases it melts and
supplies filler metal addition in the proposed
joint.”
ELECTRODE
Electrode can be divided into two groups
depending upon their functions which are given
below.
COSUMABLE NON CONSUMABLE
 ELECTRODES TYPES
ELECTRODE

BASED UPON MATERIALS BASED UPON COATING

 BASED UPON MATERIAL
1.mild steel electrodes
2.low alloy steel electrodes
3.stainless steel electrodes
4.electrodes for cast iron
5.copper and copper alloy electrode
6.nickel and nickel alloy electrode
7.aluminium and aluminium alloy
electrode
 BASED ON COATING
 Cellulose type
 Rutile type
 Acid type
 Oxidizing type
 Basic type
 CELLULOSE TYPE
 The cellulose is a organic material which
contain 30 % in the electrode coating by weight.
It decomposes in the arc and produce a gas
shield which protects arc from atmospheric
oxygen and nitrogen.
 Electrodes which have cellulose content impart
deep penetration & increased electrode burn off
rate.
 RUTILE TYPE
 Rutile (titania) electrode give a smooth &
quiet arc, negligible spatter, & easily
removable slag. The electrode will work on
both AC & DC. Generally use for vertical
and overhead positions.
 ACID TYPE
This type of coating contain iron-oxide as
a major constituent. During welding it
produce a iron-manganese oxide –silica
fluid slag whose metallurgical effect is
acidic. This slag solidifies like honey-
combstructure and easily detached.
 OXIDIZING TYPE

 It contain mainly iron-oxide and silicates

with or with out manganese oxides. it
produce a heavy slag which has oxidizing
properties.
 This type electrode is limited in use
because the resultant weld metal is soft
and low mechanical properties.
 BASIC TYPE
 This type of coating contains calcium
carbonates (CaCo3), calcium fluoride
(CaF2) & metal powder .
 This results in a chemically basic slag,
which is fairly fluid.
 The electrodes having this type of coating
is preferred to use for minimize the risk of
hydrogen-induced cracking or cold
cracking in the base metal.
 TYPE OF COATING

 Coating factor =Dia. of the electrode/dia. of

core wire

 Lightly coated electrodes: Electrodes with a

coating factor approx 1.25 .
 Medium coated electrodes: Electrodes with a
coating factor about1.45.
 Heavily coated electrodes: The coating factor
is between 1.6&2.2.
 NOMENCLATURE(AWS)
 EXXXX first two numbers refer to
tensile strength of the deposited weld
metal.
for example : E6010
“60” means 60, 000 psi tensile strength
of the deposited weld metal.
EXX XX third number is denoting the
position in which the electrode can be
used.
example:
“1” for all position (f, v, oh,h)
“2” for flat and h-fillet position.
“3” for flat only.
 EXXXX last number refers to chemical
composition present in the electrode
coating. for example :
 “0” cellulose- sodium
 “1” cellulose- potassium
 “2” rutile –sodium
 “3” rutile – potassium
 “4” rutile iron powder
 “5,6,8” low hydrogen
 Manufacture of electrode

1. Wires of different composition are

obtained.
2. Cut wire into different
lengths(300,350, 450 mm etc.)
3. Flux coating ->
 Dipping method
 Extrusion method
 DRYING OF ELECTRODE

All electrodes must be

dried to the right level to
perform properly. Even a
small amount of moisture
in electrodes can lead to
major weld problems such
as internal porosity, weld
cracking or poor operating
characteristics.

17
 Selection of electrodes
1. Chemical composition of base metal
2. Thickness of work piece
3. Nature of the electrode coating
(cellulose, rutile ,low hydrogen etc)
4. Position(flat ,horizontal ,vertical
,overhead)
5. Type of joint(lap ,butt ,fillet ,etc.)
6. Type of power source(AC and DC)
7. Type of polarity(DCSP ,DCRP)
 Selection of electrodes

8. Weld bead geometry and shape of the

weld bead surface.
9. Amount of weld metal to be deposited
and deposition efficiency of electrode.
10. Surface finish and quality of the weld
metal.
11. Mechanical and other properties in the
welded joint.
12. Cost of electrode.
 Manganese(Mn)

 1. Atomic weight =54.9

2. Melting point is 1242 C˚
3. Manganese is used as a deoxidizer in steel
4. Manganese increases the hardenability of steel
5. It prevent the formation of iron sulphide which

causes hot cracking difficulties

6.In carbon steel 1.5% Mn
7.Above 1.5% Mn in steel is low alloy steel
8.About 2.5% mn is found in only high-aloy steel
 Silicon(Si)
1.Atomic weight is 28
2.Melting point is 1426 C˚
3.It lower the δ-γ transformation and raise the γ-α
transformation in iron alloy, so it is called the ferrite
forming element
4.It is deoxidizer element and use to control the oxygen
content
5.Improve hardenability, mechanical property
 Phosphorus(P)
1.Atomic weight 31 and melting point is 43.89 C˚
2.Regarded as impurity due to tendency to segregate
3.Phosphorus has mild beneficial effect on the
properties of some steel
4. It is added in amount up to 0.10 % to improve the
strength and corrosion resistance of low-alloy high-
strength steel. Similar amount help the machineability
of many steel
 Sulfur(S)

1.Atomic weight is 32 and melting

point is 118.89 C˚
2.Soluble in molten iron , but due to low boiling
point can not be held in large quantities.
3.Alloying addition of 0.10% to 0.30% improve
machining properties of steel
4.Sulfur present in material causes short pieces
of chips during machining of parts.
 Molybdenum(Mo)

1.Atomic weight 96 and melting point is 2620

C˚
2.It is stronger ferrite former
3.In steel strong tendency to form carbide and
improve hardenability
4. 0.25 to 0.30% are adequate to secure high
hardenability
5.Mo in alloying steel 0.5 to 1.5% is often
added to improve strength and creep
resistence
 Testing of electrode

 Tension test
 Bend test
 Radiography test
 Chemical analysis
 Radiography test
 Radiography is a mature NDT method that can be
used to effectively detect several types of
discontinuities embedded within a variety of
types of materials and components.
 The part is placed between the radiation source
and a piece of film. The part will stop some of the
radiation. Thicker and denser area will stop more
of the radiation.
 Chemical Composition Analysis
Test
 A weld pad for determining the chemical
composition of a filler metal must be prepared.
 Number of layers are required to assure that the top
surface has no dilution with the base metal.  
 The welds are deposited in the flat position.  After
welding, the top surface is machined or ground
smooth to remove all foreign matter.
  A sample is taken from this surface for chemical
analysis.
 OUR PROJECT
 Our project is “to develop inconel
consumable for overlay application”.

 Overlay: it is a layer of weld material

put on the base metal.
 Requirements
1. Electrode shall be suitable for use in all position.
2. Electrode when used for overlaying on 1.25Cr-
0.5Mo material, shall meet the following chemical
composition at 2 mm from base metal
C Mn Si S P Cr Mo

0.1 1 to 3.5 0.75 0.015 0.03 13 to 17 0.5 to 2.5

Fe Cu Ni
12 0.5 62 (min)

UTS (Mpa) - 550(min)

% elongation- 30(min)
 Cromotherme-1
C Mn Si S P Cr Mo

0.061 0.99 0.51 0.011 0.013 1.25 0.50

 1200 T(NS)

C Mn Si S P Cr Mo
0.1 1 to 3.5 0.75 0.02 0.03 13 to 17 0.5 to 2.5

Fe Cu Ni
12 0.5 62 (min)
Company Name D&H Secheron Ele. Identification
Welding Process MMAW Authorized By
Process Type Manual Date

Position
Joint design used 1G
Welding position
Joint type Butt Weld
Joint design Single V
Root Gap 3 mm Electrical Characteristics
Groove Angle 60o
Backing Strip ---- Current AC/DC
Root Face 2.0 mm Polarity +

Technique
Base Metal
Stringer/weave bead Stringer
Material specification BQMS Multi/single pass As per joint 1
Plate length 300 (per Side) Brushing & Grinding
Plate width 200 Inter-pass cleaning
Thickness 22 mm

Filler Metal Preheat

Brand Name Chromotherme-1
AWS Code E8018 Preheat temp. Room temp.
Redry at 3000C Inter-Pass Temp. (Max.) 1000C
Layer & Bead /
Pass
Process Current Voltage Time (Sec.) Length of Heat
Amps (V) Bead (mm) Input
Joint
KJ/mm details
Size (mm)

1st 1 MMAW 80-85 22-24 270 300 1.70

3.15*450

2nd 1 MMAW 120-125 24-26 260 300 2.65

4.0*450

3rd 1 MMAW 120-125 24-26 148 300 1.51

4.0*450
2 MMAW 120-125 24-26 165 300 1.68

4th 1 MMAW 120-125 24-26 160 300 1.63

4.0*450
2 MMAW 120-125 24-26 170 300 1.73

3 MMAW 120-125 24-26 163 300 1.66

 Heat input

 Heat input =V*I*T/L

where,

V=voltage in volt
I=current in
amp.
T=time in sec
L=bead length
in mm
 More is the heat input more is the carbide
formation and hence the following result
occur-

1. Ductility increase
2. Ultimate tensile strength increase
3. % elongation decrease
4. Brittleness increase
5. Impact strength decrease
 references
 http://www.esabna.com/euweb/awtc/
Lesson10_13.htm.
Thanks