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Relationships between coating composition, all weld metal properties,

operational behaviour, and diffusible hydrogen in weld metal from rutile
electrodes of types ANSI/AWS A5.1–91...

Article  in  Science and Technology of Welding & Joining · June 1999

DOI: 10.1179/136217199101537671

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RUTILE ELECTRODES : new research of a neglected topic

Relationships between coating composition, all-weld metal

properties, operational behaviour and diffusible hydrogen in
weld metal from electrodes of the types ANSI/AWS A5.1-91
E6013 and E7024.

Estela S. Surian (*) and Noemí M. Ramini de Rissone (*)

ABSTRACT

Manual rutile electrodes of types ANSI/AWS A5.1-91 E6013 and E7024, which
represent the highest percentage in tons of the total production of manual electrodes,
have been manufactured for many years. Nevertheless, there are few publications on
systematic studies to relate coating composition, operating behaviour, all-weld metal
properties and diffusible hydrogen in the deposit. It is only recently that information of
this kind has become available (as, for example, for E7018 electrodes).The present
work is intended to summarise and review all studies on manual rutile electrodes
presented in Sub-Commission II-A of the International Institute of Welding from 1994
to 1997. The aim is to contribute to a better understanding of the metallurgy of weld
metal deposited by C-Mn steel welding electrodes.

(*) Universidad Tecnológica Nacional, Facultad Regional San Nicolás. San Nicolás,
Province of Buenos Aires, Argentina.

Introduction
 During the last twenty to thirty years, there has been a world-wide
tendency to replace manual welding with coated electrodes by other processes
offering a higher deposition rate and/or capable of automation (Ref.1).
However, due to some particular features of the manual metal arc process
(Ref.2), a wide variety of coated electrodes continues to be manufactured for
many different purposes. Everything seems to indicate that their use will
stabilise at about 30% of the weld metal deposited by all the arc welding
processes (Ref. 1).

Among the range of manual coated electrodes, rutile electrodes of the

types ANSI/AWS A5.1-91 (Ref. 3) E6013 and E7024 are very popular for
welding C-Mn steels due to the following characteristics:

Stability and ease of arc initiation

Easy handling
Low fume emission
Easy removal of slag
Smooth bead appearance
Suitable for all-position welding
E7024 can be used for gravity welding
Low sensitivity to wind in outdoor welding

The above characteristics contribute to the fact that rutile electrodes

represent an important percentage of the total production of welding
consumables manufacturers. In most companies, sales of rutile type electrodes
exceed those of basic coated electrodes (types ANSI/AWS A5.1-91 E7015,
E7016 and E7018), so that the former type makes a substantial contribution to
turnover. Furthermore, there is nowadays a marked interest in studying the
behaviour of rutile electrodes, for they seem to be the most suitable ones for
underwater wet welding (Refs. 4 and 5). It is economical to use manual
electrodes to generate basic knowledge on consumables with the same type of
slag. These data can then be transferred to other processes in order to obtain
consumables which would otherwise require a more expensive development
process (e.g.: flux cored wire for all-position gas shielded arc welding).

Where mechanical properties are concerned, basic electrodes are widely

preferred over rutile ones. Many studies have been carried out recently in order
to improve the mechanical properties of weld metal deposited by E6013 and
E7024 rutile electrodes. These studies have yielded new data on the specific
effects that variations in the coating composition have on all-weld-metal
properties, operational behaviour and diffusible hydrogen (Ref. 6-21).

This paper is a review of recent research on rutile electrodes presented

to Sub-Commission II-A of the International Institute of Welding. This
knowledge can be applied to improve rutile electrodes as well as consumables
for other welding processes.

1. Manual coated electrode ANSI/AWS A5.1-91 E6013

1.1 Influence of chemical composition of the coating

1.1.1. Effect of Calcium Carbonate

The effect of adding CaCO3 to the coating of an E6013 electrode has

been studied systematically, showing a direct and clear relationship between
the weld-metal properties and coating composition (Refs. 6 and 7).

The effect of CaCO3, was first studied (Ref. 6) by designing three

electrodes E6013 with 5, 10 and 15 % calcite (natural CaCO3) at the expense
of cellulose and materials containing silicon in the coating dry mix (Table 1).
Iron and manganese powder additions to the mixture were also adjusted to
obtain similar contents of Mn in the weld metal with each electrode in order not
to incorporate another variable to the system under consideration. The content
of TiO2 (as rutile, the characteristic component of this type of electrode)
remained almost constant.

There was an increase of slag basicity as calcite increased in the

coating, while a decrease in the levels of silicon (Table 1) and oxygen in the
deposited metal was observed. Chromium, nickel, molybdenum and titanium
contents were not affected, but niobium and vanadium levels increased.

Table 1 shows a decrease in all-weld-metal values of yield and tensile

strengths as a result of silicon decrease, due to CaCO3 increase.

The impact results can be seen in Table 1 and Fig.1, which shows all-
weld-metal toughness improvement with the addition of CaCO3 : as slag
basicity increased and, as a result, oxygen content in all-weld-metal decreased,
there was an increment in Charpy-V impacts, thus reaching the requirement of
Ship Classification Societies (47 J average at -20ºC and 33 J for each individual
value) (Ref. 22). The values obtained also exceeded the 27 J minimum at -29ºC
for basic electrodes required by ANSI /AWS A5.1-91 for E7016 and E7018
(Ref. 3).

The microstructure of the weld metal deposited by these electrodes

showed only slight changes with addition of CaCO3 (Table 1), but volumetric
fraction of inclusions decreased. This latter effect could have contributed to the
improvement of toughness.

Boniszewski et al. also studied the effect of increasing CaCO3 in the

coating (Ref. 7), through the formulation of E6013 rutile electrodes with 5, 10,
15 and 18 % CaCO3 in the coatings, at the expense of cellulose and iron
powder, with no SiO2 variation (Table 2). Manganese and carbon levels in the
deposited all-weld metal were similar for all electrodes used in this study.

In this case, the addition of CaCO3 resulted in a decrease of silicon

content of the weld metal from 0.35 to 0.13 %. The quantity of residual
elements also diminished. Moreover, mechanical properties (Table 2) showed,
in all cases, a decrease of yield and tensile strengths and an improvement in
the impact values of the deposited metal, especially at -20°C. Previous work
(Ref. 6) gave similar results as regards both tensile properties and impact
values.

These alterations in the coating chemical composition of an E6013

electrode made a contribution to the achievement of toughness values required
for Grade 3 rutile electrodes according to Ship Classification Societies (Ref. 22)
and the properties resembled those obtainable with basic electrodes.

1.1.2. Effect of wollastonite

In order to study the effect of an increase in slag basicity in a simple and

clear way (Ref.8), the approach was to replace in the coating of an E6013
electrode, 0, 8 and 16 % quartz (100 % SiO2) with wollastonite (50 % SiO2 / 50
% CaO), which is the same as replacing 0, 4 and 8 % SiO2 with CaO (Table 3).

As CaO increased in the coating as well as in the slag, contents of silicon

and oxygen in the deposited metal decreased and changes were also observed
in the microstructure of the “as welded” deposit. Table 3 shows the acicular
ferrite increase at the expense of both primary ferrite and ferrite with second
phase. This microstructural change was reflected in the impact properties,
which improved with the slag basicity increase (Fig. 2). In this way, the results
achieved satisfied the minimal requirements of 47 J at -20ºC for Grade 3 rutile
electrodes (Ref. 22).

The increase in the CaO of the coating had no noticeable influence on

hardness and tensile properties of the weld metal (Table 3).

1.2. Influence of all-weld-metal chemical composition

1.2.1. Effect of silicon level

When silicon level increases in all-weld metal of C-Mn steels, yield and
tensile strengths values will also increase, while a detrimental effect is observed
as regards toughness. This happens especially at low temperatures where
cleavage is the dominant fracture mechanism. Tables 1 and 2 (Refs. 6 and 7)
show this effect, as reported in both studies of rutile electrodes with CaCO3
addition.

Supporting data are shown in Fig. 3 (Ref.10) from a study in which

E6013 electrodes were designed to contain 15% CaCO3 and around 50% TiO2
with an addition of 0 to 3 % ferrosilicon (45 % Si). In order to balance the effect
that increments of silicon in the deposited metal have on tensile strength
values, Boniszewski and Evans reduced manganese powder content in the
coating from 11 to 7% (Ref.10). In this way, yield and tensile strengths values
remained constant and it was possible to study solely the effect of silicon on
resistance to cleavage.

The deoxidising effect of silicon has been studied by Boniszewski and

Evans (Ref. 11) through the addition of ferrosilicon (45 % Si) in the coating of
E6013 electrodes. Different levels of this element in the all-weld metal were
obtained (Table 4). In this study, the weld metal chemical composition was as
follows : manganese remained almost constant, silicon was between 0.14 and
0.48 % and oxygen content decreased from 840 down to 637 ppm. Toughness
values were very similar for all electrodes as shown in Fig. 4. These results
confirmed that detrimental effect of silicon was balanced by the reduction of
oxygen level in the deposited metal.

1.2.2. Effect of manganese level

As regards ferritic all-weld metal with up to 500 ppm oxygen, normally

achieved with basic coated electrodes, it is well known that 1.5 % Mn is the
optimum level to obtain the best impact properties in the deposited metal
alloyed with carbon, manganese and silicon (Refs. 23, 24 and 25).

Attempts have been made to obtain similar results with rutile electrodes
(Ref.14) without affecting their operating properties. In this case, Boniszewski
and Malsingh studied an E6013 electrode with a coating composition of 48%
TiO2, 17% CaCO3, 3 % cellulose, deoxidised with 2.5% titanium and 2%
magnesium (both of them strong deoxidising elements). Metallic manganese
content in the coating was modified to obtain contents of 1.1, 1.4 and 1.7 % Mn
in the all-weld-metal.

These manganese contents (over 1%) produced levels of acicular ferrite

of around 55% in the deposited metal microstructure (Ref.14). This acicular
ferrite level resembles that found in the deposited metal of basic electrodes with
similar manganese and oxygen contents (Ref.23).

As expected with this type of steel, all-weld-metal yield and tensile

strengths both increased with manganese increments. Fig. 5 shows this effect
in the results obtained with different series of electrodes examined by the
authors of that study (Ref.14).

The improvement of toughness with manganese in the weld metal

deposited from rutile electrodes is not the same as that obtained for the basic
weld metal. Table 5 presents impact test results showing constant absorbed
energy values for the different levels of Mn at -20°C as well as better values for
the lowest levels of manganese at -30 and -40°C. The authors suggested that
the presence of residual elements in the deposited metal, such as V and Nb
(usually related to rutile), had been the cause of the unsatisfactory results,
despite the high levels of Mn. This view was then confirmed by Elvander in Ref.
18, where toughness was improved (Table 7, tests B7R and B8) by lowering the
contents of V and Nb, by producing electrodes with Ti dioxide (free from these
residual elements), instead of rutile.

1.2.3. Effect of oxygen content

The oxygen content found in C-Mn weld-metal is closely related to the

amount of inclusions present. This phenomenon has been studied thoroughly
for basic electrode deposits (Ref. 26 and 27) where oxygen levels are not as
high as those in rutile electrode deposits. Chemical composition, quantity, size
and distribution of inclusions in the weld pool as well as in the solidified metal
depend directly on oxygen content and, therefore, on deoxidising elements
(Ref.28). Taking into account the effect of inclusions on secondary
transformation of steels and the resulting microstructure (Ref.29), oxygen is
expected to have a strong influence on all-weld metal properties.

Boniszewski and other researchers formulated electrodes deoxidised

with magnesium (Ref.12) as well as magnesium plus titanium (Ref.13) in
several different series of rutile electrodes. This was done in order to study
rutile weld metal with oxygen levels similar to those found in basic weld metal.
Energy absorbed in the ‘lower shelf’ has been studied in Ref. 12 as well as its
marked increase through the deoxidising effect of magnesium (Table 6) and the
consequent oxygen decrease. This result was confirmed by Ref. 13, where
magnesium and titanium were used jointly as deoxidising elements: in series 1,
Mg level was varied between 0 and 3% for 2.5% Ti, consequently reaching the
best all-weld metal impact values for the lower oxygen levels, at -20 and -30°C.

The reduction of oxygen content decreases the number of large

inclusions, which otherwise initiate and propagate cracks (Ref.27). As a result,
resistance to cleavage increases and the generation of microstructures
contributing to increase toughness is also favoured.

In Ref. 13, toughness values were surprisingly high at very low

temperatures (100 J to -40 °C) with 1366 electrode, Table 6, for which the
deposited metal contained around 600 ppm oxygen, approaching the 300 to
500 ppm obtained with E7016 and E7018 basic coated electrodes (Ref. 23 to
26).

1.3 Round robin test with electrode “1366”

The toughness results obtained with electrode “1366” (Ref. 13), which
are unusually high for such low temperature called for a round robin test in Sub-
Commission II-A of the International Institute of Welding. The aim was to
discover whether consistent toughness values could be obtained when
electrodes were manufactured with raw materials of different origins and from
different laboratories.

Eight laboratories produced 12 test electrodes using “1366” original

formula and another 12 including some variations (replacement of metallic
titanium with ferrotitanium, manganese increment or decrease, substitution of
rutile for highly pure white titanium dioxide, etc.). The results, showing
considerable variation (Table 7), can be summarised (Refs. 15-18) as follows :

• it was not possible to obtain exactly the same toughness values as in

electrode “1366”. However, they could be approached as long as chemical
composition of the deposited metal was near to that of the original electrode.
This meant that Si had to remain at approximately 0.20% (Table 6), which
confirms what was previously mentioned in section 1.2.1 and nitrogen at a
maximum of 110 ppm. Thus the electrode had to be manufactured with wire
 containing Si 0.015 % maximum in order to control Si values (Table 7) as it
was shown in Ref. 16.
• metallic titanium could be replaced by ferrotitanium without affecting the Ti
content and without alterations in toughness values. This result is very
favourable, since metallic titanium is very expensive and is hazardous to
transport.

Furthermore, it was very interesting to detect the marked differences in

operability among the various electrodes produced in the laboratories: even
when all electrodes kept the typical characteristics of the rutile type, spatter,
bead formation and speed of slag detachment were quite different. The
electrodes manufactured by the participant laboratories were tested in the First
Intermediate Meeting 1996/1997 of Sub-Commission II-A of the International
Institute of Welding in Berlin, November 1996.

This confirms a view which is common among those who develop

welding consumables: contrary to what is usually thought, a complete electrode
formula is not only a list of the amounts of the coating dry mixture components
but must also include the raw materials, manufacturing equipment and full
conditions required to process it. Even when these factors are taken into
account, it is necessary to adapt the manufacturing process to the specific
conditions of the place where the electrode will be made (climatic factors for
example). Nevertheless, reproducibility of an electrode cannot still be assured.

2. Manual coated electrode ANSI/AWS A5.1-91 E7024

2.1. Influence of chemical composition of the coating

Surian (Ref. 20) has carried out systematic studies on E7024 rutile
electrodes with different contents of metallic magnesium in their coating
composition. For that purpose three electrodes containing 0, 2 and 4% Mg were
designed, balancing Mn and Si additions in order to maintain similar values of
these elements in the all-weld-metal (Table 8).

The Mg additions to the coating decreased the oxygen content in the

deposited metal (because of Mg being a strong deoxidant and the formation of
MgO encreasing slag basicity) and increased the weld metal toughness. There
were no important variations in hardness nor in yield and tensile strengths
values (Table 8).

Metallographic analysis showed 100% recrystallized structures in the

Charpy-V notch location and more refined microstructures as well as fewer and
smaller non-metallic inclusions with the increasing Mg content in the coating.
These factors would have contributed to the improvement of toughness
(Ref.30).

2.2. Influence of all-weld metal chemical composition

To study the effect of carbon content variations on the mechanical

properties of the E7024 rutile weld metal, Surian et al. (Ref.19) designed four
E7024 electrodes, systematically increasing graphite in coating. Table 9 shows
carbon variations, from 0.03 to 0.13%, in the all-weld-metal, while the
remainder of the main elements remained almost constant. Oxygen content
decreased with the increasing carbon content because carbon is a deoxidant.

Table 9 also shows the results of tensile and Charpy-V impact tests
performed on the four all-weld-metals. As carbon level increased from 0.03 to
0.10% yield and tensile strengths also increased. From 0.10% to 0.13 %
carbon, the rate of increase in tensile strength became less marked. Highest
toughness levels were found at lower carbon contents of 0.03 to 0.06 %. As
carbon increased from 0.10 to 0.13%, toughness decreased steadily.

This paper shows that it is possible to reach tensile, ductility and

toughness values as high as those required for E7018 basic electrodes with
E7024 electrodes depositing weld metal containing between 0.06 and 0.10% C
with 0.7% Mn and 0.25% Si (Ref.3).

3. Effect of coating and/or weld metal changes on the operability of rutile

electrodes

Variations in the coating composition of E6013 and E7024 electrodes

were reflected in some differences of their operational behaviour.

E6013: the increases of slag basicity achieved through the additions of

either calcite (Ref.6) or Wollastonite (Ref.8) produced a slightly detrimental
effect on the bead appearence in the down-hand position, and some increase
in spatter. In the vertical position, bead shape improved due to the faster
solidification of the slag. In addition, using AC (Ref.9), arc stability increased
with the addition of wollastonite, but there was no difference with DC of both
polarities (FE1 did not change significantly). Metal transfer mechanism was
unaffected with AC or DC (Table 10).

E7024: graphite had no influence in the operational behaviour but Mg

addition improved bead shape in the horizontal position, although there was a
slight increase of spatter. As regards arc stability, Mg did not affect charge
σI y U/σ
transfer (I/σ σU did not change for DC, nor B* for AC). Metal transfer did not
vary markedly, especially with AC (Ref.21), Table 10.

Except for some slight changes, both types of electrodes maintained the
excellent operational properties of manual rutile electrodes which make them so
valuable and useful.

4. Effect of coating changes on diffusible hydrogen.

It is well known that, unlike basic weld metal, the weld metal deposited
from rutile flux covered electrodes contains high diffusible hydrogen (DH) levels
(Ref. 31). Manual basic electrodes are dried at a very high temperature (400-
450°C), which allows the elimination of excess water (not chemically bonded),
which is the main source of hydrogen. Rutile electrodes need humidity to
operate correctly, since water is one of the components of the gas shield
generated by the coating to protect the molten metal transferred through the arc
from contamination by the surrounding atmosphere, especially nitrogen (Ref.
31).

The high diffusible hydrogen content found in metal deposited by rutile

electrodes makes them unsuitable for those applications where there is risk of
hydrogen-induced cracking. Therefore, it would be desirable to diminish
diffusible hydrogen content in rutile electrodes without altering their operational
properties.

E6013: Table 11 shows a decrease in the diffusible and residual

hydrogen contents (Ref. 7), with the increasing slag basicity resulting from the
increase of calcite in the coating. In these electrodes calcite additions were
achieved at the expense of cellulose (a potent hydrogen source) and iron
powder. From this it can be concluded that the above decrease could be
associated with the decrease in the cellulose content of the coating. When
replacing silica with wollastonite (Ref. 8), i.e. SiO2 with CaO, to increase slag
basicity, the moisture content of the coatings of all the electrodes was the same
(as they were produced with the same raw materials, except for wollatonite and
quartz that had approximately the same loss at 1000°C, around 0.30 %). As a
direct result of this replacement, DH level obtained with the most basic
electrode (highest wollastonite content) was markedly lower (Table 11). This
shows the relationship between DH content and slag basicity.

E7024: The addition of metallic Mg to the coating not only lowered the
level of oxygen in the arc (since Mg is a powerful deoxidising element), but also
increased Boniszewski’s Slag Basicity Index (Ref.32). This is because Mg
oxidises and then passes into the slag as Mg oxide. As a result of the Mg
increment in the coating for equal drying conditions (Table 11), a marked
decrease of DH (Ref.20) was also observed.

As expected, increasing the electrode drying temperature for both E6013

and E7024 electrodes, Table 11, resulted in progressive lowering of the DH
content in the weld metal (Ref. 31).

Conclusions

1. The oxygen content in the rutile weld metal can be decreased through
modifications in either the slag basicity or the addition of strong deoxidising
elements, Ti and Mg. Consequently, although rutile coatings contain a high
percentage of acid constituents it is possible to decrease the oxygen level in
the rutile weld metal close to that found in the basic weld metal. This leads to
the improvement in toughness with no detrimental effect on good operating
characteristics of the rutile electrodes.

2. The lowering of the oxygen content in the rutile weld metal and the resulting
increase in toughness were associated with the generation of more
favourable microstructure and/or the decrease in quantity and size of non-
metallic inclusions which are known to be cleavage crack initiators.
3. The information presented broadens the spectrum of metallurgical
knowledge regarding the metal deposited by manual electrodes for C-Mn
steels. It allows the properties of weld metal deposited by rutile and basic
electrodes to be thought of as a continuous system in which variations occur
as a function of oxygen content, among other factors.

4. Changes in the coating of electrodes to improve toughness did not affect

their typical operating characteristics.

5. The relationship existing between slag basicity and the diffusible hydrogen in
the weld metal was clearly demonstrated by the research reviewed.

6. The round robin test carried out in Sub-Commission II-A of the International
Institute of Welding is another clear example of the importance of teamwork
in gaining knowledge to the benefit of the welding community in an economic
and reliable way.

Acknowledgments

The authors wish to recognize Mr David Jordan for his help with editing this
paper and Dr Tad Boniszewski for his permanent and fruitful technical
contribution and friendly support. They also thank Ms. Daniela Mayoral for the
translation of this paper from Spanish to English.

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(26) ABSON, D. J. AND EVANS, G.M. 1989. “A study of the manganese-

oxygen system in low hydrogen MMA all-weld metal deposits” IIW-IIS Doc. II-A-
770-89.

(27) SURIAN, E.S., TROTTI, J.L. AND BONISZEWSKI, T. 1992. ”Effect of

Oxygen content on Charpy-V notch toughness in 3% Ni Steel SMA weld metal”.
IIW-IIS Doc. II-A-795-89. Welding Journal,71(7) :263s-268s.

(28) LIU, S. and OLSON, D. L. 1986. “The role of inclusions in controlling HSLA
Steel weld microstructures” Welding Journal, 65(6) 139s to 149-s.

(29) FROST, R.H., OLSON, D.S. and LIU,S. 1992. “Influence of solidification on
inclusion formation in welds” Proc. of the 3rd International Conference on
Trends in Welding Research. Gatlinburg. June 1-5 pp 205- 209.

(30) ABSON, D.J. and PARGETER, R.J. “Factors influencing the as-deposited
strength, microstructure and toughness of manual arc welds suitable for C-Mn
steel fabrication”. IIW-IIS Doc. II-1092-87.

(31) BONISZEWSKI, T. “Manual metal arc welding - old process, new

developments. Part II : Understanding MMA electrodes”. The Metallurgist and
Materials Technologist, Vol. 11, November 1979.

(32) TULIANI, S.S., BONISZEWSKI T. AND EATON, N.F. "Notch toughness of

commercial submerged-arc weld metal" Welding Met. Fab., Aug.1969, 37, pp
327-339.
 ELECTRODES
E5497 E5498 E5499

COATING DRY MIXTURE (%)

TiO2 52 52 55
SiO2+Al2O3 21 19 13
CaCO3 5 10 15
Cellulose 6 3 0
Mn+Fe 15 15 16
K2O 1 1 1

COLUMNAR ZONE MICROCONSTITUENTS (%)

Acicular Ferrite 28 26 32
Primary Ferrite 44 42 44
Ferrite with second 28 32 24
phase

ALL-WELD METAL Si
CONTENT (%)
0.34 0.24 0.13

TENSILE PROPERTIES

Elongation (%) 22 26 24
Yield Strength (N/mm2) 533 481 463
2
Tensile Strength (N/mm ) 603 556 541

CHARPY-V TEST RESULTS

Absorbed Energy (J)

+ 20 0 C 65 81 97
00 C 41 50 69
- 10 0 C 26 34 72
- 20 0 C 21 17 61
- 30 0 C 10 12 31
- 40 0 C 8 8 16

Table 1: Coating compositions and all-weld metal microstructure, silicon

content and mechanical properties of electrodes elaborated with 5 % (test
5497), 10 %(test 5498) and 15 % (test 5498) of calcite, Ref. 6.
 ELECTRODES
R1 R2 R3 R4 R5

COATING DRY MIXTURE (%)

Fe powder 6 5 3.5 1 2.5
Electrolytic Mn 9 10 11 12 10.5
Fe-Si45 0 0 0 0.5 0.5
Rutile 60 mesh 52 50 48 46 46
TiO2 (white pigment) 2 2 2 2 2
Calcite 5 10 15 18 18
Cellulose 6 3 0 0 0
CMC 0 0 0.5 0.5 0.5
Muscovite mica 8 8 8 8 8
Kaolin 6 6 6 6 6
Potassium feldspar 3 3 3 3 3
Sillitin (SiO2) 3 3 3 3 3

ALL WELD METAL Si CONTENT (%)

0.35 0.25 0.14 0.15 0.13

TENSILE PROPERTIES
Yield Strength
(N/mm2) 468 465 435 443 420
Tensile Strength
2
(N/mm ) 528 514 494 499 484
Elongation
(%) 24.0 25.0 25.6 24.2 24.2

CHARPY-V TEST RESULTS

Absorbed Energy (J)
+ 20 ºC 91 105 108 119 114
0 ºC 76 90 103 110 102
- 20 ºC 31 35 71 64 81

Table 2. Coating composition and all-weld metal silicon content and mechanical
properties of electrodes elaborated with calcite variations from 5 % to 18 %,
Ref. 7
 ELECTRODES
0 - CaO 4 - CaO 8 - CaO

COATING COMPONENTS (%)

Rutile 55.0 55.0 55.0
Calcite 7.0 7.0 7.0
Cellulose 6.0 6.0 6.0
Mn powder 9.0 7.5 6.0
Fe powder 7.0 8.5 10.0
Quartz 16.0 8.0 0.0
Wollastonite 0 8.0 16.0
SLAG CHEMICAL COMPOSITION (%)
TiO2 48.9 50.7 52.4
SiO2 22.3 20.7 17.6
ZrO2 0.28 0.32 0.29
Al2O3 0.35 0.21 0.20
MnO 11.6 9.2 8.0
K2O 4.3 4.5 4.3
FeO 9.1 7.5 6.1
CaO 3.9 7.7 11.3
BASICITY INDEX 0.39 0.44 0.51
COLUMNAR ZONE MICROCONSTITUENTS (%)

Acicular Ferrite 24 28 40
Primary Ferrite 49 45 42
Ferrite with second 27 27 18
phase
TENSILE PROPIETIES

Yield Strength (N/mm2) 463 465 450

Tensile Strength (N/mm2) 534 528 533
Elongation (%) 31.5 26.0 26.4
CHARPY-V NOTCH MICROHARDNESS (Hv)
Columnar zone 180 170 166
Fine recrystallized zone 177 178 173
Coarse recrystallized 176 174 166
zone

Table 3: Coating components, slag chemical composition and all-weld-metal

microstructure and mechanical properties of electrodes with 0, 8 and 16 % of
wollastonite, Ref. 8.
 ELECTRODES
R3 R7 R7A R8 R8A R9 R9A R10 R10A

COATING COMPONENTS (%)

Fe powder 3.5 3.6 3.5 3.9 2.7 4.5 1.9 4.5 0
Electrolytic Mn 11.0 10.0 10.0 9.0 9.5 8.0 9.0 7.0 8.5
FeSi-45 0 0.9 1.0 1.6 2.3 2.0 3.6 3.0 6.0
Rutile 60 mesh 48.0 48.0 48.0 48.0 48.0 48.0 48.0 48.0 48.0
TiO2 (pigment) 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Calcite 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0
CMC 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Mica 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
Kaolin 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
Feldspar 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0
Silicon oxide 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0

ALL-WELD METAL CHEMICAL COMPOSITION

C (%) 0.055 0.058 0.052 0.053 0.056 0.052 0.054 0.053 0.046
Mn (%) 0.63 0.64 0.62 0.57 0.61 0.50 0.61 0.46 0.65
Si (%) 0.14 0.23 0.21 0.24 0.25 0.24 0.33 0.27 0.48
S (%) 0.008 0.008 0.007 0.008 0.007 0.008 0.007 0.007 0.006
P (%) 0.010 0.010 0.006 0.010 0.006 0.009 0.007 0.009 0.007
O (ppm) 840 767 707 711 672 839 658 835 637
N (ppm) 104 103 96 105 98 108 101 118 106

Table 4 : Coating components and all-weld-metal chemical composition of

electrodes studied in Ref. 10 (R3, R7, R8, R9 and R10) and Ref. 11 (R3, R7,
R7A, R8A, R9A and R10A).
 ELECTRODES
1399 1450 1481

ALL-WELD-METAL Mn CONTENT (%)

1.7 1.4 1.1

CHARPY-V TESTS
Absorbed Energy (J)

-20ºC 78 78 104
-30ºC 57 46 85
-40ºC 47 38 61

Table 5. All-weld-metal manganese content and Charpy-V values of electrodes

deoxidized with Ti and Mg with increasing Mn content. Ref. 14.
 ELECTRODES
A* B* C*

ALL-WELD METAL O CONTENT (ppm)

750 600 480

CHARPY-V TEST RESULTS

Absorbed Energy (J)

-20ºC 50 62 103

ELECTRODES
1230** 1231** 1232** 1233** 1366***

ALL-WELD METAL O CONTENT (ppm)

778 770 704 635 614

CHARPY-V TESTS

Absorbed Energy (J)

-20ºC 34 21 70 66 115
-30ºC 21 16 53 63 116
-40ºC 18 23 19 11 101

Table 6. All-weld-metal oxygen content and Charpy-V results of electrodes

deoxidized with Mg, from Ref. 12 (Series *) and with Mg + Ti from Ref. 13
(Series 1** and Series 4***)
Laboratory wire All-weld metal chemical composition (%) Charpy-V Impact “1366” electrode remarks
% Si (O and N in ppm) Absorbed Energy (J)
C Mn Si S P O N -20°C -30°C -40°C
“1366” 0.012 0.069 0.54 0.214 0.013 0.012 614 88 115 116 101 original formula “1366”
Conarco B 0.07 0.05 0.56 0.28 0.009 0.013 601 112 92 61 42 original formula “1366”
XO 0.52 0.24 616 114 94 88 64 original formula “1366”
NU < 0.01 0.56 0.22 534 87 116 87 77 original formula “1366”
Hobart C1 0.010 0.071 0.45 0.19 0.024 0.012 516 366 25 6 14 original formula “1366”
C2 0.010 0.070 0.52 0.24 0.016 0.008 897 307 30 19 11 original formula “1366”
C3 traces 0.056 0.43 0.20 0.020 0.016 1000 255 18 23 8 original formula “1366”
Zika D 0.063 0.67 0.327 0.010 0.012 599 38 17 13 9 original formula “1366”
Smitweld 0.064 0.53 0.22 520 130 original formula “1366”
Elga F 0.064 0.67 0.37 0.004 0.008 993 131 21 11 original formula “1366”
Esab G1 0.055 0.056 0.53 0.36 0.009 0.007 599 104 27 and 22 18 and 12 16 and 9 original formula “1366”
A5 0.09 0.056 0.59 0.36 0.007 0.008 622 101 27 and 22 18 and 12 16 and 9 less Mn
B7 0.09 0.064 0.62 0.34 0.010 0.008 386 278 74 40 34 FeTi (40 %) instead of Ti
C7 0.09 0.07 0.61 0.29 0.011 0.008 467 277 60 30 21 FeTi ( 26%) instead of Ti
B7R 0.09 0.072 0.67 0.40 0.011 0.010 505 101 47 64 45 rutile (TiO2), FeTi, no Ti
B8 0.09 0.070 0.67 0.46 0.012 0.009 423 96 108 61 52 anatase, FeTi instead of Ti
Lincoln X1 0.06 0.074 0.76 0.36 0.016 0.013 490 160 42 19 14 FeTi instead of Ti
X2 0.06 0.058 0.46 0.16 0.017 0.012 800 150 80 65 57 no FeTi, no Ti, only Mg
X3 0.03 0.078 0.50 0.31 0.010 0.009 520 140 45 34 15 less Mn
X4 0.03 0.069 0.57 0.25 0.010 0.009 600 170 45 43 39 no FeTi, no Mg
X5 0.03 0.069 0.47 0.23 0.010 0.009 600 130 77 53 24 ½ FeTi + Mg
X6 0.03 0.067 0.45 0.18 0.010 0.009 700 120 85 58 45 only Mg
Böhler 0.02 0.072 0.50 0.27 0.008 0.015 670 100 101 57 46 FeTi instead of Ti
Metrode traces 0.081 0.58 0.23 0.012 0.013 77 22 welded on CC(+) to electrode

Table 7. Results from the Round Robin test performed in IIW Sub-commission II-A with electrode 1366 formula. Refs. 15 to 18.

19
 20

ELECTRODES
Mg-0 Mg-2 Mg-4

COATING COMPONENTS (%)

Rutile 13.6 13.6 13.6

Si bearing materials 12.5 11.0 9.2
Carbonates 7.5 7.5 7.5
Mn powder 7.5 5.6 4.0
Fe powder 57.4 58.8 60.2
Mg powder 0 2 4

SLAG CHEMICAL COMPOSITION (%)

CaO 0.30 0.34 0.35

Al2O3 3.8 3.7 4.0
FeO 13.1 10.2 9.8
MnO 17.6 12.6 8.9
TiO2 26.6 27.4 27.8
K2O 1.34 1.49 1.39
SiO2 30.0 28.1 25.2
MgO 6.8 13.3 20.2

TYPE OF CURRENT

DC(-) AC DC(-) AC DC(-) AC

ALL-WELD METAL O CONTENT (ppm)

960 945 778 761 694 613

TENSILE PROPERTIES

Yield Strength
2 383 428 399 435 400 422
(N/mm )
Tensile Strength
2 473 498 498 511 501 492
(N/mm )
Elongation
23.6 26.0 30.7 25.2 25.0 29.1
(%)
CHARPY-V TEST RESULTS

Absorbed Energy (J)

+20ºC 98 105 109 115 128 123

0ºC 94 96 101 104 112 117
-20ºC 70 68 73 75 80 97
-30ºC 52 40 69 61 80 69
-40ºC 50 39 51 47 53 65

Table 8. Coating components, slag chemical composition and all-weld-metal oxygen

content and mechanical properties from E7024 electrodes with Mg coating additions.
Ref. 20
 21

ELECTRODES
5458 5092 5093 5094

ALL-WELD METAL CHEMICAL COMPOSITION

C (%) 0.029 0.058 0.10 0.125

Mn (%) 0.73 0.68 0.70 0.68
Si (%) 0.25 0.23 0.25 0.24
S (%) 0.011 0.014 0.012 0.013
P (%) 0.008 0.013 0.014 0.015
O (ppm) 839 867 809 748

TENSILE PROPERTIES

Yield Strength 430 457 505 513

2
(N/mm )
Tensile Strength 475 518 569 576
2
(N/mm )
Elongation 20.5 25.2 26.8 21.7
(%)

CHARPY-V TEST RESULTS

Absorbed Energy (J)

+20 ºC 91 93 82 72
0 ºC 88 83 77 75
-10 ºC 80 81 72 56
-20 ºC 67 71 57 49
-30 ºC 48 48 51 39
-40 ºC 44 43 30 30
-50 ºC 26 34 22 26
-60 ºC 14 26 16 21
-70 ºC 8 20 14 13

Table 9. All-weld-metal chemical composition and mechanical properties from E7024

electrodes with C coating additions. Ref. 19

ELECTRODES
 22

0 - CaO* 4 - CaO* 8 - CaO*

TYPE OF CURRENT

DC(+) DC(-) AC DC(+) DC(-) AC DC(+) DC(-) AC

METAL TRANSFER

f(Hz) 1.28 1.67 1.26 2.50 3.50 0.78 1.33 0.83 0.78
tcc(ms) 3.51 3.39 3.45 3.89 4.00 3.35 3.65 3.61 3.42

ELECTRIC CHARGE TRANSFER (with short-circuit occurrence)

-1 -1
FE1 (W s ) 1.79 1.92 -- 1.81 2.02 -- 2.30 1.67 --
RE1 1.03 0.97 -- 1.09 1.06 -- 1.09 1.08 --
+ -1 -1
B (Ω s ) -- -- 2322 -- -- 2540 -- -- 2945
+
RB -- -- 3.45 -- -- 3.85 -- - 4.54

ELECTRODES
A** : Mg 0 % B** : Mg 1% C** : Mg 2% D** : Mg 3% E** : Mg 4%

TYPE OF CURRENT

DC+ DC- AC DC+ DC- AC DC+ DC- AC DC+ DC- AC DC+ DC- AC

METAL TRANSFER

f(Hz) 0.17 1.41 0.83 0.17 2.26 0.94 -- 2.32 0.55 -- 2.37 0.99 -- 3.44 0.41
tcc(ms) 2.38 3.19 1.95 2.77 3.08 2.13 -- 2.37 2.08 -- 3.08 1.56 -- 3.37 1.89

ELECTRIC CHARGE TRANSFER (without short-circuit occurrence)

σI
I/σ 1.94 2.09 - 1.95 2.8 - 1.95 2.8 - 1.94 2.06 - 1.95 2.09 -
σU
U/σ 5.02 4.86 - 5.00 4.99 - 5.00 4.79 - 5.28 5.12 - 4.90 4.61 -

Table 10. Arc stability results from E6013 and E7024 type electrodes with
wollastonite and Mg coating additions, from Refs. 9* and 21** respectively.

f y tcc : frequency and time of short-circuit

FE1 : inverse of the restriking mean energy, after the short-circuit occurrence
B+ : mean speed of increase in electrical conductivity of the interelectrode space
U/σσU y I/σσI : the inverses of the relative root-mean-square deviations of U and I, respectively.
 23

E6013 ELECTRODES
R1* R2* R3* R4*

HYDROGEN RESULTS (mlH2/100g)

DIFFUSIBLE H 42.9 39.6 34.7 34.3

RESIDUAL H 9.7 7.4 5.6 5.5
TOTAL H 52.6 47.0 40.3 39.8

E6013 ELECTRODES
0-CaO** 4-CaO** 8-CaO**

DIFFUSIBLE HYDROGEN RESULTS (mlH2/100g)

Drying T (2 hours)

120 ºC 41.1 33.1 23.5

220 ºC 36.2 32.9 22.2
320 ºC 28.0 25.4 14.0
420 ºC 10.7 7.3 7.9

E7024 ELECTRODES
Mg-0*** Mg-2*** Mg-4***

DIFFUSIBLE HYDROGEN RESULTS (mlH2/100g)

Drying T (2 hours)

150 ºC 49.3 42.6 39.5

350 ºC 42.4 39.8 29.5
450 ºC 26.5 23.7 19.5

Table 11. Diffusible hydrogen results from E6013 electrodes with calcite coating
variations (Ref. 7*) and wollastonite coating additions (Ref. 8**) and E7024
electrodes with Mg coating additions (Ref. 20***).

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