AS/NZS 1553.1:1995 Australian/New Zealand Standard Covered electrodes for welding Part 1: Low carbon steel electrodes for manual metal-arc welding of carbon steels and carbon-manganese steelsASINZS 155: 995 This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee WD/2, Welding Consumables. It was approved on behalf of the Council of ‘Standards Australia on 2 November 1994 and on behalf of the Council of Standards New Zeuland on 7 February 1995. It was published on 5 March 1995. ‘The following interests are represented on Committee WD/2: Australian Chamber of Commerce and Industry Australian Institute of Steel Construction Bureau of Steel Manufacturers of Austra Division of Manufacturing and Technology, CSIRO| Electricity Supply Association of Australia Lloyd's Register of Shipping Metal Trades Industry Association of Australia Now Zealand Manufacturers Federation Railways of Australia Committee Welding Technology Institute of Australia Review of Standards, To keep abreast of progress in industry, Joint Australian/New Zealand Standards are subject to periodic review and are kepi up to date by the issue ‘of amendments or new editions as necessary. It is important therefore that Standards uusers ensure that they are in possession of the latest edition, and any amendments thereto, Full details of all Joint Standards and related publications will be found in the Standards Australia and Standards New Zealand Catalogue of Publications; this information is supplemented each month by the magazines “The Australian Standard’ and ‘Standards New Zealand’, which subscribing members receive, and which give details of new publications, new editions and amendments, and of withdrawn Standards, ‘Suggestions for improvements to Joint Standards. addressed to the head office of either Standards Australia or Standards New Zealand, are weleomed. Notification of any inaccuracy or ambiguity found in a Joint Australian/New Zealand Standard should be made without delay in order that the matter may be investigated and appropriate action taken, This Standard was issued in draft form for comment as DR 93199.AS/NZS 1553.1:1995 Australian/New Zealand Standard Covered electrodes for welding Part 1: Low carbon steel electrodes for manual metal-arc welding of carbon steels and carbon-manganese steels PUBLISHED JOINTLY BY: STANDARDS AUSTRALIA 1 The Crescent, Homebush NSW 2140 Australia STANDARDS NEW ZEALAND Level 10, Standards House, 155 The Terrace. Wellington 6001 New Zealand ISBN 0 7262 9457 8AS/NZS 1553.1:1998 PREFACE This edition of this Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee WD/2 on Welding Consumables to supersede AS 1553.1 —1983. In preparing this edition, cognizance has been taken of ANSI/AWS AS.1—91 Specifications for carbon steel electrodes for shielded metal arc welding, and ISO/DIS 2560, Specification for carbon-manganese steel electrodes for shielded metal arc welding (Revision of ISO 2560—1973). This edition incorporates the following significant technical changes from the 1983 edition (@) Optional indicator for supplemental notch toughness, diffusible hydrogen and resistance {0 coating moisture absorption have been added to the designation system of electrodes. (6) Classification designation EXX19 has been added, and cla EXX45 deleted. (©) Impact test grades and requirements have been reviewed. ation designation (@)__ Diffusible hydrogen levels requirements have been reviewed. (©) Coating moisture absorption resistance test has been added. jon, editorial changes and adjustments have been made, including the following: (i) Update of referenced Standards. Gi) Alignment with current Standards Australia policy. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance. ‘This Standard has undergone a considerable number of changes and revisions. Details of the publishing history can be obtained from Standards Australia’s Information Centre and from Standards New Zealand's Information Centre. © Copyright — STANDARDS AUSTRALIA /STANDARDS NEW ZEALAND, Users of Standards ae reminded that copytight subsists in all Slantards Australia and Standards New Zealand publications and stare Except whore the ‘Copsrisht Act allows “and “except whore. proviged Tor below "no publications "of software produced by Standards Austra or Standards New Zealand may be roped, stoed- ama rescval system n any form oe anand Wy any mica ‘without price peamission in writing Irom Standards Australia or Standards New Zealand Permission may be condivionl on an appreciate say pm aan {as for permission and informaiton on commercial software royalties should be inated the head ‘office of Sandurds Ansa, New Zealand requests should be directed Io Standards New Zealand 'Up to 10 peroont of the technical content pages of a Standard my be copied for use exclusively in-house by purchasers of the ‘Standard without payment of ryaly or advice to Standards Australia or Standards New Zealand Inclusion of copsright msteral in computer software programs i also permited without royaky payment provided such programs fre tsed exehaely income By the eros of the progr’. Care shouldbe ken to ensure that teil used is fm dhe current edition ofthe Standard and that i is upated whenever the Staind {s tmonddl or revised. The rmber and das of the Standard shoud therefone be clear ene ‘The use of material in print form or in computer software programe to be wed commercially, with oe witht payment, oF in commercial conuass Is subject co the payment a roslty. Ths policy may be varied y Standards Austala or Standards New Zealand al any Ue:3 ASINZS 1558.1:1995 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 4 1.2. REFERENCED DOCUMENTS 4 1.3. DEFINITIONS . 5 1.4 CLASSIFICATION AND DESIGNATION . 3 SECTION 2 PROPERTIES AND REQUIREMENTS 21 GENERAL . veces seve 7 2.2 CHEMICAL COMPOSITION 7 23 PHYSICAL REQUIREMENTS ..... 2.0... .00e00cseeseeeeeenens 9 2.4 DIFFUSIBLE HYDROGEN CONTENT veceeeeeeeee HL 2.5 COATING MOISTURE ABSORPTION RESISTANCE... .. 4 2.6 DEPOSITION EFFICIENCY—IRON POWDER ELECTRODES ......... 14 27 FILLET WELD TEST REQUIREMENTS . ..... .. voce Wd 2.8 SIZE OF ELECTRODES ....... 2.22.00 s0eeeseseeeeu eee 1s 2.9 CORE WIRE Is 2.10 FLUX COVERING ...... . cece we. 16 2.11 BARED ENDS. . 16 2.12 IDENTIFICATION . 16 2.13 PACKING .. 7 2.14. MARKING 7 2.15 GENERAL SAFETY WARNING . 7 2.16 STORAGE 18 APPENDICES, A. DESCRIPTION AND INTENDED USE OF ELECTRODES 19 B METHODS OF TEST . : cee cevteveeeeseeees 24 © HEALTH AND SAFETY ...... i i : wees 33 Originated in Australia as AS B28— 1931 Previous edition AS 1553.1 — 1983 Jointly revised and designated as Joint Standard ASINZS 1553.1: 1995,AS/NZS 1553.1:1998 4 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Covered electrodes for welding Part 1: Low carbon steel electrodes for manual metal-arc welding of carbon steels and carbon-manganese steels SECTION 1 SCOPE AND GENERAL 1.1 SCOPE This Standard specifies requirements for unalloyed low carbon steel covered electrodes for the manual metal-are welding of carbon steels. and carbon-manganese steels. The electrodes may also be used for the welding of certain low alloy steels, including quenched and tempered steels. NOTE: Appendix A gives additional information on the description and intended use of electrodes, 1.2 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1050 Methods for the analysis of iron and steel 1544 Methods for impact tests on metals 1544.2 Part 2: Charpy V-notch 1674 Safety in welding and allied processes 2177 Radiography of welded butt joints in metal 2177.1 Part 1: Methods of Test 2205 Methods of destructive testing of welds in metal 2205.2. Method 2: Tensile tests 2205.21 Method 2.1: Transverse butt tensile test 2205.22 Method 2.2: All-weld-metal tensile test 2205.3 Method 3: Bend tests 2205.31 Method 3.1: ‘Transverse guided bend test 2205.4 Method 4: Break tests 2205.4.2 Method 4.2: Fillet break test 2205.7 Method 4: Fracture toughness tests 2205.7. Method 7.1: Charpy V-notch impact test 2812 Welding, brazing and cutting of metals—Glossary of terms 3545 Welding positions 3678 Structural steel—Hot-rolled plates, floorplates and slabs 3752 Welding—Methods for determination of the diffusible hydrogen content of ferritic weld metal produced by are welding Ki Methods for the sampling and analysis of iron and steel WTIA (Welding Technology Institute of Australia) Technical Note 3—Care and conditioning of are-welding consumables Technical Note 7—Health and safety in welding ‘COPYRIGHTs ASINZS 1558.1:1995 ANSVAWS A5.01 Filler metal procurement guidelines 1.3 DEFINITIONS For the purpose of this Standard, the definitions given in AS 2812, AS 3545 and those below apply. 1.3.1 Shall—indicates that a statement is mandatory. 1.3.2. Should—indicates a recommendation. 14 CLASSIFICATION AND DESIGNATION 1.4.1 Basis of classification Electrodes shall be classified on the basis of the tensile properties of the deposited weld metal and the operational characteristics of the electrodes. An electrode classified under one classification shall not be classified under any other classification. 1.4.2 Designation The designation system is illustrated in Figure 1.1 and shall consist of the following: (a) A letter prefix E, denoting electrode. () A 2digit number which represents approximately one-tenth of the allowable ‘minimum tensile strength of the deposited weld metal, in megapascals, in two groupings nominally referred to as E41XX and E48XX (see Table 2.4), (©) A 2-digit number which indicates the welding position or positions in which the electrode is capable of making satisfactory welds, the type of welding current to be used with the electrode and the type of covering on the electrode, in conformity with Table 1.1. (@) Optional indicators relating to notch toughness grading, attainable diffusible hydrogen status and coating moisture absorption resistance. E XX xx X HR I tH Electrose |{ Approximately one-tertn |[ Welding position. || Optional incicators for notcn Of the minimum tensile || welding current’ |} toughness. lower nycogen sirengtn (MPa) ‘and covering Slatus and movsiure absorption resistance FIGURE 1.1 PRINCIPLES OF DESIGNATION ‘COPYRIGHTAS/NZS 1553.1:1998 6 TABLE 11 WELDING POSITION, CURRENT AND COVERING Tiisdmd —] Walng Spe ferent ; wort eat va petty To tcoveig of designation (see Note 1) (see Note 2) nee v0 aon | de: esse pate | Highline rr Font | Scvords-okrmd | Mighell 2 nuns | Rover de; lame | High a vow sag 2 voor | Rtvorde seam | gh asi nid dag pale or pas 4 vont | Rtvoracckamae | Low ton powder tai pare origare is yous | Exeamd postive | Hotgen como, tse i vont | Sevrdectesw | Huge coma, bl 8 rwconst | Toa. cksmie | tyouen cnt, bv pane Low on powder » sonst | 20M cracetoee | tow ole tna potas 2 ats | Rivwrds ckamede | gh nm ox M rats | Rvoraeceamie | High rm ower, ana n ravine | Mode cena pale ormgaive ® raise | Mavards eke | Hpdogn com igh ie pace per 4 vdown | Evrae. dooraio | Hyogo cma, bs ont” | posatne “6 ato, | Rover ds ekstode | Hpdogn som basi ont” | pine vow in wee % As gcd ty | Re specie by A ded by mamfcene tae” | movie NOTES 1 The abbreviations F, V, V-down, OH, H, H-illet indicate the following welding positions, as defined in AS 2812 and AS 3545, F lat Vo = Vertical V-down on H forizontal Heillet = Horizontal fillet (position 2F in AS 3 2 See Appendix A for possible exceptions. ‘COPYRIGHT7 AS INES 1583.1:1995 SECTION 2 PROPERTIES AND REQUIREMENTS 2.1 GENERAL 2.1.1 Manufacture Electrodes may be made by any method that will yield a product complying with this Standard. 2.1.2 Qualification tests Electrodes shall be qualified by compliance with the requirements of this Section, when subjected to the tests listed in Table 2.2 by the methods of test given in Appendix B. 2.1.3 Conformance tests To ensure that electrodes continue to comply with this Standard the following tests should be carried out using 4 mm electrodes, at intervals not exceeding I year: (a) Chemical composition test, (See Clause 2.2). (b) All-weld-metal tensile test. (See Clause 2.3.2.1), (©) All-weld-metal impact test. (See Clause 2.3.2.2) Results of tests hould be recorded and should be made available on request. 2.14 Number of test specimens The number of test specimens required shall be as listed in Table 2.2. 2.1.5. Retests Where a specimen fails a test, other than the Charpy V-notch test where special retest provisions apply (see Clauses 2.3.2.2 and 2.3.3.2), two more test specimens shall be tested and shall comply with this Standard. 2.2 CHEMICAL COMPOSITION When determined in accordance with Paragraph B6.3 of Appendix B, the analysis of the all-weld-metal test specimen shall comply with the chemical composition requirements given in Table 2.1 TABLE 2.41 CHEMICAL COMPOSITION REQUIREMENTS OF DEPOSITED WI cl ‘Chemical composition, maximum percent Weation. |e s P| Mme Nit cre Mo | ve BUXX | O15 | 0030 | 0030 Values not specified Basxd 125 | 090 EAsxs. 125 | 0.00 EAEXG 160 | 075 : Essxe |} ois |} 0030 |} oox0) 1 | 275 1) 930 |} 020 030 |} 00s Essie 160 | 0.75 EAsXs. r60_| 0.90 EAXD ‘As specified by the manufacturer * Total of all these elements not to exceed the follow Basxa E48x5J 1.5 percent Eusx6 E48X7 } 1.75 peroent EASXS COPYRIGHTAS/NZS 1583.1:1995 8 TABLE 2.2 SUMMARY OF TESTS REQUIRED FOR ELECTRODES: 1 2 I 3 4 5 6 on tes Property| ‘Test method of Test Number of | Rlectrode Welding | sequirenents | "Appendix vpecimens | ameter | Bann, Chemical 7 tam Fat | Che 22] Paragraph Boo composition ! 3mm Fat Alk-veld metal 1 7am Fa) Chase 231 | Parazaph Boa raver &mme Fat allweld wet 7 Tm Fa] Che 2321 | Pargaph BOD? rene i 3 mm Fat Alkweld metal 3 4mm Fit | Clase 2322 | Paraph BO23 ‘pact 3 3mm Fat But waldiemiis | ter? | Various Fa) Chwe 2331 | Pargrph BA Kore 2 | “dened Wore 3) Horizontal 1 Note 4) Vevtcal ep 1 Note 4) Vesical down 1 ‘Overhead But wellimpact | 30r6 [As conesponting| Fat | Clause 2332 | Paragraph B83 ee temite test | _Verieat up Vertoal dave Buit weldbend | ord [As conesponding| Fat | Clause 2333 | Paragaph BEA vow 2) | bun weld ens 2 ore 3) tes Horizont 2 (Nowe 2 Vertical up 2iNote 8) Vertical don 3 ‘Overhead 3 Tam Fa) Cane 24) Pargaph Bo Iyiogen 6 thoes) Absorbed 3 rm Fa) Chwse 25 | Paragraph B10 toate (Note 6) Dept to Ta | Cause 26 | Paragraph BIT eceney asmmorsmm| Flat Noe N smn Fat Filer weld T | See Appenais B.] tein | Clase 27] Paragraph Biz Page BIL * Gr largest diameter tmatactoned, whichever isthe salle Notes: 1 Potions ace at deniled im Table 11, Testi ae not required for positions aot recommended by nace 2 ‘The auditional specimens are required when electrode is classified for flat and H-fillet welding, ie EXX20, EXX24, EXX27, EXX28, and should be token from a second est plate. (See Appendix B, Paragraph B7.2(a). ‘These specimens not required when electrode also classified for vertical position, ‘The test plate is welded in the position for which classification is sought ‘This testis required only where electrode is hydrogen-controlled (ype, i. EXXXS, EXXX6, EXXX8, ‘This testis required only whore an *R’ indicator is sought (see Clause 2.5), ‘This testis roquired only whore electrode is an iron powder type, ie. EXXX4, EXXX7, EXXXS, COPYRIGHT° AS INES 1583.1:1995 2.3. PHYSICAL REQUIREMENTS 2.3.1. Soundness Radiographs made in accordance with Paragraph B6.1 of Appendix B, which show inclusions or zones of incomplete fusion shall be indicative of ‘no test” and a sce shall be welded and radiographed. Cracks shall not be accepted. Porosity and inclusions shall not exceed the acceptance levels given in Table 2.3 and Figure 2.1 The acceptance level achieved shall be recorded TABLE 23 POROSITY AND INCLUSION ACCEPTANCE LEVELS Classification | Radiographic level EXXXS EXXX6 EXX 18 EXX19 EXX20 EXXA8 Level 1 EXXX0 EXXXI EXXX2 EXXX3 EXXX4 EXX27 EXX28 EXX99 Level I 2.3.2. All-weld-metal properties 2.3.2.1 Tensile properties When all-weld-metal test specimens are prepared and tested in accordance with Paragraph B6.2.2 of Appendix B, ic. in the as-welded condition, they shall comply with the requirements for tensile properties given in Table 2.4 For electrodes in the tensile strength range 430 MPa to 550 MPa (reference (1) Table 2.4), the yield strength or the tensile strength, or both, may, with each increase of I percent in the value of the elongation over the minimum, decrease 10 MPa to a minimum of — (a) for the yield strength 330 MPa; and (b) for the tensile strength... 2 - 410 MPa. For electrodes nthe tensile. strength range 500 MPa 10 620 MPa (reference (2) Table 2.4), the yield strength or the tensile strength, or both, may, with each increase of I percent in the value of the elongation over the minimum, decrease 10 MPa to a minimum of — (i) for the yield strength 400 MPa; and Gi) for the tensile strength... 2... . 480 MPa. 232.2 Impact energy value When a set of three Charpy V-notch test specimens is prepared and tested for impact properties in accordance with the method described in Paragraph B6.2.3 of Appendix B, the specimens shall comply with the requirement appropriate to the grade of electrode given in Table 2.5, subject to the following limitations and modifications: (a) Where the set of three test specimens has an average impact energy value that complies with Column 3 of Table 2.5 but contains one or more values tess than those given in Column 4 of Table 2.5, the set shall be discarded. A further set of three Charpy V-notch test specimens shall be prepared and tested in its place and this set shall comply with Columns 3 and 4 of Table 2.5 COPYRIGHTAS/NZS 1583.1:1995 0 TABLE 24 TENSILE PROPERTIES OF DEPOSITED WELD METAL, IN ALL-WELD-METAL TESTS. Mimo] Minimum creme | it clngation tite ‘strength* on 5.6585, Mie reat Tie | Row] aa 2 EASXX 500 to 620 420 * For oumbers in brackets, se0 Clause 2.3.2. (b) Where the set of three test specimens has an average impact energy value less than that given in Column 3 of Table 2.5 but not less than the value given in Column 5 of Table 2.5, a set of three additional specimens shall be prepared and tested. The results, when added to those previously obtained to form a new average, shall comply with Table 2.5, Columns 3 and 4. (©) Where the set of three test specimens has an average impact energy value less than that given in Column 5 of Table 2.5, the set shall be discarded. Six additional test specimens shall then be prepared and tested. The average impact energy value of the six additional specimens shall comply with Table 2.5, Columns 3 and 4. NOTE: The additional Charpy V-notch test specimens in Items (a), (b) and (¢) above may be taken from the same test piece, or may be taken from a new test piece welded with electrodes taken from the same batch as the electrodes used for the first test piece. TABLE 25 AVERAGE IMPACT ENERGY VALUES-DEPOSITED WELD METAL 1 2 7 7 ; ‘Minimum - erage value of | Minimum Sie rade ‘set of 3 | individual value | IVer#Ke, value on specimens before reject co) o o o 2 No requirement | No equirement | No requirement a o 3 ro 3 40 4 5 é 2.3.3 Butt weld properties 2.3.3.1 Tensile strengths When butt-weld test specimens are prepared and tested in accordance with Paragraph B8.2 of Appendix B, the tensile strengths of the specimens shall be not less than— (a) for BAIXX electrodes (b) for BA8XX electrodes 2.3.3.2. Impact energy value prepared and tested for impact properties in accordance with 430 MPa; and 500 MPa, When a set of three Charpy V-notch test specimens is Paragraph B8.3 of Appendix B, the specimens shall comply with the requirement appropriate to the grade of electrode COPYRIGHT en in Table 2.6, subject (o the following limitations and modifi ations" AS INES 1583.1:1995 (a) Where the set of three test specimens has an average impact value, appropriate to its grade, conforming to Column 3 or Column 4 of Table 2.6, but containing one or more values below those given in Columns 5 or 6 of Table 2.6, the set shall be discarded. A further set of three Charpy V-notch set specimens shall be prepared and tested in its place and this set shall comply with the requirements given in Table 2.6. TABLE 26 IMPACT ENERGY VALUES—BUTT WELDS T 3 + | 6 reat Average value of Individual value below which at a set of 3 specimens initial results are discarded temperature i" o Grade verti ‘All other All other c Vertical up | positions Vertical up| positions 2 No No No No No % | requiggment | requement | rqurement | reuizmen reguiemen ° 0 Et a B 3L 2 20 34 min. $7-min 2 31 34, | Plectodes classified as Grades 3, 4,5 and 6 shall comply withthe requirements of Grade 2 3.8 | ani in dion, withthe equrchenis of Table 25 “ (b) Where the set of three test specimens has an average impact energy value not more than 15 percent below the values in Column 3 or Column 4 of Table 2.6 as appropriate for each grade, a set of three additional specimens shall be prepared and tested. The results, when added to those previously obtained to form a new average, shall comply with the requirements given in Table 2.6. (©) Where the set of three test specimens has an average impact energy value of more than 15 percent below the values in Column 3 or Column 4 of Table 2.6 as appropriate for each grade, the set shall be discarded. Six additional test specimen pieces shall then be prepared and tested. The average impact energy value of the six additional specimens shall comply with the requirements given in Table 2.6, NOTE: The additional test specimens in Items (a), (b) and (c) above may be taken from the same test piece, or may be taken from a new test piece welded with electrodes taken from the same batch as the electrodes used for the first test piece. 2.3.3.3 Bending properties. When a test specimen is bent in accordance with Paragraph B8.4 of Appendix B, there shall be— (a) no crack or defect at the outer surface of the test specimen that can be seen when bent through 120 degrees: or (b) no crack or defect at the outer surface of the test specimen greater than 3 mm in any direction when bent through 180 degrees Premature failure at the edges of the test specimen shall not se rejection. 2.4 DIFFUSIBLE HYDROGEN CONTENT When tested in accordance with Paragraph B9 of Appendix B, electrodes of designation EXXXS, EXXX6 and EXXX8 shall not exhibit hydrogen in excess of 15 mL per 100 g of deposited weld metal, and shall be classified as hydrogen-controlled electrodes. Hydrogen-controlled electrodes which can be shown to meet the lower maximum levels of 10 mL/100 g or 5 mL/100 g of diffusible hydrogen, when tested in accordance with Paragraph B9 of Appendix B, may carry the optional designators of Hj. or H, respectively. COPYRIGHTST3A31 FONVLd390V NOISNIONI GNW ALISOHOd (ued ul!) 1 ‘06 = prom Jo ww! ost Aue ul suoHespu yo JoquunY xe ‘Upuu goo FD ozs aNIS Sh = prem Jo wu) 964 Aue uy suoyeoypus jo soquind ey 1 0 2S winiaant 8= pm Jowui ost Aue uy suoyeojou yo saquunu xe yp wis 124 az 3DHvT ‘01 5 (ep ww 7904 ¥') weUg ‘$5 (ep ww z'L 0} #0) unpoW, > (Bip ual 9, 0121) 06:07 ‘suoouysa) Buimo}o} Woh "Bh = Prom Jowui 9gh Aue ul suoeDpu Jo JoquunU xe Tp UW 9's 0 yD eZS aaLuoss¥ SNOLLVOIGNI LHOIAdOD @ aunold 13aa7 S6L:TYSST SZNSYLHOIAdOD $13A31 3ONVLd399¥ NOISNTONI GNV ALISOHOd (wed ui) 12 aYNDIS popuedausip 2g. joys yiBua| 40 sarap Uy aM spyus ‘uomeotiqey (esoUa8 Joy postnbar 2q Kew yoru 2soqs soueuti0yu0> ue piu avout axe spjaays9) 2801p 40} swswauinbas siydesZorpex a1p “sasodind 189) a4 ur uosaud voneoqisse|> Joy Azoresogey amy uy pet 5 mm 35 mm, 24112 Are end Electrodes shall be bare and clean at the are end, or be provided with starting compound, to permit easy striking of the are. The covering shall be tapered and, the core wire covered for at least 50 percent of the circumference of the electrode at the following maximum distance from the are end: (a) For hydrogen-controlled electrodes . . . . . 50 percent of the diameter of the core wire or 1.6 mm, whichever is the lesser. (b) For all other electrodes 67 percent of the diameter of the core wire or 2.4 mm, whichever is the lesser. 2.12 IDENTIFICATION Each electrode shall be clearly marked with at least one legible imprint of the classification number of the electrode, e.g. 4110, in block type. (The letter E may be omitted from the classification number.) The imprint shall be as near as COPYRIGHT” AS INES 1583.1:1995 practicable to the holder end but not more than 65 mm from the holder end. The imprint shall be legible both before and after normal welding operations. 2.13 PACKING Electrodes shall be packaged to guard against damage during normal transportation, handling and storage so that they will be capable of complying with the test requirements of this Standard after being stored in accordance with Clause 2.16. 2.14 MARKING The following information shall be marked on each package of electrodes or on a label securely attached thereto: (a) The number of this Standard and the electrode designation marking, e.g., AS 1553.1/E4113, (b) Trade designation of electrodes. (©) Name of manufacturer or supplier. (A) Size of electrodes (millimetres), net mass of electrodes (kilograms), (©) Batch number. (The manufacturer shall ensure that the manufacturing history can be traced from this number.) NOTE: Procurement guidelines for electrodes are given in ANSI/AWS AS.01. (f) Recommended minimum open-circuit voltage (where a specific open-circuit voltage is required for satisfactory welding), (g) Recommended current range (minimum and maximum current). (hb) Recommendations for special storage conditions (see Clauses 2.13 and 2.16). (@ Recommendations for drying prior to use including conditioning for special levels of controlled hydrogen, where applicable (if recommended by the manufacturer). (General safety warning, (Clause 2.15 gives minimum requirements.) NOTE: Manufacturers making a statement of compliance with this Australian Standard on a product, packaging, or promotional material related to that product are advised to ensure that such compliance is capable of being verified. 2.13 GENERAL SAFETY WARNING A label shall be attached or a statement prominently displayed with at least the following warming: WARNING: PROTECT YOURSELF AND OTHERS, READ AND UNDERSTAND THIS LABEL. FUMES AND GASES CAN BE DANGEROUS TO YOUR HEALTH. ARC RADIATION CAN INJURE EYES AND BURN SKIN. ELECTRIC SHOCK CAN KILL. * READ AND UNDERSTAND THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS, AND YOUR EMPLOYER'S SAFETY PRACTICES, * KEEP YOUR HEAD OUT OF THE FUMES. * USE ENOUGH NATURAL VENTILATION, EXHAUST VENTILATION, OR BOTH, AT THE FUME SOURCE TO KEEP FUMES AND GASES FROM THE. BREATHING ZONE AND THE GENERAL AREA. * WEAR CORRECT EYE, EAR, AND BODY PROTECTION * DO NOT TOUCH LIVE ELECTRICAL PARTS. COPYRIGHTAS/NZS 1583.1:1995 8 * SEE AS 1674 AND WTIA TECHNICAL NOTE 7 OR YOUR CONSUMABLE SUPPLIER'S RECOMMENDATIONS FOR FURTHER INFORMATION. DO NOT REMOVE OR COVER THIS WARNING. NOTE: Appendix C gives additional advice on health and safety for users, 2.16 STORAGE When stored by the manufacturer or distributor, the electrodes shall be kept in their original packages in a dry storeroom, and, if the composition of the flux. covering is such that special protection during storage is prescribed by the manufacturer, then the electrode shall have such special protection NOTES: 1 The purchaser should also store the electrode under the conditions outlined above. 2 Guidance on care and conditioning of welding consumables is given in WTIA Technical Note 3. COPYRIGHTrr AS INES 1583.1:1995 APPENDIX A. DESCRIPTION AND INTENDED USE OF ELECTRODES. (Informative) AL SCOPE This Appendix sets out additional information for users of this. Standard on the following topies related to the description of the electrodes and their intended use: (a) Composition of electrode covering. (b) Are characteristics. (©) Slag characteristics. (2) Metal characteristics. (e) Power source characteristics (f) Recommended usage. (g) Application to deep penetration welding (h) Precautions. NOTE; The letters *XX° as used in the classification designations in this Appendix stand for the various strength levels of electrodes (see Clause 1.4.2). A2 EXX10 AND EXXI1 ELECTRODES Electrodes of EXX10 and EXX11 classifications have thin coatings which contain at least 15 percent cellulose and up to 30 percent of titania as rutile or titanium white, They operate with a forceful, deeply penetrating, spray-type are with fairly high spatter, A voluminous gas shield is formed as a result of the decomposition of the cellulose material in the arc region, which protects the weld metal from atmospheric contamination, The slag is very fluid, may not appear to completely cover the deposit, and is thin, friable and easily removed when cool. Horizontal fillet welds are usually flat in profile and have a rather coarse, unevenly spaced ripple. EXX10 electrodes are designed to operate using dic. electrode ive, however dc. electrode negative is sometimes used to reduce problems such as internal undercut and hollow bead in pipe welding and is also suitable for thin wall pipe applications. EXX 1 electrodes are designed to operate satisfactorily using a.c. or d.c. electrode positive. These electrodes are suitable for all types of welding on low carbon steel and because of the are characteristics and the small slag volume are particularly easy to use in all welding positions. They are specially recommended for applications which involve changes in welding position during the running of the electrode, e.g. pipe welding in situ. Sizes larger than 5 mm are not generally used out of position The maximum current that can be used with these electrodes is sometimes limited owing to bum-out of the coating and high spatter loss, however welding currents near the maximum are commonly used by skilled operators in field pipeline welding, where the consequent high stubs losses are accepted in view of the high productivity which can be achieved. For optimum performance, the coating of these electrodes must contain 3 percent to 7 percent moisture. Excessive drying will adversely affect their operating characteristics. Suppliers should be consulted for suitable drying conditions before any re-drying operations are attempted. COPYRIGHTAS/NZS 1583.1:1995 20 A3 EXX12 ELECTRODES Electrodes of EXX12 classifications have thin coatings containing a high proportion of titania, usually as mineral rutile. They operate with a quiet, medium penetrating arc with low spatter. The slag is fairly viscous, with a full covering and easily removed when cool, except, perhaps, from the first run of a deep vee. Horizontal-fillet welds tend to be convex in profile, with a smooth, even ripple. These electrodes are designed to operate satisfactorily from ac. or from dc. electrode-positive or electrode-negative power sources, and the are is usually stable with low open-circuit voltages. These electrodes are noted for general ease of handling in all welding positions and an ability to bridge gaps in work having poor fit-up. Ordinarily a larger size fillet must be made in the vertical and overhead positions than with EXX10 or EXXI1 electrodes of the same diameter, if good fusion and profile are to be obtained. For this reason, the electrode used is frequently one size smaller than would be used with EXX10 or EXX1 I electrodes. Some of these electrodes are suitable for use in the vertical down position. Sizes larger than 5 mm are not usually used for vertical up or overhead positions. These electrodes are. recommended for general shop and structural fabrication including sheet steels Ad EXX13 ELECTRODES Electrodes of EXX13 classifications have thin coatings containing a high proportion of titania, usually as mineral rutile, with the addition of basic materials to increase the fluidity of the slag, They operate with a quiet, medium penetrating arc with low spatter. The slag is fluid, full covering and easily removed when cool, even from the first run of a deep vee. Horizontal-fillet welds have a flat profile with a fine ripple and very neat appearance These electrodes are designed to operate satisfactorily from ac. or from de clectrode-positive or electrode-negative power sources, and the arc is usually stable with low open-circuit voltages These electrodes have similar are characteristics to EXX12 electrodes, but are more suitable for welding in the vertical up and overhead positions. They are recommended for general shop and structural fabrication. Small sizes are used for sheet steel welding, Sizes larger than 5 mm are generally restricted to the flat and horizontal-fillet positions. AS EXX14 ELECTRODES Electrodes of EXX14 classifications have medium thick coatings containing a high proportion of titania, usually as mineral rutile, and sufficient iron powder to give metal recovery rates of 105 percent to 130 percent of the mass of the core wire melted. They operate with a smooth, medium penetrating arc with low spatter. The slag is fairly viscous full covering and easily removed when cool and often self-releasing. Horizontal-fillet welds tend to be convex in profile with a fine ripple. These electrodes are designed to operate satisfactorily from a.c. or from dc. electrode-positive or electrode- negative power sources and the are is usually stable with low open-circuit voltages. These electrodes are suitable for both single-run and multiple-run welds in all welding positions and can sometimes be used to bridge gaps in work having poor fit-up. The use of a medium thick coating which does not give excess slag improves the operating characteristics and allows touch welding to be used. They are recommended for general shop and structural fabrication. Some of these electrodes are suitable for use in the vertical down position. Sizes larger than 5 mm are generally restricted to the flat and A6 EXXIS AND EXX16 ELECTRODES Electrodes of EXX15 and EXX16 classifications have coatings containing a high proportion of basic material, such as COPYRIGHT21 AS INES 1583.1:1995 limestone, and of fluorides, such as fluorspar. The coating ingredients are specially selected for low hydrogen content and during manufacture the electrodes are baked at a high temperature to remove moisture. They operate with a quiet, medium penetrating arc with globular transfer of metal from the electrode to the weld pool and moderate spatter. The Slag is very fluid, full covering, and readily removed when cool. The weld metal is noted for its low hydrogen content and consequent reduction in ‘underbead cracking’. The weld metal has superior low temperature notch ductility. Horizontal-fillet welds tend to be convex in profile, with a smooth even ripple, EXXi5, electrodes are designed to operate from d.c. electrode-positive power source. EXX16 electrodes are designed to operate satisfactorily from a.c. or from d.c. electrode-positive power sources. These electrodes are suitable for both single-run and multiple-run welds in all positions. They are particularly recommended for the welding of medium and high carbon and low alloy high tensile steels, where ‘underbead cracking’ is a danger. The virtual elimination of hydrogen from the are atmosphere of these electrodes reduces the possibility of underbead cracking occurring in the “difficult to weld’ steels and this, together with the excellent weld metal quality, permits a reduction in preheat and postheat treatment of weldments. They are recommended for the welding of heavy sections in low carbon steel Welds made on severely restrained joints show much less tendency to cracking due to contraction stresses. They are also useful for welding high sulphur (free machining) steels and other ferrous materials such as malleable cast iron which cannot be welded satisfactorily with carbon steel electrodes other than hydrogen-controlled electrodes. It is recommended that as short an arc as possible be maintained in all positions of welding to prevent porosity and that the electrodes be used in a properly dried condition. AT _EXX18 ELECTRODES Electrodes of EXX18 classifications have medium thick coatings containing a high proportion of basic material, such as limestone, and of fluorides, such as fluorspar, and sufficient iron powder to give metal recovery rates of 105 percent to 130 percent of the mass of the core wire melted. As with EXX16 electrodes, coating ingredients are carefully selected for their low hydrogen contents, and manufacturing treatment is similar. They operate with a quiet, medium penetrating are, with smooth transfer of metal from the electrode to the weld pool and low spatter. The slag is fluid, full covering and readily removed when cool The deposition rate is higher than with EXX15 or EXX16 owing to the iron powder content and the thickness of the coating giving ability to carry a higher current for a corresponding core wire diameter. Horizontal-fillet welds tend to be convex in profile. These electrodes are designed to operate satisfactorily from ac. or from de. electrode-positive power sources. These electrodes are generally superior to EXX15 and EXX16 electrodes in all welding positions. In all other respects the remarks concerning EXX1S and EXX16 electrodes apply equallly to these electrodes. As with EXX16 electrodes, it is recommended that a short arc be maintained at all times, and that the electrodes be used in a properly dried condition. AS EXX19 ELECTRODES Electrodes of EXX19 classification have coatings based on the mineral ilmenite and consequently an are action and slag characteristics intermediate between the EXX12/13 titania types and the EXX20 iron/manganese oxide type. COPYRIGHTAS/NZS 1583.1:1995 2 The electrodes are characterised by a rather fluid slag system, provide deeper penetration than the EXX13 group and excellent radiographic quality weld metal, meeting the Level 1 standard. They are designed for use on a.c. or d.c. electrode negative or positive, and are suitable for multipass welding up to 25 mm thick steel. Stable are and good operational characteristics provide smooth even beads in all positions including the vertical (using the upward progression only). The weld metal has excellent ductility and crack resistance with good impact properties. A9 EXX20 ELECTRODES Electrodes of EXX20 classifications have medium thick coatings containing a high proportion of oxides or silicates of iron and manganese. They operate with a spray-type are with medium to deep penetration according to the current used. The slag is fluid, voluminous, completely covers the deposit, and when cool is honeycombed on the underside, friable, and easily removed, even from the first run of a deep vee. Horizontal-fillet welds tend to have a flat or concave profile with a smooth even ripple. In many cases the surface of the deposit is dimpled. The more restricted the opening in which the metal is deposited the greater the tendency to produce dimples. No undesirable mechanical or physical defects are associated with this surface condition. These clectrodes are designed to operate satisfactorily in the horizontal-fillet position from a.c. or from dc. clectrode-negative. power sources, and in the flat position from ac. or from dec. electrode-positive or electrode-negative power sources, These electrodes are principally used for horizontal-fillet and flat butt welds in heavy carbon steel plate where good penetration is required. Some varieties can be used for deep penetration welding by taking advantage of the vigorous arc action available at high current values. A10 EXX24 ELECTRODES Electrodes of EXX24 classifications have thick coatings containing a high proportion of titania, usually as mineral rutile, and sufficient iron powder to give metal recovery rates in excess of 130 percent of the mass of the core wire melted. They operate with a low to medium penetrating, smooth spray-type are with very low spatter. The slag is fairly fluid, full covering, dense and when cool, is self-releasing or easily removed. The deposition rate is very fast owing to the high iron powder content and thickness of the coating giving ability to carry a high current in relation to the core wire diameter Horizontal-fillet welds have a flat to slightly convex profile with a fine ripple and good blending with the plate at the edges. ‘These electrodes are designed to operate satisfactorily from a.c. or from dc. electrode-positive or electrode-negative power sources. ‘These electrodes are recommended for the high speed welding of low carbon steel in the flat and horizontal-fillet positions. Touch welding technique is normally used. All EXX27 ELECTRODES Electrodes of EXX27 classifications have thick coatings containing a high proportion of oxides or silicates of iron and manganese, and sufficient iron powder to give metal recovery rates in excess of 130 percent of the mass of the core wire melted. They operate with a vigorous, spray-type arc with medium to deep penetration according to the current used. The slag is fluid, voluminous, completely covers the deposit, and when cool is well honeycombed on the underside, friable and easily removed, even from the first run of a deep vee. Horizontal-fillet welds are generally flat to slightly concave in profile with a smooth even ripple and good blending with the plate at the edges. The electrodes are designed to COPYRIGHT2 AS INES 1583.1:1995 operate satisfactorily in the horizontal-fillet position from a.c. or from d.c. electrode- negative power sources, and in the flat position from ac. or from dc. electrode-positive or electrode-negative power sources. The deposition rate is very fast owing to the high iron powder content and thickness of the coating giving ability to carry a high current in relation to the core wire diameter. These electrodes are recommended for use in the flat and horizontal-fillet positions and are particularly applicable to high speed welding of low carbon steel where good penetration and ease of deslagging are required. Touch welding techniques are normally used Al2 EXX28 ELECTRODES Electrodes of EXX28 classifications have thick coatings containing a high proportion of basic material, such as limestone, and of fluorides, such as fluorspar, and sufficient iron powder to give metal recovery rates in excess of 130 percent of the mass of the core wire melted. They operate with a medium penetrating spray type are and low spatter. The slag is fluid, full covering and easily removed The deposition rate is fast owing to the high iron powder content and thickness of the coating giving ability to carry a high current in relation to the core wire diameter. Horizontal-fillet_ welds are usually slightly convex to slightly concave in profile with a smooth finely rippled surface. The electrodes are designed to operate satisfactorily from a.c, or from d.c. electrode-positive power sources. These electrodes are generally restricted to use in the flat and horizontal-fillet positions. They are particularly applicable to welding heavy sections in low carbon steel where a large amount of low hydrogen weld metal is required. Touch welding techniques are usually used. It is recommended that as short an arc as possible be maintained to prevent porosity and that the electrodes be used in a properly dried condition. AI3 EXX46 AND EXX48 ELECTRODES Electrodes of EXX46 and EXX48 classifications have respectively the same usability, composition and design characteristics as EXX16 and EXXI8 electrodes and, in addition, are specifically designed for exceptionally good vertical-down welding. Some electrodes of this type are designed to provide a flat to slightly concave fully loaded penetration bead without undercut on single vee welding, such as in piping and pipelines. Al4_ EXX99 ELECTRODES The coatings and running characteristics of electrodes of EXX99 classifications are such that one or more features prevent their classification in any of the preceding classes. Power source requirements, running characterist penetration, weld metal soundness, deposition rates, suitable welding positions and examples of intended applications will be as described by the manufacturer. For successful application, it is therefore essential that the manufacturer's instructions be obtained and applied. Clearly these electrodes should not be used under conditions or for purposes other than those covered by the manufacturer's instructions. COPYRIGHTAS/NZS 1583.1:1995 Py APPENDIX B METHODS OF TEST (Normative) BL SCOPE This Appendix sets out methods of testing electrodes for purpose of classification in accordance with this Standard B2 TEST CONDITIONS Electrodes are classified by tests made on weld metal, deposited under controlled conditions as described hereunder, B3_ MATERIAL FOR TEST PIECES The parent metal for all-weld-metal tests shall be selected from AS 3678 Grade 250, or equivalent. For all other tests, the material shall be compatible with and shall have physical and mechanical properties not less than the specified minimum of the electrode under test B4 ELECTRODES FOR TEST B4.1 Length The electrodes used for the tests shall be the longest produced by the manufacturer in the classification, grade and size concerned. NOTE: Compliance with the requirements of the test by the longest electrodes may be taken as proof that electrodes of shorter lengths comply. B4.2 Conditioning of electrodes Hydrogen-controlled electrodes in hermetically sealed containers, and all other electrodes, shall be tested in the ‘as received’ condition, Hydrogen-controlled electrodes (EXXX5, EXXX6, EXXX8) that are not hermetically sealed shall be conditioned by heating at 250 + 10°C for 2 h prior to testing, unless other temperatures and times are recommended by the manufacturer. Bs T ! PIECES FOR ALL-WELD-METAL TESTS, BS.1 Preparation Two all-weld-metal test pieces are required in conformance with Table 2.1. Test pieces shall be prepared in accordance with Figure BI. Beyelling of the edges shall be carried out by machining or mechanized thermal-cutting. Where edges are thermally cut, any remaining scale shall be removed from the bevelled edges. BS.2 Position Test pieces shall be welded in the flat position, unless the electrode is, not classified for use in the flat position, in which case the welding position shall be one for which the electrode is classified by the manufacturer. BS.3. Welding The temperature of the parent metal shall be between 10°C and 30°C immediately before the first run of weld metal is deposited, ‘The welding current used shall be within the range recommended by the manufacturer and, where an electrode is stated to be suitable for both ac. and d.c., a.c. shall be used for the preparation of the test assemblies. The weld metal shall be deposited in single or multirun layers and the direction of deposition of each layer shall be alternately from each end of the test piece. The thickness, of each run of weld metal shall be not less than 2 mm or more than 4 mm. After the test piece has reached a temperature of 250°C, it shall be left in still air between runs until it has cooled to a temperature not exceeding 250°C nor less than 200°C, the temperature being taken on the weld surface midway along the run. Should the temperature fall below 200°C for any reason, the test piece shall be reheated to between 200°C and 250°C before welding is resumed. COPYRIGHT2s AS INES 1583.1:1995 Impact specimens Chemical FS t analysis. — Sufficient length to suit specimen wd nade umber of specimens and ‘any additional retests it required by this standard Tensile specimen 3 approx weld reinforcement Notch perpendicular 19” LI thesurface ofthe plate “| mt anaspecimen tobeim. |. 90 | entre of plate tuckciess VIEW IN DIRECTION OF ARROW Y DIMENSIONS IN MILLIMETRES FIGURE B1 METHOD OF PREPARATION OF ALL-WELD-METAL TEST PIECE BS.4 Postweld heat treatment When the test piece has been completely welded, it shall be left to cool in still air and shall not be subjected to any mechanical or thermal treatment other than that required by this Standard. B6 ALL-WELD-METAL TESTS B6.1 Radiography B6.L.1 Thermal treatment Thermal treatment shall not be performed on the test piece subsequent to the welding operation and before radiography. COPYRIGHTAS/NZS 1583.1:1995 26 B6.1.2. Preparation for radiographic testing ‘The test piece shall be prepared for radiographic testing in accordance with the following: (a) ‘The backing strip shall be removed by mechanical means or by any suitable process that does not heat the test piece above 200°C. (b) Weld ripples or weld surface irregularities on either side of the test piece shall be removed by any suitable mechanical process to the degree necessary to ensure that resulting radiographic images due to surface irregularities cannot mask, or be confused with, the image of any discontinuity. B6.1.3 Radiographic testing The radiograph shall_be obtained in accordance with AS 2177. 1, Method XR2. The following shall apply: (a) IQI sensitivity level equal to or better than— (i) for a wire-type IQ... so noes Hass ses eves a wone 1S pentane Gi) for a step-type IQL 2.8 percent (b) 25 mm at each end of the weld shall be disregarded in the assessing of the radiograph, B6.2. Mechanical testing B6.2.1 Preparation After radiography (where applicable), test pieces shall be cut for removal of test specimens (see Figure BI). Appropriate mechanical cutting may be used for test specimen separation. Thermal cutting shall not be used closer than 20 mm to the toe of the weld for longitudinal cuts, or within 20 mm of the notch area of the impact specimens for transverse cuts. Where required to assist in the cutting out of the specimens, etching may be carried out. 6.2.2 Tensile test All-weld-metal tensile test specimens shall be prepared in accordance with AS 2205.2.2. Test specimens, other than those prepared from hydrogen-controlled electrodes, shall then be subjected to a temperature of 250 + 10°C for a period of between 15h and 16h for hydrogen removal, prior to testing. No thermal treatment shall be applied to specimens prepared from hydrogen-controlled electrodes. After having cooled to ambient temperature, the test specimens shall be tested in accordance with AS 2205.2.2. B6.2.3 Impact test For other than Z-grade electrodes, three Charpy V-notch test specimens shall be taken from each test piece as shown in Figure BI in accordance with AS 2205.7.1 and AS 1544.2. ‘The specimens shall be tested in accordance with AS 1544.2 at a temperature appropriate to the electrode grade specified in Table 2.5. B6.3 Chemical composition B6.3.1 Sample for analysis Chemical analysis for the elements listed in Table 2.2 shall be made in accordance with the methods of AS 1050 or AS K1, or by methods not less accurate, The sample for chemical analysis of metal deposited by the electrodes shall be taken— (@ from the all-weld-metal test piece on the axis of the weld at its midheight and within 5 mm of the axis, either— (i) from a test specimen specially cut for the purpose; or Gi) from the all-weld-metal tensile test specimen after fracture. ed in Paragraph B6.3.2. (b) from the alternative sample for analysis des COPYRIGHT” AS INES 1583.1:1995 B6.3.2. Alternative sample for analysis The alternative sample for analysis shall be taken from a weld pad prepared to the dimensions given in Table B1. All deposition shall be done in the flat position, Each bead of each layer shall be deposited as a straight stringer bead without weaving. After each layer has been deposited, the weld pad may be cooled by immersion in water and then dried before welding is resumed. The top surface of the deposit shall be removed and discarded, and the sample for analysis shall be taken so that no metal shall be removed closer to the surface of the parent metal than the distance given in Table BL TABLE BL DIMENSIONS OF WELD PAD FOR CHEMICAL ANALYSIS Blectrode | Minimum pad size diameter} (deposited metal) arent metal 40 x40x 12 8 5 50x50 14 10 B7_ TEST PIECES FOR BUTT WELD TESTS B7.1 Preparation Butt weld test pieces in conformance with Table 2.1 shall be prepared in accordance with Figure B2. Bevelling of the edges shall be carried out by machining or by mechanized thermal cutting. Where edges are thermally cut, any remaining scale shall be removed from the bevelled edges. B7.2. Positions Butt weld test pieces shall be welded in each of the welding positions (flat, horizontal, vertical, ot overhead) for which the electrode is recommended by the manufacturer, subject to the following conditions: (a) Where the electrode is to be classified for welding in the flat and H-fillet positions only, an additional test piece shall be welded in the flat position (b) Where the electrode is to be classified for welding in the horizontal and vertical positions, a test piece in the horizontal position shall not be required. (©) Where the electrode is to be classified for welding in the vertical position, test plates shall be welded in the direction(s) for which qualification is required B7.3. Welding ‘The temperature of the parent metal shall be between 10°C and 30°C immediately before the first run of weld metal is deposited, The welding current used shall be within the range recommended by the manufacturer, and, where an electrode is stated to be suitable for both a.c. and d.c., a.c. shall be used for the preparation of the test assemblies. The welding procedure in making the test pieces shall comply with Table B2 according to the position of welding. Where the electrode is classified for flat and H-fillet welding only, test pieces shall be welded by both procedures (a) and (b) in Table B2. Where the electrode is classified for additional positions, procedure (a) shall be used for deposition on the flat position test piece. In all cases, after the cutting of a groove in the root to clean metal, backing runs shall be made with 4 mm electrodes in the welding position applicable to each test piece. Test pieces may be tumed over to carry out the backing run for electrodes classified for welding in the flat position. They shall be welded using normal practice, and after the test COPYRIGHTAS/NZS 1583.1:1995 28 piece has reached a temperature of 250°C it shall be left in still air between runs until it has cooled to a temperature not exceeding 250°C nor less than 200°C, the temperature being taken on the weld surface midway along the run, Should the temperature fall below 200°C for any reason, the test piece shall be reheated to between 200°C and 250°C before welding is resumed. B74 Heat treatment When the test piece has been completely welded, it shall be left to cool in still air and shall not be subjected to any mechanical or thermal treatment other than that required by this Standard. TABLE B2 WELDING PROCEDURE FOR PREPARATION OF BUTT WELD TEST PIECES Welding position Wel 18 procedure FLAT (1. the test piece is within 5 degrees of the horizontal plane and is welded downhand from the upper surface) (@) Fist run with 4 mm electrode, “Subsequent runs (except last two layers) with 4.8 mm electrodes of above according to normal practice with the electrodes. Runs of last two layers with largest size of electrode manufactured of 8 mm clectrode, whichever is the lesser (©) First run with 4 mm electode, "Second run with an clectrode in the range of 4.8 mm to 6.3 mm, Subsequent runs with largest size of electrode manufactured! or 8 mm clectrode, whichever is the lesser. HORIZONTAL (12. the test piece is within 5 degrees of the vertical plane, and the weld joint is within 5S degrees of the horizontal plane) First run with 4 mm, 4.8 mm or S mm electrode. Subsequent runs ‘with 4.8 mm or 5 mm electrode VERTICAL (ie. the test piece is within 5 degrees of the vertical plane and the weld joint is welded either upward oF downward) [Fist run with 3.2 mam electrode, Subsequent rune with 4 mm electrode or, if recommended by manufacturer for this position, with 4.8 mm or 5 mm electrode, All runs may be made with 3.2 mm electrode where the metal recovery exceeds 10S percent OVERHEAD (ic, the test piece is within 5 degrees of the horizontal plane and is welded overhead from Firs run with 3.2 mim electrods, Subsequent runs with 4 mm electrode or, if recommended by manufacturer for this position, with 4.8 mm or $ mm electrode, ATI uns may be made with the bottom surface) 3.2 mm electrode where the metal recovery exceeds 105 percent or iron powder el trodes, 3.2 mm electrodes may be used for the first run in the fat position. B8 BUTT WELD TESTS B8.1 Preparation In conformance with Table 2.1, each test piece shall be cut to provide one butt-weld tensile test specimen, one face-bend test specimen and one-root bend test specimen as shown in Figure B2, and in addition three Charpy V-notch test specimens for each flat and vertical test piece. Where a specimen is sheared or thermally cut, an adequate allowance shall be left for any necessary machining of the material affected by the shearing or thermal cutting operations. Where required, to assist in the cutting out of the specimens, etching may be carried out. BS8.2. Tensile test with AS 2205.2.1 B8.3 Impact test For other than electrodes of Z grade, three Charpy V-notch test specimens 10 mm square shall be taken from the test pieces shown in Figure B2 in accordance with AS 2205.7.1 Method A and AS 1544.2, ‘The butt weld tensile test specimen shall be prepared in accordance The specimens shall be tested in accordance with AS 1544.2, at a temperature appropriate to the electrode grade specified in Table 2.6. COPYRIGHT29 AS INES 1583.1:1995 B8.4 Bend test Face-bend and root-bend butt weld test specimens shall be prepare accordance with AS 2205.3.1. The test specimens shall be tested in accordance with AS 2205.3.1 with a former whose diameter is 3 times the thickness of the specimen. If a crack or defect is visible at the outer surface of the test specimen after being bent through 120 degrees, the bending shall be continued through 180 degrees. T /40max Length to uit aumber of specimens and ary retests required by this s:anca"a appropiate '9 the postion of welding Charpy Venorch test 5 soecimene fom fat and 130 plus allowance for y machining \ 30 plus 2 lowance for Sf post aera aay Oiscars oma oa The plates may 22 preset <== eimaae i tallow for sight elstor'on 200 min 100 ein ue to welaing DIMENSIONS IN MILLIMETRES FIGURE B2 METHOD OF PREPARATION OF BUTT WELD TEST PIECE B9 METHODS FOR THE DETERMINATION OF DIFFUSIBLE HYDROGEN CONTENT The methods for the determination of diffusible hydrogen content shall be in accordance with AS 3752. B10 REFEREE METHOD OF EXPOSURE FOR THE DETERMINATION OF COATING MOISTURE ABSORPTION RESISTANCE B10.1 Principle of method The electrodes to be tested are exposed in a suitably calibrated and controlled environmental chamber for 9h minimum at 27°C, +3, -0°C, and 80 percent, +5 percent, -0 percent relative humidity. COPYRIGHTAS/NZS 1583.1:1995 0 B10.2 Conditioning of electrodes If the electrodes are conditioned prior to exposure, that fact, along with the method used for conditioning, and the time and temperature involved in conditioning, shall be noted on the test record. Conditioning of electrodes after exposure is not permitted. B10.3 Apparatus The environmental chamber shall_meet the following design requirements: (a) It shall be an insulated humidifier which produces the temperature of adiabatic saturation through regenerative evaporation or vaporization of water. (b) It shall have an average airspeed within the envelope of air surrounding the covered electrode of 0.5 to 1.7 mi (©) It shall have a drip-free area where the covered electrode up to 450 mm in length can be positioned with length as perpendicular as practicable to the general airflow. (4) It shall have a calibrated means of continuously measuring and recording the dry bulb temperature and either the wet bulb temperature or the differential between the dry bulb and wet bulb temperature over the period of time required (©) It shall have an airspeed of at least 4.5 m/s over the wet bulb sensor, unless the wet bulb sensor can be shown to be insensitive to airspeed or has a known correction factor that will provide for an adjusted wet bulb reading equal to the temperature of adiabatic saturation. (1) It shall have the wet bulb sensor located on the suction side of the fan so that there is an absence of heat radiation on the sensor. B10.4 Procedure The exposure procedure shall be as follows: (a) The electrode sample in unopened packages, or from reconditioned lots, shall be heated (o a temperature not greater than 6°C above the dewpoint of the chamber at the time of loading (b) The electrode sample shall be loaded into the chamber without delay after the packages are opened. (©) The electrodes shall be placed in the chamber in a vertical or horizontal position on ‘minimum 25 mm centres, with the length of the electrode perpendicular as practical to the general airflow. (4) Time, temperature, and humidity shall be continuously recorded for the period that the electrodes are in the chamber. (8) Counting of the exposure time shall start when the required temperature and humidity in the chamber are established BIL DEPOSITION EI ENCY TE ECTRODES BLL1 Test plate The test plate shall be of weldable grade carbon steel and shall have the following dimensions [IRON POWDER E (a) Width 75 mm, (b) Thickness -. 12 mm. (©) Length... . the length shall provide a surface area of such magnitude that the ‘metal deposited upon it in the testing of the electrode under consideration is at least 20 percent of the mass of the plate. The surface of the plate on which the deposit is to be made shall be cleaned, if necessary, by light grinding or other suitable means so that it is free from scale, rust, paint and oil. After cleaning and before welding, the plate shall be weighed to an accuracy of +1 g (m). COPYRIGHTau ASINZS 1553.1:1995, B11.2 Determination of electrode length and core wire diameter Five electrodes of the same nominal diameter (see Clause 2.7) with lengths equal within 40.5 mm shall be selected to give at least a value of m,/5 g of weld metal. The mass m, of core wire can be obtained by weighing five core wires having the same nominal diameter and length as the electrodes or by stripping the covering from five similar electrodes and weighing to an accuracy of +1 g. If this is not possible, the mass m, may be calculated from the following formula xd*SpL 4000 m= @® where d= nominal diameter of electrode core wire, in millimetres Pp = 7.85 g/em’ for steel L = length of electrode (40.5 mm). Hence m, = 0.031 L(g). BIL3 Welding The five electrodes shall then be deposited on the test plate in the flat position using the welding current approximately in the middle of the range indicated by the electrode manufacturer for the flat position; the deposition shall be such as will yield a sound deposit throughout its length. The machine setting shall be kept constant during. the whole test. Electrodes suitable for welding on dc. only, or those for which the manufacturer specifies that d.c. is preferable, shall be tested on dc. with the polarity recommended by the manufacturer. For electrodes suitable for welding on either de. or a.c., a.c. shall be used. Each electrode shall be deposited without interruption until a stub length of approximately 50 mm remains. It is recommended that the required length of stub end be marked on the electrode before welding is started. When one bead has been deposited, all slag and spatter shall be removed from the bead and the plate before another bead is deposited. The interrun temperature shall not exceed 100°C. Quenching in water between runs is permissible, On completion of welding, all slag and spatter shall be removed from the beads and plate, and the plate and weld cooled to ambient temperature before weighing. This mass m, shall be determined to an accuracy of +1 g, B14 Removal of covering from stub ends All covering shall be removed from the five stub ends before weighing, and their mass m, shall be determined to an accuracy of 1 g and recorded. BILLS Calculation of deposition efficiency The nominal deposition efficiency Ry shall be calculated from the following formula: RA%) = M2" y 109 my my where m, = _mass of the test plate before welding (+1 g) my = combined mass of the test plate and of the weld metal deposited onto it Gig) my = _mass of the core wire of the five whole electrodes (£1 g) m, = mass of the core wire in the five stub ends remaining after welding GL 9). COPYRIGHTB12. FILLET WELD TEST BI2.1. Preparation The test piece shall be prepared in accordance with AS 2205.4.2 using the form of test piece shown in Figure I(a) of AS 2205.4.2. Both ends of the plates forming the test piece shall be secured by tack welds. Plate thickness shall be at least 12 mm, B12.2 Welding Using the largest diameter of electrode manufactured and recommended for H-fillet welding, a single-run fillet weld shall be deposited on one side of the joint in the H-fillet position for approximately the full length of the test piece. For electrodes of 4 mm diameter or less, the fillet size shall be 6 mm, For electrodes over 4 mm, the fillet size shall be in the range of 6 mm to 8 mm. BI2.3 Testing After welding the following procedure shall be carried out (a) The completed weld shall be brushed clean of slag and visually examined for surface imperfections. (b) A macro-section test specimen approximately 25 mm wide shall be removed from a point approximately half-way along the weld leaving two other test specimens of approximately equal length. (©) One surface of the macro-section shall be polished, etched and scribed as shown in Figure B3(b) (The size, reinforcement (if convex fillet weld), and leg lengths of the fillet weld shall be determined to the nearest 0.4 mm by actual measurement of the polished and etched macro-section (see Figure B3(b)). (e) The two remaining test specimens then shall be broken as fillet break specimens in accordance with AS 2205.4.2. If necessary to facilitate fracture, reinforcing welds as shown in Figure B3(a) may be added to cach leg of the weld. (f) The fractured surfaces shall be visually examined without magnification, Actual throat thickness, Fracturing Reinforcement force. Design throat 7 besa tag of ‘thickness filet J Size of + weld ke a Size of weld Leg of fillet (a) REINFORCING WELDS (b) DIMENSIONS OF FILLET WELD FIGURE B3 METHOD OF FRACTURING AND DIMENSIONS OF FILLET WELD COPYRIGHTa ASINZS 1553.1:1995, APPENDIX C HEALTH AND SAFETY (nformative) C1 ELECTRICAL Manual welding equipment may give the welder an electric shock if contact is made between the body and both the electrode and the work (including cables). Contact seldom oceurs during the running of an electrode, but rather when changing electrodes. The severity of the electric shock depends on voltage and the electrical resistance of the skin at the places of contact. The electrical resistance of the skin is least when moist. Welding must never be continued if hot, wet or humid conditions cause electrical contact through moist boots or clothing. This may require special precautions in confined spaces or vessels or on preheated work. Where possible, the work must be isolated from the surroundings and the work lead must not be ‘earthed’, The electrode or holder must never be held under the arm. The cable must never be wrapped around any part of the body, even if its insulation is thought to be satisfactory. Two a.c. power supplies must never be used on the same job without special checking by an electrician. The voltage that a welding power supply applies between the welding electrode and the work is greatest when electric current ix not flowing. This ‘open-circuit voltage” (OCV) is limited to 115 V in dc, machines and 80 V in ac. machines. Additional devices are available to limit the OCV to, for example, 24 V, and to apply the full welding voltage only when the electrode is touched to the work. C2 FUME The degree of gaseous and particulate fumes from manual metal-arc welding electrodes varies with flux coating and type of core wire, Protection from fumes is based on ventilation systems which— (a) prevent the plume of fumes rising into the welder’s breathing zone; and (b) limit the background level of fumes breathed in by the welder and others in the shop. For unalloyed electrodes within the scope of this Standard, ventilation is required only to limit the nuisance dust and iron oxide content of the air breathed. The fume from low hydrogen electrodes contains fluoride in addition to this contamination but not at sufficient levels to require increased ventilation. Welding shops must have a steady natural or induced draught to keep background fume below danger levels. If this draught docs not keep the plume of fume from the welder’s own breathing zone, additional mechanical ventilation must be supplied. Special precautions are required in confined spaces or vessels. Special measures are also needed if galvanized or painted steel is being welded, C3 BURNS AND FIRES The welder’s clothing and helmet must provide protection from spatter. The surroundings must be clear of combustible material because of the risk that spatter, hot slag or electrode stubs will start a fire, If such material cannot be cleared away, a fire watcher must attend at all times during welding and for 30 min after. Stubs should be disposed of properly, preferably in a bin for this purpose. C4 FURTHER INFORMATION The International Institute of Welding has a constant program of investigation and revision of its recommendations and suggestions for national standards, The Welding Technology Institute of Australia also has a panel (Panel 9) dealing with this, matter, and for guidance has published Technical Note 7. AS 1674 also gives guidance in this respect COPYRIGHTThis page has been left blank intentionally.