') LEARNING CENTRE ELECTRODES AND CONSUMABLES MODULE 6 Copyright © 2006 by The CWB Group - Industry Services Revised September 2006 All rights reserved, Although due care has been taken in the preparation of this module neither the ‘CWB Learning Centre nor any contriuting author can accept any liability arising {rom the use of misuse of any information contained herein or for any errors that may be contained in the module. Information is presented for educational purposes ‘and should not be used for design, material selection, procedure selection or similar purposes without independent verication. Where reference to other documents, such as codes and standards, is made readers are encouraged to consult the ‘original sources in detail LEARNING CENTRE 7250 West Credit Avenue, Mississauga, ON LSN SN Tel: 1-800-844-6790/905-542-2176 Fax: 905-542-1837, vwnw.cwblearing.org') LEARNING CENTRE') LEARNING CENTRE MODULE 6 ELECTRODES AND CONSUMABLES Table of Contents Terms and Definitions 3 Introduction oe on 7 1.0 Covered Electrodes pecechon seo ode sonbece 8 1.4 Core Wire meee 9 1.2 Flux Coating . oo 9 13. Manufacture of Covered Electrodes... 9 1.4 Functions of Electrode Coatngs : Bebe se 1.5 Functions of the Slag .. tees bet icone 12 4.8 Specific Materials in Electrode Coatings Be ee 2) 1.7 Classification of SMAW Electrodes 2.2.22... eeeeee eee cee 5 1.8 Classification System for Covered Electrodes for Carbon and Low Alloy Steels, : ee 16 1.9 Characteristics of Covered Electrodes. 22 1.10 Specific Electrode Types .... 5 22 4.11 Summary of Electrode Characteristics... 30 1.12, Example of Electrode Selection ............ 32 1.13 Principles of Electrode Selection a2 4.14 Detrimental Action of Moisture and Hydrogen from Electrode Coatings... . 33 1.15. Storage of Arc Welding Electrodes «2... .........seeeeeeteeee eevee 35 1.16 Moisture Resistant Electrodes oe 1.17 Low Alloy Steel Arc Welding Electrodes . fee 2 39 1.18 Moisture and Hydrogen Tests Wee 4) 2.0 Solid Electrodes and Rods for Welding eens sade ue eassene des ans 47 24 Cast and Helix iti ises 749) 22 Solid Carbon Steel Filler Metals for Gas Shielded Arc Welding . 49 23. Specific Electrode Types oe 53 2.4 Welding Conditions and Shielding Gases . 54 2.5 Mode of Metal Transfer . . : 55 26 Tensile Properties of As-Welded Deposits . -.57 2.7 _ Impact Properties of As-Welded Deposits cece OT') LEARNING CENTRE 3.0 Flux and Metal Cored Wires ..... 3.1 Types of Flux Cored Wires 0.0.0... c cece sees 3.2. Shielding Gases .. Oe ees 3.3. Self Shielded Electrodes 3.4 Standards and Specifications for Flux and Metal Cored Arc Welding Electrodes dees 3.5 Chemical Requirements 3.6 Mechanical Properties ...... 3.7 Description of the Flux Cored Arc Vielding Electrode Classifications 3.8 Description of the Metal Cored Arc Welding Electrode Classifications ....... 3.9 Optional Supplemental Designators .............. 3.10. Low Alloy Flux and Metal Cored Electrodes .. 4.0 Submerged Arc Welding Consumables ........... 4.1 Submerged Arc Wires - 4.2. Fluxes for Submerged Arc Welding 4.3. Chemical Action of Fluxes ..... 4.4 Oxygen Transfer . 4.5 Specification of Submerged Arc Welding Consumables 4.6 Classification of Submerged Arc Welding Consumables 4.7 Examples of SAW Flux/Electrode Classifications 4.8 Choices of Fluxes feose-esen 4.9 Crushed Slags 4.10 Ad Diffusible Hydrogen ...... 4.11 Low Alloy Steel Electrodes for SAW 5.0 Tungsten Electrodes ...... 5.1 Alloy Application AWS Classification Colour Code 6.0 Aluminum and Aluminum Alloy Electrodes 6.1 General....... 62 Shielded Metal Arc Welding 6.3 Gas Shielded Arc Welding Process2s 6.4 Selection and Use of Electrodes 7.0 _ Stainless and Heat Resisting Steel Electrodes ..... ponder 7.1 Classification Systems for Stainless Steel Electrodes |... 7.2 Chemical Composition : Recommended Reading List of CSA Standards Covering Consumables for Welding List of AWS Filler Metal Related Documents ......... Guides and Exercises ‘Test and Answer Sheets .. -58 2 163 65 - 66 - 69 73 75 7 78 78 79 -.81 +83 83 - 84 88 91 92 93 -- 93 94 96 96 = 98 = 98 99 104 104 106 109 - 109 110 111 119') LEARNING CENTRE Terms and Definitions absorbed admixture adsorbed composite electrode conduction deformation density deoxidizing sucked up or in and retain the act or state of being mingled or mixed the result of being drawn in. Where a gas, vapour or dissolved matter is assimilated by the surface of a solid. to make or form into a rounded mass. having a pH greater than 7. a unit of electrical current. A solution of one or more elements in face centered cubic iron. The solute is generally considered to be carbon. a metal whose dominant structure is austenite, consumable whose coating contains large amounts of calcium carbonate, These electrodes are intended to produce weld deposits of controlled or low hycrogen content. Any of the multi-component filler metals available in various forms such as; stranded wires, covered tubular cores and covered wires. the transmission or conveying of something through a medium. In arc welding we experience conduction of heat and electricity. preserved or finished by a chemical or physical process to alter the shape of by pressure or stress. the mass per unit volume of a substance, under specified standard conditions of pressure and temperature an action element or compound which is intended to remove chemically combined oxygen"> LEARNING CENTRE to remove oxygen from. In welding, elements are added to filler metals, to promote the removal of oxygen absorbed by the liquid during the welding process. diffuse to spread out. Diffusion is the act of gradual mixing of two or more substances. dilution a change in the chemical composition of the weld deposit from the composition of the filler metal due to admixture of base metal or previous weld metal diffusible hydrogen hydrogen which can spread out in a steel. Considered to be single ‘atoms when absorbed by the weld pool and the cause of cold cracking and embrittlement of carbon and low alloy steels once single hydrogen atoms recombine after cooling, dissociate to separate. Dissociation is the chemical process where a change in Physical condition causes molecules to separate into smaller groups, single atoms or ions. ductility the ability of a material to become permanently deformed without failure. elongation the act of lengthening or extending ‘embrittlement a loss of ductility. energy the work that a physical system is capable of doing in changing from its actual state to a specified reference state. ferrite In steel: a solid solution of carbon in body-centered cubic iron. There are two ferrite regions on the iron-iron carbide equilibrium diagram, separated by an austenite area. The upper ferrite is referred to as ‘delta ferrite’ and the lower is referred to as ‘alpha ferrite’ freezing range a range of temperatures over which a liquid becomes a solid friable easily crumbled; brittle fusible capable of being melted by heating 4) LEARNING CENTRE. fusion boundary hygroscopic inorganic ionization grain hardness. heat affected zone killed steel martensite microstructure oxidation potential parameter penetration plastic deformation the junction between metal which has been melted and the unmelted base metal. capable of readily absorbing moisture from the atmosphere substances or compounds not containing carbon having electrons either removed or added to a neutral atom or molecular compound An individual crystal in a polycrystalline metal or alloy. in metals; resistance of a metal to plastic deformation usually by indentation. In some ways a measure of the material's abilty to flow without fracturing that portion of the base metal which has not been melted but whose mechanical properties or microstructure have been altered by the heat of welding, a steel which has 9een deoxidized while liquid through additions of strong oxide forming elements a phase of steel formed by transformation of austenite below the usual transformation temperature range, achieved by rapid cooling. Its appearance is needle like crystals which are a supersaturated solution of carbon in iron, the structure of polished and etched metals as revealed by a microscope at a magnification greater than 10 diameters. a measure (in volts) of the driving influence of @ metal or compound to form an oxide a variable a non-standard term for joint penetration or root penetration deformation that does or will remain permanent after removal of the load which causec it.) LEARNING CENTRE preheat rimmed steel saturate semi-killed steel solute solubility solution supersaturated surface tension toughness iscosity voltage welding procedure to heat beforehand. In welding, preheat is often described as the minimum temperature of the material at any time before ‘commencement of welding. an ingot cast steel product which has not been deoxidized to soak, imbue or impregnate thoroughly. an ingot cast steel which has had some of its excess oxygen removed by the addition of small amounts of deoxidizing agents the component of either a liquid or solid that is present to a lesser or minor extent the amount of one substance which can be dissolved in a given amount of another substance the state of being dissolved to saturate a solution beyond the point normal under a given temperature. In steels, a martensitic structure is considered to be supersaturated body centered cubic iron carbon (excess carbon). a property of liquids resulting from unbalanced attractive forces between molecules at or near their surfaces the ability of a material to resist the growth of a crack the degree to which a licuid resists flow under an applied force Auunit of electrical potersial or electromotive force equal to the difference of electrical potential between two points on a conductor carrying a constant current of one ampere when the power dissipated is one watt, the electromotive force or potential difference expressed in volts ‘A recipe for creating a welded connection. A document providing details of relevant variables for a specific application to assure repeatable results by qualified personnel,|) LEARNING CENTRE Introduction The purpose of this module is to acquaint the student with the major types of electrodes and consumables available and their characteristics. Completion of this module should provide the student with a knowledge of: 1. ‘The major electrodes covered in various CSA and AWS standards. 2, The main groupings of electrodes. 3, The function of SMAW electrode coatings. 4, Materials used in coatings. 5. Requirements of various standards 6. Operating characteristics of electrodes. 7. Solid, flux cored and metal cored wires. 8. Submerged arc wires and fluxes. 9. Low alloy and stainless steel electrodes. 10. Other consumables for welding, In most welding operations, additional “filler metar' is added to the joint to complete the weld. In consumable electrode electric arc welding, this comes from the melting of the electrode itself which may be a covered electrode, or a continuously fed wire or tube filled with various compounds. In non-consumable electrode welding, or oxy-fuel-gas welding, the filler metal is added as a separate rod. The electrode may also introduce other materials such as fluxes, deoxidants and alloy elements which can have an affect on the welding operation. Electrodes can therefore be complex. A wide range of operating characteristics and weld metal properties may be achieved using different electrodes. As a result of this, meny specifications have been written by the Canadian Standards Association (CSA), the American Welding Society (AWS), the International Organization for Standards (ISO), and cther organizations covering a wide range of filler materials. The most important of these will be discussed in this module.) LEARNING CENTRE 1.0 Covered Electrodes The shielded metal arc welding (SMAW) process using covered electrodes (also known as coated or stick electrodes) is the most versatile process, and is still widely used. The electrode comprises a core wire which is coated with a layer of flux materials and other ingredients which provide the specific operating characteristics and properties. Covered electrodes have a long history of development starting from the original bare electrodes, progressing to the lightly dipped electrodes having a thin layer of lime, to the asbestos wrapped electrodes, and finally to the modem electrode with a relatively thick and complex coating ‘The main features of the covered electrode are shown in Figure 1.1. The heat of the are melts both the core wire and the coating. (The latter, in some electrodes, melts at a slower rate, thus forming a collar around the arc and allowing the electrode to be dragged on the work piece.) The molten slag separates from the molten metal and solidifies as a hard layer on the surface of the weld. The weld metal is protected from contamination from the air by gases from the flux and/or by the molten slag in contact with the metal. _-core wire solidified slag coating weld pool protective atmosphere are column molten slag Dernrtc Figure 1.1 - Covered Electrode (SMAW)') LEARNING CENTRE 4.1 Core Wire In the past, the core wire was made from rimmed steel. However, with the advent of continuous casting, it became cheaper to make killed Fot rolled steel rod, and rimmed steel became difficult to obtain in large quantities. As a result, most electrodes now have a core of continuous cast or Killed steel. Any alloying elements are generally added through the flux, except in the higher alloyed stainless and heat resisting steels. (Even here, the analysis of the core wire is often quite different from that of the final weld. For this reason, itis definitely not recommended that core wires stripped of their coating be used as iller rods in GTAW or similar processes.) Electrode core wires for carbon and low alloy steels are typically low in carbon (<0.10%), manganese (0.25 = 0.60%), silicon (0.10 - 0.35%), sulphur (<0.02%) and phosphorus (<0.02%).. 1.2. Flux Coating The flux coating consists of various minerals, chemicals and alloy materials which provide arc stability and shielding of the molten weld metal, and also control the mechanical properties, chemical analysis and metallurgical properties of the weld metal. It is this flux covering that determines the properties, or classification, of the electrode. A “binder’, usually sodium and/or potassium silicate, is added to the dry mix of minerals and alloys to form a paste which can be extruded onto the core wire. 1.3 Manufacture of Covered Electrodes The various steps in the manufacture of coated electrodes are shown in the block diagram in Figure 1.3, although there may be some variation. (Examples: Identification may be stamped on the electrodes before baking. Electrodes may be stabilized, or ‘air dried” before baking.) The coating is applied by an extrusion process which squeezes a paste of the coating mixture around the core wire to form a concentric covering (Figure 1.2). Concentricity is extremely important to the handling of the electrode. If the coating is extruded off center, the arc will be deflected to the side where the coating is electrode thinnest and most easily burned off. Asimplified core wire diagram of the extrusion process is shown in Figure 1.4. Electrodes are usually produced in standard lengths, the most popular being 360mm (14") and 450mm (18°), and diameters from 2.4mm (3/32") to 6.0mm (1/4"), although other sizes are available. The diameter refers to the core wire, not the overall electrode diameter. 9LEARNING CENTRE COATING CORE WIRE Formula proportion weighted Hot rolled to about 9.5mm (3/8") diameter Dry mixed bale ect! Binder added and wet mixed Straightened Slug prepared (if required) Cut to length Uniform concentric coating extruded onto core wire Coating removed from contact and holder ends Electrode dried in oven at suitable temperature Electrode stamped with identification Packaged for shipments Figure 1.3: Steps in The Manuiacture of Covered Electrodes The thickness of the coating depends on the type of electrode. Lightly coated electrodes have about 10 to 20 percent electrode weight in the coating. Medium coated electrodes comprise about 20 to 35 percent electrode weight in the coating and iron powder is usually an important constituent Heavily coated electrodes may have up to 55 percent electrode weight in the coating and have a high iron powder content. This contributes to a high deposition rate and these are popular electrodes for production welding in the flat position. 10") LEARNING CENTRE cing bare core wire paste form _ . Figure 1.4: Extrusion of Covered Electrodes 1.4 Functions of Electrode Coatings The coating on the electrode may perform a wide variety of functions depending on the composition. The primary function is the protection of the molten metal from contamination by the air through the formation of shielding gases and a molten slag. Several other functions may be important depending on the type of electrode and application. Among the more important functions are the following: + Protect the molten metal by gas and slag formation, + Influence the arc characteristics such as striking, ionization, stability, arc force, side arcing + Influence bead shape + Aid slag removal + Influence penetration + Add alloying elements to the weld metal + Increase deposition rate + Control chemical and mechanical properties of the weld metal * Control the hydrogen introduced into the weld metal + Influence the ease of manufacture such as extrudability ") LEARNING CENTRE 1.5. Functions of the Slag The chief function of the molten slag that is formed from the flux coating is to protect the liquid ‘weld metal from contamination from the air. It does this by forming a physical gaseous shield or barrier, and also by reacting chemically to reduce the gas content of the weld metal. Fluxes are carefully formulated to give what the designer believes is the best combination of slag viscosity, surface tension, freezing range, etc to promote ‘wetting’ of the surface of the base material and molten weld metal, to hold and shape the weld metal as it freezes, and to control the strength and toughness of the final weld metal. As individual designers will have differing views on what “optimum conditions" mean, electrodes from different manufacturers will have different characteristics. The handling characteristics of the same designation electrode produced by different manufacturers will be totally different. Thus, we may have one electrode giving (for example) better impact properties than another of the same classification, but possibly at the expense of ease of welding. Certain electrodes will sacrifice some “welder appeal" in order to create superior mechanical properties. ‘The main functions of the slag may be summarized as follows: + To protect the weld metal from contamination + To reduce the amount of oxygen and other impurities in the weld metal + To control the bead shape and smoothness 1.6 Specific Materials in Electrode Coatings Having seen the functions of electrode coatings, it is of interest to examine the functions of specific ingredients. The materials used include various organic materials, minerals, chemical compounds, clays and ferro-alloys. Among the nore important materials used are the following. Cellulose This may be a product of wood pulp, or cotton. Sugar, flour and starches may also also be used. Such materials can disintegrate in the arc to form large volumes of carbon dioxide and water vapour which provide a protective gas shield to the weld weld metal. The penetration characteristics of the electrode are increased Calcium Calcium carbonate (found as limestone, calcite or marble) is an important Carbonate ingredient in basic, low hydrogen electrodes. It breaks down in the arc to produce carbon dioxide, which shields the weld metal and lowers the hydrogen content of the arc atmosphere. Lime helps tre resulting slag maintain low sulphur and ‘oxygen levels in the weld metal, giving sound deposits with good mechanical properties. 12) LEARNING CENTRE Fluorspar Rutile Potassium Compounds Ferro-alloys Sodium Silicate Iron Oxide Iron Powder Fluorspar (or fluorite) is the natural form of calcium fluoride and is used to control the fluidity of the slag, and allow gases to escape. It is widely used in ow hydrogen electrodes where it also helps to maintain a low gas content in the weld metal. Minerals, such as rutile and ilmenite, which contain high concentrations of titania, help to make the arc stable and form a fluid, quick freezing slag. This increases welder appeal, end results in a fine, smooth finish to the weld. (Note: Titania is the common name often given to titanium dioxide, TiO,.) ‘A number of different potassium compounds such as potassium feldspar and Potassium titanate may be used in electrode coatings. Potassium aids in ionization and therefore helps to stabilize the arc and promote arc ignition. It is often used in electrodes intended to operate on alternating current Where additional alloys or deoxidizing agents are required, these are often added in the form of ferro-alloys. The common additions are ferromanganese and ferrosilicon, both of which act as deoxidants in the weld metal. Manganese, and silicon, recovered in tre weld metal, can improve the mechanical properties of the weld deposit. ‘Also known as water glass this is a liquid binder which, when mixed with the dry minerals and ferro-alloys of the flux, forms a paste that facilitates extrusion of the flux around the core wire. It also affects the fluidity of the slag, and has an arc stabilizing effect. Some, or all, of the sodium can be replaced with Potassium, which can further stabilize the arc, allowing operation on AC current. Iron oxide in the form of ores, such as magnetite and hematite, is included in some electrode coatings principally as a slag former. In some electrode coatings, iron powder may be added, sometimes up to 50% or more of the flux mass. The main purpose is to increase the deposition rate of the electrode since the iron powder melts and adds to the weld metal. It may also influence the bead apsearance, and can aid in the formation of a cup at the electrode tip that allows a “drag” technique to be used. 13') LEARNING CENTRE Coating Functions Consthoente Primary ‘Secondary Coltulose Gaseous Protection ‘Are Force Calcium Carbonate Gaseous Protection Fluxing Agent Fluorspar Slag Formation Fixing Agent Dolomite Gaseous Protection Fluxing Agent Rutile (Titanium Dioxide) | Slag Formation ‘Are Stabilization Potassium Titanate Arc Stabilization Slag Formation Feldspar Slag Formation Ae Stabilization Mica Extrusion Ad Arc Stabilization clay Extrusion Aid Slag Formation Silica Slag Formation - Manganese Oxide SSlag Formation Alloying tron Orde Slag Formation - Iron Powder Increases Deposition Rate Drag" Technique Ferrosilicon Deoxidation Alloying (Si) Ferromanganese Alloying (Mtn) Deaxidation Sodium Siicate Binder Fluxing Agent Potassium Silicate Are Stabilization Binder Table 1.1: Summary of Main Functions of Electrode Coating Constituents The effects of some of the major flux ingredients are summarized in Table 1.1 Most coatings would employ about six to twelve different ingredients. However, one or two of them always dominate, and this allows an eectrode to be characterized by the principal ingredients in the coating, e.g. cellulose type or rutile type. As a result, classification of SMAW electrodes is on the basis of the main ingredient(s) in the flux coating. (This does not apply to all welding processes.) 14') LEARNING CENTRE 1.7 Classification of SMAW Electrodes The large number of electrodes available, and the wide range of operating characteristics and properties that can be achieved, initially resulted in much confusion in the welding industry. For this reason, standards organizations and societies in many countries have issued standards and specifications for welding electrodes. In Canada, the CSA Standard W48 is issued by the Canadian Standards Association (CSA), while in the USA, the AWS AS series of specifications is issued by the American Welding Society (AWS). The Canadian standard is similar to, but not necessarily the same as, the AWS specifications. Other U.S. organizations such as the ‘American Society of Mechanical Engineers (ASME) adopt the AWS system. The AWS system is in US customary units, whereas the CSA Standards are in SI (Metric) units. At the time of writing, the AWS is revising its specifications to include metric versions, some already being available. For example, the specifications for SAW carbon steel welding electrodes and fluxes is available as AWS AS.17 (US customary units) and AWS A5.17M (SI metric units). CSA Sandee | ANS Specteaton Wing Pecos | FlerNet Sanat | ANS Spas Sled Wal ae WRecangQVAWN Tor | Covered electrode wee st |eeeeesee | : 7 SNAW ter Staios See | covered tectede wee a4 SWAW er Lowhioy See Covered lec we ass Gas Metal Arc Welding ~ |{GuintorGanen ® | Sly ectte(on | yyy ast | Ses _ cas Tungsn A | soa wre Wesangeraayir [Ske rodcsly | yay ante Canon Seals Fux Code | Pucaorea wre Wiidng aWyer | eared (on cl wee as20 Caron'Seos | Sibnerget A Wedng{eAn)ior | SOldwreeecote(on | yap anit Geren Seas “These standards caver the consumable elecroses. For the tungsten, non-consumable electro, s00 AWS AS.12. Table 1.2: Specifications and Standards for Mild Stee! Electrodes 15) LEARNING CENTRE Table 1.2 shows the consumables covered by the CSA Standard W48, and the equivalent AWS specifications. The CSA standard and a complete list of the AWS specifications are shown at the end of this module. ‘The CSA and AWS classification systems for carbon steels and low alloy steel covered electrodes are established according to: 1, weld deposit strength (MPa, psi) 2. type of coating (rutile, cellulosic, basic) 3. _ position of welding (flat and horizontal only, all positions) 4, type of current (DCEP, DCEN, AC) The standards describe the various tests that have to be carried out and list the requirements that must be met if the electrode is to be considered as meeting the requirements of a certain classification. Usually, a standard allows an electrode to be designated under one classification only, although there are some exceptions. Each classification has a code number and this number must be imprinted on each electrode near the grip end so that itis properly identified Proper identification is of great importance since the use of an incorrect electrode could be extremely dangerous, The student should be clear on the differences between the CSA standard and AWS specifications. The CSA Standard W48 uses the “Systeme International’ (SI) metric measuring system, and is designed to be administered by a third party cettfication agency. The AWS AS series uses U.S. customary measuring units (altiough, as mentioned earlier, they are now also issuing alternate SI metric specifications) but they are designed for application by the manufacturer. Thus, a statement on the label that an electrode meets AWS AS.1 classification E6011 does not necessarily mean that the manufacturer has performed tests in the recent past. However, a statement that the electrode is certified by Canadian Welding Bureau (CWB) to CSA W48, E4311, means that CWB has witnessed tests on that electrode, as required by CSA W48, and has issued a document of certification that oartfies the electrode meets all the requirements of that classification. This can be an extremely useful quality control tool for fabricators. The CSA standard identifies regular periodic retesting of the manufacturers’ electrodes to ensure that, they continue to meet the requirements of their designation 1.8 Classification System for Covered Electrodes for Carbon and Low Alloy Steels The system used by CSA and AWS standards for classification of carbon steel SMAW electrodes comprises the letter E (denoting an electric arc electrode) followed by four or more digits. For low alloy electrodes, this is followed by a desigrator defining the chemical analysis of the weld deposit, 16") LEARNING CENTRE For CSA W48, the first two digits denote the minimum tensile strength of the deposited weld ‘metal in the as-welded condition in units of megaPascals (MPa) divided by 10. In the AWS A5.1 US customary units version, the first two digits denote the minimum tensile strength in A5.1 in ksi (.e., thousands of pounds per square inch). For example, in W48 the symbol E4918 indicates an electrode with a minimum tensile strength of 490 megaPascals, whilst US ‘customary units version, an E7018 indicates that the electrode has a minimum tensile strength (of 70 ksi or 70,000 psi (pounds per square inch). (Note: Tihe CSA W48 Technical Committee on Welding Electrodes adopted the European system in Marcn 2001. AWS is also considering the European System which Uses just two digits to denote strength. Consequently the former E48018 designation has become an £4918. In the new designation the 9 is another adjustment tothe Europen System), Tir 1 Ee LEARNING CENTRE in keeping electrodes dry in field conditions (Figure 1.7). Any basic electrodes which are ‘exposed to the atmosphere for periods longer than four hours should be rebaked, or discarded, Many manufacturers supply their electrodes in small packages so that only a few electrodes are exposed at one time. 4310 and £4311 electrodes should not be rebeked because the coverings for these types are designed to have moisture levels of 3 to 7% and excessive drying may substantially affect their operation. A holding oven containing basic electrodes should not contain anything else, - even other types of electrode, ‘Store rooms for electrodes should have a controlled humidity of less than 50% (relative humidity) by using a dehumidifier and sealing the room. Smaller quantities of electrodes may be stored in unheated containers that use silica gel or other material to maintain a dry atmosphere. 36') LEARNING CENTRE. csAWas “Ambient Air ‘Storage Rebaking Filer Material ____| Temperature (°0) Temperature ‘Carbon Stee! Covered Electrodes | X10, BOTT io 70% re. Humdiy ‘Not required ‘Consult manufacturer Bonz, Bos A0t0 +30°C thr @ 135415 Bena, Bo? 50% max relative 10.25 above Exxad’, Boar humidity ambient between 2 hr @ 230 or hr ExxXIs; BOE @420 Exxie; Bove Not recommended 12010 150 (Consult manufacturer) EXX48 (Gr and Gr-Ni Covered Electrodes a 225-300 for? hr EXXXXE Not recommended 12010 180 300 — 400 for + hr BOOT i 340 ~ 440 for t he Low Alloy Stee! Covered Electrodes [exxto, a Exxit ‘Ambiont temperature 40-50 max consult manufacturer EXXI5X EXXI6X Not recommended 120t0 150 1 hr@ 370-490 EXX18X ‘Consult manufacturer Discard rusty electrodes. | Allsubmerged are fuxes: Consult manufacturer Note: (1) Manufacturer should be consulted for exact drying conditions because of difference in coating materials. Generally, i the electrode coating flakes after drying, it has been dried at too high a temperature. If porosity is evident, moisture levels may still be too high, indicating that drying temperature was too low. (2) Unusually high ambient moisture levels may necessitate use of holding ovens. Table 1.10: Storage and Rebaking of Filler Metals (After opening package) 37) LEARNING CENTRE Figure 1.6 - Electrode Storage Oven 1.16 Moisture Resistant Electrodes Recent developments in basic electrode design have resulted in electrodes which resist, to varying degrees, moisture pick-up when exposed to the atmosphere. High extrusion pressures and careful selection of binding agents produce an extremely dense flux coating, with a hard “skin’. Such moisture resistant electrodes are designated by the use of an “R” suffix in AWS, AS.1, as in E7018-R. Under normal exposure conditions, up to about 30°C and 80% relative humidity, moisture pick-up is small, and confinad to the surface of the electrode. Also, flux ingredients are chosen that do not form a chemical bond with water. Any moisture adsorbed is merely attached to the surface. During welding, the electrical heating of the electrode can drive ff much of this surface adsorbed water before it reaches the arc. However, more deeply absorbed water cannot reach the surface in time and would likely be absorbed, in part, into the weld deposit, Unfortunately, at time of writing, there is no defintive test that can prove that an electrode meets, all the requirements of the "R" designator. Round robin tests between laboratories have shown that tests within a laboratory are reproducible. However, the figures obtained at different laboratories may not agree. This is because the levels of moisture being measured are extremely low, and small variations in laboratory procedures can produce quite different results. In addition, the precise control of exposure temperature and relative humidity over the hours required by AWS A5.1 is very difficult, and can give results that vary from one laboratory to another. This makes third party certificatior of moisture resistant electrodes practically impossible. For these reasons, User standards such as CSA W59 have not recognized moisture resistant electrodes. If a Fabricator plans to use such electrodes, reference should be made to the Authority having jurisdiction. 38) LEARNING CENTRE 1.17 Low Alloy Steel Arc Welding Electodes All the electrodes described in the preceding sections produce, essentially, carbon steel weld deposits (although the manganese and silicon content may, for some electrode types, exceed the normally considered levels for a carbon steel). Weld metal of higher strength may be obtained by using low alloy steel electrodes. Requirements for these types of consumables are covered by CSA Standard W48 and AWS Specification A5.5. The alloy elements are usually introduced through the flux, as ferro-alloys, although there are some manufacturers who add some or all alloys through the core wire. There are differences between the American and Canadian standards, but the electrode classifications are essentially the same. E5518 —XX (E8018) ee indicates chemical composition ofthe deposited weld metal. CSA W48 and AWS A5.1 require testing of carbon steel electrodes to be carried out in the as- welded condition. Many low alloy steel electrodes give weld metal that is quite brittle in the as- welded condition. As a result, many classifications for low alloy steel electrodes in CSA W48, and AWS A5.5-96 require the mechanical testing to be carried out in the post weld heat treated (PWHT) condition. Users wishing to take advantage of higher strength, better impact properties, or even improved corrosion resistance, should also consider the heat treatment requirements necessary to ensure that the properties of the final welds meet the requirements. It is sometimes impractical (and expensive) to heat treat the finished structure! Tables 1.11 and 1.12 summarize the types of low alloy steel electrodes covered in the CSA and AWS standards, Increased strength may be obtained in a variety of ways and the chemical composition of different welds of the same strength level may not be the same. It is extremely important that attention be given to the suffix of the low alloy steel electrode classification. In fact, the suffix is an essential part of the electrode classification. The user must ensure that ALL of the requirements of the electrode classification are understood. It could be disastrous if an E5518- B3 was used where an E5518-C3 was specified. The former is intended for use in structures that must resist high temperature creep, and require PWHT at 690°C. The latter is designed to give high impact properties in the as weldad condition. There is no such thing as an "E5518" ‘The suffix is required to properly define the classification, When making the weld deposit for the purpose of testing the electrodes to the appropriate standard, the preheat, interpass temperature, and stress relief time and temperature are specified. These may be different for the various classifications. These testing temperatures (particularly those of preheat) may not necessarily be the same as those used on the job for the same electrode. 39LEARNING CENTRE CSA Standard W48 Type of Classification [A ered er Sabstacioy Welds | Type of Curent Coveing cosa ‘as | Sdisfactory Welds ras igh exluose, sodium EWIOX —ETOTOX EVO H [ae etre postive High coluiose, potassium | EABI-X —E7OITX FVO4H | acordc electrode postive Basi, soa EWISX — EDISK FVOHH | de-letrode postive Basi, potas.um EGI6X EVOIOX FVO4H | acorce elecrode postive Basi, fon powder EaNBX _EPIOX FVO4H | aserde eecrode postive = See ia —— | High esiuiose, seam ESIOX EDI EVOH.H [de electrode postive High celuiose,potaesum | ESSIX — EBDITX FVOAH | asorde electrode postive Basic sodium ESSISX ESOISX FVO4H | declectroce postive Basi, potassium ESSIBX FAOIBX FVO4H | acorde elecrode postive Basi, ron powder Essex EV.08H | corde electode postive igh cellos, sodium EBHOX EV,ORH [deeteciode postive High celiiose potassium | E6211 FV,08H | acorde elecrode postive ‘Basic, sodium | E6215-X, FV, OH, H de electrode positive Basic potassium | Eeoiex FV0HH | scorde elecrode postive Basie on powder EBX EVO |acorde clectode postive igh seluiose soi =eROX —ETOOIOX EV,O8 H [de eeciode postive High celliose potassium — | E601 E10017-X F-V.0H.H | scorde electrode postive Bate sod EepISx E1005 x FVOHH | deelectose postive Suse potnesum [eeiox E1o01ex FV.On H | acoras elecrode posive Basie ron powder EGex — E10v1ex FV.OHH | corde electrode posive Basie sodium EWISK EVIOISX | _FVOH.H [de electiode postive Basie potassium Eveiex Enoiex | -FVOHH | acordeeledrode postive Basic, on powder SVX EN01X | __FVOHH | scorde electro poste Base Sedum Ea'SX —EiDOISx FVOW.H [aeelectode postive Basie potassium Ees'ex E12018x FV.0H.H | acorde elecrode postive Basie, ron ponder EesOX E12018X FV.OH,H | acerde electrode postive Table 1.11 - Low Alloy Stes! Arc Welding Electrodes 40') LEARNING CENTRE = — STENT — Gasseanon? “compe: eee ee me (ie Uelate vane Egan jz [ash |e Jem [eae sense HEN gz [am [em ee [eee pete gona (22 [3s [es ea [aes sane ST ae Same] Fae Eouse [oe few [om [an [oss Tele [oouve swum |oosmor [om [oss [ors [ose outeaes | otnmoss meus lemme [om [em |e [es sageeds [sues asia: amo [ess | ot [oso ron iz0 | eames ing ap ee |e fa Weis /eanes exo aoe [om [om [aus free ssenie | oom SEES |e [es |e [ew fast aeene [smeiz sass [copes [om Jom [exe [rm rew2e [amma Segeee (a8 feet | aah Jasg Gee [ager wwe [aoe fom [ots feos [ron ew [omens sanes |aormese [oswor fom em fosomose | |asmo | sau13 | ex exitgs, [aoewow [ico [au |am [88 - [ou |eowee | osmoe sites |agete [ig lem jam [oss lest (igeee ogee SIN [REGS [18 [em |es as [ee [tapes /emeee exon, [aoe [iso [am |am [os ow leower | ersnoe stat. ag fie lem |am fogs lowe leguee Jeguee EE ie (18 [em jag ee eg /esees eseee HEI [GREEE IB |08 88 [E $8 EEE [Sees ewer [aoe [iso [aur [am [ove | ous | sone gitst je [im fem jam foes lest Jase menst [ie iB fem |g 3a [ERE exces |aoswow | 100 om [am ose | ou | sons sits amece [i lem jem [ome lous /agegs eens [ambom [18 [tm [28 (88 28 / SRE exon [aoe [iso am [am ove | ous | somos iter jag fig fem Jew fe 3 |iseas const [2 18 (tm [am (ees ess ashes exces |aowors [12s oor [aor [ose | a0 |sonve ossvean [oa sees famesn [2 (en jas (ew [ts |e Sete [5x Table 1.11 Cont'd: Low Alloy Steel Arc Welding Electrodes a') LEARNING CENTRE. (2) The suffix (A1, B3, C2, etc.) designates the chemical composition, and is an essential part @) ofthe electrode classification Nb 0.03 - 0.10; N 0.02 - 0.07; Al 0.04 max. (4) The letters "XX used in the classification designations in this table stand for the various strength levels in MPa/10 (5) In order to meet the alloy requirements of the G group, the weld deposit must have the minimum of nly one of the specified elements as indiczted (6) 10.05 max. Note: The chemical requirements for AWS AS.5-96 are similar to CSA Standard W48 Table 1.12 - Chemical Requirements for CSA W48 Electrodes 42 Sonesta [eae S weve eee] oa fee pT eset | ov | tm | om | oe | seo amuse cuosen | oo | 1a | om | om | oso | 2mwzm coc | oe | i | om | om | si | 3mumar come | 6 | td | Sm | bes | sie | sma essiecz | 01 | 125 | om | 00 | 060 | sanioars comer | oi | 12 | om | be | seo | Smmse cisiscn | oo | sas | om | 0m | 050 | santas cower | Ge | i | om | be | si |smmse ciomex | oo | 13 | om | Go | sso | suas essincs | 012 | osnietas| om | oc | oso |omim| or | ox | os Sewer | O12 | omistzs| Sm | Ses | 88 /omaim) oi | oa | Sos exces | or | 1 | om | om | ooo | ss1200 gua | $i | 38 | oa | be | te |isein, EERE Teeie oe pee | te | est | om eT esis | G4 |iswss | eo | Se | oe | a9 [oawees ezso1 | 012 |roowim | om | om | aco | om |ozsaes cent | G32 |taooiss | Se | Ses | Sa | 38 oseess gzorson | ors |resioam | om | 00s | oso | om |ozsveoas ceo | 635 |igwesm | Sos | Se | Seo | Se loseecs sewor | oi |igweam | So | Ge | Se | a6 |oeeess SaTe Toma Pes | Set | Sa | oa Came oat | oa Boorse Tome | sar | be [omme | osm | saint | oamn [ome | came Ba joome | S03 | 003 |oscmme | csome | oatmet | sapnn | orome | oaomme Buse itome | 86 | 86 /Ostmee | Sanne | oSsme | Sasmn | rome | oanme cxreu | 010 |oepir3 | eo | om | os |racir| ors [oss 0s gor | Gio layioie | om | fe | 360 |taesi) os |Gieom| Sos gore | Gio |"zowta | om | gee | seo |timam| aco |aasmom | Sos coset | G10 [15329 | or | Ses | 880 | tre2% |osmmse |aaswos | fos mar | ow Jomwsm | oo [oon] oss |smesw| oes |ozmnoso| os essitawt | 010 Jooows2| om | oo2 | aco | oss 01 oaoieaes| oo2 | ov cower | om [ia aa | om] om | 10 | ow | os | ow esuer | om [1% ats | ce | oe | im | si | os | Si ciuw | 012 [owen | ows | e0as | oaico7 | ozo | oxs.o030 ace | zoos cssmw | 613 Jassiota | Gar | vo [ossmom | oarwaes | osters odore0% Notes: (1) ‘Single values are maximum, unless specified otherwise.LEARNING CENTRE 1.18 Moisture and Hydrogen Tests It was pointed out earlier that electrodes with a basic coating are designed to produce a weld deposit with a low hydrogen content. If the moisture level of these electrodes is too high, they will not be capable of producing low hydrogen levels. This applies equally to the controlled hydrogen electrodes of the FCAW process. ‘As a result, some countries have adopted standards to specify low hydrogen levels and the test methods to measure them. In the Sections of CSA Standard W48 describing the requirements for carbon and low alloy steel 'SMAW electrodes, a diffusible hydrogen test is mandatory for the basic classifications, and an optional test is available in the section relating to FCAW electrode requirements for manufacturers who wish to classify their FCAW electrodes as hydrogen controlled. In the AWS specifications for carbon and low alloy steel SMAW electrodes (A5.1 and A5.5), a moisture test is required. However, AWS Specifications for most processes dealing with these steels provide an optional test for diffusible hydrogen. Percentage moisture in an electrode flux is not a good measure of the amount of diffusible hydrogen to be expected in a weld deposit. As mentioned in the discussion on Storage of Arc Welding Electrodes, above, the form in which the moisture is adsorbed on the surface, or absorbed deep into the flux materials, can have a strong effect on hydrogen content in the weld, The parameters used in making the weld (especially FCAW), and even the atmospheric moisture can affect the results. Figure 1.8 shows a typical welding fixture to hold the test piece during welding. An altemate method, which eliminates the dangers inherent in using mercury (Ha), is Gas Chromatography. In both test methods, a weld bead is depostted on a small plate held in a copper clamp, and then immediately quenched in water. It is then placed in a tube containing mercury, (see Figure 1.9 for a typical example) or in an enclosed capsule for Gas Chromatography. The time between depositing the weld, and containing it, is carefully controlled. The tubes, or capsules, are held for a specified time under closely controlled conditions so that the hydrogen can diffuse out. The amount of hydrogen evolved is measured and the hydrogen content of the weld metal is calculated. AWS A4.3 Standard Procedures for the Determination of the Diffusible Hydrogen Content of Martensitio, Bainitic and Ferritic Stee! Weld Metal Produced by Arc Welding covers both the mercury and the Gas Chromatographic methods. Also recognized in Canada is the ISO 3690 Determination of Hydrogen in Deposited Weld Metal Arising from the Use of Covered Electrodes for Welding Mild and Low Alloy Steels, which is for the mercury method only. Although the amount of moisture in different electrode coatings may not be an accurate measure of the effective diffusible hydrogen in the weld metal, it can be a very effective quality control parameter for a particular electrode. Electrode manufacturers can measure moisture levels quite rapidly, compared to diffusible hydrogen determination, and use them extensively in ‘ensuring that the electrode manufacturing process is operating correctly. 43') LEARNING CENTRE. Figure 1.8: Typical Copper Fixture for Determining Diffusible Hydrogen jin Weld Metal (fiom AWS A4.3) (Photo courtesy of Lincoln Electric Co, of Canad) op. [7 salto Tube 250mm Figure 1.9: Typical Eudiometer Tube and (from AWS A4.3) 160mm 63") ‘mercury (Ha) eles 44') LEARNING CENTRE ja E4818. 21°C (E7018, 7-F). COMA, oe 8 Sor BL 3s “\__ as manufactured Bot coating motu BL £ ger 2 |. \ __rtyerates fom o04% 2 snufacire costing moisture aL 7. er ° 02 oc 08 08 Coating Moisture, wi% Note: Fora given total moisture level, as manufactured moisture level is far more harmful than rehydrated moisture. Figure 1.10: Relation Between Moisture in a Typical Electrode Coating ‘and Weld Metal Hydrogen Content (From AWS A4.3) £4916(E7016), 0.08% Coating Moisture 8 28 5 7 Bs gs 104, 60% RH. ae t 86 F BO%RH, B35 6, 6% RI 3 t 22 s8F,60% RI 5 1 ° ° 10 20 30 40 ‘Atmospheric Moisture, mm Hg Partial Pressure of Water Vapour Figure 1.11: Approximate Effect of Atmospheric Moisture at Time of Welding on Diffusible Hydrogen with a Very Dry Covered Electrode (from: AWS A4.3-93) 45') LEARNING CENTRE. ‘The approximate relationship between the moisture content and the level of diffusible hydrogen is shown in Figure 1.10, which also shows the more harmful effect of the humidity coming from the manufacturing process compared to the absorbed humidity. The reason for this relates to the manufactured humidity in an electrode beng distributed evenly throughout the coating. Moisture absorbed by the coating after the electrode has been manufactured is generally close to the surface and may be eliminated from heating the electrode during the welding process. In Figure 1.11, the effect of the amount of moisture in the air at the time of welding is shown for a typical electrode. It must be understood that Figures 1.10 and 1.11 are for test results on a specific electrode. The results for a different electrode could be quite different. Nevertheless, it is obvious that basic electrodes should be kept dry if their low hydrogen properties are to be maintained. Figure 1.12: Electrode handling container to help reduce the rate of moisture pickup. (Not a substitute for heated storage) 46') LEARNING CENTRE 2.0 Solid Electrodes and Rods for Welding Solid electrodes and rods are used in many Hot Rolled Stee! Rod welding processes. (It is an electrode when itactually carries the current. Itis a rod when it does not carry the current, but is inserted into the weld pool as a filler metal.) In Descale, Pickle Draw io Size contrast to the core of covered electrodes, solid wires are usually made from steel aoe Fate. containing deliberate alloy additions. The Final Sizing general sequence for the manufacture of wires is shown in Figure 2.1 Wind-on Spool, Package ; Most solid welding wires have a thin coating of copper, which may assist with current Figure 2.1: Sequence in the Manufacture of Wires pick-up in the contact tube and prevent for Welding corrosion of the wire when stored. When these electrodes were first manufactured, the copper coating was used as a lubricant in the drawing process. Modem drawing lines do not need the help of copper. In fact, copper may actually cause trapping of other lubricants between the copper plating and the underlying steel. Welding personnel have become so used to the copper coating that manufacturers add it at the final sizing stage for the sake of appearance. Non-copper coated wires are becoming more popular since the requirements of nuclear reactor construction made extra low copper electrodes necessary. Welding performed with non-copper coated electrodes demonstrated that the copper coating was not necessary for gaod welds. In addition, some fears of the toxic effects of copper are supporting the increased use of non-copper coated electrodes. Solid wire electrodes and rods are available in a wide range of sizes and can be supplied in cut lengths, coils, spools or large drums, and pay-off packs. The sizes of wires, and the dimensions and weights of spools etc., are specified in relevant specifications or standards. 47') LEARNING CENTRE Figure 2.2: Wire Electrode Packaging Identification of the wire is most important and the outside of each package of certified electrodes must have at least the following information: + Classification and specification numbers + Suppliers’ name and trade designation + Electrode size and net weight + Lot, control, or heat number + Country of manufacture + statement that the electrode is certified by CWB Electrodes and wires may be tested in accordance with other designation systems such as AWS ‘specifications and a statement of compliance by the manufacturer must appear on the outside of the package. (ie., ER70S-3 per AWS A5.18) Welding standards and codes often specify the qualification requirements for filler metals and must be checked to ensure these requirements JO 48') LEARNING CENTRE 24 Cast and Helix ‘An important aspect of coiled wires is the unrestrained shape the wire takes up after it comes off the coil. This can have an important effect on the welding operation, particularly in robotic, applications, affecting arc wander or a misplaced weld bead. The cast is the diameter that a single loop of wire assumes when a length is cut from the coil and placed unrestrained on a flat surface. The helix is defined in the standards as the maximum distance from any point on the Wire to the flat surface when a single unrestrained loop is placed on that surface. The helix for all coils larger than 4 inch spools should not exceed 1 inch (24 mm). Figure 2.3 illustrates the meaning of cast and helix. Figure 2.3 2.2 Solid Carbon Steel Filler Metals for Gas Shielded Metal Arc Welding Wires for Gas Shielded Metal Arc Welding may be used as either an electrode (i.., forming part of the electrical circuit) as in Gas Metal Arc Welding (GMAW), or as a rod separately fed into the arc as in Gas Tungsten Arc Welding (GTAW). Although called carbon (or mild) steel, they do contain alloy elements which are used for deoxidation. These are mainly manganese and silicon but some wires may contain additional elements such as aluminum and titanium. Deoxidation is particularly important when carbon dioxide is used as the shielding gas, since this gas has a relatively high oxidation potential, reacting with the molten steel to form iron oxides. The amount of deoxidation required also depends on the type of steel being welded. More deoxidation is required for welding rimmed steel, than for semi-killed and killed steels. Rimmed steels contain comparatively large amounts of oxygen, and as a result, can be prone to creating porosity when Welded, The same is true when welding steel with rust or scale on it. 49") LEARNING CENTRE GMAW wire electrodes and deposits are specified by CSA W48-06. In the 2006 edition of ‘CSA W48, the designations and classifications have changed and are now specified as per CANICSA-ISO 14341. Since this change is relatively new, the old designations specified in CSA W48-01 will remain with us for some time to come. A cross reference of electrode designations is found in Table 24 CANCSAISO V841 | GSAWAB-OT | (CSAWHE.485) 36 @azcGo, BGdAZMGO or EREESG ERABOS-O BGMAZAGT = BCsA3CG2 ERGs? RABBI BoWa2cGa ERGs ERABOSS™ BGsAICG4ERAGS4—_ERAROS-a™ BowAaCGS ERAGS6 ERAROSE™ BG 48A3CG7 ER4SS-7, TeRaeo3s-7~ BGSASAGNE BGssPeAGNS — B.GSSPTAGNTI BG 55A3C GN2MGT — ‘Composition and shitting gases used shal be the same Not to be considered for equivalency Column 1 shal be consisered as equvalet to Columns 2 and forthe purpose of using exiting POR, WPDS, or ‘WPS. (Columns 3 & 4 are fr information only and are not censcered for equivalency Table 2.1: Cross Reference of GMAW Classifications Between Standards 50') LEARNING CENTRE Example: Minimum tensile strength of 490 MPa with impact of 275 ‘at -60°C in the AW condition using mix gas & wire G3 ‘chemical composition. Note: North America uses B system. 180 14341 Standard BB sysiem based on TS and impact 274 ‘A Asystem based on YS and impact 47) 6 Doposilgas shielded motal arc woldng Tensile Strength 43 TS=43010 600 MPa YS=330 MPa EL=20% 49 TS=490 0 670 MPa YS=390 MPa EL=18% '55 TS=550 0 740 MPa YS=460 MPA EL=17% 57 TS=57010 770 MPa YS=490 MPa EL=17% Impact specimens condition "As welded conation Post weld hoa treated conition “Temperature used for Impact Energy of27 J Z norequrements v20re ve 20°C 30°C aoe “oC “B0rc ‘Optional symbol for impact Energy of 47 J u Shieling Gas © 100% co. M Ar#20%025% CO, A A+ 1108%0, Chemical Composition Geox 38 cferent chemical composions for 8 system Figure: 2.4 51') LEARNING CENTRE. The old version of CSA Standard W48-01, and AWS Specification A5.18-93, covered solid mild steel filler metals for gas shielded arc welding. The meaning of the symbols used for classification is explained as follows: ER 49 S—X Lhasa ee exons Solid Wire Rod (lor GTAW, PAW or OFW) 49 = minimum tensile strong in MPa/10 which means 490 MPa as per WAB) 70= minimum tensile strength in ksi (AWS AS. 18-83), Figure: 2.5 Note that the welding position is not included in the classification as it is with covered or tubular electrodes. The ability to weld out-of-position is actually determined by the wire diameter, shielding gas and mode of metal transfer. The chemical requirements for these wires are summarized in Table 2.2. Minor differences between the AWS and CSA Standards are to be noted, but are not significant in regard to the behaviour of the wires. The various classifications differ mainly in the level of deoxidizing elements contained in the wires. Gasification ‘Gherieal Composition" — — Was.01 ‘S. 7 a a Buss2 | 40_| Wao 07O__| 0951 OTS [OUI Gost0O 18 | ERAS 3 (0.9010 140 | 045 t0 0.75 5 fs ERAS «| 0010 1.50 [065 100.95 : EROS 5 [09010 1.40 [03010060 [0060.90 ERASE 140 to 185 | O80 115. FRIST 16010200 [05010080 a ERAS S ‘Chanical Requirements. ae Notes: 4, Single values shown are maximum, 2. Total copper content, including any coating, shall be 0.50% maximum, ‘3. Sulphur is 0.035% maximum, and phosphorus is 0.025% maximum, 4. AWS A5.18 silicon is 0.65 to 0.85 ‘5. Mangenese may exceed the 2.00, provided carbon maximum levels are reduced 0.01% for leach 0,05% increase in manganese. Table 2.2: CSA W48-01 and AWS AS.18 Chemical Requirements for GMAW Electrodes and GTAW Rods 52') LEARNING CENTRE 2.3 Specific Electrode Types ‘The main characteristics of the wires are as follows. (CAN/CSA-ISO 14341 Electrodes in Brackets) 2.3.1 ER49S-2 (B-G49A 3062) This classification covers multiple deoxidized stee! filer metals which contain nominal amounts of zirconium, titanium and aluminum in addition to the silicon and manganese content. These filer metals are capable of producing sourd welds in semi-illed and rimmed steels, especially using the short-circuiting mode of metal transfer, as well as in killed steels of various carbon levels. Because of the added deoxidants they can be used for welding steels that have a rusty or dirty surface, with a possible sacrifice of weld quality depending upon the degree of surface contamination. These filler metals can be used with CO,, argon-oxygen or argon-CO, shielding gases. Although the nominal amounts of titanium, zirconium and aluminum contribute to deoxidation of weld metal during welding of rimming and semi-tilled steels, the amounts remaining in the finished weld are generally too low to adversely affect impact levels. This is a triple deoxidized steel electrode which is capable of making sound welds in rimmed and semi-killed steels even whan some rusty conditions exist. Shielding gases permitted are carbon dioxide, argon and oxygen (1-5% 02)and argon-CO, mixtures. 2.3.2 ER49S-3 (B-G49A 2CG3) ‘These filler metals are used for single-pass and multiple-pass welds, especially when welding killed and semi-killed steel. They can be used for out-of-position welding with small diameter electrodes using the short-circuiting type transfer with argon-O, or argon-CO, shielding gases. Carbon dioxide shielding gas will result in a greater loss of alloying elements than in the case of argon-oxygen (1-5%) or argon-CO,, (5-25%) applications. This may result in some loss of tensile strength, especially if high heat inputs are used. 2.3.3 ER49S-4 (B-G49A 3CG4) These filler metals contain slightly more manganese and silicon than the ER49S-3 classification and produce a weld deposit of higher tensile strength. The primary use for these electrodes is for CO, shielded applications where a slightly longer arc or base metal conditions or both require more deoxidation than filler metals of the ER49S-3 classification provide. The ER49S-4 classification of electrodes is considered to be intermediate between the ER49S-3 & ER49S-6 types, combining some of the advantages of both classifications. 53’) LEARNING CENTRE 23.5 ER49S-6 (B-G49A 308) Filler metals of this classification have the highest combination of manganese and silicon and will produce welds that will meet the highest impact property requirements of this Standard when using CO, shielding gas. They may be used with high currents when welding rimmed steels and may also be used to weld sheet metal where smooth weld beads are desired. They can be used for out-of-position welding using the short-circuiting mode of transfer. These filler metals can be used for welding steels that have a rusty or dirty surface with a possible sacrifice of weld quality, depending upon the degree of surface contamination. The high levels of manganese and silicon in the filler metal cause this classification to be particularly liable to give welds of higher strength and lower ductility when used with shielding gases of low oxidation potential. A minimum oxygen potential shielding gas is usually needed to prevent excess hardness resulting from retaired manganese in the deposit. 2.3.6 ER49S-7 (B-G49A 3CG7) These electrodes have higher manganese, but lower silicon, contents when compared to the ER49S-6 classification. This provides slighty better wetting action and improved weld appearance and may permit higher welding speads. They are generally recommended for use with argon-oxygen shielding gas, but are also usable with argon-CO, and CO, shielding. 23.7 ER49S-G (B-G49A ZCGO) (B-G49A MGO) (B-G49A AGO) This classification is for filler metals which do not meet all the requirements of any of the preceding classes. They are not required to meet any specific chemistry requirements and are Not tested for impact values, but must meet all the other requirements of this Standard. The filer metal supplier should be consulted for the characteristics and intended use of these filler metals. 2.4 Welding Conditions and Shielding Gases In all cases, except the ER495-G, the filler metal qualification test is performed with 100% CO, shielding gas. (The shielding for the “G" classification is not specified, and is by arrangement with the electrode manufacturer.) CSA W48 specifies the range of shielding gas composition") LEARNING CENTRE qualified with each electrode classification, based on the amount of deoxidants in the wire. The Qualified range of shielding gas composition is based upon a formula which establishes “Oxygen Equivalent’. The formula for calculating oxygen equivalent is: OE (%) = (%0) + 0.5(%CO2) For those electrode classifications with lower levels of Mn and Si, ER49S-2, ER49S-3 and ER49S-4, the Oxygen Equivalent (OE) shall be not less than 2.0%. For the electrodes having higher Mn and Si contents, ER49S-6 and ER49S-7, OE shall be not less than 4.0%. Shielding gases may contain up to 5% O, and 30% He. The chemical composition of the weld metal will vary with shielding gas used. The use of mixtures of argon with CO, andlor O,, with or without additions of helium, will increase the levels ‘of manganese and silicon in the weld deposit as compared with CO, shielding. Increasing the ‘amount of alloy elements in the weld metal may result in higher tensile and yield strengths and correspondingly lower elongations. It may also affect impact properties. Users are cautioned that shielding gases of low oxidation potential should be used only after consultation with the electrode manufacturer, and careful evaluation of the welding procedure since such gases may lead to tensile strengths higher than the maximum, and elongations below the minimum allowable in CSA W48. 2.5 Mode of Metal Transfer 2.5.1, General Gas metal arc welding can be divided into three categories based on the mode of metal transfer. These are known as spray, globular and short-circuiting transfer. Spray transfer occurs as a stream of fine droplets. In globular trans‘er, the drops are typically larger than the electrode diameter and more erratic transfer can result. Short-circuiting transfer, also known as dip transfer, deposits the weld metal by frequent short-circuiting of the electrode into the weld puddle. 2.5.2 Transition Point Axial-spray transfer in argon-rich shielding gases is mainly related to the magnitude and polarity of the arc current and the electrical resistance heating of the electrode. The high droplet rate (Le, 250 droplets/sec or more) develops suddenly above a critical current level, commonly referred to as the transition current. Below this current, the metal is transferred in drops generally larger in diameter than the electrode at a rate from 10 to 20droplets/sec (globular transfer). The transition current is dependent to a great extent upon current density, electrical stick-out and electrode composition, as well as the shielding gas. (See Module 4) For 1.6 mm 55) LEARNING CENTRE (1/16 in) diameter mild stee! electrodes, with argon plus oxygen shielding, a transition current of 270.A(DCEP) is common. Alternating current is not recommended. 25.3 Spray Transfer Spray transfer welding of carbon steels is most commonly done with argon plus oxygen in the range 2-5%, or argon plus CO, in the range 5-15%. A characteristic of spray transfer welding is the smooth arc plasma, with a distinctive “Humm’, through which hundreds of droplets per second are transferred axially from the electrode to the weld puddle. If the current is below the transition point for a given size of electrode, trarsfer tends to be globular and erratic. 2.54 Globular Transfer With 100% CO, as the shielding gas, the transition level is practically never exceeded and thus spray transfer is not obtained. At high current values, transfer will occur at rates of 30 to 70 globules/second. The globules are usually larger in diameter than the electrode. With a current near 275 A for a 1.2 mm diameter electrode, or 350 A for a 1.6 mm size, relatively small welds can be obtained with deep penetration and high tavel speeds. To minimize spatter, itis common practice to keep arc voltage low, which “buries” the arc below the work surface. At lower current levels stable transfer can be produced a rate of only a few droplets/second. This type of transfer produces smooth beads but only shallow penetration. Its use is commonly restricted to fill and ‘capping passes of vertical welds. 2.5.5 Short-circuiting Transfer This mode of GMAW transfer is generally used with smaller diameter (0.8 - 1.2 mm) electrodes. Arc voltages and currents are lower than for spray transfer. The electrode feed rate is higher than the burn-off rate, and the electrode actually touches the surface of the work piece. The surge of current resulting from this short-circuit melts the electrode tip and re-establishes the arc, when the process starts again. The rate at whic1 these short-circuits occur can vary from 50 to 250 times per second. Metal transfers from eectrode to work piece during the short circuit period. Little or no transfer occurs across the arc itself. Short-circuiting GMA welding of carbon steels is most commonly done with 100% CO, or argon- CO, mixtures. Penetration is usually greater with the pure CO,, compared to A + CO, Use of argon containing 60 - 80% CO, can result in a higher short-circuiting rate with lower currents and voltages, which can be an advantage when welding thin sheet. 56') LEARNING CENTRE 2.5.6 Pulsed - Spray Transfer In pulsed arc welding, the mode of transferis generally spray, although the average current may be well below the transition current needed for spray. This is made possible by using a relatively low “back-ground” current with a pulses of high current superimposed on it. The background current is sufficient to maintain the arc, but cannot give the spray type transfer on its own. At the peaks of the pulses, transfer of weld metal droplets ocours in spray mode. The background current then maintains a stable arc while reshaping the electrode end in preparation for the next droplet detachment. (See Moulde 4). Typisally, only one or two droplets will be “squeezed off” during each pulse of current. This mode permits out-of-position welding, but with the advantages of the deeper penetration and lower spatter levels usually associated with spray transfer. 2.6 Tensile Properties of As-Welded Deposits ‘The CSA W48 mechanical properties requirements for all classifications of solid carbon steel filler metals are as follows: Tensile Strength | ~~ 490-650 Mpa” 14-942 ksi) AWS A5.18-93 requirements are similar but, being strictly a classification document rather than a certification standard, it does not have eny restrictions on oxidation potential of the shielding gas, nor does it impose a maximum on the tensile strength of the weld metal 2.7 Impact Properties of As-welded Deposits The only major difference between the CSA and AWS documents is that impact properties are defined in “Joules” at a Celsius temperature in the former, whilst the latter gives “foot-pounds” at Fahrenheit temperatures. No impact levels are specified for ER49S-5 or ER49S-G. For ER49S-3, the requirement is 27J @ -20°C (or 20f-Ib @ 0°F). For all others except ER70S-4, impact toughness must meet a minimum of 27J @ -30°C (20f-Ib @ -20°F). The ER70S-4 under AWS A5.18 has no impact requirements. (It also has a slightly different chemical analysis range.) 57') LEARNING CENTRE 3.0 Flux- and Metal-Cored Wires The flux-cored arc welding (FCAW) process employs wires comprising an outer metal sheath with a core containing fluxing and alloying components. Some wires are designed to be used with a shielding gas in a manner similar to gas metal arc welding, whereas others can be used without any additional shielding gas. In a relatively recent innovation, wires have been introduced which have cores comprising metal powders and only small additions of arc stabilizers and fluxing ingredients. These are generally referred to as metal-cored, or composite, wires. Certain cored wires can also be used with the submerged arc process, and these will be discussed in a later section. In many cases, wren reference is made to flux-cored arc welding electrodes, the term is (incorrectly) assumed to embrace both flux-cored and metal-cored electrodes. However, although the distinction becomes blurred at high metal and low flux contents, this text will endeavour to maintain the correct distinction, Flux or ‘Metal Powder and Arc Stabilizers Figure 3.1: FCAWIMCAW Process 58') LEARNING CENTRE Flux- and metal-cored wires are available as coils without supports, coils with supports, spools, or in drums and pay-off packs. Figure 3.2: FCAW Packaging Identification of the wire is most important and the outside of each package of certified electrodes will have at least the following information: + Classification and specification numbers + Suppliers’ name and trade designation + Electrode size and net weight + Lot, control, or heat number + Country of Manufacture + Astatement that the electroda is certified by CWB Electrodes and wires may be tested in accordance with other designation systems such as AWS ‘specifications, and a statement of compliance by the manufacturer must appear on the outside of the package. (ie., £71T-9 per AWS A5.20) Welding standards and codes often specify the qualification requirements for filler metals and must be checked to ensure these requirements are being met ‘The sequence of manufacture of flux- and metal-cored wires is summarized in Figure 3.3 and the fabrication method is illustrated in Figure 3.4. A steel strip is passed through a set of rolls 59LEARNING CENTRE ‘which form it into a U shape. The flux is poured in, maintaining a careful steelflux ratio, and the U closed up to make a tubular wire which is then drawn down to final size. Sometimes the wire receives a baking treatment during manufacture depending on the type of wire and flux formulation. The type of closure may vary and examples of various cross-sections are illustrated in Figure 3.5. The close-butt joint illustrated on the left is the type most often encountered now. Generally, cored wires are not copper coated because there is @ seam along the wire. However, seamless wires are made by drawing down seemless tubes filled with flux, and these may be copper coated. Mild Stee! Strip Core Ingredients Weigh and combine Dry mix formula Fabricate into tube Draw to size ‘Spool and package Figure 3.3: Sequence of Manufacture of Flux Cored Wires 60" LEARNING CENTRE flux hopper flux poured at “U” forming rolls this point reel of formed electrode Fig. 3.4: Simplified Schematic of the Manufacture of Flux Cored Wires. Butt Folded Overlap Fig. 3.5: Typical Cross-Section of Flux Cored Wires Cored wires are available in a range of diameters from more than 3.2mm (1/8 inch) to less than (0.8mm (0.030 inch). The 1.6mm (1/16 inch) may be the most widely used, although 1.2mm (0.045 inch) is also used in many applications. The availabilty of the very small diameters has allowed the use of flux cored wires in welding in the vertical and overhead positions. 61') LEARNING CENTRE. 3.1. Types of Flux Cored Wires As with covered electrodes, the operating characteristics and the resulting weld metal properties, of flux- and metal-cored wires depend largely on the composition of the filing. They are broadly divided into two main classes, those intended for use with an extemal gas shield and those operating without a separate gas shield (self-stielding types). The self-shielded types can be very complex and contain elements to compensate for the effects of oxygen and nitrogen absorbed from the air, which can also affect the operating characteristics. 3.1.1. Gas Shielded Electrodes Within the gas shielded classifications, the avalable wires can be broadly grouped into three major categories: + Rutile, or titania, types + Lime, or basic, types + Metal cored types In Canada, CSA W48 covers in the same tables, the classification of both flux and metal cored electrodes. In the U.S., flux cored and metal cored electrodes are separated. The flux cored electrodes are classified in AWS AS5.20, while metal cored electrodes are included in the solid wire specification AWS A5.18. The two flux cored categories operate with very different welding characteristics. The rutile types operate on DCEP and generally give a smooth, spray type arc with litle spatter. The weld bead is flat to slightly convex and the slag completely covers the bead. Out of position welding is often possible with smaller diameters. Rutile classifications are the E49XT-1, E49XT-2, E49XT-9 and E49XT-12. (Where the X indicates either 1 or 2.) The basic cored wires are more difficult to handle, and thus have lower ‘welder appeal”. They operate on either DCEP or DCEN, and are characterized by a globular type transfer, convex beads and a thin slag which may not fully cover the bead. They are not as easily used out of position, but some electrodes can give acceptatle vertical and overhead welds with DCEN and small diameters. They typically give welds with superior impact properties, and have a high resistance to hot and cold cracking. The basic classification is E49XT-5. Metal-cored electrodes are somewhat similar to the rutile electrodes in operation, but exhibit some of the characteristics of solid wires. The arc is smooth, with low spatter, and the transfer is in the form of fine globules. With argon-CO, mixtures, a pure spray transfer can be obtained. The weld bead is flat to slightly convex, and slag volume is low, usually consisting of small islands. It should be noted that the definition of a metal cored wire differs between CSA and 62