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Lesson 1
The Basics of Arc

Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
BASIC
for Welding
Mild Steels WELDING FILLER METAL
Lesson 4
TECHNOLOGY
Covered Electrodes
for Welding Low
Alloy Steels
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy LESSON I
Steel Filler Metals -
GMAW,GTAW,SAW THE BASICS OF ARC WELDING
Lesson 7
An Introduction to Metals
Flux Cored Arc
Electricity for Welding
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
©COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 1
The Basics of Arc
Welding
Lesson 2
TABLE OF CONTENTS
Common Electric
Arc Welding
LESSON I
Processes THE BASICS OF ARC WELDING
Lesson 3
Covered Electrodes
for Welding
PART A. AN INTRODUCTION TO METALS
Mild Steels
Section Nr. Section Title Page
Lesson 4 1.1 Source and Manufacturing............................................................. 1

Covered Electrodes 1.1.1 Rimmed Steel ................................................................................... 2
for Welding Low
Alloy Steels 1.1.2 Capped Steel .................................................................................... 2
1.1.3 Killed Steel ........................................................................................ 3
1.1.4 Semi-Killed Steel............................................................................... 3
Lesson 5
1.1.5 Vacuum Deoxidized Steel ................................................................. 3
for Stainless Steels 1.2 Classification of Steels................................................................... 3
1.2.1 Carbon Steel ..................................................................................... 3
1.2.2 Low Alloy Steel.................................................................................. 3
Lesson 6 1.2.3 High Alloy Steel ................................................................................. 4
Carbon & Low Alloy
Steel Filler Metals - 1.3 Specifications ................................................................................. 5
GMAW,GTAW,SAW 1.4 Crystalline Structure of Metals ...................................................... 6
1.4.1 Grains and Grain Boundaries ........................................................... 7
Lesson 7 1.5 Heat Treatment ................................................................................ 8
Flux Cored Arc 1.5.1 Preheat ............................................................................................. 8
Electrodes Carbon
Low Alloy Steels 1.5.2 Stress Relieving ................................................................................ 9
1.5.3 Hardening ......................................................................................... 9
1.5.4 Tempering ......................................................................................... 9
Lesson 8 1.5.5 Annealing .......................................................................................... 9
Hardsurfacing
Electrodes 1.5.6 Normalizing ....................................................................................... 10
1.5.7 Heat Treatment Trade-Off ................................................................. 10
1.6 Properties of Metals........................................................................ 10
Lesson 9 1.6.1 Tensile Strength ................................................................................ 10
Estimating &
1.6.2 Yield Strength.................................................................................... 11
Comparing Weld
Metal Costs 1.6.3 Ultimate Tensile Strength .................................................................. 11
1.6.4 Percentage of Elongation ................................................................. 11
Lesson 10
Filler Metals
© COPYRIGHT 1998 THE ESAB GROUP, INC

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON I - Con't.
Lesson 2
Common Electric
Arc Welding Section Nr. Section Title Page
Processes
1.6.5 Reduction of Area ............................................................................. 11

Lesson 3 1.6.6 Charpy Impacts ................................................................................. 11
Covered Electrodes
for Welding 1.6.7 Fatigue Strength ............................................................................... 12
Mild Steels 1.6.8 Creep Strength.................................................................................. 13
1.6.9 Oxidation Resistance ........................................................................ 13
Lesson 4 1.6.10 Hardness Test ................................................................................... 13
Covered Electrodes 1.6.11 Coefficient of Expansion ................................................................... 14
for Welding Low
Alloy Steels 1.6.12 Thermal Conductivity ........................................................................ 14
1.7 Effects of Alloying Elements .......................................................... 14
1.7.1 Carbon .............................................................................................. 14
Lesson 5
1.7.2 Sulphur ............................................................................................. 14
for Stainless Steels 1.7.3 Manganese ....................................................................................... 15
1.7.4 Chromium ......................................................................................... 15
1.7.5 Nickel ................................................................................................ 15
Lesson 6 1.7.6 Molybdenum ..................................................................................... 15
Carbon & Low Alloy
Steel Filler Metals - 1.7.7 Silicon ............................................................................................... 15
GMAW,GTAW,SAW 1.7.8 Phosphorus....................................................................................... 15
1.7.9 Aluminum .......................................................................................... 15
Lesson 7 1.7.10 Copper .............................................................................................. 15
Flux Cored Arc 1.7.11 Columbium........................................................................................ 16
Electrodes Carbon
Low Alloy Steels 1.7.12 Tungsten ........................................................................................... 16
1.7.13 Vanadium .......................................................................................... 16
1.7.14 Nitrogen ............................................................................................ 16
Lesson 8 1.7.15 Alloying Elements summary ............................................................. 16
Hardsurfacing
Electrodes
PART B. ELECTRICITY FOR WELDING

Lesson 9
Estimating & 1.8 Electricity for Welding ....................................................................... 17
Comparing Weld 1.8.1 Principles of Electricity ...................................................................... 17
Metal Costs
1.8.2 Ohm’s Law ........................................................................................ 18
1.8.3 Electrical Power ................................................................................ 19
1.8.4 Power Generation ............................................................................. 20
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
` TABLE OF CONTENTS
LESSON I - Con't.
Lesson 2
Common Electric
Processes
1.8.5 Transformers .................................................................................... 22

Lesson 3 1.8.6 Power Requirements ........................................................................ 24
Covered Electrodes
for Welding 1.8.7 Rectifying AC to DC .......................................................................... 25
Mild Steels 1.9 Constant Current or Constant Voltage .............................................. 26
1.9.1 Constant Current Characteristics ...................................................... 26
Lesson 4 1.9.2 Constant Voltage Characteristics ...................................................... 26

Covered Electrodes 1.9.3 Types of Welding Power Sources ..................................................... 27
for Welding Low
Alloy Steels 1.9.4 Power Source Controls ..................................................................... 28
Appendix A Glossary of Terms ............................................................................. 29

Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON I, PART A
The Basics of Arc
Welding
AN INTRODUCTION TO METALS
Lesson 2
Common Electric 1.1 SOURCE AND MANUFACTURING
Arc Welding
Processes
Metals come from natural deposits of ore in the earth’s crust. Most ores are contaminated
with impurities that must be removed by mechanical and chemical means. Metal extracted
Lesson 3 from the purified ore is known as primary or virgin metal, and metal that comes from scrap
Covered Electrodes
for Welding is called secondary metal. Most mining of metal bearing ores is done by either open pit or
Mild Steels underground methods. The two methods of mining employed are known as “selective” in
which small veins or beds of high grade ore are worked, and “bulk” in which large quantities
Lesson 4 of low grade ore are mined to extract a high grade portion.
Covered Electrodes
for Welding Low 1.1.0.1 There are two types of ores, ferrous and nonferrous. The term ferrous comes
Alloy Steels
from the Latin word “ferrum” meaning iron, and a ferrous metal is one that has a high iron
content. Nonferrous metals, such as copper and aluminum, are those that contain little or
Lesson 5 no iron. There is approximately 20 times the tonnage of iron in the earth’s crust compared
to all other nonferrous products combined; therefore, it is the most important and widely
used metal.
1.1.0.2 Aluminum, because of its attractive appearance, light weight and strength, is the
Lesson 6
Carbon & Low Alloy next most widely used metal. Commercial aluminum ore, known as bauxite, is a residual
Steel Filler Metals - deposit formed at or near the earth’s surface.
GMAW,GTAW,SAW
1.1.0.3 Some of the chemical processes that occur during steel making are repeated
Lesson 7 during the welding operation and an understanding of welding metallurgy can be gained by
Flux Cored Arc imagining the welding arc as a miniature steel mill.
Electrodes Carbon
Low Alloy Steels
1.1.0.4 The largest percentage of commercially produced iron comes from the blast
furnace process. A typical blast furnace is a circular shaft approximately 90 to 100 feet in
Lesson 8 height with an internal diameter of approximately 28 feet. The steel shell of the furnace is
Hardsurfacing lined with a refractory material, usually a hard, dense clay firebrick.
Electrodes
1.1.0.5 The iron blast furnace utilizes the chemical reaction between a solid fuel charge
and the resulting rising column of gas in the furnace. The three different materials used for
Lesson 9
Estimating & the charge are ore, flux and coke. The ore consists of iron oxide about four inches in
Comparing Weld diameter. The flux is limestone that decomposes into calcium oxide and carbon dioxide.
Metal Costs
The lime reacts with impurities in the ore and floats them to the surface in the form of a
slag. Coke, which is primarily carbon, is the ideal fuel for blast furnaces because it
produces carbon monoxide gas, the main agent for reducing iron ore into iron metal.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.1.0.6 The basic operation of the blast furnace is to reduce iron oxide to iron metal and
to remove impurities from the metal. Reduced elements pass into the iron and oxidized
Lesson 2 elements dissolve into the slag. The metal that comes from the blast furnace is called pig
Common Electric
Arc Welding iron and is used as a starting material for further purification processes.
Processes
1.1.0.7 Pig iron contains excessive amounts of elements that must be reduced before
steel can be produced. Different types of furnaces, most notably the open hearth, electric
Lesson 3
and basic oxygen, are used to continue this refining process. Each furnace performs the
Covered Electrodes
for Welding task of removing or reducing elements such as carbon, silicon, phosphorus, sulfur and
Mild Steels nitrogen by saturating the molten metal with oxygen and slag forming ingredients. The
oxygen reduces elements by forming gases that are blown away and the slag attracts
Lesson 4 impurities as it separates from the molten metal.
Covered Electrodes
for Welding Low 1.1.0.8 Depending upon the type of slag that is used, refining furnaces are classed as
Alloy Steels
either acid or basic. Large amounts of lime are contained in basic slags and high quantities
of silica are present in acid slags. This differential between acid and basic slags is also
Lesson 5 present in welding electrodes for much of the same refining process occurs in the welding
operation.
1.1.0.9 After passing through the refining furnace, the metal is poured into cast iron ingot
molds. The ingot produced is a rather large square column of steel. At this point, the metal
Lesson 6
Carbon & Low Alloy is saturated with oxygen. To avoid the formation of large gas pockets in the cast metal, a
Steel Filler Metals - substantial portion of the oxygen must be removed. This process is known as deoxidation,
GMAW,GTAW,SAW
and it is accomplished through additives that tie up the oxygen either through gases or in
slag. There are various degrees of oxidation, and the common ingots resulting from each
Lesson 7 are as follows:
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 1.1.1 Rimmed Steel - The making of rimmed steels involves the least deoxidation. As
the ingots solidify, a layer of nearly pure iron is formed on the walls and bottom of the mold,
and practically all the carbon, phosphorus, and sulfur segregate to the central core. The
Lesson 8 oxygen forms carbon monoxide gas and it is trapped in the solidifying metal as blow holes
Hardsurfacing
Electrodes that disappear in the hot rolling process. The chief advantage of rimmed steel is the excel-
lent defect-free surface that can be produced with the aide of the pure iron skin. Most
rimmed steels are low carbon steels containing less than .1% carbon.
Lesson 9
Estimating & 1.1.2 Capped Steel - Capped steel regulates the amount of oxygen in the molten
Comparing Weld
Metal Costs metal through the use of a heavy cap that is locked on top of the mold after the metal is
allowed to reach a slight level of rimming. Capped steels contain a more uniform core
composition than the rimmed steels. Capped steels are, therefore, used in applications
Lesson 10
Filler Metals

The Basics of Arc
Welding
that require excellent surfaces, a more homogenous composition, and better mechanical
properties than rimmed steel.
Lesson 2
Common Electric 1.1.3 Killed Steel - Unlike rimmed or capped steel, killed steel is made by completely
Arc Welding
Processes removing or tying up the oxygen before the ingot solidifies to prevent the rimming action.
This removal is accomplished by adding a ferro-silicon alloy that combines with oxygen to
form a slag, leaving a dense and homogenous metal.
Lesson 3
Covered Electrodes 1.1.4 Semi-killed Steel - Semi-killed steel is a compromise between rimmed and killed
for Welding
Mild Steels steel. A small amount of deoxidizing agent, generally ferro-silicon or aluminum, is added.
The amount is just sufficient to kill any rimming action, leaving some dissolved oxygen.
Lesson 4 1.1.5 Vacuum Deoxidized Steel - The object of vacuum deoxidation is to remove
Covered Electrodes
for Welding Low oxygen from the molten steel without adding an element that forms nonmetallic inclusions.
Alloy Steels This is done by increasing the carbon content of the steel and then subjecting the molten
metal to vacuum pouring or steam degassing. The carbon reacts with the oxygen to form
Lesson 5 carbon monoxide, and as a result, the carbon and oxygen levels fall within specified limits.
Welding Filler Metals Because no deoxidizing elements that form solid oxides are used, the steel produced by
this process is quite clean.
Lesson 6 1.2 CLASSIFICATIONS OF STEEL

Carbon & Low Alloy
Steel Filler Metals - The three commonly used classifications for steel are: carbon, low alloy, and high alloy.
GMAW,GTAW,SAW
These are referred to as the “type” of steel.
Lesson 7 1.2.1 Carbon Steel - Steel is basically an alloy of iron and carbon, and it attains its
Flux Cored Arc strength and hardness levels primarily through the addition of carbon. Carbon steels are
Electrodes Carbon
Low Alloy Steels classed into four groups, depending on their carbon levels.
Low Carbon Up to 0.15% carbon
Lesson 8 Mild Carbon Steels .15% to 0.29% carbon

Hardsurfacing Medium Carbon Steels .30% to 0.59% carbon
Electrodes
High Carbon Steels .60% to 1.70% carbon
Lesson 9 1.2.1.1 The largest tonnage of steel produced falls into the low and mild carbon steel
Estimating & groups. They are popular because of their relative strength and ease with which they can
Comparing Weld
Metal Costs be welded.
1.2.2 Low Alloy Steel - Low alloy steel, as the name implies, contains small amounts
Lesson 10 of alloying elements that produce remarkable improvements in their properties. Alloying
Filler Metals

The Basics of Arc
Welding
elements are added to improve strength and toughness, to decrease or increase the
response to heat treatment, and to retard rusting and corrosion. Low alloy steel is gener-
Lesson 2 ally defined as having a 1.5% to 5% total alloy content. Common alloying elements are
Common Electric
Arc Welding manganese, silicon, chromium, nickel, molybdenum, and vanadium. Low alloy steels may
Processes contain as many as four or five of these alloys in varying amounts.
1.2.2.1 Low alloy steels have higher tensile and yield strengths than mild steel or carbon
Lesson 3
structural steel. Since they have high strength-to-weight ratios, they reduce dead weight in
Covered Electrodes
for Welding railroad cars, truck frames, heavy equipment, etc.
Mild Steels
1.2.2.2 Ordinary carbon steels, that exhibit brittleness at low temperatures, are unreliable
in critical applications. Therefore, low alloy steels with nickel additions are often used for
Lesson 4
Covered Electrodes low temperature situations.
for Welding Low
Alloy Steels 1.2.2.3 Steels lose much of their strength at high temperatures. To provide for this loss
of strength at elevated temperatures, small amounts of chromium or molybdenum are
Lesson 5 added.
for Stainless Steels 1.2.3 High Alloy Steel - This group of expensive and specialized steels contain alloy
levels in excess of 10%, giving them outstanding properties.
Lesson 6 1.2.3.1 Austenitic manganese steel contains high carbon and manganese levels, that
Carbon & Low Alloy give it two exceptional qualities, the ability to harden while undergoing cold work and great
GMAW,GTAW,SAW toughness. The term austenitic refers to the crystalline structure of these steels.
1.2.3.2 Stainless steels are high alloy steels that have the ability to resist corrosion. This
Lesson 7 characteristic is mainly due to the high chromium content, i.e., 10% or greater. Nickel is
Flux Cored Arc
Electrodes Carbon also used in substantial quantities in some stainless steels.
Low Alloy Steels
1.2.3.3 Tool steels are used for cutting and forming operations. They are high quality
steels used in making tools, punches, forming dies, extruding dies, forgings and so forth.
Lesson 8 Depending upon their properties and usage, they are sometimes referred to as water
Hardsurfacing
Electrodes hardening, shock resisting, oil hardening, air hardening, and hot work tool steel.
1.2.3.4 Because of the high levels of alloying elements, special care and practices are
Lesson 9 required when welding high alloy steels.

Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.3 SPECIFICATIONS
Lesson 2 Many steel producers have developed steels that they market under a trade name such as
Common Electric Cor-Ten, HY-80, T-1, NA-XTRA, or SS-100, but usually a type of steel is referred to by its
Arc Welding
specification. A variety of technical, governmental and industrial associations issue
Processes
specifications for the purpose of classifying materials by their chemical composition,
properties or usage. The specification agencies most closely related to the steel industry
Lesson 3 are the American Iron and Steel Institute (AISI), Society of Automotive Engineers (SAE),
Covered Electrodes
for Welding American Society for Testing and Materials (ASTM), and the American Society of
Mild Steels Mechanical Engineers (ASME).
1.3.0.1 The American Iron and Steel Institute (AISI) and the Society of Automobile
Lesson 4
Covered Electrodes Engineers (SAE) have collaborated in providing identical numerical designations for their
for Welding Low specifications. The first two digits of a four digit index number refer to a series of steels
Alloy Steels
classified by their composition or alloy combination. While the last two digits, which can
change within the same series, give an approximate average of the carbon range. For
Lesson 5 example, the first two digits of a type 1010 or 1020 steel indicate a “10” series that has
carbon as its main alloy. The last two digits indicate an approximate average content of
.10% or .20% carbon, respectively. Likewise, the “41” of a 4130 type steel refers to a group
that has chromium and molybdenum as their main alloy combination with approximately
Lesson 6 .30% carbon content.
Carbon & Low Alloy
Steel Filler Metals - 1.3.0.2 The AISI classifications for certain alloys, such as stainless steel, are somewhat
GMAW,GTAW,SAW
different. They follow a three digit classification with the first digit designating the main
alloy composition or series. The last two digits will change within a series, but are of an
Lesson 7 arbitrary nature being agreed upon by industry as a designation for certain compositions
Flux Cored Arc
Electrodes Carbon within the series. For example, the “3” in a 300 series of stainless steel indicates chromium
Low Alloy Steels and nickel as the main alloys, but a 308 stainless has a different overall composition than a
347 type. The “4” of a 400 series indicates the main alloy as chromium, but there are
different types such as 410, 420, 430, and so forth within the series.
Lesson 8
Hardsurfacing
Electrodes 1.3.0.3 The American Society for Testing and Materials (ASTM) is the largest
organization of its kind in the world. It has compiled some 48 volumes of standards for
materials, specifications, testing methods and recommended practices for a variety of
Lesson 9 materials ranging from textiles and plastics to concrete and metals.
Estimating &
Comparing Weld
Metal Costs 1.3.0.4 Two ASTM designated steels commonly specified for construction are A36-77
and A242-79. The prefix letter indicates the class of a material. In this case, the letter “A”
indicates a ferrous metal, the class of widest interest in welding. The numbers 36 and 242
Lesson 10
Filler Metals

The Basics of Arc
Welding
are index numbers. The 77 and 79 refer to the year that the standards for these steels
were originally adopted or the date of their latest revision.
Lesson 2
Common Electric 1.3.0.5 The ASTM designation may be further subdivided into Grades or Classes. Since
Arc Welding many standards for ferrous metals are written to cover forms of steel (i.e., sheet, bar, plate,
Processes
etc.) or particular products fabricated from steel (i.e., steel rail, pipe, chain, etc.), the user
may select from a number of different types of steel under the same classification. The
Lesson 3 different types are than placed under grades or classes as a way of indicating the
Covered Electrodes
for Welding differences in such things as chemistries, properties, heat treatment, etc. An example of a
Mild Steels full designation is A285-78 Grade A or A485-79 Class 70.
1.3.0.6 The American Society of Mechanical Engineers (ASME) maintains a widely used
Lesson 4
ASME Boiler and Pressure Vessel Code. The material specification as adopted by the
Covered Electrodes
for Welding Low ASME is identified with a prefix letter “S”, while the remainder is identical with ASTM with
Alloy Steels the exception that the date of adoption or revision by ASTM is not shown. Therefore, a
common example of an ASME classification is SA 387 Grade 11, Class 1.
Lesson 5
1.4 CRYSTALLINE STRUCTURE OF METALS
When a liquid metal is cooled, its atoms will assemble into a regular crystal pattern and we
Lesson 6 say the liquid has solidified or crystallized. All metals solidify as a crystalline material. In a
Carbon & Low Alloy crystal the atoms or molecules are held in a fixed position and are not free to move about
as are the molecules of a liquid or gas. This fixed position is called a crystal lattice. As the
GMAW,GTAW,SAW
temperature of a crystal is raised, more thermal energy is absorbed by the atoms or
molecules and their movement increases. As the distance
Lesson 7
4000 between the atoms increases, the lattice breaks down and
Flux Cored Arc
Electrodes Carbon the crystal melts. If a lattice contains only one type of atom,
Low Alloy Steels as in pure iron, the conditions are the same at all points
LIQUID
3000 throughout the lattice, and the crystal melts at a single
2795°F
temperature (see Figure 1).
Lesson 8
Hardsurfacing
Electrodes 2000
Lesson 9 1000
Estimating &
Comparing Weld
SOLID
Metal Costs
TIME
SOLID-LIQUID TRANSFORMATION, PURE IRON
Lesson 10 FIGURE 1
Filler Metals
© COPYRIGHT 1999 THE ESAB GROUP

The Basics of Arc
Welding
1.4.0.1 However, if the lattice contains two
Liquid
or more types of atoms, as in any alloy-steel,
Lesson 2 it may start to melt at one temperature but not
Common Electric
be completely molten until it has been heated Liquid and Solid
Arc Welding
Processes to a higher temperature (See Figure 2). This
creates a situation where there is a
Lesson 3 combination of liquids and solids within a

Covered Electrodes range of temperatures.
for Welding Solid
Mild Steels 1.4.0.2 Each metal has a characteristic
crystal structure that forms during
Lesson 4 solidification and often remains the permanent TIME
Covered Electrodes form of the material as long as it remains at Solid-Liquid Transformation, Alloy Metal
for Welding Low
Alloy Steels room temperature. However, some metals FIGURE 2
may undergo an alteration in the crystalline

form as the temperature is changed. This is known as phase transformation. For example,
Lesson 5
Welding Filler Metals pure iron solidifies at 2795°F, the delta structure transforms into a structure referred to as
for Stainless Steels gamma iron. Gamma iron is commonly known as austenite and is a nonmagnetic
structure. At a temperature of 1670°F., the pure iron structure transforms back to the delta
iron form, but at this temperature, the metal is known as alpha iron. These two phases are
Lesson 6 given different names to differentiate between the high temperature phase (delta) and the
Carbon & Low Alloy
Steel Filler Metals - low temperature phase (alpha). The capability of the atoms of a material to transform into
GMAW,GTAW,SAW two or more crystalline structures at different temperatures is defined as allotropic. Steels
and iron are allotropic metals.
Lesson 7
Flux Cored Arc 1.4.1 Grains and Grain Boundaries - As the metal is cooled to its freezing point, a
Electrodes Carbon small group of atoms begin to assemble into crystalline form (refer to Figure 3). These
Low Alloy Steels
small crystals scattered throughout the body of the liquid are oriented in all directions and
as solidification continues, more crystals are formed from the surrounding liquid. Often,
Lesson 8 they take the form of dendrites, or a treelike structure. As crystallization continues, the
Hardsurfacing crystals begin to touch one another, their free growth hampered, and the remaining liquid
Electrodes
freezes to the adjacent crystals until solidification is complete. The solid is now composed
of individual crystals that usually meet at different orientations. Where these crystals meet
Lesson 9 is called a grain boundary.

Estimating &
Comparing Weld 1.4.1.2 A number of conditions influence the initial grain size. It is important to know that
Metal Costs
cooling rate and temperature has an important influence on the newly solidified grain
structure and grain size. To illustrate differences in grain formation, let's look at the cooling
Lesson 10 phases in a weld.

Filler Metals

The Basics of Arc
Welding
GRAIN
BOUNDARIES
Lesson 2
Common Electric
Arc Welding
BASE
Processes METAL
DENDRITE INITIAL COMPLETE

FORMATION CRYSTAL FORMATION SOLIDIFICATION
Lesson 3
Covered Electrodes FIGURE 3
for Welding
Mild Steels 1.4.1.3 Initial crystal formation begins at the coolest spot in the weld. That spot is at the
point where the molten metal and the unmelted base metal meet. As the metal continues
Lesson 4 to solidify, you will note that the grains in the center are smaller and finer in texture than the
Covered Electrodes grains at the outer boundaries of the weld deposit. This is explained by the fact that as the
for Welding Low
Alloy Steels weld metal cools, the heat from the center of the weld deposit will dissipate into the base
metal through the outer grains that solidified first. Consequently, the grains that solidified
first were at high temperatures for a longer time while in the solid state and this is a
Lesson 5
situation that encourages grain growth. Grain size can have an effect on the soundness of
for Stainless Steels the weld. The smaller grains are stronger and more ductile than the larger grains. If a
crack occurs, the tendency is for it to start in the area where the grains are largest.
Lesson 6 1.4.1.4 To summarize this section, it should be understood that all metals are composed
Carbon & Low Alloy of crystals of grains. The shape and characteristics of crystals are determined by the
GMAW,GTAW,SAW arrangement of their atoms. The atomic pattern of a single element can change its
arrangement at different temperatures, and that this atomic pattern or microstructure
determines the properties of the metals.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 1.5 HEAT TREATMENT
The temperature that metal is heated, the length of time it is held at that temperature, and
Lesson 8 the rate that it is cooled, all have an effect on a metal's crystalline structure. This crystalline
Hardsurfacing structure, commonly referred to as "microstructure," determines the specific properties of
Electrodes
metals. There are various ways of manipulating the microstructure, either at the steel mill
or in the welding procedure. Some of the more common ways are as follows:
Lesson 9
1.5.1 Preheat - Most metals are rather good conductors of heat. As a result, the heat
Estimating &
Comparing Weld in the weld area is rapidly dispersed through the whole weldment to all surfaces where it is
Metal Costs
radiated to the atmosphere causing comparatively rapid cooling. In some metals, this rapid
cooling may contribute to the formation of microstructures in the weld zone that are detri-
Lesson 10 mental. Preheating the weldment before it is welded is a method of slowing the cooling
Filler Metals

The Basics of Arc
Welding
rate of the metal. The preheat temperature may vary from 150°F to 1000°F, but more
commonly it is held in the 300°F to 400°F range. The thicker the weld metal, the more
Lesson 2 likely will it be necessary to preheat, because the heat will be conducted away from the
Common Electric weld zone more rapidly as the mass increases.
Arc Welding
Processes
1.5.2 Stress Relieving - Metals expand when heated and contract when cooled. The
amount of expansion is directly proportional to the amount of heat applied. In a weldment,

Lesson 3 the metal closest to the weld is subjected to the highest temperature, and as the distance
Covered Electrodes
for Welding from the weld zone increases, the maximum temperature reached decreases. This nonuni-
Mild Steels form heating causes nonuniform expansion and contraction and can cause distortion and
internal stresses within the weldment. Depending on its composition and usage, the metal
Lesson 4 may not be able to resist these stresses and cracking or early failure of the part may occur.
Covered Electrodes One way to minimize these stresses or to relieve them is by uniformly heating the structure
for Welding Low
Alloy Steels after it has been welded. The metal is heated to temperatures just below the point where a
microstructure change would occur and then it is cooled at a slow rate.
Lesson 5 1.5.3 Hardening - The hardness of steel may be increased by heating it to 50°F to
Welding Filler Metals 100°F above the temperature that a microstructure change occurs, and then placing the
metal in a liquid solution that rapidly cools it. This rapid cooling, known as "quenching,"
locks in place microstructures known as "martensite" that contribute to a metal's hardness
Lesson 6 characteristic. The quenching solutions used in this process are rated according to the
Carbon & Low Alloy speed that they cool the metal, i.e., Oil (fast), Water (faster), Salt Brine (fastest).
GMAW,GTAW,SAW 1.5.4 Tempering - After a metal is quenches, it is then usually tempered. Tempering is
a process where the metal is reheated to somewhere below 1335°F, held at that tempera-
Lesson 7 ture for a length of time, and then cooled to room temperature. Tempering reduces the
Flux Cored Arc
Electrodes Carbon brittleness that is characteristic in hardened steels, thereby producing a good balance
Low Alloy Steels between high strength and toughness. The term toughness, as it applies to metals, usually
refers to resistance to brittle fracture or notch toughness under certain environmental
conditions. More information on these properties will be covered later in this lesson and in
Lesson 8
subsequent lessons. Steels that respond to this type of treatment are known as "quenched
Hardsurfacing
Electrodes and tempered steels."
1.5.5 Annealing - A metal that is annealed is heated to a temperature 50° to 100°
Lesson 9 above where a microstructure change occurs, held at that temperature for a sufficient time
Estimating &
for a uniform change to take place, and then cooled at a very slow rate, usually in a fur-
Comparing Weld
Metal Costs nace. The principal reason for annealing is to soften steel and create a uniform fine grain
structure. Welded parts are seldom annealed for the high temperatures would cause
distortion.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.5.6 Normalizing - The main difference between normalizing and annealing is the
method of cooling. Normalized steel is heated to a temperature approximately 100° above

Lesson 2 where the microstructure transforms and then cooled in still air rather than in a furnace.
Common Electric
Arc Welding 1.5.7 Heat Treatment Trade-Off - It must be noted that these various ways of control-
Processes
ling the heating and cooling of metals can produce a desired property, but sometimes at the
expense of another desirable property. An example of this trade-off is evident in the fact
Lesson 3 that certain heat treatments can increase the strength or hardness of metal, but the same
Covered Electrodes
for Welding treatments will also make the metal less ductile or more brittle, and therefore, susceptible
Mild Steels to welding problems.
Lesson 4 1.6 PROPERTIES OF METALS

Covered Electrodes
for Welding Low
Alloy Steels The usefulness of a particular metal is determined by the climate and conditions in which it
will be used. A metal that is stamped into an automobile fender must be softer and more
pliable than armor plate that must withstand an explosive force, or the material used for an
Lesson 5 oil rig on the Alaska North Slope must perform in a quite different climate than a steam
for Stainless Steels boiler. It becomes obvious that before a material is recommended for a specific use, the
physical and mechanical properties of that metal and the weld metal designed to join it
must be evaluated. Some of the more important properties of metals and the means of
Lesson 6 evaluation are as follows:
Carbon & Low Alloy
Steel Filler Metals - 1.6.1 Tensile Strength - Tensile strength is one of the most important determining
GMAW,GTAW,SAW
factors in selecting a metal, especially if it is to be a structural member, part of a machine,
or part of a pressure vessel.
Lesson 7
Flux Cored Arc
Electrodes Carbon 1.6.1.1 The tensile test is performed as shown in Figure 4. The test specimen is
Low Alloy Steels machined to exact standard dimensions and clamped into the testing apparatus at both
ends. The specimen is then
RECORDING
pulled to the point of fracture DIAL
Lesson 8 TEST
and the data recorded. SPECIMEN
Hardsurfacing
Electrodes
1.6.1.2 The tensile strength
test gives us 4 primary pieces
Lesson 9
of information: (1) Yield
Estimating &
Comparing Weld Strength, (2) Ultimate Tensile
FORCE
Metal Costs Strength, (3) Elongation, and (4)
Reduction in Area.
TENSILE TESTING APPARATUS
Lesson 10 FIGURE 4
Filler Metals

The Basics of Arc
Welding
1.6.2 Yield Strength - When a metal is placed in tension, it acts somewhat like a
rubberband. When a load of limited magnitude is applied, the metal stretches, and when
Lesson 2 the load is released, the metal returns to its original shape. This is the elastic characteristic
Common Electric
Arc Welding of metal and is represented by letter A in Figure 5. As a greater load is applied, the metal
Processes will reach a point where it will no longer return to its original shape but will continue to
stretch. Yield strength is the point where the metal reaches the limit of its elastic character-
istic and will no longer return to its original shape.
Lesson 3
Covered Electrodes
for Welding 1.6.3 Ultimate Tensile Strength - Once a metal has exceeded its yield point, it will
Mild Steels continue to stretch or deform, and if the load is suddenly released, the metal will not return
to its original shape, but will remain in its elongated form. This is called the plastic region of
Lesson 4 the metal and is represented by the letter B in Figure 5. As this plastic deformation in-
Covered Electrodes creases, the metal strains
for Welding Low
Alloy Steels against further elongation, and
Ultimate Strength an increased load must be

Elong- Reduction applied to stretch the metal. As
of Area Yield Strength Fracture
Lesson 5 ation
the load is increased, the metal
for Stainless Steels will finally reach a point where it
A B C STRAIN - INCHES
no longer resists and any fur-
NOMINAL STRESS - STRAIN CURVE ther load applied will rapidly
Lesson 6 FIGURE 5 cause the metal to break. That
Carbon & Low Alloy
Steel Filler Metals - point at which the metal has
GMAW,GTAW,SAW withstood or resisted the maximum applied load is its ultimate tensile strength. This infor-
mation is usually recorded in pounds per square inch (psi).
Lesson 7
Flux Cored Arc 1.6.4 Percentage of Elongation - Before a tensile specimen is placed in the tensile
Electrodes Carbon tester, two marks at a measured distance are placed on the opposing ends of the circular
Low Alloy Steels
shaft. After the specimen is fractured, the distance between the marks is measured and
recorded as a percentage of the original distance. See Figure 5. This is the percentage of
Lesson 8 elongation and it gives an indication of the ductility of the metal at room temperature.
Hardsurfacing
Electrodes 1.6.5 Reduction of Area - A tensile specimen is machined to exact dimensions. The
area of its midpoint cross-section is a known figure. As the specimen is loaded to the point
of fracture, the area where it breaks is reduced in size. See Figure 5. This reduced area is
Lesson 9
Estimating & calculated and recorded as a percentage of the original cross-sectional area. This informa-
Comparing Weld tion reflects the relative ductility or brittleness of the metal.
Metal Costs
1.6.6 Charpy Impacts - Metal that is normally strong and ductile at room temperature
may become very brittle at much lower temperatures, and thus, is susceptible to fracture if
Lesson 10
Filler Metals

The Basics of Arc
Welding
a sharp abrupt load is applied to it. An impact tester measures the degree of susceptibility
to what is called brittle fracture.
Lesson 2
Common Electric 1.6.6.1 The impact specimen is machined to exact dimensions (Figure 6) and then
Arc Welding
Processes notched on one side. Quite often, the notch is in the form of a "V" and the test in this case
is referred to as a Charpy V-Notch Impact Test. The specimen is cooled to a
predetermined temperature and then placed in a stationary clamp at the base of the testing
Lesson 3
machine. The specimen is in the direct path of a weighted hammer attached to a
Covered Electrodes
for Welding pendulum (Figure 6).
Mild Steels
Lesson 4
Covered Electrodes ENERGY
for Welding Low IN FT/LBS
Alloy Steels
FRACTURES CRACKS DEFORMS
Lesson 5
CHARPY V-NOTCH
SPECIMEN
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - CHARPY IMPACT TEST MACHINE
GMAW,GTAW,SAW
CHARPY V-NOTCH IMPACT TEST
FIGURE 6
Lesson 7
Flux Cored Arc 1.6.6.2 The hammer is released from a fixed height and the energy required to fracture
Electrodes Carbon
Low Alloy Steels the specimen is recorded in ft-lbs. A specimen that is cooled to -60°F and absorbs 40 ft-lbs
of energy is more ductile, and therefore, more suitable for low temperature service than a
specimen that withstands only 10 ft-lbs at the same temperature. The specimen that
Lesson 8 withstood 40 ft-lbs energy is said to have better toughness or notch toughness.
Hardsurfacing
Electrodes
1.6.7 Fatigue Strength - A metal will withstand a load less than its ultimate tensile
strength but may break if that load is removed and then reapplied several times. For ex-
Lesson 9 ample, if a thin wire is bent once, but if it is bent back and forth repeatedly, it will eventually
Estimating & fracture and it is said to have exceeded its fatigue strength. A common test for this
Comparing Weld
Metal Costs strength is to place a specimen in a machine that repeatedly applies the same load first in
tension and then in compression. The fatigue strength is calculated from the number of
cycles the metal withstands before the point of failure is reached.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.6.8 Creep Strength - If a load below a metal's tensile strength is applied at room
temperature (72°F), it will cause some initial elongation, but there will be no further measur-
Lesson 2 able elongation if the load is kept at a constant level. If that same load were applied to a
Common Electric
Arc Welding metal heated to a high temperature, the situation would change. Although the load is held
Processes at a constant level, the metal will gradually continue to elongate. This characteristic is
called creep. Eventually, the material may rupture depending on the temperature of the
metal, the degree of load applied and the length of time that it is applied. All three of these
Lesson 3
Covered Electrodes factors determine a metal's ability to resist creep, and therefore, its creep strength.
for Welding
Mild Steels 1.6.9 Oxidation Resistance - The atoms of metal have a tendency to unite with oxy-
gen in the air to form oxide compounds, the most visible being rust and scale. In some
Lesson 4 metals, these oxides will adhere very tightly to the skin of the metal and effectively seal it
Covered Electrodes from further oxidation as is evident in stainless steel. These materials have high oxidation
for Welding Low
Alloy Steels resistance. In other metals, the bond is very loose, creating a situation where the oxides
will flake off, and the metal gradually deteriorates as the time of exposure is extended.
Lesson 5 1.6.10 Hardness Test - The resistance of a metal to indentation is a measure of its
hardness and an indication of the materials's strength. To test for hardness, a fixed load
forces an indenter into the test material (Figure 7). The depth of the penetration or the size
of the impression is measured. The measurement is converted into a hardness number
Lesson 6 through the use of a variety of established tables. The most common tables are the Brinell,
Carbon & Low Alloy Vickers, Knoop and Rockwell. The Rockwell is further divided into different scales, and
GMAW,GTAW,SAW
HARDNESS TEST SHAPE OF INDENTER INDENTER DESCRIPTION
ROCKWELL
Lesson 7
A Diamond
Flux Cored Arc
Electrodes Carbon
C
D
} Cone
Low Alloy Steels

B 1/16 in. Diameter
F
G
} Steel Sphere
Lesson 8 1/8 in. Diameter

Hardsurfacing E Steel Sphere
Electrodes
10 mm Sphere of Steel
BRINNELL or Tungsten Carbide
Lesson 9
VICKERS Diamond Pyramid
Estimating &
Comparing Weld
Metal Costs
KNOOP Diamond Pyramid
Types of Indenters - Hardness Tests

Lesson 10 FIGURE 7
Filler Metals

The Basics of Arc
Welding
depending on the material being tested, the shape of the indenter and the load applied, the
conversion tables may differ. For example, a material listed as having a hardness of Rb or
Lesson 2 Rc means its hardness has been determined from the Rockwell "B" scale or the Rockwell
Common Electric
Arc Welding "C" scale.
Processes
1.6.11 Coefficient of Expansion - All metals expand when heated and contract when
cooled. This dimensional change is related to the crystalline structure and will vary with
Lesson 3
different materials. The different expansion and contraction rates are expressed numeri-
Covered Electrodes
for Welding cally by a coefficient of thermal expansion. When two different metals are heated to the
Mild Steels same temperature and cooled at the same rate, the one with the higher numerical coeffi-
cient will expand and contract more than the one with the lesser coefficient.
Lesson 4
Covered Electrodes 1.6.12 Thermal Conductivity - Some metals will absorb and transmit heat more readily
for Welding Low than others. They are categorized as having high thermal conductivity. This characteristic
Alloy Steels
contributes to the fact that some metals will melt or undergo transformations at much lower
temperatures than others.
Lesson 5
for Stainless Steels 1.7 EFFECTS OF THE ALLOYING ELEMENTS
Alloying is the process of adding a metal or a nonmetal to pure metals such as copper,
Lesson 6 aluminum or iron. From the time it was discovered that the properties of pure metals could
Carbon & Low Alloy be improved by adding other elements, alloy steel has increased by popularity. In fact,
GMAW,GTAW,SAW metals that are welded are rarely in their pure state. The major properties that can be
improved by adding small amounts of alloying elements are hardness, tensile strength,
ductility and corrosion resistance. Common alloying elements and their effect on the
Lesson 7
Flux Cored Arc properties of metals are as follows:
Electrodes Carbon
Low Alloy Steels 1.7.1 Carbon - Carbon is the most effective, most widely used and lowest in cost
alloying element available for increasing the hardness and strength of metal. An alloy
containing up to 1.7% carbon in combination with iron is known as steel, whereas the
Lesson 8
Hardsurfacing combination above 1.7% carbon is known as cast iron. Although carbon is a desirable
Electrodes alloying element, high levels of it can cause problems; therefore, special care is required
when welding high carbon steels and cast iron.
Lesson 9 1.7.2 Sulphur - Sulphur is normally an undesirable element in steel because it causes
Estimating &
Comparing Weld brittleness. It may be deliberately added to improve the machinability of the steel. The
Metal Costs sulphur causes the
machine chips to break rather than form long curls and clog the machine. Normally, every
effort is made to reduce the sulphur content to the lowest possible level because it can
Lesson 10
Filler Metals

The Basics of Arc
Welding
create welding difficulties.
1.7.3 Manganese - Manganese in contents up to 1% is usually present in all low alloy

Lesson 2
Common Electric steels as a deoxidizer and desulphurizer. That is to say, it readily combines with oxygen
Arc Welding
Processes and sulphur to help negate the undesirable effect these elements have when in their natu-
ral state. Manganese also increases the tensile strength and hardenability of steel.
Lesson 3 1.7.4 Chromium - Chromium, in combination with carbon, is a powerful hardening

Covered Electrodes
alloying element. In addition to its hardening properties, chromium increases corrosion
for Welding
Mild Steels resistance and the strength of steel at high temperatures. Chromium is the primary alloying
element in stainless steel.
Lesson 4 1.7.5 Nickel - The greatest single property of steel that is improved by the presence of
Covered Electrodes
for Welding Low nickel is its ductility or notch toughness. In this respect, it is the most effective of all alloy-
Alloy Steels ing elements in improving a steel's resistance to impact at low temperatures. Electrodes
with high nickel content are used to weld cast iron materials. Nickel is also used in combi-
Lesson 5 nation with chromium to form a group known as austenitic stainless steel.
for Stainless Steels 1.7.6 Molybdenum - Molybdenum strongly increases the depth of the hardening
characteristic of steel. It is quite often used in combination with chromium to improve the
strength of the steel at high temperatures. This group of steels is usually referred to as
Lesson 6 chrome-moly steels.
Carbon & Low Alloy
GMAW,GTAW,SAW 1.7.7 Silicon - Silicon is usually contained in steel as a deoxidizer. Silicon will add
strength to steel but excessive amounts can reduce the ductility. Additional amounts of
silicon are sometimes added to welding electrodes to increase the fluid flow of weld metal.
Lesson 7
Flux Cored Arc
Electrodes Carbon 1.7.8 Phosphorus - Phosphorus is considered a harmful residual element in steel
Low Alloy Steels because it greatly reduces ductility and toughness. Efforts are made to reduce it to its very
lowest levels; however, phosphorus is added in very small amounts to some steels to
increase strength.
Lesson 8
Hardsurfacing
1.7.9 Aluminum - Aluminum is primarily used as a deoxidizer in steel. It may also be
Electrodes
used in very small amounts to control the size of the grains.
1.7.10 Copper - Copper contributes greatly to the corrosion resistance of carbon steel
Lesson 9
Estimating & by retarding the rate of rusting at room temperature, but high levels of copper can cause
Comparing Weld
Metal Costs welding difficulties.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.7.11 Columbium - Columbium is used in austenitic stainless steel to act as a stabi-
lizer. Since the carbon in the stainless steel decreases the corrosion resistance, a means
Lesson 2 of making carbon ineffective must be found. Columbium has a greater affinity for carbon
Common Electric
Arc Welding than chromium, leaving the chromium free for corrosion protection.
Processes
1.7.12 Tungsten - Tungsten is used in steel to given strength at high temperatures.
Tungsten also joins with carbon to form carbides that are exceptionally hard, and therefore
Lesson 3
have exceptional resistance to wear.
Covered Electrodes
for Welding
Mild Steels 1.7.13 Vanadium - Vanadium helps keep steel in the desirable fine grain condition after
heat treatment. It also helps increase the depth of hardening and resists softening of the
steel during tempering treatments.
Lesson 4
Covered Electrodes
for Welding Low 1.7.14 Nitrogen - Usually, efforts are made to eliminate hydrogen, oxygen and nitrogen
Alloy Steels from steel because their presence can cause brittleness. Nitrogen has the ability to form
austenitic structures; therefore, it is sometimes added to austenitic stainless steel to reduce
Lesson 5 the amount of nickel needed, and therefore, the production costs of that steel.
for Stainless Steels 1.7.15 Alloying Elements Summary - It should be understood that the addition of
elements to a pure metal may influence the crystalline form of the resultant alloy. If a pure
metal has allotropic characteristics (the ability of a metal to change its crystal structure) at a
Lesson 6 specific temperature, then that characteristic will occur over a range of temperatures with
Carbon & Low Alloy
Steel Filler Metals - the alloyed metal. The range in which the change takes place may be wide or narrow,
GMAW,GTAW,SAW depending on the alloys and the quantities in which they are added. The alloying element
may also effect the crystalline changes by either suppressing the appearance of certain
Lesson 7 crystalline forms or even by creating entirely new forms. All these transformations induced
Flux Cored Arc by alloying elements are dependent on heat input and cooling rates. These factors are
Electrodes Carbon
Low Alloy Steels closely controlled at the steel mill, but since the welding operation involves a nonuniform
heating and cooling of metal, special care is often needed in the welding of low and high
alloy steel.
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON I, PART B
The Basics of Arc
Welding
1.8 ELECTRICITY FOR WELDING
1.8.1 Principles of Electricity - Arc welding is a method of joining metals accom-
Lesson 2
Common Electric plished by applying sufficient electrical pressure to an electrode to maintain a current path
Arc Welding
(arc) between the electrode and the work piece. In this process, electrical energy is
Processes
changed into heat energy, bringing the metals to a molten state; whereby they are joined.
The electrode (conductor) is either melted and added to the base metal or remains in its
Lesson 3 solid state. All arc welding utilizes the transfer of electrical energy to heat energy, and to
Covered Electrodes
for Welding understand this principle, a basic knowledge of electricity and welding power sources is
Mild Steels necessary.
1.8.1.1 The three basis principles of static electricity are as follows:

Lesson 4
Covered Electrodes 1. There are two kinds of electrical charges in existence - negative and positive.
for Welding Low
Alloy Steels 2. Unlike charges attract and like charges repel.
3. Charges can be transferred from one place to another.
Lesson 5 1.8.1.2 Science has established that all matter is made up of atoms and each atom
for Stainless Steels contains fundamental particles. One of these particles is the electron, which has the ability
to move from one place to another. The electron is classified as a negative electrical
charge. Another particle, about 1800 times as heavy as the electron, is the proton and
Lesson 6 under normal conditions the proton will remain stationary.
Carbon & Low Alloy
Steel Filler Metals - 1.8.1.3 Material is said to be in an electrically uncharged state when its atoms contain an
GMAW,GTAW,SAW
equal number of positive charges (protons) and negative charges (electrons). This balance
is upset when pressure forces the electrons to move from atom to atom. This pressure,
Lesson 7
sometimes referred to as electromotive force, is commonly known as voltage. It should be
Flux Cored Arc
Electrodes Carbon noted that voltage that does not move through a conductor, but without voltage, there would
Low Alloy Steels be no current flow. For our purposes, it is easiest to think of voltage as the electrical
pressure that forces the electrons to move.
Lesson 8 1.8.1.4 Since we know that like charges repel and unlike charges attract, the tendency is
Hardsurfacing
Electrodes for the electrons to move from a position of over-supply (negative charge) to an atom that
lacks electrons (positive charge). This tendency becomes reality when a suitable path is
provided for the movement of the electrons. The transfer of electrons from a negative to a
Lesson 9 positive charge throughout the length of a conductor constitutes an electrical current. The
Estimating &
rate that current flows through a conductor is measured in amperes and the word ampere
Comparing Weld
Metal Costs is often used synonymously with the term current. To give an idea of the quantities of
electrons that flow through a circuit, it has been theoretically established that one ampere
equals 6.3 quintillion (6,300,000,000,000,000,000) electrons flowing past a fixed point in a
Lesson 10 conductor every second.
Filler Metals

The Basics of Arc
Welding
1.8.1.5 Different materials vary in their ability to transfer electrons. Substances, such as
wood and rubber, have what is called a tight electron bond and their atoms greatly resist
Lesson 2 the free movement of electrons. Such materials are considered poor electrical conductors.
Common Electric
Arc Welding Metals, on the other hand, have large amounts of electrons that transfer freely. Their
Processes comparatively low electrical resistance classifies them as good electrical conductors.
1.8.1.6 Electrical resistance is primarily due to the reluctance of atoms to give up their
Lesson 3
electron particles. It may also be thought of as the resistance to current flow.
Covered Electrodes
for Welding
Mild Steels 1.8.1.7 To better understand the electrical terms discussed above, we might compare
the closed water system with the electrical diagram shown in Figure 8. You can see that as
the pump is running, the water will move in the direction of the arrows. It moves because
Lesson 4
Covered Electrodes pressure has been produced and that pressure can be likened to voltage in an electrical
for Welding Low circuit. The pump can be compared to a battery or a DC generator. The water flows
Alloy Steels
VALVE
SWITCH
Lesson 5
for Stainless Steels RESISTOR
10 OHM
LARGE
SMALL PIPE
PIPE PUMP
BATTERY
Lesson 6 12 VOLT
Carbon & Low Alloy CLOSED WATER SYSTEM ELECTRICAL DIAGRAM
GMAW,GTAW,SAW FIGURE 8
through the system at a certain rate. This flow rate in an electrical circuit is a unit of
Lesson 7
measure known as the ampere. The small pipe in the fluid circuit restricts the flow rate and
Flux Cored Arc
Electrodes Carbon can be likened to a resistor. This unit resistance is known as the ohm. If we close the
Low Alloy Steels
valve in the fluid circuit, we stop the flow, and this can be compared to opening a switch in
an electrical circuit.
Lesson 8 1.8.2 Ohm's Law - Resistance is basic to electrical theory and to understand this
Hardsurfacing
Electrodes principle, we must know the Ohm's Law, which is stated as follows: In any electrical circuit,
the current flow in amperes is directly proportional to the circuit voltage applied and in-
versely proportional to the circuit resistance. Directly proportional means that even though
Lesson 9 the voltage and amperage may change, the ratio of their relationship will not. For example,
Estimating &
Comparing Weld if we have a circuit of one volt and three amps, we say the ratio is one to three. Now if we
Metal Costs increase the volts to three, our amperage will increase proportionately to nine amps. As
can be seen, even though the voltage and amperage changed in numerical value, their
ratio did not. The term "inversely proportional" simply means that if the resistance is
Lesson 10
Filler Metals

The Basics of Arc
Welding
doubled, the current will be reduced to one-half. Ohm's Law can be stated mathematically
with this equation:
Lesson 2
Common Electric I=E÷R or E=I×R or R=E÷I
Arc Welding
(E = Volts, I = Amperes, R = Resistance (Ohms))
Processes
1.8.2.1 The equation is easy to use as seen in the following problems:

Lesson 3
Covered Electrodes 1) A 12 volt battery has a built-in resistance of 10 ohms. What is the amperage?
for Welding
Mild Steels 12 ÷ 10 = 1.2 amps
2) What voltage is required to pass 15 amps through a resistor of 5 ohms?

Lesson 4 15 × 5 = 75 volts
Covered Electrodes
for Welding Low
Alloy Steels 3) When the voltage is 80 and the circuit is limited to 250 amps, what is the value
of the resistor?
80 ÷ 250 = .32 ohms

Lesson 5
for Stainless Steels 1.8.2.2 The theory of electrical resistance is of great importance in the arc welding
process for it is this resistance in the air space between the electrode and the base metal
that contributes to the transfer of electrical energy to heat energy. As voltage forces the
Lesson 6
Carbon & Low Alloy electrons to move faster, the energy they generate is partially used to overcome the
Steel Filler Metals - resistance created by the arc gap. This energy becomes evident as heat. In the welding
GMAW,GTAW,SAW
process, the temperature increases to the point where it brings metals to a molten state.
Lesson 7
1.8.3 Electrical Power - The word "watt" is another term frequently encountered in
Flux Cored Arc electrical terminology. When we pay our electrical bills, we are actually paying for the
Electrodes Carbon
Low Alloy Steels power to run our electrical appliances, and the watt is a unit of power. It is defined as the
amount of power required to maintain a current of one ampere at a pressure of one volt.
The circuit voltage that comes into your home is a constant factor, but the amperage drawn
Lesson 8 from the utility company depends on the number of watts required to run the electrical
Hardsurfacing
appliance. The watt is figured as a product of volts times amperes and is stated math-
Electrodes
ematically with the following equation:
W =E × I E =W÷I I =W÷E
Lesson 9
Estimating & (W = Watts, E = Volts, I = Amperes)
Comparing Weld
Metal Costs
1.8.3.1 The amperage used by an electrical device can be calculated by dividing the
watts rating of the device by the primary voltage for which it is designed.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.8.3.2 For example, if an appliance is designed for the common household primary
voltage of 115 and the wattage stamped on the appliance faceplate is 5, then the
Lesson 2 amperage drawn by the appliance when in operation is determined as shown:
Common Electric
Arc Welding
Processes 5 ÷ 115 = .04 amperes
1.8.3.3 Kilowatt is another term common in electrical usage. The preface "kilo" is a
Lesson 3 metric designation that means 1,000 units of something; therefore, one kilowatt is 1,000
Covered Electrodes
for Welding watts of power.
Mild Steels
1.8.4 Power Generation - Electrical energy is supplied either as direct current (DC) or
alternating current (AC). With direct current, the electron movement within the conductor is
Lesson 4
in one direction only. With alternating current, the electron flow reverses periodically. Al-
Covered Electrodes
for Welding Low though some types of electrical generators will produce current directly (such as batteries,
Alloy Steels dry cells, or DC generators), most direct current is developed from alternating current.
1.8.4.1 Through experimentation, it was discovered that when a wire is moved through a
Lesson 5
Welding Filler Metals magnetic field, an electrical current is induced into the wire, and the current is at its
for Stainless Steels maximum when the motion of the conductor is at right
angles to the magnetic lines of force. The sketch GALVANOMETER
in Figure 9 will help to illustrate this principle.

Lesson 6
Carbon & Low Alloy
1.8.4.2 If the conductor is moved upwards in
GMAW,GTAW,SAW the magnetic field between the N and S poles,
the galvanometer needle will deflect plus (+).
Lesson 7 Likewise, if the conductor is moved downwards

Flux Cored Arc the needle will deflect minus (-). With this
Electrodes Carbon
principle of converting mechanical energy into
Low Alloy Steels ELECTRO-MAGNETIC
electrical energy understood, we can apply it to INDUCTION
the workings of an AC generator.

Lesson 8
Hardsurfacing 1.8.4.3 Figure 10 is a simplified sketch of an AC FIGURE 9
Electrodes generator. Starting at 0° rotation, the coil wire is moving
parallel to the magnetic lines of force and cutting none of them. Therefore, no current is
being induced into the winding.
Lesson 9
Estimating &
Comparing Weld 1.8.4.4 From 0° to 90° rotation, the coil wire cuts an increasing number of magnetic lines
Metal Costs of force and reaches the maximum number at 90° rotation. The current increases to the
maximum because the wire is now at right angles to the lines of force.
Lesson 10
Filler Metals

The Basics of Arc
Welding
ROTATING COIL 0° 90°
OR ARMATURE
N S N S
Lesson 2
Common Electric N
Arc Welding
Processes 180° 270°
N S N S
S
Lesson 3
Covered Electrodes
for Welding
Mild Steels
PERMANENT MAGNETS
CONTACTS OR FIELD COILS
BASIC AC POWER GENERATION

Lesson 4
for Welding Low
Alloy Steels 1.8.4.5 From 90° to 180° rotation, the coil wire cuts a diminishing number of lines of
force and at 180° again reaches zero.
Lesson 5
Welding Filler Metals 1.8.4.6 From 180° to 270°, the current begins to rise again but in the opposite direction
for Stainless Steels because now the wire is in closer proximity to the opposite pole.
1.8.4.7 One cycle is completed as the coil wire moves from 270° to 0° and the current
Lesson 6 again drops to zero.
Carbon & Low Alloy
1.8.4.8 With the aid of a graph, we can visualize the rate at which the lines of force are
GMAW,GTAW,SAW
cut throughout the cycle. If we plot the current versus degree of rotation, we get the
familiar sine wave as seen in Figure 11.
Lesson 7
Flux Cored Arc
1.8.4.9 With this sine wave, we can
Electrodes Carbon (+) MAXIMUM (+)
Low Alloy Steels see that one complete cycle of
alternating current comprises one
positive and one negative wave
0
Lesson 8 (negative and positive meaning
0 0
Hardsurfacing
Electrodes electron flow in opposing directions).
The frequency of alternating current is
the number of such complete cycles
MAXIMUM (–)
Lesson 9 per second. For most power (–)
Estimating & 0°
START
90°
1/4 TURN
180°
1/2 TURN
270°
3/4 TURN
360°
FULL TURN
Comparing Weld applications, 60 cycles per second (60

Metal Costs Hertz) is the standard frequency in
ONE CYCLE - ALTERNATING CURRENT
North America.
FIGURE 11
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.8.4.10 Some welders use a three-phase AC supply. Three-phase is simply three
sources of AC power as identical voltages brought in by three wires, the three voltages or
Lesson 2 phases being separated by 120 electrical degrees. If
Common Electric 120° 240°
Arc Welding the sine wave for the three phases are plotted on one
Processes line, they will appear as shown in Figure 12. 0°
1.8.4.11 This illustrates that three-phase power is

Lesson 3
smoother than single-phase because the overlapping 1 CYCLE
Covered Electrodes
for Welding three phases prevent the current and voltage from THREE PHASE AC
Mild Steels falling to zero 120 times a second, thereby producing a

FIGURE 12
smoother welding arc.
Lesson 4
Covered Electrodes 1.8.4.12 Since all shops do not have three-phase power, welding machines for both
for Welding Low single-phase and three-phase power are available.
Alloy Steels
1.8.5 Transformers - The function of a transformer is to increase or decrease voltage
Lesson 5 to a safe value as the conditions demand. Common household voltage is usually 115 or
Welding Filler Metals 230 volts, whereas industrial power requirements may be 208, 230, 380, or 460 volts.
Transmitting such relatively low voltages over long distances would require a conductor of
enormous and impractical size. Therefore, power transmitted from a power plant must be
stepped up for long distance transmission and then stepped down for final use
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 1.8.5.1 As can be seen in Figure 13, the voltage is generated at the power plant at
GMAW,GTAW,SAW 13,800 volts. It is increased, transmitted over long distances, and then reduced in steps for
the end user. If power supplied to a transformer circuit is held steady, then secondary
Lesson 7 current (amperes) decreases as the primary voltage increases, and conversely, secondary
Flux Cored Arc current increases as primary voltage decreases. Since the current flow (amperes)
Electrodes Carbon
Low Alloy Steels determines the wire or conductor size, the high voltage line may be of a relatively small
diameter.
Lesson 8
4,600
Hardsurfacing HIGH VOLTAGE
V
Electrodes 34,000 V
208V
13,800 V 230V
287,000 132,000 V 460V
POWER V FINAL
STEP
Lesson 9 PLANT STEP
DOWN
USE
UP
Estimating &
300 MILES
Comparing Weld
Metal Costs POWER TRANSMISSION
FIGURE 13
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.8.5.2 The transformer in a welding machine performs much the same as a large power
plant transformer. The primary voltage coming into the machine is too high for safe
Lesson 2 welding. Therefore, it is stepped down to a useable voltage. This is best illustrated with an
Common Electric
Arc Welding explanation of how a single transformer works.
Processes
1.8.5.3 In the preceding paragraphs, we have found than an electrical current can be
induced into a conductor when that conductor is moved through a magnetic field to
Lesson 3
produce alternating current. If this alternating current is passed through a conductor, a
Covered Electrodes
for Welding pulsating magnetic field will surround the exterior of that conductor, that is the magnetic
Mild Steels field will build in intensity through the first 90 electrical degrees, or the first cycle. From that
point, the magnetic field will decay during the next quarter cycle until the voltage or current
Lesson 4 reaches zero at 180 electrical degrees. Immediately, the current direction reverses and the
Covered Electrodes magnetic field will begin to build again until it reaches a maximum at 270 electrical degrees
for Welding Low
Alloy Steels in the cycle. From that point the current and the magnetic field again begin to decay until
they reach zero at 360 electrical degrees, where the cycle begins again.
Lesson 5 1.8.5.4 If that conductor is wound around a material with high magnetic permeability
(magnetic permeability is the ability to accept large amounts of magnetic lines of force)
such as steel, the magnetic field permeates that core. See
STEEL CORE
Figure 14. This conductor is called the primary coil, and if
PRIMARY SECONDARY
Lesson 6 voltage is applied to one of its terminals and the circuit is COIL COIL
Carbon & Low Alloy completed, current will flow. When a second coil is wound 460 V
Steel Filler Metals - 80 V
GMAW,GTAW,SAW around that same steel core, the energy that is stored in 80
460 TURNS
this fluctuating magnetic field in the core is induced into
TURNS
this secondary coil.
Lesson 7 BASIC TRANSFORMER
Flux Cored Arc
Electrodes Carbon 1.8.5.5 It is the build-up and collapse of this magnetic
Low Alloy Steels FIGURE 14
field that excite the electrons in the secondary coil of the
transformer. This causes an electrical current of the same frequency as the primary coil to
flow when the secondary circuit is completed by striking the welding arc. Remember that
Lesson 8
Hardsurfacing all transformers operate only on alternating current.
Electrodes
1.8.5.6 A simplified version of a welding transformer is schematically shown in Figure 15.
This welder would operate on 230 volts input power and the primary winding has 230 turns
Lesson 9 of wire on the core. We need 80 volts for initiating the arc in the secondary or welding
Estimating &
Comparing Weld circuit, thus we have 80 turns of wire in the secondary winding of the core. Before the arc
Metal Costs is struck, the voltage between the electrode and the work piece is 80 volts. Remember that
no current (amperage) flows until the welding circuit is completed by striking the arc.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.8.5.7 Since the 80 volts
9600 WATTS 9600 WATTS
necessary for initiating the arc
230 TURNS 80 TURNS
Lesson 2 is too high for practical 41.74 32 VOLTS
Common Electric AMPS 300 AMPS
welding, some means must be 230 80
Arc Welding VOLTS PRIMARY SECONDARY OCV
Processes used to lower this voltage to a
suitable level. Theoretically, a OUTPUT
CONTROL
variable resistor of the proper
Lesson 3
Covered Electrodes SIMPLIFIED WELDING TRANSFORMER
value could be used as an
for Welding output control since voltage is FIGURE 15
Mild Steels
inversely proportional to
resistance as we saw when studying Ohm's Law. Ohm's Law also stated that the
Lesson 4 amperage is directly proportional to the voltage. This being so, you can see that adjusting
Covered Electrodes
for Welding Low the output control will also adjust the amperage or welding current.
Alloy Steels
1.8.5.8 After the arc is initiated and current begins to flow through the secondary or
welding circuit, the voltage in that circuit will be 32 volts because it is then being controlled
Lesson 5
by the output control.
1.8.6 Power Requirements - We can make another calculation by looking back at
Figure 15, and that is power consumption. Earlier, we explained that the watt was the unit
Lesson 6 of electrical power and can be calculated by the formula:
Carbon & Low Alloy
Steel Filler Metals - Watts = Volts × Amperes
GMAW,GTAW,SAW
1.8.6.1 From Figure 15, we can see that the instantaneous power in the secondary
Lesson 7 circuit is:
Flux Cored Arc Watts = 32 × 300
Electrodes Carbon
Low Alloy Steels Watts = 9600 Watts
1.8.6.2 The primary side of our transformer must be capable of supplying 9600 watts
Lesson 8 also (disregarding losses due to heating, power factor, etc.), so by rearranging the formula,
Hardsurfacing we can calculate the required supply line current or amperage:
Electrodes
Amperage = Watts ÷ Volts
A = 9600 ÷ 230 = 41.74 Amps
Lesson 9
Estimating & 1.8.6.3 This information establishes the approximate power requirements for the welder,
Comparing Weld
Metal Costs and helps to determine the input cable and fuse size necessary.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.8.7 Rectifying AC to DC - Although much welding is accomplished with AC welding
power sources, the majority of industrial welding is done with machines that produce a
Lesson 2 direct current arc. The commercially produced AC
Common Electric
Arc Welding power that operates the welding machine
Processes must then be changed (rectified) to direct
current for the DC arc. This is accom-
plished with a device called a rectifier.
Lesson 3
Covered Electrodes Two types of rectifiers have been used
for Welding extensively in welding machines, the
Mild Steels
SELENIUM RECTIFIER
old selenium rectifiers and the more SILICON RECTIFIER
modern silicon rectifiers, often referred FIGURE 16
Lesson 4 to as diodes. See Figure 16.
Covered Electrodes
for Welding Low
Alloy Steels 1.8.7.1 The function of a rectifier in the
circuit can best be shown by the use of the
AC sine wave. With one diode in the circuit,
Lesson 5
half-wave rectification takes place as shown
Welding Filler Metals SINGLE PHASE HALF WAVE RECTIFICATION
for Stainless Steels in Figure 17. FIGURE 17
1.8.7.2 The negative half-wave is simply cut off and a pulsating DC is produced. During
Lesson 6 the positive half-cycle, current is allowed to flow through the rectifier. During the negative
Carbon & Low Alloy half-cycle, the current is blocked. This produces a DC composed of 60 positive pulses per
GMAW,GTAW,SAW second.
1.8.7.3 By using four rectifiers connected in a

Lesson 7 certain manner, a bridge rectifier is created, producing
Flux Cored Arc
Electrodes Carbon full wave rectification. The bridge rectifier results in
Low Alloy Steels 120 positive half-cycles per second, producing a
SINGLE PHASE FULL WAVE RECTIFICATION
considerably smoother direct current than half-wave FIGURE 18
rectification. See Figure 18.
Lesson 8
Hardsurfacing
Electrodes 1.8.7.4 Three-phase AC can be rectified to 1 CYCLE
produce an even smoother DC than single-phase
AC. Since three-phase AC power produces three
Lesson 9 times as many half-cycles per second as single-
Estimating &
Comparing Weld phase power, a relatively smooth DC voltage
Metal Costs 3 PHASE FULL WAVE RECTIFICATION
results as shown in Figure 19.
FIGURE 19
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.9 CONSTANT CURRENT OR CONSTANT VOLTAGE
Lesson 2 Welding power sources are designed in many sizes and shapes. They may supply either
Common Electric AC or DC, or both, and they may have various means of controlling their voltage and
Arc Welding
amperage output. The reasons for this is that the power source must be capable of
Processes
producing the proper arc characteristics for the welding process being used. A power
source that produces a satisfactory arc when welding with coated electrodes will be less
Lesson 3 than satisfactory for welding with solid and flux cored wires.
Covered Electrodes
for Welding
Mild Steels 1.9.1 Constant Current Characteristics - Constant current power sources are used
primarily with coated electrodes. This type of power source has a relatively small change in
amperage and arc power for a corresponding relatively large change in arc voltage or arc
Lesson 4
Covered Electrodes length, thus the name constant current. The characteristics of this power source are best
for Welding Low illustrated by observing a graph that plots the volt-
Alloy Steels
ampere curve. As can be seen in Figure 20, the 80
VOLT / AMPERE CURVE
curve of a constant current machine drops down- CONSTANT CURRENT
70
Lesson 5 ward rather sharply and for this reason, this type of
Welding Filler Metals 60
machine is often called a "drooper."
V
50
O 34V - 290
1.9.1.1 In welding with coated electrodes, the L A
T 40
output current or amperage is set by the operator S 32V - 300 A
Lesson 6
Carbon & Low Alloy while the voltage is designed into the unit. The 30
30V - 308 A
Steel Filler Metals - operator can vary the arc voltage somewhat by
GMAW,GTAW,SAW 20
increasing or decreasing the arc length. A slight
10
increase in arc length will cause an increase in arc
Lesson 7 voltage and a slight decrease in amperage. A slight 100 200 300
Flux Cored Arc
AMPERES
Electrodes Carbon decrease in arc length will cause a decrease in arc
CONSTANT CURRENT VOLT / AMPERE CURVE
Low Alloy Steels voltage and a slight increase in amperage. FIGURE 20
1.9.2 Constant Voltage Characteristics - Constant voltage power sources, also

Lesson 8 known as constant potential, are used in welding with solid and flux cored electrodes, and
Hardsurfacing
Electrodes as the name implies, the voltage output remains relatively constant. On this type of power
source, the voltage is set at the machine and amperage is determined by the speed that
the wire is fed to the welding gun. Increasing the wire feed speed increases the amperage.
Lesson 9 Decreasing the wire feed speed decreases the amperage.
Estimating &
Comparing Weld
Metal Costs 1.9.2.1 Arc length plays an important part in welding with solid and flux cored electrodes,
just as it does in welding with a coated electrode. However, when using a constant voltage
power source and a wire feeder that delivers the wire at a constant speed, arc length
Lesson 10 caused by operator error, plate irregularities, and puddle movement are automatically
Filler Metals

The Basics of Arc
Welding
compensated for by the characteristics of this process. To understand this, keep in mind
that with the proper voltage setting, amperage setting, and arc length, the rate that the wire
Lesson 2 melts is dependent upon the amperage. If the amperage decreases, this melt-off rate
Common Electric
Arc Welding decreases and if the amperage increases, so does the melt-off rate.
Processes
1.9.2.2 In Figure 21, we see that condition #2 produces the desired arc length, voltage,
and amperage. If the arc length is increased as in #1, the voltage increases slightly; the
Lesson 3
amperage decreases considerably, and therefore, the melt-off rate of the wire decreases.
Covered Electrodes
for Welding The wire is now feeding faster than it is melting
1 2 3
Mild Steels off. This condition will advance the end of the
wire towards the work piece until the proper arc
Lesson 4 length is reached where again, the melt-off rate 40
Covered Electrodes equals the feeding rate. If the arc length is
for Welding Low
Alloy Steels decreased as in #3, the voltage drops off 30
V
slightly, the amperage is increased O
L
considerably, and the melt-off rate of the wire T 20
Lesson 5 S
increases. Since the wire is now melting off
for Stainless Steels faster than it is being fed, it melts back to the 10
proper arc length where the melt-off rate

equals the feeding rate. This is often referred
100 200 300 400
Lesson 6 to as a self-adjusting arc. These automatic AMPERES
Carbon & Low Alloy
VOLT / AMPERE CURVE - CONSTANT VOLTAGE
Steel Filler Metals - corrections take place in fractions of a second,
FIGURE 21
GMAW,GTAW,SAW and usually without the operator being aware
of them.
Lesson 7
Flux Cored Arc 1.9.2.3 There are a variety of different welding machines, each with its own unique
Electrodes Carbon internal design. Our purpose is not to detail the function of each part of the machine, but to
Low Alloy Steels
emphasize that their main difference is in the way they control the voltage and amperage
output.
Lesson 8
1.9.3 Types of Welding Power Sources - A great variety of welding power sources
Hardsurfacing
Electrodes are being built today for electric arc welding and we shall mention some of the major types
briefly. Welding power sources can be divided into two main categories: static types and
rotating types.
Lesson 9
Estimating & 1.9.3.1 Static Types - Static type power sources are all of those that use commercially
Comparing Weld
Metal Costs generated electrical power to energize a transformer that, in turn, steps the line voltage
down to useable welding voltages. The two major categories of static power sources are
the transformer type and the rectifier type.
Lesson 10
Filler Metals

The Basics of Arc
Welding
1.9.3.1.1 The transformer type produce only alternating current. They are commonly
called "Welding Transformers." All AC types utilize single-phase primary power and are of
Lesson 2 the constant current type.
Common Electric
Arc Welding 1.9.3.1.2 The rectifier types are commonly called "Welding Rectifiers" and produce DC or,
Processes
AC and DC welding current. They may utilize either single phase or three phase input
power. They contain a transformer, but rectify the AC or DC by the use of selenium
Lesson 3 rectifiers, silicon diodes or silicon controlled rectifiers. Available in either the constant
Covered Electrodes
for Welding current or the constant voltage type, some manufacturers offer units that are a combination
Mild Steels of both and can be used for coated electrode welding, non-consumable electrode welding
and for welding with solid or flux cored wires.
Lesson 4
1.9.3.2 Rotating Types - Rotating type power sources may be divided into two classifi-
Covered Electrodes
for Welding Low cations:
Alloy Steels 1. Motor-Generators
2. Engine Driven
Lesson 5 1.9.3.2.1 Motor-generator types consist of an electric motor coupled to a generator or
for Stainless Steels alternator that produces the desired welding power. These machines produced excellent
welds, but due to the moving parts, required considerable maintenance. Few, if any, are
being built today.
Lesson 6
Carbon & Low Alloy 1.9.3.2.2 Engine driven types consist of a gasoline or diesel engine coupled to a generator
GMAW,GTAW,SAW or alternator that produces the desired welding power. They are used extensively on jobs
beyond commercial power lines and also as mobile repair units. Both rotating types can
deliver either AC or DC welding power, or a combination of both. Both types are available
Lesson 7
Flux Cored Arc as constant current or constant voltage models.
Electrodes Carbon
Low Alloy Steels 1.9.4 Power Source Controls - Welding power sources differ also in the method of
controlling the output current or voltage. Output may be controlled mechanically as in

machines having a tapped reactor, a moveable shunt or diverter, or a moveable coil. Elec-
Lesson 8
trical types of controls, such as magnetic amplifiers or saturable reactors, are also utilized
Hardsurfacing
Electrodes and the most modern types, containing silicon controlled rectifiers, give precise electronic
control.
Lesson 9 1.9.4.1 A detailed discussion of the many types of welding power sources on the market
Estimating &
today is much too lengthy a subject for this course, although additional information on the
Comparing Weld
Metal Costs type of power sources for the various welding processes will be covered in Lesson II.
1.9.4.2 Excellent literature is available from power source manufacturers, however, and
Lesson 10 should be consulted for further reference.
Filler Metals

Lesson 1 LESSON I, GLOSSARY
The Basics of Arc
Welding
APPENDIX A
LESSON I - GLOSSARY OF TERMS
Lesson 2
Common Electric
Arc Welding
Processes
AISI — American Iron and Steel Institute
Lesson 3
Covered Electrodes Allotropic — A material in which the atoms are capable of transforming into two
for Welding or more crystalline structures at different temperatures.
Mild Steels
Alternating — An electrical current which alternately travels in either direction in a

Lesson 4 Current conductor. In 60 cycles per second (60 Hz) AC, the frequency
Covered Electrodes
used in the U.S.A., the current direction reverses 120 times every
for Welding Low
Alloy Steels second.
Ampere — Unit of electrical rate of flow. Amperage is commonly referred to as

Lesson 5
Welding Filler Metals the “current” in an electrical circuit.
ASME — American Society of Mechanical Engineers
Lesson 6
ASTM — American Society for Testing and Materials
Carbon & Low Alloy
GMAW,GTAW,SAW Atom — The smallest particle of an element that posses all of the
characteristics of that element. It consists of protons, neutrons,
Lesson 7 and electrons.
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels Carbon Steel — (Sometimes referred to as mild steel.) An alloy of iron and carbon.
Carbon content is usually below 0.3%.
Lesson 8 — A material which has a relatively large number of loosely bonded

Conductor
Hardsurfacing
Electrodes electrons which may move freely when voltage (electrical pressure)
is applied. Metals are good conductors.
Lesson 9 Constant Current — (As applied to welding machines.) A welding power source which
Estimating &
Comparing Weld will produce a relatively small change in amperage despite
Metal Costs changes in voltage caused by a varying arc length. Used mostly
for welding with coated electrodes.
Lesson 10
Filler Metals

The Basics of Arc
Welding
Constant Voltage — (As applied to welding machines.) A welding power source which
will produce a relatively small change in voltage when the
Lesson 2 amperage is changed substantially. Used mostly for welding with
Common Electric
Arc Welding solid or flux cored electrodes.
Processes
Direct Current — An electrical current which flows in only one direction in a
conductor. Direction of current is dependent upon the electrical
Lesson 3
Covered Electrodes connections to the battery or other DC power source. Terminals on
for Welding all DC devices are usually marked (+) or (-). Reversing the leads
Mild Steels
will reverse the direction of current flow.
Lesson 4 Electron — Negatively charged particles that revolve around the positively
Covered Electrodes
for Welding Low charged nucleus in an atom.
Alloy Steels
Ferrous — Containing iron. Example: carbon steel, low alloy steels, stainless
Lesson 5 steel.
Hertz — Hertz (Hz) is the symbol which has replaced the term “cycles per
second.” Today, rather than saying 60 cycles per second or simply
60 cycles, we say 60 Hertz or 60 Hz.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - High Alloy Steels — Steels containing in excess of 10% alloy content. Stainless steel is
GMAW,GTAW,SAW
considered a high alloy because it contains in excess of 10%
chromium.
Lesson 7
Flux Cored Arc
Electrodes Carbon Induced Current or
Low Alloy Steels Induction — The phenomena of causing an electrical current to flow through a
conductor when that conductor is subjected to a varying magnetic
field.
Lesson 8
Hardsurfacing
Electrodes Ingot — Casting of steel (weighing up to 200 tons) formed at mill from melt
of ore, scrap limestone, coke, etc.
Lesson 9
Estimating & Insulator — A material which has a tight electron bond, that is, relatively few
Comparing Weld electrons which will move when voltage (electrical pressure) is
Metal Costs
applied. Wood, glass, ceramics and most plastics are good
insulators.
Lesson 10
Filler Metals

The Basics of Arc
Welding
Kilowatt — 1,000 watts
Lesson 2 Low Alloy Steels — Steels containing small amounts of alloying elements (usually 1½%
Common Electric
Arc Welding to 5% total alloy content) which drastically improves their
Processes properties.
Lesson 3 Non-Ferrous — Containing no iron. Example: Aluminum, copper, copper alloys.

Covered Electrodes
for Welding
Mild Steels
Ohm — Unit of electrical resistance to current flow.
Lesson 4
Phase
Covered Electrodes
for Welding Low Transformation — The changes in the crystalline structure of metals caused by
Alloy Steels temperature and time.
Lesson 5 Proton — Positively charged particles which are part of the nucleus of atoms.
Rectifier — An electrical device used to change alternating current to direct
current.
Lesson 6
Carbon & Low Alloy SAE — Society of Automotive Engineers
GMAW,GTAW,SAW
Transformer — An electrical device used to raise or lower the voltage and inversely
change the amperage.
Lesson 7
Flux Cored Arc
Electrodes Carbon Volt — Unit of electromotive force, or electrical pressure which causes
Low Alloy Steels current to flow in an electrical circuit.
Watt — A unit of electrical power. Watts = Volts x Amperes

Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
for Welding
Mild Steels
WELDING FILLER METAL
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels A Correspondence Course
Lesson 5
Lesson 6 LESSON II
Carbon & Low Alloy
GMAW,GTAW,SAW
COMMON ELECTRIC ARC
WELDING PROCESSES
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON II
Lesson 2
Common Electric COMMON ELECTRIC ARC WELDING
Arc Welding
Processes PROCESSES
Lesson 3 Section Nr. Section Title Page

Covered Electrodes
for Welding
Mild Steels 2.1 INTRODUCTION .............................................................................. 1
2.2 SHIELDED METAL ARC WELDING ............................................... 1

Lesson 4
Covered Electrodes 2.2.1 Equipment & Operation ..................................................................... 2
for Welding Low 2.2.2 Welding Power Sources .................................................................... 2
Alloy Steels
2.2.3 Electrode Holder................................................................................ 4
2.2.4 Ground Clamp ................................................................................... 4
Lesson 5 2.2.5 Welding Cables ................................................................................. 4
Welding Filler Metals 2.2.6 Coated Electrodes ............................................................................ 4
2.3 GAS-TUNGSTEN ARC WELDING .................................................. 5
2.3.1 Equipment & Operation ..................................................................... 6
Lesson 6
2.3.2 Power Sources .................................................................................. 7
Carbon & Low Alloy
Steel Filler Metals - 2.3.3 Torches.............................................................................................. 10
GMAW,GTAW,SAW
2.3.4 Shielding Gases ................................................................................ 11
2.3.5 Electrodes ......................................................................................... 12
Lesson 7 2.3.6 Summary ........................................................................................... 13
Flux Cored Arc
Electrodes Carbon 2.4 GAS METAL ARC WELDING .......................................................... 13
Low Alloy Steels
2.4.1 Current Density .................................................................................. 14
2.4.2 Metal Transfer Modes ........................................................................ 15
Lesson 8 2.4.3 Equipment and Operation .................................................................. 17
Hardsurfacing 2.4.4 Power Source.................................................................................... 18
Electrodes
2.4.5 Wire Feeder ...................................................................................... 19
2.4.6 Welding Gun ...................................................................................... 20
Lesson 9 2.4.7 Shielding Gases ................................................................................ 21
Estimating & 2.4.7.1 Short Circuiting Transfer .................................................... 22
Comparing Weld
Metal Costs 2.4.7.2 Spray Arc Transfer ............................................................ 23
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON II - Con't.
Lesson 2
Common Electric
Arc Welding
Processes Section Nr. Section Title Page
Lesson 3 2.4.7.3 Pulse Spray Transfer ......................................................... 23

Covered Electrodes 2.4.8 Electrodes ......................................................................................... 23
for Welding
Mild Steels
2.5 FLUX CORED ARC WELDING ....................................................... 24
2.5.1 Self-Shielded Process ....................................................................... 24
Lesson 4 2.5.2 Gas Shielded Process....................................................................... 25
Covered Electrodes
2.5.3 Current Density .................................................................................. 26
for Welding Low
Alloy Steels 2.5.4 Equipment ......................................................................................... 26
2.5.5 Power Source.................................................................................... 26
2.5.6 Wire Feeder ...................................................................................... 26
Lesson 5
Welding Filler Metals 2.5.7 Welding Guns .................................................................................... 26
for Stainless Steels 2.5.8 Shielding Gases ................................................................................ 27
2.6 SUBMERGED ARC WELDING ....................................................... 27

Lesson 6 2.6.1 Submerged Arc Flux .......................................................................... 28
Carbon & Low Alloy
2.6.2 The Welding Gun ............................................................................... 28
GMAW,GTAW,SAW 2.6.3 Power Sources .................................................................................. 28
2.6.4 Equipment ......................................................................................... 28
2.6.5 Electrodes ......................................................................................... 29
Lesson 7
Flux Cored Arc 2.6.6 Summary ........................................................................................... 29
Electrodes Carbon
Low Alloy Steels 2.7 ELECTROSLAG AND ELECTROGAS WELDING .......................... 30
2.7.1 Electroslag Welding........................................................................... 30
2.7.2 Flux ................................................................................................... 30
Lesson 8
Hardsurfacing 2.7.3 Process ............................................................................................. 30
Electrodes 2.7.4 Equipment......................................................................................... 31
2.7.5 Summary .......................................................................................... 31
Lesson 9 Appendix A - GLOSSARY OF TERMS ................................................................. 32

Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON II
Welding
COMMON ELECTRIC ARC WELDING PROCESSES

Lesson 2
Common Electric
Arc Welding
Processes
2.1 INTRODUCTION
Lesson 3 After much experimentation by others in the early 1800's, an Englishman named Wilde
Covered Electrodes
obtained the first electric welding patent in 1865. He successfully joined two small pieces of
for Welding
Mild Steels iron by passing an electric current through both pieces producing a fusion weld. Approximately
twenty years later, Bernado, a Russian, was granted a patent for an electric arc welding
process in which he maintained an arc between a carbon electrode and the pieces to be
Lesson 4
Covered Electrodes joined, fusing the metals together as the arc was manually passed over the joint to be welded.
for Welding Low
Alloy Steels 2.1.0.1 During the 1890's, arc welding was accomplished with bare metal electrodes that
were consumed in the molten puddle and became part of the weld metal. The welds were of
Lesson 5 poor quality due to the nitrogen and oxygen in the atmosphere forming harmful oxides and
Welding Filler Metals nitrides in the weld metal. Early in the Twentieth Century, the importance of shielding the arc
from the atmosphere was realized. Covering the electrode with a material that decomposed in
the heat of the arc to form a gaseous shield appeared to be the best method to accomplish
this end. As a result, various methods of covering electrodes, such as wrapping and dipping,
Lesson 6
Carbon & Low Alloy were tried. These efforts culminated in the extruded coated electrode in the mid-1920's,
Steel Filler Metals - greatly improving the quality of the weld metal and providing what many consider the most
GMAW,GTAW,SAW
significant advance in electric arc welding.
Lesson 7 2.1.0.2 Since welding with coated electrodes is a rather slow procedure, more rapid
Flux Cored Arc
welding processes were developed. This lesson will cover the more commonly used electric
Electrodes Carbon
Low Alloy Steels arc welding processes in use today.
2.2 SHIELDED METAL ARC WELDING

Lesson 8
Hardsurfacing
Electrodes Shielded Metal Arc Welding*, also known as manual metal arc welding, stick welding, or
electric arc welding, is the most widely used of the various arc welding processes. Welding is
performed with the heat of an electric arc that is maintained between the end of a coated metal
Lesson 9 electrode and the work piece (See Figure 1). The heat produced by the arc melts the base
Estimating &
Comparing Weld metal, the electrode core rod, and the coating. As the molten metal droplets are transferred
Metal Costs across the arc and into the molten weld puddle, they are shielded from the atmosphere by the
gases produced from the decomposition of the flux coating. The molten slag floats to the top
of the weld puddle where it protects the weld metal from the atmosphere during solidification.
Lesson 10
Filler Metals

Lesson 1
Welding
Other functions of the coating are to provide
arc stability and control bead shape. More COATING
Lesson 2 information on coating functions will be
Common Electric
covered in subsequent lessons. CORE ROD
Arc Welding
Processes SHIELDING
* Shielded Metal Arc Welding (SMAW) is the GASES
SOLIDIFIED
terminology approved by the American MOLTEN SLAG
Welding Society. POOL
Lesson 3 WELD METAL
Covered Electrodes
for Welding 2.2.1 Equipment & Operation - One WORK PIECE
Mild Steels
SHIELDED METAL ARC WELDING
reason for the wide acceptance of the SMAW
process is the simplicity of the necessary equipment. FIGURE 1
Lesson 4
The equipment consists of the following items. (See
Covered Electrodes
for Welding Low Figure 2) AC OR DC
Alloy Steels POWER
SOURCE
1. Welding power source
ELECTRODE
2. Electrode holder CABLE
Lesson 5
ELECTRODE
Welding Filler Metals 3. Ground clamp HOLDER
ELECTRODE
4. Welding cables and connectors
GROUND
5. Accessory equipment (chipping WORK
CABLE
Lesson 6 hammer, wire brush) SHIELDED METAL ARC WELDING CIRCUIT
Carbon & Low Alloy
Steel Filler Metals - 6. Protective equipment (helmet, gloves, etc.) FIGURE 2
GMAW,GTAW,SAW
2.2.2 Welding Power Sources - Shielded metal arc welding may utilize either
alternating current (AC) or direct current (DC), but in either case, the power source selected
Lesson 7
Flux Cored Arc must be of the constant current type. This type of power source will deliver a relatively constant
Electrodes Carbon
amperage or welding current regardless of arc length variations by the operator (See Lesson I,
Low Alloy Steels
Section 1.9). The amperage determines the amount of heat at the arc and since it will remain
relatively constant, the weld beads produced will be uniform in size and shape.
Lesson 8
Hardsurfacing 2.2.2.1 Whether to use an AC, DC, or AC/DC power source depends on the type of welding
Electrodes to be done and the electrodes used. The following factors should be considered:
1. Electrode Selection - Using a DC power source allows the use of a greater range
Lesson 9 of electrode types. While most of the electrodes are designed to be used on AC or
Estimating &
Comparing Weld DC, some will work properly only on DC.
Metal Costs
2. Metal Thickness - DC power sources may be used for welding both heavy
sections and light gauge work. Sheet metal is more easily welded with DC
because it is easier to strike and maintain the DC arc at low currents.
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
3. Distance from Work - If the distance from the work to the power source is great,
AC is the best choice since the voltage drop through the cables is lower than with
Lesson 2 DC. Even though welding cables are made of copper or aluminum (both good
Common Electric
Arc Welding conductors), the resistance in the cables becomes greater as the cable length
Processes increases. In other words, a voltage reading taken between the electrode and the
work will be somewhat lower than a reading taken at the output terminals of the
power source. This is known as voltage drop.
Lesson 3
Covered Electrodes 4. Welding Position (See Appendix A - Glossary of Terms) - Because DC may be
for Welding
Mild Steels operated at lower welding currents, it is more suitable for overhead and vertical
welding than AC. AC can successfully be used for out-of-position work if proper
electrodes are selected.
Lesson 4
Covered Electrodes 5. Arc Blow - When welding with DC, magnetic fields are set up throughout the
for Welding Low weldment. In weldments that have varying thickness and protrusions, this magnetic
Alloy Steels
field can affect the arc by making it stray or fluctuate in direction. This condition is
especially troublesome when welding in corners. AC seldom causes this problem
Lesson 5 because of the rapidly reversing magnetic field produced.
2.2.2.2 Combination power sources that produce both AC and DC are available and
provide the versatility necessary to select the proper welding current for the application.
Lesson 6
2.2.2.3 When using a DC power source, the question of whether to use electrode negative
Carbon & Low Alloy
Steel Filler Metals - or positive polarity arises. Some electrodes operate on both DC straight and reverse polarity,
GMAW,GTAW,SAW and others on DC negative or DC positive polarity only. Direct current flows in one direction in
an electrical circuit and the direction of current flow and the composition of the electrode
Lesson 7 coating will have a definite effect on the welding arc and weld bead. Figure 3 shows the
Flux Cored Arc
connections and effects of straight and reverse polarity.
Electrodes Carbon
Low Alloy Steels
2.2.2.4 Electrode negative (-) produces welds with shallow penetration; however, the
electrode melt-off rate is high. The weld bead is rather wide and shallow as shown at "A" in
Lesson 8 Figure 3. Electrode
A B
Hardsurfacing positive (+) DC DC
Electrodes POWER SOURCE POWER SOURCE
produces welds with HIGHER BURN-OFF RATE, DEEP PENETRATION,
LESS PENETRATION LOW BURN-OFF RATE
deep penetration
Lesson 9 and a narrower weld ELECTRODE ELECTRODE
Estimating & bead as shown at
Comparing Weld
Metal Costs "B" in Figure 3.
WORK PIECE WORK PIECE
STRAIGHT POLARITY REVERSE POLARITY
Lesson 10 FIGURE 3
Filler Metals
© COPYRIGHT 1998 THE ESAB GROUP, INC.

Lesson 1
Welding
2.2.2.5 While polarity affects the penetration and burn-off rate, the electrode coating also
has a strong influence on arc characteristics. Performance of individual electrodes will be
Lesson 2 discussed in succeeding lessons.
Common Electric
Arc Welding
2.2.3 Electrode Holder - The electrode holder connects to the welding cable and con-
Processes
ducts the welding current to the electrode. The insulated handle is used to guide the electrode
over the weld joint and feed the electrode over the weld joint and feed the electrode into the
Lesson 3
weld puddle as it is consumed. Electrode holders are available in different sizes and are rated
Covered Electrodes
for Welding on their current carrying capacity.
Mild Steels
2.2.4 Ground Clamp - The ground clamp is used to connect the ground cable to the work
piece. It may be connected directly to the work or to the table or fixture upon which the work is
Lesson 4
Covered Electrodes positioned. Being a part of the welding circuit, the ground clamp must be capable of carrying
for Welding Low the welding current without overheating due to electrical resistance.
Alloy Steels
2.2.5 Welding Cables - The electrode cable and the ground cable are important parts of
Lesson 5 the welding circuit. They must be very flexible and have a tough heat-resistant insulation.
Welding Filler Metals Connections at the electrode holder, the ground clamp, and at the power source lugs must be
soldered or well crimped to assure low electrical resistance. The cross-sectional area of the
cable must be sufficient size to carry the welding current with a minimum of voltage drop.
Increasing the cable length necessitates increasing the cable diameter to lessen resistance
Lesson 6
Carbon & Low Alloy and voltage drop. The table in Figure 4 lists the suggested American Wire Gauge (AWG)
Steel Filler Metals - cable size to be used for various welding currents and cable lengths.
GMAW,GTAW,SAW
Welding Total Cable Length (Ground Lead Plus Electrode Lead) Voltage
Lesson 7 Service Up to 50 ft. Up to 100 ft. Up to 250 ft. Up to 500 ft. Drop
Flux Cored Arc Range Cable Voltage Cable Voltage Cable Voltage Cable Voltage Figured
Electrodes Carbon (Amperes) Size Drop Size Drop Size Drop Size Drop At
Low Alloy Steels
20 to 180 #3 1.8 #2 2.9 #1 5.7 #0 9.1 180 Amps
30 to 250 #2 1.8 #1 2.5 #0 5.0 #0 9.9 200 Amps
60 to 375 #0 1.7 #0 3.0 #00 5.9 #000 9.3 300 Amps
80 to 500 #00 1.8 #000 2.5 #0000 5.0 #0000 9.9 400 Amps
Lesson 8 100 to 600 #00 2.0 #0000 2.5 ... ... ... 500 Amps
Hardsurfacing
Electrodes Voltage drops indicated do not include any drop caused by poor connection, electrode holder, or work metal
FIGURE 4
Lesson 9 2.2.6 Coated Electrodes - Various types of coated electrodes are used in shielded
Estimating &
Comparing Weld metal arc welding. Electrodes used for welding mild or carbon steels are quite different than
Metal Costs those used for welding the low alloys and stainless steels. Details on the specific types will be
covered in subsequent lessons.
Lesson 10
Filler Metals

Lesson 1
Welding
2.3 GAS TUNGSTEN ARC WELDING
Gas Tungsten Arc Welding* is a welding process performed using the heat of an arc
Lesson 2
Common Electric established between a nonconsumable tungsten electrode and the work piece. See Figure 5.
Arc Welding
The electrode, the arc, and the area surrounding the molten weld puddle are protected from
Processes
the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in
shielded metal arc welding. If a filler metal is
Lesson 3 necessary, it is added to the leading
Covered Electrodes
for Welding the molten puddle as shown in
TRAVEL
Mild Steels DIRECTION
TORCH
2.3.0.1 Gas tungsten arc welding
produces exceptionally clean welds
Lesson 4
Covered Electrodes no slag is produced, the chance
for Welding Low TUNGSTEN
inclusions in the weld metal is ELECTRODE
Alloy Steels
and the finished weld requires SHIELDING GAS
ARC NOZZLE
virtually no cleaning. Argon
Lesson 5 and Helium, the primary
shielding gases employed,
are inert gases. Inert gases INERT GAS
SHIELD
do not chemically combine FILLER
METAL
with other elements and WORK PIECE
Lesson 6
Carbon & Low Alloy therefore, are used to exclude GAS TUNGSTEN ARC WELDING
GMAW,GTAW,SAW the reactive gases, such as oxygen and
nitrogen, from forming compounds that could FIGURE 5
be detrimental to the weld metal.

Lesson 7
Flux Cored Arc
Electrodes Carbon 2.3.0.2 Gas tungsten arc welding may be used for welding almost all metals — mild steel,
Low Alloy Steels low alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys, nickel
and nickel alloys, magnesium and magnesium alloys, titanium, and others. This process is
most extensively used for welding aluminum and stainless steel alloys where weld integrity is of
Lesson 8
Hardsurfacing the utmost importance. Another use is for the root pass (initial pass) in pipe welding, which
Electrodes requires a weld of the highest quality. Full penetration without an excessively high inside bead
is important in the root pass, and due to the ease of current control of this process, it lends
itself to control of back-bead size. For high quality welds, it is usually necessary to provide an
Lesson 9
Estimating & inert shielding gas inside the pipe to prevent oxidation of the inside weld bead.
Comparing Weld
Metal Costs
* Gas Tungsten Arc Welding (GTAW) is the current terminology approved by the American Welding Society,
Lesson 10 formerly known as "TIG" (Tungsten Inert Gas) welding.
Filler Metals

Lesson 1
Welding
2.3.0.3 Gas tungsten arc welding lends itself to both manual and automatic operation. In
manual operation, the welder holds the torch in one hand and directs the arc into the weld joint.
Lesson 2 The filler metal is fed manually into the leading edge of the puddle. In automatic applications,
Common Electric
Arc Welding the torch may be automatically moved over a stationary work piece or the torch may be
Processes stationary with the work moved or rotated in relation to the torch. Filler metal, if required, is
also fed automatically.
Lesson 3
2.3.1 EQUIPMENT AND OPERATION - Gas tungsten arc welding may be accomplished
Covered Electrodes
for Welding with relatively simple equipment, or it may require some highly sophisticated components.
Mild Steels Choice of equipment depends upon the type of metal being joined, the position of the weld
being made, and the quality of the weld metal necessary for the application. The basic equip-
Lesson 4 ment consists of the following:
Covered Electrodes
for Welding Low 1. The power source
Alloy Steels
2. Electrode holder (torch)
3. Shielding gas
Lesson 5 4. Tungsten electrode
for Stainless Steels 5. Water supply when necessary
6. Ground cable
7. Protective equipment
Lesson 6
Carbon & Low Alloy
Figure 6 shows a basic gas tungsten arc welding schematic.
GMAW,GTAW,SAW
REGULATOR
FLOW METER
Lesson 7
Flux Cored Arc GAS HOSE (WATER COOLED ONLY)
Electrodes Carbon
Low Alloy Steels TORCH
GAS COOLED ONLY
* COMPOSITE CABLE
WELDING CABLE
WATER COOLER
Lesson 8
WORK
Hardsurfacing
Electrodes
* COMPOSITE CABLE
POWER GAS COOLED TORCH.
WATER WATER CURRENT IN & GAS IN.
SOURCE
FROM TO
Lesson 9 TORCH TORCH WATER COOLED TORCH.
Estimating & CURRENT IN & WATER OUT
Comparing Weld GROUND CABLE
Metal Costs
SHIELDING
GAS SUPPLY GAS TUNGSTEN ARC WELDING CONNECTION SCHEMATIC
FIGURE 6
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
2.3.2 Power Sources - Both AC and DC power sources are used in gas tungsten arc
welding. They are the constant current type with a drooping volt-ampere curve. This type of
Lesson 2 power source produces very slight changes in the arc current when the arc length (voltage) is
Common Electric
Arc Welding varied. Refer to Lesson I, Section 1.9.
Processes
2.3.2.1 The choice between an AC or DC welder depends on the type and thickness of the
metal to be welded. Distinct differences exist between AC and DC arc characteristics, and if
Lesson 3
DC is chosen, the polarity also becomes an important factor. The effects of polarity in GTAW
Covered Electrodes
for Welding are directly opposite the effects of polarity in SMAW as described in paragraphs 2.2.2.3
Mild Steels through 2.2.2.5. In SMAW, the distribution of heat between the electrode and work, which
determines the penetration and weld bead width, is controlled mainly by the ingredients in the
Lesson 4 flux coating on the electrode. In GTAW where no flux coating exists, heat distribution between
Covered Electrodes the electrode and the work is controlled solely by the polarity. The choice of the proper welding
for Welding Low
Alloy Steels current will be better understood by analyzing each type separately. The chart in Figure 7 lists
current recommendations.
Lesson 5
Welding Filler Metals WELDING CURRENT SHIELDING GAS
for Stainless Steels Material & AC
Thickness DCEN DCEP High Freq. Argon Helium Ar/He
Aluminum
Under 1/8" 2 1 1 2
Lesson 6 Over 1/8" 2&3 1 1 3 2
Carbon & Low Alloy Magnesium
Steel Filler Metals - Under 1/16" 2 1 1 2
Over 1/16" 1 1
GMAW,GTAW,SAW
Carbon Steel
Under 1/8" 1 1
Over 1/8" 1 1 2 3
Lesson 7
Stainless Steel
Flux Cored Arc Under 1/8" 1 1 2
Electrodes Carbon Over 1/8" 1 1 2
Low Alloy Steels Copper
Under 1/8" 1 1
Over 1/8" 1 1
Nickel Alloys
Lesson 8 Under 1/8" 1 1 3 2
Hardsurfacing Over 1/8" 1 2 1
Electrodes Titanium
Under 1/8" 1 1 2
Over 1/8" 2 1
1. Preferred Choice - Manual Welding

Lesson 9 2. Preferred Choice - Automatic Welding
Estimating & 3. Second Choice - Automatic Welding
Comparing Weld CURRENT/SHIELDING GAS SELECTION, TUNGSTEN GAS ARC WELDING
Metal Costs
FIGURE 7
Lesson 10
Filler Metals

Lesson 1
Welding
2.3.2.2 Direct current electrode negative (DCEN) is produced when the electrode is
connected to the negative terminal of the power source. Since the electrons flow from the
Lesson 2 electrode to the plate, approximately 70% of the heat of the arc is concentrated at the work,
Common Electric
Arc Welding and approximately 30% at the electrode end. This allows the use of smaller tungsten elec-
Processes trodes that produce a relatively narrow concentrated arc. The weld shape has deep penetra-
tion and is quite narrow. See Figure 8. Direct current electrode negative is suitable for weld-
ing most metals. Magnesium and aluminum have a refractory oxide coating on the surface that
Lesson 3
Covered Electrodes must be physically removed immediately prior to welding if DCSP is to be used.
for Welding
Mild Steels 2.3.2.3 Direct current electrode positive (DCEP) is produced when the electrode is
connected to the positive terminal of the welding power source. In this condition, the electrons
Lesson 4 flow from the work to the electrode tip, concentrating approximately 70% of the heat of the arc
Covered Electrodes at the electrode and 30% at the work. This higher heat at the electrode necessitates using
for Welding Low
Alloy Steels larger diameter tungsten to prevent it from melting and contaminating the weld metal. Since
the electrode diameter is larger and the heat is less concentrated at the work, the resultant
weld bead is relatively wide and shallow. See Figure 8.
Lesson 5
for Stainless Steels Electrode Oxide Heat
Polarity Penetration Cleaning Concentration
_ Direct Current Deep

GAS IONS Penetration None At
Lesson 6 Straight Polarity Narrow Work
ELECTRON Electrode Negative Bead
Carbon & Low Alloy +
FLOW
GMAW,GTAW,SAW Medium Penetration Good Cycle
Alternating Current Medium Width Cleans Oxide Alternates Between
+ _ Bead on Each Half Electrode and Work
Lesson 7
Flux Cored Arc + Direct Current
Electrodes Carbon Shallow Penetration At
Maximum
Low Alloy Steels Reverse Polarity Wide Bead Electrode
_ Electrode Positive
EFFECTS OF CURRENT TYPE - GAS TUNGSTEN ARC WELDING

Lesson 8
Hardsurfacing FIGURE 8
Electrodes
2.3.2.4 Aluminum and magnesium are two metals that have a heavy oxide coating that acts
as an insulator and must be removed before successful welding can take place. Welding with
Lesson 9 electrode positive provides a good oxide cleaning action in the arc. If we were to study the
Estimating &
Comparing Weld physics of the welding arc, we find that the electric current causes the shielding gas atoms to
Metal Costs lose some of their electrons. Since electrons are negatively charged, these gas atoms now
are unbalanced and have an excessive positive charge. As we learned in Lesson I, unlike
charges attract. These positively charged atoms (or positive ions as they are known in
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
chemical terminology) are attracted to the negative pole, in this case the work, at high velocity.
Upon striking the work surface, they dislodge the oxide coating permitting good electrical
Lesson 2 conductivity for the maintenance of the arc, and eliminate the impurities in the weld metal that
Common Electric
Arc Welding could be caused by these oxides.
Processes
2.3.2.5 Direct current electrode positive is rarely used in gas-tungsten arc welding. Despite
the excellent oxide cleaning action, the lower heat input in the weld area makes it a slow
Lesson 3
process, and in metals having higher thermal conductivity, the heat is rapidly conducted away
Covered Electrodes
for Welding from the weld zone. When used, DCEP is restricted to welding thin sections (under 1/8") of
Mild Steels magnesium and aluminum.
2.3.2.6 Alternating current is actually a combination of DCEN and DCEP and is widely
Lesson 4
Covered Electrodes used for welding aluminum. In a sense, the advantages of both DC processes are combined,
for Welding Low and the weld bead produced is a compromise of the two. Remember that when welding with
Alloy Steels
60 Hz current, the electron flow from the electrode tip to the work reverses direction 120 times
every second. Thereby, the intense heat alternates from electrode to work piece, allowing the
Lesson 5 use of an intermediate size electrode. The weld bead is a compromise having medium
penetration and bead width. The gas ions blast the oxides from the surface of aluminum and
magnesium during the positive half cycle. Figure 8 illustrates the effects of the different types
of current used in gas-tungsten arc welding.
Lesson 6
Carbon & Low Alloy 2.3.2.7 DC constant current power sources - Constant current power sources, used for
Steel Filler Metals - shielded metal arc welding, may also be used for gas-tungsten arc welding. In applications
GMAW,GTAW,SAW
where weld integrity is not of utmost importance, these power sources will suffice. With
machines of this type, the arc must be initiated by touching the tungsten electrode to the work
Lesson 7 and quickly withdrawing it to maintain the proper arc length. This starting method
Flux Cored Arc
Electrodes Carbon contaminates the electrode and blunts the point which has been grounded on the electrode
Low Alloy Steels end. These conditions can cause weld metal inclusions and poor arc direction. Using a
power source designed for gas tungsten arc welding with a high frequency stabilizer will
eliminate this problem. The electrode need not be touched to the work for arc initiation.
Lesson 8
Hardsurfacing Instead, the high frequency voltage, at very low current, is superimposed onto the welding
Electrodes current. When the electrode is brought to within approximately 1/8 inch of the base metal, the
high frequency ionizes the gas path, making it conductive and a welding arc is established.
The high frequency is automatically turned off immediately after arc initiation when using direct
Lesson 9
Estimating & current.
Comparing Weld
Metal Costs 2.3.2.8 AC Constant Current Power Source - Designed for gas tungsten arc welding,
always incorporates high frequency, and it is turned on throughout the weld cycle to maintain a
stable arc. When welding with AC, the current passes through 0 twice in every cycle and the
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
arc must be reestablished each time it does so. The oxide coating on metals, such as
aluminum and magnesium, can act much like a rectifier as discussed in Lesson I. The positive
Lesson 2 half-cycle will be eliminated if the arc does not reignite, causing an unstable condition.
Common Electric
Arc Welding Continuous high frequency maintains an ionized path for the welding arc, and assures arc re-
Processes ignition each time the current changes direction. AC is extensively used for welding aluminum
and magnesium.
Lesson 3 AC/DC Constant Current Power Sources - Designed for gas tungsten arc
2.3.2.9
Covered Electrodes
for Welding welding, are available, and can be used for welding practically all metals. The gas tungsten
Mild Steels arc welding process is usually chosen because of the high quality welds it can produce. The
metals that are commonly welded with this process, such as stainless steel, aluminum and
Lesson 4 some of the more exotic metals, cost many times the price of mild steel; and therefore, the
Covered Electrodes power sources designed for this process have many desirable features to insure high quality
for Welding Low
Alloy Steels welds. Among these are:
1. Remote current control, which allows the operator to control welding amperage
Lesson 5 with a hand control on the torch, or a foot control at the welding station.
2. Automatic soft-start, which prevents a high current surge when the arc is
initiated.
Lesson 6 3. Shielding gas and cooling water solenoid valves, which automatically control
Carbon & Low Alloy
Steel Filler Metals - flow before, during and for an adjustable length of time after the weld is completed.
GMAW,GTAW,SAW
4. Spot-weld timers, which automatically control all elements during each
spot-weld cycle.
Lesson 7
Flux Cored Arc
Electrodes Carbon Other options and accessories are also available.
Low Alloy Steels
2.3.2.10 Power sources for automatic welding with complete programmable output are also
available. Such units are used extensively for the automatic welding of pipe in position. The
Lesson 8 welding current is automatically varied as the torch travels around the pipe. Some units
Hardsurfacing
Electrodes provide a pulsed welding current where the amperage is automatically varied between a low
and high several times per second. This produces welds with good penetration and improved
weld bead shape.
Lesson 9
Estimating & 2.3.3 Torches - The torch is actually an electrode holder that supplies welding current to
Comparing Weld
Metal Costs the tungsten electrode, and an inert gas shield to the arc zone. The electrode is held in a
collet-like clamping device that allows adjustment so that the proper length of electrode pro-
trudes beyond the shielding gas cup. Manual torches are designed to accept electrodes of 3
Lesson 10
Filler Metals

Lesson 1
Welding
inch or 7 inch lengths. Torches may be either air or water-cooled. The air-cooled types actu-
ally are cooled to a degree by the shielding gas that is fed to the torch head through a compos-
Lesson 2 ite cable. The gas actually surrounds the copper welding cable, affording some degree of
Common Electric
Arc Welding cooling. Water-cooled torches are usually used for applications where the welding current
Processes exceeds 200 amperes. The water inlet hose is connected to the torch head. Circulating
around the torch head, the water leaves the torch via the current-in hose and cable assembly.
Cooling the welding cable in this manner allows the use of a smaller diameter cable that is
Lesson 3
Covered Electrodes more flexible and lighter in weight.
for Welding
Mild Steels 2.3.3.1 The gas nozzles are made of ceramic materials and are available in various sizes
and shapes. In some heavy duty, high current applications, metal water-cooled nozzles are
Lesson 4 used.
Covered Electrodes
for Welding Low 2.3.3.2 A switch on the torch is used to energize the electrode with welding current and start
Alloy Steels
the shielding gas flow. High frequency current and water flow are also initiated by this switch if
the power source is so equipped. In many installations, these functions are initiated by a foot
Lesson 5 control that also is capable of controlling the welding current. This method gives the operator
full control of the arc. The usual welding method is to start the arc at a low current, gradually
increase the current until a molten pool is achieved, and welding begins. At the end of the
weld, current is slowly decreases and the arc extinguished, preventing the crater that forms at
Lesson 6 the end of the weld when the arc is broken abruptly.
Carbon & Low Alloy
Steel Filler Metals - 2.3.4 Shielding Gases - Argon and helium are the major shielding gases used in gas
GMAW,GTAW,SAW
tungsten arc welding. In some applications, mixtures of the two gases prove advantageous.
To a lesser extent, hydrogen is mixed with argon or helium for special applications.
Lesson 7
Flux Cored Arc 2.3.4.1 Argon and helium are colorless, odorless, tasteless and nontoxic gases. Both are
Electrodes Carbon
Low Alloy Steels inert gases, which means that they do not readily combine with other elements. They will not
burn nor support combustion. Commercial grades used for welding are 99.99% pure. Argon
is .38% heavier than air and about 10 times heavier than helium. Both gases ionize when
Lesson 8 present in an electric arc. This means that the gas atoms lose some of their electrons that
Hardsurfacing
Electrodes have a negative charge. These unbalanced gas atoms, properly called positive ions, now
have a positive charge and are attracted to the negative pole in the arc. When the arc is
positive and the work is negative, these positive ions impinge upon the work and remove
Lesson 9 surface oxides or scale in the weld area.
Estimating &
Comparing Weld
Metal Costs 2.3.4.2 Argon is most commonly used of the shielding gases. Excellent arc starting and
ease of use make it most desirable for manual welding. Argon produces a better cleaning
action when welding aluminum and magnesium with alternating current. The arc produced is
Lesson 10
Filler Metals

Lesson 1
Welding
relatively narrow. Argon is more suitable for welding thinner material. At equal amperage,
helium produces a higher arc voltage than argon. Since welding heat is the product of volts
Lesson 2 times amperes, helium produces more available heat at the arc. This makes it more suitable
Common Electric
Arc Welding for welding heavy sections of metal that have high heat conductivity, or for automatic welding
Processes operations where higher welding speeds are required.
2.3.4.3 Argon-helium gas mixtures are used in applications where higher heat input and the
Lesson 3
desirable characteristics of argon are required. Argon, being a relatively heavy gas, blankets
Covered Electrodes
for Welding the weld area at lower flow rates. Argon is preferred for many applications because it costs
Mild Steels less than helium.
2.3.4.4 Helium, being approximately 10 times lighter than argon, requires flow rates of 2 to
Lesson 4
Covered Electrodes 3 times that of argon to satisfactorily shield the arc.
for Welding Low
Alloy Steels 2.3.5 Electrodes - Electrodes for gas tungsten arc welding are available in diameters
from .010" to 1/4" in diameter and standard lengths range from 3" to 24". The most commonly
Lesson 5 used sizes, however, are the .040", 1/16", 3/32", and 1/8" diameters.
for Stainless Steels 2.3.5.1 The shape of the tip of the electrode is an important factor in gas tungsten arc
welding. When welding with DCEN, the tip must be ground to a point. The included angle at
which the tip is ground varies with the application, the electrode diameter, and the welding
Lesson 6 current. Narrow joints require a relatively small included angle. When welding very thin
Carbon & Low Alloy
Steel Filler Metals - material at low currents, a needlelike point ground onto the smallest available electrode may
GMAW,GTAW,SAW be necessary to stabilize the arc. Properly ground electrodes will assure easy arc starting,
good arc stability, and proper bead width.
Lesson 7
Flux Cored Arc 2.3.5.2 When welding with AC, grinding the electrode tip is not necessary. When proper
Electrodes Carbon welding current is used, the electrode will form a hemispherical end. If the proper welding
Low Alloy Steels
current is exceeded, the end will become bulbous in shape and possibly melt off to
contaminate the weld metal.
Lesson 8
Hardsurfacing 2.3.5.3 The American Welding Society has published Specification AWS A5.12-80 for
Electrodes tungsten arc welding electrodes that classifies the electrodes on the basis of their chemical
composition, size and finish. Briefly, the types specified are listed below:
Lesson 9 1) Pure Tungsten (AWS EWP) Color Code: Green

Estimating &
Comparing Weld Used for less critical applications. The cost is low and they give good results at
Metal Costs
relatively low currents on a variety of metals. Most stable arc when used on AC, either
balanced wave or continuous high frequency.
Lesson 10
Filler Metals

Lesson 1
Welding
2) 1% Thoriated Tungsten (AWS EWTh-1) Color Code: Yellow
Good current carrying capacity, easy arc starting and provide a stable arc. Less
Lesson 2
Common Electric susceptible to contamination. Designed for DC applications of nonferrous materials.
Arc Welding
3) 2% Thoriated Tungsten (AWS EWTh-2) Color Code: Red
Processes
Longer life than 1% Thoriated electrodes. Maintain the pointed end longer, used for
light gauge critical welds in aircraft work. Like 1%, designed for DC applications for
Lesson 3
Covered Electrodes nonferrous materials.
for Welding
Mild Steels 4) .5% Thoriated Tungsten (AWS EWTh-3) Color Code: Blue
Sometimes called "striped" electrode because it has 1.0-2.0% Thoria inserted in a
Lesson 4 wedge-shaped groove throughout its length. Combines the good properties of pure
Covered Electrodes and thoriated electrodes. Can be used on either AC or DC applications.
for Welding Low
Alloy Steels 5) Zirconia Tungsten (AWS EWZr) Color Code: Brown
Longer life than pure tungsten. Better performance when welding with AC. Melts more
Lesson 5 easily than thoriam-tungsten when forming rounded or tapered tungsten end. Ideal for
Welding Filler Metals applications where tungsten contamination must be minimized.
2.3.6 Summary - Gas Tungsten Arc Welding is one of the major welding processes
Lesson 6
Carbon & Low Alloy today. The quality of the welds produced and the ability to weld very thin metals are the major
Steel Filler Metals - features. The weld metal quality is high since no flux is used, eliminating the problem of slag
GMAW,GTAW,SAW
inclusions in the weld metal. It is used extensively in the aircraft and aerospace industry, where
high quality welds are necessary and also for welding the more expensive metals where the
Lesson 7 weld defects become very costly. Metals as thin as .005" can be welded due to the ease of
Flux Cored Arc
Electrodes Carbon controlling the current.
Low Alloy Steels
2.3.6.1 The major disadvantages of the process are that it is slower than welding with
consumable electrodes and is little used on thicknesses over 1/4" for this reason. Shielding
Lesson 8 gas and tungsten electrode costs make the process relatively expensive.
Hardsurfacing
Electrodes
2.4 GAS METAL ARC WELDING
Lesson 9 Gas Metal Arc Welding* is an arc welding process that uses the heat of an electric arc
Estimating & established between a consumable metal electrode and the work to be welded. The electrode
Comparing Weld
Metal Costs is a bare metal wire that is transferred across the arc and into the molten weld puddle. The
* Gas Metal Arc Welding (GMAW) is the current technology approved by the American Welding Society.
Lesson 10 Formerly known as "MIG" (Metal Inert Gas) Welding.
Filler Metals

Lesson 1
Welding
wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a
gaseous shield. Inert gases, reactive gases, and gas mixtures are used for shielding. The
Lesson 2 metal transfer mode is dependent on shielding gas choice and welding current level. Figure 9
Common Electric
Arc Welding is a sketch of the process showing the basic features.
Processes
TRAVEL WELDING WIRE
DIRECTION
WELDING CABLE
Lesson 3
Covered Electrodes SOLID WIRE SHIELDING GAS
for Welding ELECTRODE
Mild Steels GAS NOZZLE
GAS SHIELD CONTACT TIP
Lesson 4 ARC
Covered Electrodes WELD METAL
for Welding Low WORK PIECE
Alloy Steels
MOLTEN POOL
GAS METAL ARC WELDING

Lesson 5
for Stainless Steels FIGURE 9
2.4.0.1 Gas metal arc welding is a versatile process that may be used to weld a wide
Lesson 6 variety of metals including carbon steels, low alloy steels, stainless steels, aluminum alloys,
Carbon & Low Alloy
Steel Filler Metals - magnesium, copper and copper alloys, and nickel alloys. It can be used to weld sheet metal or
GMAW,GTAW,SAW relatively heavy sections. Welds may be made in all positions, and the process may be used
for semiautomatic welding or automatic welding. In semiautomatic welding, the wire feed
Lesson 7 speed, voltage, amperage, and gas flow are all preset on the control equipment. The operator
Flux Cored Arc needs merely to guide the welding gun along the joint at a uniform speed and hold a relatively
Electrodes Carbon
Low Alloy Steels constant arc length. In automatic welding, the gun is mounted on a travel carriage that moves
along the joint, or the gun may be stationary with the work moving or revolving beneath it.
Lesson 8 2.4.0.2 Practically all GMAW is done using DCEP (Electrode positive). This polarity
Hardsurfacing provides deep penetration, a stable arc and low spatter levels. A small amount of GMAW
Electrodes
welding is done with DCEN and although the melting rate of the electrode is high, the arc is
erratic. Alternating current is not used for gas metal arc welding.
Lesson 9 Current Density - To understand why gas metal arc welding can deposit weld
2.4.1
Estimating &
Comparing Weld metal at a rapid rate, it is necessary that the term "current density" be understood. Figure 10
Metal Costs shows a 1/4" coated electrode and a 1/16" solid wire drawn to scale. Both are capable of
carrying 400 amperes. Notice that the area of the 1/16" wire is only 1/16 that of the core wire
of the coated electrode. We can say that the current density of the 1/16" wire is 16 times
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
greater than the current density AREA = .049 SQ. IN.
of the 1/4" wire at equal welding

CORE WIRE
Lesson 2 currents. The resultant melt-off AREA = .0031 SQ. IN.
Common Electric
Arc Welding rate of the solid wire is very high. A
A × 16
Processes If we were to increase the current
through the 1/4" coated 1/16"
FLUX
Lesson 3 electrode to increase the current COATING
SOLID WIRE
Covered Electrodes density, the resistance heating
1/4"
for Welding through the 14" electrode length would be
Mild Steels COATED ELECTRODE .049 ÷ .0031 = 16
excessive, and the rod would become so
hot that the coating would crack, rendering RELATIVE SIZE OF ELECTRODES FOR WELDING AT 400 AMPS
Lesson 4 it useless. The 1/16" wire carries the high
Covered Electrodes
current a distance of less than 3/4", the FIGURE 10
for Welding Low
Alloy Steels approximate distance from the end of the contact tip to the arc.
2.4.2 Metal Transfer Modes

Lesson 5
Welding Filler Metals Spray transfer is a high current density process that rapidly deposits weld metal in
2.4.2.1
droplets smaller than the electrode diameter. They are propelled in a straight line from the
center of the electrode. A shielding gas mixture of Argon with 1% to 2% Oxygen is used for
Lesson 6 welding mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for weld-
Carbon & Low Alloy ing aluminum, magnesium, copper, and nickel alloys. Welding current at which spray transfer
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SPRAY GLOBULAR PULSE 1 2 3

Lesson 8 TRANSFER TRANSFER TRANSFER SHORT CIRCUITING ARC METAL TRANSFER
Hardsurfacing
Electrodes MODES OF METAL TRANSFER
FIGURE 11
Lesson 9
Estimating &
takes place is relatively high and will vary with the metal being welded, electrode diameter, and
Comparing Weld
Metal Costs the shielding gas being used. Deposition rates are high and welding is usually limited to the
flat or horizontal fillet position. See Figure 11.
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
2.4.2.2 Globular transfer takes place at lower welding currents than spray transfer. There
is a transition current where the transfer changes to globular even when shielding gases using
Lesson 2 a high percentage of argon are used. When carbon dioxide (CO2) is used as a shielding gas,
Common Electric
Arc Welding the transfer is always globular. In globular transfer, a molten drop larger than the electrode
Processes diameter forms on the end of the electrode, moves to the outer edge of the electrode and falls
into the molten puddle. Occasionally, a large drop will "short circuit" across the arc, causing
the arc to extinguish momentarily, and then instantaneously reignite. As a result, the arc is
Lesson 3
Covered Electrodes somewhat erratic, spatter level is high, and penetration shallow. Globular transfer is not
for Welding suitable for out-of-position welding. See Figure 11.
Mild Steels
2.4.2.3 Short circuiting transfer is a much used method in gas metal arc welding. It is
Lesson 4 produced by using the lowest current-voltage settings and the smaller wires, usually .030",
Covered Electrodes .035", and .045" diameters. The low heat input makes this process ideal for sheet metal, out-
for Welding Low
Alloy Steels of-position work, and poor fit-up applications. Often called "short arc welding" because metal
transfer is achieved each time the wire actually short circuits (makes contact) with the weld
puddle. This happens very rapidly. It is feasible for the short circuit frequency to be 20-200
Lesson 5
times a second, but in practice, it occurs from 90-100 times a second. Each time the
for Stainless Steels electrode touches the puddle, the arc is extinguished. It happens so rapidly that it is visible
only on high speed films.
Lesson 6 2.4.2.4 Pulse transfer is a mode of metal transfer somewhat between spray and short
Carbon & Low Alloy circuiting. The specific power source has built into it two output levels: a steady background
GMAW,GTAW,SAW level, and a high output (peak) level. The later permits the transfer of metal across the arc.
This peak output is controllable between high and low values up to several hundred cycles per
second. The result of such a peak output produces a spray arc below the typical transition
Lesson 7
Flux Cored Arc current.
Electrodes Carbon
Low Alloy Steels 2.4.2.4.1 Figure 11 shows the transfer method. The arc is initiated by touching the wire to the
work. Upon initial contact, a bit of the wire melts off to form a molten puddle. The wire feeds
forward until it actually contacts the work again, as at 1 in Figure 11, and the arc is
Lesson 8
Hardsurfacing extinguished. The short circuiting current causes the wire to neck down, as shown in 1, until it
Electrodes melts off, as shown at 2. As soon as the wire is free of the puddle, the arc is reignited and a
molten ball forms at the end of the electrode, as at 3. The wire continues to move forward until
it makes contact with the puddle, and the cycle is repeated.
Lesson 9
Estimating &
2.4.2.5 Gas metal arc spot welding is a variation of the process that allows spot welding
Comparing Weld
Metal Costs of thinner gauge metals, or of a thin gauge metal to a heavier section. The gun is placed
directly against the work and is equipped with a special nozzle to allow escape of the shielding
gas. When the trigger switch is actuated, the following sequence takes place. The shielding
Lesson 10
Filler Metals

Lesson 1
Welding
gas flows for a short interval before wire feeding starts; wire feeding starts; the arc is initiated
and continues for a preset time (usually a few seconds). The welding current and wire feeding
Lesson 2 stops, and the shielding gas flows for a short interval before it automatically stops. The
Common Electric
Arc Welding process is also useful for tacking welding pieces in position prior to running the final weld
Processes bead.
2.4.3 EQUIPMENT AND OPERATION - The equipment used for gas metal arc welding
Lesson 3
is more complicated than that required for shielded metal arc welding. Initial cost is relatively
Covered Electrodes
for Welding high, but the cost is rapidly amortized due to the savings in labor and overhead achieved by
Mild Steels the rapid weld metal deposition.
2.4.3.1 The equipment necessary for gas metal arc welding is listed below:
Lesson 4
Covered Electrodes
for Welding Low 1) Power source
Alloy Steels
2) Wire feeder
3) Welding gun
Lesson 5
4) Shielding gas supply
for Stainless Steels 5) Solid electrode wire
6) Protective equipment
Lesson 6 2.4.3.2 The basic equipment necessary for semiautomatic gas metal arc welding is shown
Carbon & Low Alloy in Figure 12.
GMAW,GTAW,SAW
GAS HOSE
FLOWMETER
REGULATOR
Lesson 7
Flux Cored Arc TRIGGER WIRE SPOOL
Electrodes Carbon CONTROL LEAD
Low Alloy Steels FEED ROLLS WIRE FEEDER
VALVE
Lesson 8
Hardsurfacing
Electrodes
MAGNETIC
SHIELDING
WELD CABLE GAS
Lesson 9 115V CONTACTOR
_
+
Estimating & POWER
Comparing Weld SOURCE
Metal Costs WELDING GUN GROUND CABLE
WORK
SCHEMATIC DIAGRAM SEMI-AUTOMATIC GMAW EQUIPMENT
Lesson 10 FIGURE 12
Filler Metals

Lesson 1
Welding
2.4.4 Power Source - A direct current, constant voltage power source is recommended
for gas metal arc welding. It may be a transformer-rectifier or a rotary type unit. The lower
Lesson 2
Common Electric open circuit voltage and self-correcting arc length feature, as described in Lesson I, makes it
Arc Welding most suitable. Constant voltage power sources used for spray transfer welding and for flux
Processes
cored electrode welding (to be covered later) are the same. However, if the unit is to be used
for short-circuiting arc
Lesson 3 welding, it must have
Covered Electrodes
"slope" or slope control.
for Welding 25
Mild Steels Slope control is a
OPERATING POINT
means of limiting the V 20
CONSTANT VOLTAGE V/A CURVE
O
high short-circuit current
Lesson 4 L
15
T
Covered Electrodes that is characteristic of
S
for Welding Low this type welder. Figure
Alloy Steels 10
13 shows the effect of SHORT CIRCUITING
CURRENT NO SLOPE
slope on the short- 5 SHORT CIRCUITING CURRENT
WITH SLOPE
Lesson 5 circuiting current.
Welding Filler Metals 200 400 600 800 1000 1200 1400
2.4.4.1 If we were EFFECT OF SLOPE ON SHORT CIRCUITING CURRENT
short-arc welding at
FIGURE 13
approximately 150 amperes
Lesson 6
Carbon & Low Alloy and 18 volts, as shown in Figure 13,
and had no slope components in the power source, the current at short-circuit or when the wire
GMAW,GTAW,SAW
touches the work, would be over 1400 amperes. At this high current, a good length of the wire
would literally explode off the end, cause much spatter, and the arc would be erratic. With the
Lesson 7
slope components in the circuit, the short-circuiting current is in the neighborhood of 400
Flux Cored Arc
Electrodes Carbon amperes, and the molten ball is sort of pinched off the end of the wire more gently. For those
Low Alloy Steels with an electrical background, it might be added that in some machines, slope is achieved by
adding a reactor in the AC secondary of the power source. In others, a slope resistor is added
in the DC output portion of the circuit. Slope may be adjustable for varying wire diameters or it
Lesson 8
Hardsurfacing may be fixed, giving a good average value for .035" and .045" diameter wires, the two most
Electrodes popular sizes.
2.4.4.2 Another factor influencing the arc in short-circuiting welding is the rate that the
Lesson 9 amperage reaches the short-circuiting current level. Using the example in Figure 13, we know
Estimating &
Comparing Weld that the current goes from 150 amperes to 400 amperes during each shorting period. If we
Metal Costs were to plot the current rise on a graph, as in Figure 14, we would see that the current rise if
very rapid, as shown by the broken line.
Lesson 10
Filler Metals

Lesson 1
Welding
This rapid current rise can be
by using a device called an
Lesson 2 (sometimes called a stabilizer)
Common Electric
Arc Welding output circuit of the welder. An
Processes 400 AMPS merely an iron core wound
WITHOUT INDUCTANCE turns of heavy wire. It does
Lesson 3 current flow, but it acts

Covered Electrodes WITH INDUCTANCE
somewhat like a fly wheel or
for Welding damper by retarding the rate of
Mild Steels
rise as shown by the solid
line. By preventing the
Lesson 4 150 AMPS
rapid current rise, the arc
Covered Electrodes
for Welding Low TIME - MILLISECONDS becomes smoother,
Alloy Steels EFFECT OF INDUCTANCE ON CURRENT RISE spatter is reduced, and
FIGURE 14 bead shape and
Lesson 5 appearance are

Welding Filler Metals improved. Because the inductor influences the time function, its design determines arc on-off
time, and short-circuit frequency. Some power sources have a selector that can switch in
several different inductance values to finely tune the arc.
Lesson 6 2.4.4.4 Welding power sources designed for gas metal arc welding have a 115 volt outlet to
Carbon & Low Alloy
Steel Filler Metals - provide power to operate the wire feeder. They also have a receptacle to receive the electrical
GMAW,GTAW,SAW power required to close the main contactor in the power source, which turns on the welding
power to the welding gun when the gun trigger is actuated.
Lesson 7
Flux Cored Arc 2.4.4.5 Additional advancements in equipment technology have introduced many new
Electrodes Carbon models. Inverters, as well as microprocessor controls, have created the greatest attention. In
Low Alloy Steels
addition, multipurpose machines have provided the user with greater flexibility with a variety of
capabilities.
Lesson 8
Hardsurfacing 2.4.4.6 Global competition will continue to have a profound influence on future
Electrodes advancements in arc welding equipment. As energy prices rise, greater demands for more
efficient equipment will follow.
Lesson 9 2.4.5 Wire Feeder - When welding with a constant voltage power source, as is the case
Estimating &
Comparing Weld in most gas metal arc welding applications, the prime function of the wire feeder is to deliver
Metal Costs the welding wire to the arc at a very constant speed. Since the wire feed speed determines
the amperage, and the amperage determines the amount of heat at the arc, inconsistent wire
feed speed will produce welds of varying penetration and bead width. Advanced electronics
Lesson 10
Filler Metals

Lesson 1
Welding
technology makes it possible to design motor speed controls that will produce the same
speed, even though the load on the motor varies or the input voltage to the motor may fluctuate.
Lesson 2
Common Electric 2.4.5.1 A limited amount of gas metal arc welding is performed with constant current type
Arc Welding power sources. In this case, the motor speed automatically varies to increase or decrease the
Processes
wire feed speed as the arc length varies to maintain a constant voltage.
Lesson 3 2.4.5.2 The wire feeder also controls the main contactor in the power source for safety
Covered Electrodes reasons. This assures that the welding wire will only be energized when the switch on the
for Welding
Mild Steels welding gun is depressed.
2.4.5.3 The flow of shielding gas is controlled by a solenoid valve (magnetic valve) in the
Lesson 4 wire feeder to turn the shielding gas on and off when the gun switch is actuated. Most feeders
Covered Electrodes
utilize a dynamic breaking circuit to quickly stop the motor at the end of a weld to prevent a
for Welding Low
Alloy Steels long length of wire protruding from the gun when the weld is terminated. Most feeders have a
burn-back circuit that allows the welding current to stay on for a short period of time after wire
feeding has stopped, to allow the wire to burn back exactly the right amount for the next arc
Lesson 5
Welding Filler Metals initiation.
2.4.5.4 The feed rolls, sometimes called drive rolls, pull the wire off the spool or reel, and
push it through a feed cable or conduit to the welding gun. These rolls must usually be
Lesson 6 changed to accommodate each different wire diameter, although some rolls are designed to
Carbon & Low Alloy
Steel Filler Metals - feed a combination of sizes.
GMAW,GTAW,SAW
2.4.6 Welding Gun - The function of the welding gun, sometimes referred to as a torch, is
to deliver the welding wire, welding current, and shielding gas to the welding arc. Guns are
Lesson 7
Flux Cored Arc available for semi-automatic operation and for automatic operation, where they are fixed in the
Electrodes Carbon automatic welding head.
Low Alloy Steels
2.4.6.1 Guns for GMAW have several characteristics in common. All have a copper alloy
shielding gas nozzle, that delivers the gas to the arc area in a nonturbulent, angular pattern to
Lesson 8
prevent aspiration of air. The nozzle may be water cooled for semiautomatic welding at high
Hardsurfacing
Electrodes amperage and for automatic welding where the arc time is of long duration. Welding current is
transferred to the welding wire as the wire travels through the contact tip or contact tube
located inside the gas nozzle (Refer to Figure 9). The hole in the contact tip through which the
Lesson 9
wire passes is only a few thousandths of an inch larger than the wire diameter. A worn contact
Estimating &
Comparing Weld tip will result in an erratic arc due to poor current transfer. Figure 15 shows a few different
Metal Costs semiautomatic gun configurations that are commonly used for GMAW.
Lesson 10
Filler Metals

Lesson 1
Welding
Lesson 2 CURVED NECK PISTOL TYPE

Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes SELF CONTAINED
for Welding PULL TYPE
Mild Steels
SEMI-AUTOMATIC GMAW GUN TYPES

Lesson 4
FIGURE 15
Covered Electrodes
for Welding Low
Alloy Steels 2.4.6.2 The curved neck or "goose neck" type is probably the most commonly used. It
allows the best access to a variety of weld joints. The wire is pushed to this type of gun by the
feed rolls in the wire feeder through a feed cable or conduit that usually is 10 or 12 feet in
Lesson 5
Welding Filler Metals length. The shielding gas hose, welding current cable, and trigger switch leads are supplied
for Stainless Steels with the welding gun.
2.4.6.3 The pistol type gun is similar to the curved neck type, but is less adaptable for
Lesson 6 difficult to reach joints. The pistol type is also a "push" type gun and is more suitable for gas
Carbon & Low Alloy
Steel Filler Metals - metal arc spot welding applications.
GMAW,GTAW,SAW
2.4.6.4 The self contained type has an electric motor in the handle and feed rolls that pull the
wire from a 1 or 2 pound spool mounted on the gun. The need for a long wire feed cable is
Lesson 7
Flux Cored Arc eliminated, and wire feed speed may be controlled by the gun. Guns of this type are often
Electrodes Carbon used for aluminum wire up to .045" diameter, although they may also be used for feeding steel
Low Alloy Steels
or other hard wires.
2.4.6.5 The pull type gun has either an electric motor or an air motor mounted in the handle
Lesson 8
that is coupled to a feeding mechanism in the gun. The spool of wire is located in the control
Hardsurfacing
Electrodes cabinet that may be located as far as fifty feet from the gun. When feeding such long
distances, a set of "push" rolls located in the control cabinet assist in feeding the wire. This
then becomes known as a push-pull feed system and is especially useful in feeding the softer
Lesson 9
wires such as aluminum.
Estimating &
Comparing Weld
Metal Costs 2.4.7 SHIELDING GASES - In gas metal arc welding, there are a variety of shielding
gases that can be used, either alone or in combinations of varying degrees. The choice is
dependent on the type of metal transfer employed, the type and thickness of metal, the bead
Lesson 10
Filler Metals

Lesson 1
Welding
profile (See Figure 16), penetration, and speed of welding. In our discussion, we will deal with
the more common choices used for the various transfer processes.
Lesson 2
Common Electric FERROUS METALS NON-FERROUS METALS
Arc Welding
Processes
Lesson 3
Covered Electrodes CO2 ARGON + CO2 ARGON + O2 ARGON HELIUM
for Welding
Mild Steels BEAD PROFILE
FIGURE 16
Lesson 4
Covered Electrodes 2.4.7.1 Short Circuiting Transfer - Straight carbon dioxide (CO2) is often used for short
for Welding Low circuiting arc welding because of its low cost. The deep penetration usually associated with
Alloy Steels
CO2 is minimized because of the low amperage and voltage settings used with this process.
Compared to other gas mixes, CO2 will produce a harsher arc and therefore, greater spatter
Lesson 5 levels. Usually, this is minimized by maintaining a short arc length and by careful adjustment of
Welding Filler Metals the power supply inductance. The temperatures reached in welding will cause carbon dioxide
to decompose into carbon monoxide and oxygen. To reduce the possibility of porosity caused
by entrapped oxygen in the weld metal, it is wise to use electrodes that contain deoxidizing
Lesson 6 elements, such as silicon and manganese. If the current is increased above the short circuiting
Carbon & Low Alloy range, the use of carbon dioxide tends to produce a globular transfer.
GMAW,GTAW,SAW
2.4.7.1.1 Mixing argon in proportions of 50-75% with carbon dioxide will produce a smoother
arc and reduce spatter levels. It will also widen the bead profile, reduce penetration, and
Lesson 7 encourage "wetting". Wetting, i.e., a uniform fusion, along with joining edges of the base metal
Flux Cored Arc
Electrodes Carbon and the weld metal, minimizes the weld imperfection known as undercutting (See Figure 17).
Low Alloy Steels
Lesson 8
Hardsurfacing UNDERCUT WETTING
Electrodes
FIGURE 17
Lesson 9 2.4.7.1.2 The 75% Argon/25 CO2 mixture is often chosen for short circuit welding of thin
Estimating &
sections, whereas the 50-50 combination works well on thicker sections.
Comparing Weld
Metal Costs
2.4.7.1.3 It should be noted that shielding gases can affect the metallurgy of the weld metal.
As an example, a combination of argon and carbon dioxide may be used for welding stainless
Lesson 10 steel, but as the carbon dioxide breaks down, excessive carbon may be transferred into the
Filler Metals

Lesson 1
Welding
weld metal. Corrosion resistance in stainless steel is reduced as the carbon content
increases. To counteract this possibility, a less reactive mixture of 90% helium - 7-1/2% argon
Lesson 2 - 2-1/2% CO2 is sometimes chosen. This combination, known as a trimix, provides good arc
Common Electric
Arc Welding stability and wetting.
Processes
2.4.7.2 Spray Arc Transfer - Pure argon produces a deep constricted penetration at the
center of the bead with much shallower penetration at the edges (Figure 16). Argon performs
Lesson 3
well on nonferrous metals, but when used on ferrous metals, the transfer is somewhat erratic
Covered Electrodes
for Welding with the tendency for the weld metal to move away from the center line. To make argon suit-
Mild Steels able for spray transfer on ferrous metals, small additions of 1 to 5% oxygen have proven to
provide remarkable improvements. The arc stabilizes, becomes less spattery, and the weld
Lesson 4 metal wets out nicely. If the percentage of argon falls below 80%, it is impossible to achieve
Covered Electrodes true spray transfer.
for Welding Low
Alloy Steels
2.4.7.2.1 Pure helium or combinations of helium and argon are used for welding nonferrous
metals. The bead profile will broaden as the concentration of helium increases.
Lesson 5
Welding Filler Metals 2.4.7.3 Pulse Spray Transfer - The selection of shielding gas must be adequate enough to
support a spray transfer. Material type, thickness, and welding position are essential variables
in selecting a particular shielding gas. The following is a list of recommended gases:
Lesson 6 Carbon Steel

Carbon & Low Alloy Argon/CO2/O2/He (He less than 50%)
Alloy Steel Argon/CO2/O2/He (He less than 50%)
GMAW,GTAW,SAW
Stainless Argon/O2/CO2 (CO2 max. 2%)
Lesson 7 Copper, Nickel, & Cu-Ni Alloys Argon/Helium
Flux Cored Arc
Electrodes Carbon Aluminum Argon/Helium
Low Alloy Steels
2.4.8 Electrodes - The solid electrodes used in GMAW are of high purity when they come
from the mill. Their chemistry must be closely controlled and some types purposely contain
Lesson 8
Hardsurfacing high levels of deoxidizers for use with CO2 shielding.
Electrodes
2.4.8.1 The electrode manufacturer draws down the electrode to a finished diameter that,
with GMAW, is usually quite small. Diameters from .030" thru 1/16" are common.
Lesson 9
Estimating & 2.4.8.2 Most steel GMAW electrodes are copper plated as a means of protecting the
Comparing Weld
surface. The copper inhibits rusting, provides smooth feeding, and helps electrical
Metal Costs
conductivity.
2.4.8.3 Information on types and classifications will be covered in a future lesson.

Lesson 10
Filler Metals

Lesson 1
Welding
2.5 FLUX CORED ARC WELDING
Flux Cored Arc Welding (FCAW) is quite similar to GMAW as far as operation and
Lesson 2
Common Electric equipment are concerned. The major difference is that FCAW utilizes an electrode that is very
Arc Welding
different from the solid electrode used in GMAW. The flux cored electrode is a fabricated
Processes
electrode and as the name implies, flux material is deposited into its core. The flux cored
electrode begins as a flat metal strip that is formed first into a "U" shape. Flux and alloying
Lesson 3 elements are deposited into the "U" and then the shape is closed into a tubular configuration
Covered Electrodes
for Welding by a series of forming rolls.
Mild Steels
2.5.0.1 The flux cored electrode is a continuous electrode that is fed into the arc where it is
melted and transferred into the molten puddle. As in GMAW, the flux cored process depends
Lesson 4
Covered Electrodes on a gas shield to protect the weld zone from detrimental atmospheric contamination. With
for Welding Low FCAW, there are two primary ways this is accomplished (See Figure 18). The gas is either
Alloy Steels
applied externally, in which case the electrode is referred to as a gas shielded flux cored
electrode, or it is generated from the decomposition of gas forming ingredients contained in
Lesson 5 the electrode's core. In this instance, the electrode is known as a self-shielding flux cored
electrode. In addition to the gas shield, the flux cored electrode produces a slag covering for
CONTACT TIP
CONTACT TIP
Lesson 6 GAS CUP
Carbon & Low Alloy INSULATED
GUIDE TUBE
GMAW,GTAW,SAW GAS SHIELD
Lesson 7
Flux Cored Arc FLUX CORE FLUX CORE
Electrodes Carbon
Low Alloy Steels
Lesson 8 GAS SHIELDED SELF SHIELDED

Hardsurfacing
Electrodes FLUX-CORED ARC WELDING
FIGURE 18
Lesson 9
Estimating & further protection of the weld metal as it cools. The slag is manually removed with a wire brush
Comparing Weld
Metal Costs or chipping hammer.
2.5.1 Self Shielded Process - The main advantage of the self shielding method is that
Lesson 10 its operation is somewhat simplified because of the absence of external shielding equipment.
Filler Metals
© COPYRIGHT 1998 THE ESAB GROUP, IN

Lesson 1
Welding
Although self shielding electrodes have been developed for welding low alloy and stainless
steels, they are most widely used on mild steels. The self shielding method generally uses a
Lesson 2 long electrical stick-out (distance between the contact tube and the end of the unmelted elec-
Common Electric
Arc Welding trode) commonly from one to four inches. Electrical resistance is increased with the long
Processes extension, preheating the electrode before it is fed into the arc. This enables the electrode to
burn off at a faster rate and increases deposition. The preheating also decreases the heat
available for melting the base metal, resulting in a more shallow penetration than the gas
Lesson 3
Covered Electrodes shielded process.
for Welding
Mild Steels 2.5.1.1 A major drawback of the self shielded process is the metallurgical quality of the
deposited weld metal. In addition to gaining its shielding ability from gas forming ingredients
Lesson 4 in the core, the self shielded electrode contains a high level of deoxidizing and denitrifying
Covered Electrodes alloys, primarily aluminum, in its core. Although the aluminum performs well in neutralizing the
for Welding Low
Alloy Steels affects of oxygen and nitrogen in the arc zone, its presence in the weld metal will reduce
ductility and impact strength at low temperatures. For this reason, the self shielding method is
usually restricted to less critical applications.
Lesson 5
2.5.1.2 The self shielding electrodes are more suitable for welding in drafty locations than
the gas shielded types. Since the molten filler metal is on the outside of the flux, the gases
formed by the decomposing flux are not totally relied upon to shield the arc from the
Lesson 6 atmosphere. The deoxidizing and denitrifying elements in the flux further help to neutralize the
Carbon & Low Alloy affects of nitrogen and oxygen present in the weld zone.
GMAW,GTAW,SAW
2.5.2 The Gas Shielded Process - A major advantage with the shielded flux cored
electrode is the protective envelope formed by the auxiliary gas shield around the molten
Lesson 7 puddle. This envelope effectively excludes the natural gases in the atmosphere without the
Flux Cored Arc
Electrodes Carbon need for core ingredients such as aluminum. Because of this more thorough shielding, the
Low Alloy Steels weld metallurgy is cleaner which makes this process suitable for welding not only mild steels,
but also low alloy steels in a wide range of strength and impact levels.
Lesson 8 2.5.2.1 The gas shielded method uses a shorter electrical stickout than the self shielded
Hardsurfacing
Electrodes process. Extensions from 1/2" to 3/4" are common on all diameters, and 3/4" to 1-1/2" on
larger diameters. Higher welding currents are also used with this process, enabling high
deposition rates to be reached. The auxiliary shielding helps to reduce the arc energy into a
Lesson 9 columnar pattern. The combination of high currents and the action of the shielding gas
Estimating &
Comparing Weld contributes to the deep penetration inherent with this process. Both spray and globular
Metal Costs transfer are utilized with the gas shielded process.
Lesson 10
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
2.5.3 Current Density - Flux cored arc welding utilizes the same principles of current
density, as explained in section 2.4.1, but there is one significant difference between the flux
Lesson 2 cored electrode and the solid electrode. With the flux cored electrode, the granular core
Common Electric
Arc Welding ingredients are poor electrical conductors and therefore, the current is carried primarily
Processes through the outer metal sheathing. When an equal diam-
eter cross section of the two are compared (See Figure CURRENT PATH
Lesson 3 19), it is seen that the flux cored electrode has

Covered Electrodes a smaller current carrying area than the solid
for Welding
electrode. This greater concentration of
Mild Steels
current in a smaller area increases the
burnoff rate.
Lesson 4
Covered Electrodes 2.5.3.1 When all other factors are equal,
for Welding Low
Alloy Steels the deposition rate of the flux cored 1/16" FLUX-CORED
ELECTRODE 1/16" SOLID
electrode is somewhat higher than the ELECTRODE
solid electrode. FIGURE 19

Lesson 5
Welding Filler Metals 2.5.4 EQUIPMENT - The equipment used for flux cored arc welding is the same as
shown previously in Section 2.3.2.2, Figure 12, with the exception that the self shielded
method does not need the external gas apparatus.
Lesson 6
Carbon & Low Alloy 2.5.4.1 Flux cored arc welding is done with direct current. All of the gas shielded electrodes
Steel Filler Metals - are designed for DCEP operation. The self shielded electrodes are either designed
GMAW,GTAW,SAW
specifically for DCEN or DCEP.
Lesson 7 2.5.5 Power Source - The recommended power source is the direct current constant
Flux Cored Arc
voltage type. The constant current type can be used but with less satisfactory results.
Electrodes Carbon
Low Alloy Steels
2.5.6 Wire Feeder - The function of the wire feeder in FCAW is the same as discussed in
the section on GMAW. Since the flux cored electrode is tubular in construction, precautions
Lesson 8 must be taken not to flatten the electrode. To facilitate feeding by means other than pressure
Hardsurfacing alone, specially designed feed rolls with knurled or grooved surfaces are used. Some feeders
Electrodes
use four feed rolls rather than two to minimize unit pressure on the electrode.
2.5.7 The Welding Gun - As compared to GMAW, the main difference in FCAW welding
Lesson 9
Estimating & guns is in those used with the self shielding process. The gun is somewhat more compact due
Comparing Weld to the absence of an external gas shielding nozzle. Since the self shielding process normally
Metal Costs
requires a longer electrode extension, the self shielding gun may have an insulated guide tube
(Refer back to Figure 18) to give stability to the electrode. Water cooled guns are available for
Lesson 10 high duty semi-automatic welding and for automatic welding.

Filler Metals

Lesson 1
Welding
2.5.7.1 Flux cored welding generates fumes, that for environmental reasons, must be
removed from the welding area. This is usually done with an external exhaust system, but
Lesson 2 welding guns with internal fume extractors have been developed. They are heavier than the
Common Electric
Arc Welding regular gun and must be properly maintained so that the extracting mechanism does not
Processes disturb the shielding gas.
2.5.8 SHIELDING GASES - Carbon dioxide is the most widely used gas for auxiliary
Lesson 3
shielding of the flux cored electrode. The other commonly used gas is a mixture of 75% Argon
Covered Electrodes
for Welding and 25% CO2.
Mild Steels
2.5.8.1 A carbon dioxide shield produces deep penetration and the transfer is globular. As
Lesson 4 previously discussed, CO2 will dissociate in the heat of the arc. To counteract this
Covered Electrodes characteristic, deoxidizing elements are added to the core ingredients of the electrode. The
for Welding Low deoxidizers react to form solid oxide compounds that float to the surface as part of the slag
Alloy Steels
covering.
Lesson 5 2.5.8.2 The addition of Argon to CO2 will increase the wetting action, produce a smooth arc
Welding Filler Metals arc, and reduce spatter. The transfer is spray-like, and the penetration is somewhat less than
with the straight carbon dioxide.
2.5.8.3 While some flux cored electrodes are designed to operate well on both the 100%
Lesson 6
Carbon & Low Alloy CO2 or the 75/25 mixture, others are formulated specifically for the CO2 shield or the Argon/
Steel Filler Metals - CO2 mixture. If the recommended gas is not used with these electrodes, the weld chemistry
GMAW,GTAW,SAW may be affected. The reason for this is that inert gas, such as Argon, does not react with the
other elements; therefore, allowing them to be transferred across the arc into the weld metal.
Lesson 7 An electrode designed for CO2 shielding contains deoxidizing elements, such as silicon and
Flux Cored Arc manganese. If a high percentage of Argon is used in the shielding medium, a large portion of
Electrodes Carbon
Low Alloy Steels these elements may pass into the weld metal causing the weld metallurgy to be less ductile
than intended.
Lesson 8 2.5.8.3 The opposite happens with electrodes formulated for a 75/25 mixture. These
Hardsurfacing electrodes are usually designed for high yield and tensile strength. If a high percentage of CO2
Electrodes
is used with them, the CO2 may react with the elements needed to attain these strength levels,
thereby preventing them from passing into the weld metal.
Lesson 9
Estimating &
Comparing Weld
2.6 SUBMERGED ARC WELDING
Metal Costs
Submerged Arc Welding (SAW) is different from the previously explained arc welding
processes in that the arc is not visible. The arc is submerged beneath loose granular flux. A
Lesson 10 continuous electrode is fed by automatic drive rolls through an electrode holder where current
Filler Metals

Lesson 1
LESSON II
The Basics of Arc
Welding
is picked up at the contact tube. The electrode moves into the loose flux and the arc is
initiated. The flux is deposited from a separate container that moves at the same pace as the
Lesson 2 electrode assuring complete coverage (See Figure 20).
Common Electric
Arc Welding 2.6.1 Submerged Arc Flux - The flux helps form the molten puddle, slows the cooling
Processes
rate, and acts as a protective shield. The flux, which is in close contact with the arc, is fused
into a slag cover and that which is not fused is collected for reuse. The flux can contain alloying
Lesson 3
elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes
Covered Electrodes
for Welding are specifically prepared for their alloy altering capabilities while others, known as neutral
Mild Steels fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are
called "neutral", they still have the ability to slightly alter the weld chemistry.
Lesson 4
Covered Electrodes
for Welding Low FLUX HOPPER
Alloy Steels
Lesson 5 ELECTRODE
LOOSE GRANULAR FLUX
Lesson 6
BASE
Carbon & Low Alloy METAL
MOLTEN PUDDLE
Steel Filler Metals - FUSED SLAG COVER
GMAW,GTAW,SAW SOLIDIFIED WELD METAL
SUBMERGED ARC WELDING

Lesson 7
Flux Cored Arc FIGURE 20
Electrodes Carbon
Low Alloy Steels
2.6.2 The Welding Gun - Although there are hand-held welding guns for the submerged
arc process, the majority of SAW is done with fully automatic equipment. The basic compo-
Lesson 8 nents include a wire feeder, a power source, a flux delivery system, and in some instances, an
Hardsurfacing automatic flux recovery system.
Electrodes
2.6.3 Power Sources - The power source can be a constant current AC transformer, or it
may be a DC rectifier or generator of either the constant current or constant voltage variety.
Lesson 9
Estimating & The power source must be rated for high current output. When current requirements exceed
Comparing Weld the value of a single machine, two or more of the same type may be connected in parallel.
Metal Costs
2.6.4 Equipment - Most submerged arc welding is done with DCEP because it provides
easy arc starting, deep penetration and excellent bead shape. DCEN provides the highest
Lesson 10
Filler Metals

Lesson 1
Welding
deposition rates but minimum penetration. Alternating current is often used as a trailing arc in
tandem arc applications. In this type of application, the leading DCEP arc provides deep
Lesson 2 penetration, and the closely trailing AC arc provides high deposition with a minimum of arc
Common Electric
Arc Welding blow.
Processes
2.6.5 Electrodes - A variety of ferrous and nonferrous electrodes are used in submerged
arc welding. They are usually solid electrodes refined with the appropriate alloys at the steel
Lesson 3
mill, and then shipped to electrode manufacturers where they are drawn down to a specific
Covered Electrodes
for Welding diameter and packaged. There is another type of sub arc electrode known as a composite
Mild Steels electrode, that is fabricated in the same manner as a flux cored electrode. A chief advantage
of this type is that the alloying elements can be added to the core of the electrode more
Lesson 4 cheaply than a steel mill can produce those same alloys in a solid form. The electrodes for
Covered Electrodes SAW vary in diameter from 1/16 inch to 1/4 inch with the larger diameters being the most
for Welding Low
Alloy Steels widely used.
2.6.6 Summary - Submerged arc welding has some advantages over other welding
Lesson 5 processes. Since the radiance of the arc is blanketed by the loose flux, there is no need for a
protective welding hood (although safety glasses are recommended), there is no spatter and
only a very minimal amount of fumes escape from under the blanket. High welding currents,
quite commonly in the 300 to 1600 ampere range, are used. These high currents, combined
Lesson 6 with fast travel speeds, make SAW a high deposition process that is especially suitable for
Carbon & Low Alloy applications that require a series of repetitious welds. Some setups allow two or more elec-
GMAW,GTAW,SAW trodes to be fed simultaneously into the joint, further increasing the deposition rate and speed.
2.6.6.1 Although SAW has these advantages, it does have some limitations. The flux must
Lesson 7 be deposited and collected for every welding pass. This requires additional equipment and
Flux Cored Arc
Electrodes Carbon handling. Also because of the loose flux, the process is limited to the flat and horizontal
Low Alloy Steels positions. The equipment for SAW is commonly quite bulky which limits its mobility, and
although the process works well on thick materials, it usually is not satisfactory for thin gauge
material. The process requires care in the operation. The amperages commonly used may
Lesson 8
Hardsurfacing cause excessive heat buildup in the base metal, that may result in distortion or brittleness.
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
2.7 ELECTROSLAG AND ELECTROGAS WELDING
Electroslag Welding (ESW) and Electrogas Welding (EGW) comprise only a minor portion
Lesson 2
Common Electric of all welding done in the country, but they are uniquely adapted to certain applications,
Arc Welding
primarily the joining of very thick materials. The joining of a 12 inch material along a 40 foot
Processes
line is not an uncommon application for the Electroslag process.
Lesson 3 2.7.1 Electroslag Welding (See Figure 21) is technically not an arc welding process,
Covered Electrodes although it utilizes a current carrying consumable electrode. The only time there is an arc
for Welding
Mild Steels between the electrode and the work piece is when current is initially charged through the
electrode. This initial charge heats a layer of loose flux that becomes molten and extinguishes
the arc.
Lesson 4
Covered Electrodes
for Welding Low WATER INLET/OUTLET
Alloy Steels
ELECTRODE
COPPER SHOE
Lesson 5
Welding Filler Metals GUIDE TUBE
(CONSUMABLE GUIDE METHOD)
BASE METAL
Lesson 6 MOLTEN FLUX

Carbon & Low Alloy
GMAW,GTAW,SAW
WELD POOL SOLIDIFIED METAL
ELECTROSLAG WELDING
Lesson 7
Electrodes Carbon
Low Alloy Steels
2.7.2 Flux - The flux used in ESW is high in electrical resistance. As current is applied,
enough heat is generated from this resistance to keep the flux, base metal, and electrode in a
Lesson 8 molten state. This axis of the weld joint is on a vertical plane. The two pieces of metal, usually
Hardsurfacing
Electrodes of the same thickness, are positioned so that there is an opening between them. One or more
electrodes are fed into the opening through a welding bead that travels vertically as the joint is
filled. To contain the molten puddle, water cooled copper shoes or dams are placed on the
Lesson 9 sides of the vertical cavity. As the weld joint solidifies, the dams move vertically so as to
Estimating &
Comparing Weld always remain in contact with the molten puddle.
Metal Costs
2.7.3 Process - A variation of ESW is the consumable guide method. The process is the
same with this method except that the guide tube that feeds the electrode to the molten pool is
Lesson 10
Filler Metals

Lesson 1
Welding
also consumed. The chief advantage with this method is the elimination of the electrode
holder which must move vertically with the weld pool. Also since the guide tube is consumed,
Lesson 2 the deposition rate is slightly increased with this method.
Common Electric
Arc Welding 2.7.4 Equipment - The equipment used in ESW is all automatic and of special design.
Processes
The power source may use either AC or DC current. The electrode may be either solid or flux
cored, although if the flux cored is used, it must be specially formulated so as not to contain its
Lesson 3
normal amount of slag forming ingredients.
Covered Electrodes
for Welding
Mild Steels 2.7.5 Summary - Electrogas Welding is similar to ESW as far as the mechanical as-
pects are concerned. The equipment is automatic, the welding head travels vertically, and the
molten puddle is retained by shoes on the sides of the joint. The difference is that Electrogas
Lesson 4
Covered Electrodes Welding utilizes an arc and it is externally gas shielded. The power source is also limited to
for Welding Low DC operation. The electrodes used in EGW can be either solid or flux cored.
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
APPENDIX A
Lesson 2 LESSON II - GLOSSARY OF TERMS

Common Electric
Arc Welding
Processes
Arc Blow - Deviation of the direction of the welding arc caused by magnetic fields in the
Lesson 3
work piece when welding with direct current.
Covered Electrodes
for Welding
Mild Steels
Straight
- Welding condition when the electrode is connected to the negative terminal
Polarity
and the work is connected to the positive terminal of the welding power source.
Lesson 4
Covered Electrodes
for Welding Low
Reverse
Alloy Steels - Welding condition when the electrode is connected to the positive terminal
Polarity
and the work is connected to the negative terminal of the welding power
Lesson 5 source.
for Stainless Steels Slag - The brittle mass that forms over the weld bead on welds made with coated
electrodes, flux cored electrodes, submerged arc welding and other slag
producing welding processes. Welds made with the gas metal arc and the
Lesson 6 gas tungsten arc welding processes are slag free.
Carbon & Low Alloy
GMAW,GTAW,SAW
Manual Arc
- Welding with a coated electrode where the operator's hand controls travel
Welding
speed and the rate the electrode is fed into the arc.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Semi-Automatic
Low Alloy Steels - Welding with a continuous solid wire or flux cored electrode where the wire
Welding
feed speed, shielding gas flow rate, and voltage are preset on the equipment,
and the operator guides the hand held welding gun along the joint to be
Lesson 8
Hardsurfacing welded.
Electrodes
Slag
- A weld defect where slag is entrapped in the weld metal before it can float to
Inclusion
Lesson 9 the surface.
Estimating &
Comparing Weld
Metal Costs Root Pass - The initial pass in a multi-pass weld, usually requiring 100% penetration.
Lesson 10
Filler Metals

Lesson 1
Welding
Gas Ions - Shielding gas atoms that, in the presence of an electrical current, lose one or
more electrons and therefore, carry a positive electrical charge. The provide
Lesson 2 a more electrically conductive path for the arc between the electrode and the
Common Electric
Arc Welding work piece.
Processes
High
Frequency - (as applied to gas-tungsten arc welding)
Lesson 3
Covered Electrodes
An alternating current consisting of over 50,000 cycles per second at high
for Welding
Mild Steels voltage, low amperage that is superimposed on the welding circuit in GTAW
power sources. It ionizes a path for non-touch arc starting and stabilizes the
arc when welding with alternating current.
Lesson 4
Covered Electrodes
for Welding Low Inert Gases - Gases that are chemically inactive. They do not readily combine with other
Alloy Steels elements.
Flux - In arc welding, fluxes are formulations that, when subjected to the arc, act as
Lesson 5
a cleaning agent by dissolving oxides, releasing trapped gases and slag and
for Stainless Steels generally cleaning the weld metal by floating the impurities to the surface
where they solidify in the slag covering. The flux also serves to reduce spatter
and contributes to weld bead shape. The flux may be the coating on the
Lesson 6 electrode, inside the electrode as in flux cored types, or in a granular form as
Carbon & Low Alloy
Steel Filler Metals - used in submerged arc welding.
GMAW,GTAW,SAW
Current
Density - The amperes per square inch of cross-sectional area of an electrode. High
Lesson 7
Flux Cored Arc current density results in high electrode melt-off rate and a concentrated, deep
Electrodes Carbon penetrating arc.
Low Alloy Steels
Slope or Slope
Control - A necessary feature in welding power sources used for short circuiting arc
Lesson 8
Hardsurfacing welding. Slope Control reduces the short circuiting current each time the
Electrodes electrode touches the weld puddle (See Section 2.5.3).
Inductance - (as applies to short circuiting arc welding)

Lesson 9
Estimating & A feature in welding power sources designed for short circuiting arc welding
Comparing Weld
Metal Costs to retard the rate of current rise each time the electrode touches the weld
puddle.
Lesson 10
Filler Metals

Lesson 1
Welding
Contact Tip - That part of a gas metal arc welding gun or flux cored arc welding gun that
transfers the welding current to the welding wire immediately before the wire
Lesson 2
Common Electric enters the arc.
Arc Welding
Processes
Spray - Mode of metal transfer across the arc where the molten metal droplets are
Lesson 3 Transfer smaller than the electrode diameter and are axially directed to the weld puddle.
Covered Electrodes Requires high voltage and amperage settings and a shielding gas of at least
for Welding
80% argon.
Mild Steels
Lesson 4 Globular - Mode of metal transfer across the arc where a molten ball larger than the
Covered Electrodes electrode diameter forms at the tip of the electrode. On detachment, it takes
for Welding Low Transfer
Alloy Steels on an irregular shape and tumbles towards the weld puddle sometimes
shorting between the electrode and work at irregular intervals. Occurs when
using shielding gases other than those consisting of at least 80% argon and
Lesson 5
Welding Filler Metals at medium current settings.
Pulse - Mode of metal transfer somewhat between spray and short circuiting. The
Lesson 6 Transfer specific power source has built into it two output levels: a steady background
Carbon & Low Alloy level, and a high output (peak) level. The later permits the transfer of metal
GMAW,GTAW,SAW across the arc. This peak output is controllable between high and low values
up to several hundred cycles per second. The result of such a peak output
produces a spray arc below the typical transition current.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels Short- - Mode of metal transfer in gas metal arc welding at low voltage and amperage.
circuiting
Transfer takes place each time the electrode touches or short-circuits to the
Transfer
weld puddle, extinguishing the arc. The short-circuiting current causes the
Lesson 8
Hardsurfacing electrode to neck down, melt off, and then repeats the cycle.
Electrodes
Trimix or - A shielding gas consisting of approximately 90% helium, 7-1/2% argon, and
Lesson 9 Triple Mix 2-1/2% carbon dioxide used primarily for short-circuiting arc welding of
Estimating &
Comparing Weld stainless steels. Maintains corrosion resistance of the stainless steel and
Metal Costs produces good wetting and excellent weld bead shape.
Lesson 10
Filler Metals

Lesson 1
Welding
Electrical - In any welding process using a solid or flux cored wire, the electrical stick-out
Lesson 2 Stick-Out is the distance from the contact tip to the unmelted electrode end. Sometimes
Common Electric
called the "amount of wire in resistance". This distance influences melt-off
Arc Welding
Processes rate, penetration, and weld bead shape.
Lesson 3 - Welds made in positions other than flat or horizontal fillets.

Out-of-Position
Covered Electrodes
for Welding Welds
Mild Steels
Weld -
Lesson 4 Positions
Covered Electrodes
for Welding Low
Alloy Steels FLAT HORIZONTAL FILLET
Lesson 5
Lesson 6
Carbon & Low Alloy VERTICAL OVERHEAD
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
HORIZONTAL POSITIONED FILLET

Lesson 8 BUTT (FLAT)
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes BASIC
Lesson 3
Covered Electrodes
WELDING FILLER
for Welding
Mild Steels METAL TECHNOLOGY
Lesson 4
Covered Electrodes A Correspondence Course
for Welding Low
Alloy Steels
Lesson 5
LESSON III
Lesson 6 COVERED ELECTRODES FOR
Carbon & Low Alloy
GMAW,GTAW,SAW
WELDING MILD STEELS
Lesson 7
Flux Cored Arc An Introduction to Mild Steel
Electrodes Carbon
Low Alloy Steels
Covered Electrodes
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON III
Lesson 2
Common Electric COVERED ELECTRODES FOR WELDING
Arc Welding
Processes MILD STEELS
Lesson 3
Covered Electrodes
for Welding
Mild Steels Section Nr. Section Title Page
3.1 DEVELOPMENT OF COVERED ELECTRODES............................. 1
Lesson 4 3.2 MANUFACTURING COVERED EELCTRODES .............................. 1

Covered Electrodes
3.2.1 Functions of Electrode Coatings ....................................................... 3
for Welding Low
Alloy Steels 3.2.2 Classification of Coating Ingredients ................................................ 4
3.3 AWS SPECIFICATION A5.1-91 ........................................................ 6

Lesson 5
3.3.1 Chemical Composition of Weld Metal ............................................... 7
for Stainless Steels 3.3.2 Mechanical Properties (AWS A5.1-91) ............................................. 7
3.3.3 Individual Electrode Characteristics .................................................. 8
Lesson 6 3.4 SELECTING THE PROPER MILD STEEL ELECTRODE ................ 11

Carbon & Low Alloy
Steel Filler Metals - 3.4.1 Typical Electrode Use by Welding Classification .............................. 12
GMAW,GTAW,SAW 3.4.2 Electrode Deposition......................................................................... 14
3.5 ACID AND BASIC SLAG SYSTEMS ................................................ 15

Lesson 7
Flux Cored Arc
Electrodes Carbon 3.6 ADVANTAGES AND DISADVANTAGES OF MILD STEEL
Low Alloy Steels COVERED ELECTRODES............................................................... 15
3.7 ESAB SUREWELD MILD STEEL COVERED ELECTRODES

Lesson 8 FEATURES & DATA.......................................................................... 16
Hardsurfacing
Electrodes 3.7.1 SUREWELD 10P (AWS E6010) ....................................................... 16
3.7.2 SUREWELD 710P (AWS E7010-P1) ............................................... 17
3.7.3 SUREWELD 810P (AWS E8010-P1) ............................................... 18
Lesson 9
Estimating & 3.7.4 SUREWELD SW14 (AWS E6011).................................................... 19
Comparing Weld 3.7.5 SUREWELD SW612 (AWS E6012) ................................................. 20
Metal Costs
3.7.6 SUREWELD SW15 (AWS E6013) .................................................... 21
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric TABLE OF CONTENTS
Arc Welding
Processes LESSON III - Con't
Lesson 3
Covered Electrodes
for Welding
Mild Steels Section Nr. Section Title Page
3.7.7 6013LV (AWS E6013) ....................................................................... 21

Lesson 4
Covered Electrodes 3.7.8 SUREWELD SW15-IP (AWS E7014) ................................................ 22
for Welding Low
3.7.9 SUREWELD 70LA-2 (AWS E7016) ................................................. 23
Alloy Steels
3.7.10 ATOM ARC 7018 (AWS E7018) ........................................................ 24
3.7.11 ATOM ARC 7018AC (AWS E7018)................................................... 25
Lesson 5
Welding Filler Metals 3.7.12 SUREWELD 7024 (AWS E7024) Conforms to 7024-1 ..................... 26
Appendix A GLOSSARY OF TERMS................................................................... 27
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON III
The Basics of Arc
Welding
Lesson 2
3.1 Development of Covered Electrodes
Common Electric During the 1890's, arc welding was accomplished with bare metal electrodes. The welds produced were
Arc Welding porous and brittle because the molten weld puddle absorbed larg quantities of oxygen and nitrogen
Processes from the atmosphere. Operators noticed that a rusty rod produced a better weld than a shiny clean rod.
Observations also showed than an improved weld could be made by wrapping the rod in newspaper or by
welding adjacent to a pine board placed close to and parallel with the weld being made. In these cases,
some degree of shielding the arc form the atmosphere was being accomplished. These early observations
Lesson 3 led to the development of the coated electrode.
Covered Electrodes
for Welding 3.1.0.1 Around 1920, the A.O. Smith Corporation developed an electrode spirally wrapped with paper,
Mild Steels soaked in sodium silicate, and then baked. This was the first of the cellulosic type electrodes.
It produced an effective gas shield in the area and greatly improved the ductility of the weld metal.
3.1.0.2 Because of the method used to manufacture these paper covered electrodes, it was difficult
Lesson 4 to effectively add other ingredients to the coating. In 1924, the A.O. Smith Corporation began work
Covered Electrodes on coatings that could be extruded over the core wire. This method allowed the addition of other
for Welding Low flux ingredients to furhter improve or modify the weld metal and by 1927, these electrodes were
Alloy Steels being produced commercially.
3.1.0.3 Since 1927, many improvements have been made and many different types of electrodes have
been developed and produced. Through variations in the formulations of the covering and the amount
Lesson 5 of covering on the mild steel core wire, many different classifications of electrodes are produced today.
3.2 Manufacturing Covered Electrodes
Mild steel covered electrodes, also commonly called coated electrodes, consist of only two major elements;
the core wire or rod and the flux covering. The core wire is usually low carbon steel.
Lesson 6 It must contain only small amounts of aluminum and copper, and the sulfur and phosphorous levels
Carbon & Low Alloy must be kept very low since they can cause undesirable brittleness in the weld metal. The raw material
Steel Filler Metals - for the core wire is hot-rolled rod (commonly called "hot rod"). It is
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON III
The Basics of Arc
Welding
received in large coils, cleaned, drawn down to the proper electrode diameter, straightened,
and cut to the proper electrode length.
Lesson 2
Common Electric 3.2.0.1 The coating ingredients, from which there are literally hundreds to choose, are
Arc Welding
Processes carefully weighed, blended in a dry state, wet mixed, and compacted into a large cylinder that
fits into the extrusion press. The coating is extruded over the cut core wires which are fed
through the extrusion press at a rapid rate. The coating material is removed from the end of
Lesson 3
the electrode that is clamped into the electrode holder to assure electrical contact, and also
Covered Electrodes
for Welding from the welding end of the electrode to assure easy arc initiation.
Mild Steels
3.2.0.2 The electrodes are then stamped with the type number for easy identification before
entering the ovens, where they go through a controlled bake cycle to insure the proper mois-
Lesson 4
Covered Electrodes ture content before packaging.
for Welding Low
Alloy Steels 3.2.0.3 Of the many quality control checks made during the manufacturing process, one of
the most important is the procedure that insures that the coating thickness is uniform. In
Lesson 5 shielded metal arc welding, the coating crater, or the cup-like formation of the coating, that
Welding Filler Metals extends beyond the melting core wire, performs the function of concentrating and directing the
arc. See Figure 1.
A B
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
CONCENTRIC COATING NON-CONCENTRIC COATING
GOOD ARC DIRECTION POOR ARC DIRECTION
Lesson 8 CONCENTRATED ARCEFFECT OF COATING CONCENTRICITY

Hardsurfacing
Electrodes
FIGURE 1
Lesson 9 3.2.0.4 Concentration and direction of the arc stream is attained by having a coating crater,
Estimating & somewhat similar to the nozzle on a water hoze, directing the flow of weld metal. When the
Comparing Weld
coating is not concentric to the core wire, it can cause the condition shown at B in Figure 1.
Metal Costs
The poor arc direction causes inconsistent weld beads, poor shielding, and lack of penetra-
tion. The electrode burns off unevenly, leaving a projection on the side where the coating is the
Lesson 10 heaviest. This condition is often referred to as "fingernailing."
Filler Metals

Lesson 1 LESSON III
The Basics of Arc
Welding
3.2.1 Functions of Electrode Coatings - The ingredients that are commonly used in
coatings can be classified physically in a broad manner as liquids and solids. The liquids are
Lesson 2 generally sodium silicate or potassium silicate. The solids are powdered or granulated mate-
Common Electric
Arc Welding rials that may be found free in nature, and need only concentration and grinding to the proper
Processes particle size. Other solid materials used are produced as a result of chemical reactions, such
as alloys or other complex synthetic compounds.
Lesson 3
Covered Electrodes 3.2.1.1 The particle size of the solid material is an important factor. Particle size may be as
for Welding coarse as fine sand, or as minute as sub-sieve size.
Mild Steels
3.2.1.2 The physical structure of the coating ingredients may be classified as crystalline,
Lesson 4 fibrous or amorphous (non-crystalline). Crystalline materials such as rutile, quartz and mica
Covered Electrodes are commonly used. Rutile is the naturally occurring form of the mineral titanium dioxide and
for Welding Low
is widely used in electrode coatings. Fibrous materials such as wood fibers, and non-crystal-
Alloy Steels
line materials such as glasses and other organic compounds are also common coating ingre-
dients.
Lesson 5
Welding Filler Metals 3.2.1.3 The functions of the coating on covered electrodes are as follows:
a) Shielding of the Weld Metal - The most important function of a coating is to
shield the weld metal from the oxygen and nitrogen of the air as it is being transferred across
Lesson 6
the arc, and while it is in the molten state. This shielding is necessary to ensure the weld metal
Carbon & Low Alloy
Steel Filler Metals - will be sound, free of gas pockets, and have the right strength and ductility. At the high tem-
GMAW,GTAW,SAW
peratures of the arc, nitrogen and oxygen combine readily with iron to form iron nitrides and
iron oxides that, if present in the weld metal above certain minimum amounts, will cause brittle-
Lesson 7 ness and porosity. Nitrogen is the primary concern since it is difficult to control its effect once it
Flux Cored Arc
has entered the deposit. Oxygen can be counteracted by the use of suitable deoxidizers. In
Electrodes Carbon
Low Alloy Steels order to avoid contamination from the air, the stream of molten metal must be protected or
shielded by gases that exclude the surrounding atmosphere from the arc and the molten weld
metal. This is accomplished by using gas-forming materials in the coating that break down
Lesson 8 during the welding operation and produce the gaseous shield.
Hardsurfacing
Electrodes
b) Stabilization of the Arc - A stabilized arc is one that starts easily, burns
smoothly even at low amperages, and can be maintained using either a long or a short arc
Lesson 9 length.
Estimating &
Comparing Weld c) Alloying Additions to Weld Metal - A variety of elements such as chromium,
Metal Costs
nickel, molybdenum, vanadium and copper can be added to the weld metal by including them
in the coating composition. It is often necessary to add alloys to the coating to balance the
Lesson 10 expected loss of alloys of the core wire during the welding operation, due to volatization and
Filler Metals

Lesson 1 LESSON III
The Basics of Arc
Welding
chemical reaction. Mild steel electrodes require small amounts of carbon, manganese and
silicon in the deposit to give sound welds of the desired strength level. A portion of the carbon
Lesson 2 and manganese is derived from the core wire, but it is necessary to supplement it with
Common Electric
Arc Welding ferromanganese and in some cases ferrosilicon additions in the coating.
Processes
d) Concentration of the Arc Stream - Concentration or direction of the arc
stream is attained by having a coating crater form at the tip of the electrodes as discussed
Lesson 3
earlier. Use of the proper binders assures a good hard coating that will maintain a crater and
Covered Electrodes
for Welding give added penetration and better direction to the arc stream.
Mild Steels
e) Furnish Slag for Fluxing - The function of the slag is (1) to provide additional
protection against atmospheric contamination, (2) to act as a cleaner and absorb impurities
Lesson 4
Covered Electrodes that are floated off and trapped by the slag, (3) to slow the cooling rate of the molten metal to
for Welding Low allow the escape of gases. The slag also controls the contour, uniformity and general appear-
Alloy Steels
ance of the weld. This is particularly true in fillet welds.
f) Characteristics for Welding Position - It is the addition of certain ingredients,

Lesson 5
Welding Filler Metals primarily titanium compounds, in the coating that makes it possible to weld out-of-position ,
vertically, and overhead. Slag characteristics, primarily surface tension and freezing point,
determine to a large degree the ability of an electrode to be used for out-of-position work.
Lesson 6 g) Control of Weld Metal Soundness - Porosity or gas pockets in weld metal
Carbon & Low Alloy
Steel Filler Metals - can be controlled to a large extent by the coating composition. It is the balance of certain
GMAW,GTAW,SAW ingredients in the coating that have a marked effect on the presence of gas pockets in the
weld metal. The proper balance of these is critical to the soundness that can be produced.
Lesson 7 Ferromanganese is probably the most common ingredient used to attain the correctly bal-
Flux Cored Arc anced formula.
Electrodes Carbon
Low Alloy Steels
h) Specific Mechanical Properties to the Weld Metal - Specific mechanical
properties can be incorporated into the weld metal by means of the coating. High impact
Lesson 8 values at low temperature, high ductility, and increases in yield and tensile properties can be
Hardsurfacing attained by alloy additions to the coating.
Electrodes
i) Insulation of the Core Wire - The coating acts as an insulator so that the core
wire will not short-circuit when welding in deep grooves or narrow openings; coatings also
Lesson 9
Estimating & serve as a protection to the operator when changing electrodes.
Comparing Weld
Metal Costs 3.2.2 Classification of Coating Ingredients - Coating materials can be classified into
the following 6 major groups:
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
for Welding
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Lesson 5
for Stainless Steels LESSON IV
COVERED ELECTRODES FOR
Lesson 6
Carbon & Low Alloy
WELDING LOW ALLOY STEELS
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc AN INTRODUCTION TO LOW
Electrodes Carbon ALLOY COVERED ELECTRODES
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
Lesson 2
LESSON IV
Common Electric
Arc Welding
COVERED ELECTRODES FOR WELDING
Processes LOW ALLOY STEELS
Lesson 3 Section Nr. Section Title Page
Covered Electrodes
for Welding
Mild Steels 4.1 LOW ALLOY STEELS ...................................................................... 1
4.2 Consequence of Hydrogen in Low Alloy Steel .................................. 1

Lesson 4 4.2.1 Preheat ............................................................................................. 3
Covered Electrodes
for Welding Low
4.3 MANUFACTURING LOW HYDROGEN ELECTRODES .................. 3
Alloy Steels
4.3.1 Storage and Reconditioning.............................................................. 4
4.3.2 Moisture Resistant Coating ............................................................... 4
Lesson 5
Welding Filler Metals 4.4 AWS SPECIFICATION FOR LOW ALLOY ELECTRODES.............. 5
4.4.1 Effect of Alloying Elements ............................................................... 6
4.4.2 Mechanical Properties (AWS A5.5-96) ............................................. 7
Lesson 6 4.4.3 Impact Properties.............................................................................. 8

Carbon & Low Alloy
Steel Filler Metals - 4.5 SELECTING THE PROPER LOW ALLOY ELECTRODE ................ 8
GMAW,GTAW,SAW 4.5.1 Service Conditions ............................................................................ 8
4.5.2 Joint Design ...................................................................................... 9
Lesson 7 4.5.3 Equipment......................................................................................... 10
Flux Cored Arc
Electrodes Carbon 4.6 LOW HYDROGEN IRON POWDER ELECTRODES ....................... 11
Low Alloy Steels
4.6.1 Atom Arc 7018 (AWS E7018) ........................................................... 11
4.6.2 Atom Arc 7018 Mo (AWS E7018-A1)................................................ 11
Lesson 8 4.6.3 Atom Arc 8018N (AWS E8018-C2) ................................................... 12

Hardsurfacing 4.6.4 Atom Arc 8018CM (AWS E8018-B2) ................................................ 13
Electrodes
4.6.5 Atom Arc 8018W (AWS E8018-G).................................................... 13
4.6.6 Atom Arc 9018CM (AWS E9018-B3) ................................................ 14
Lesson 9 4.6.7 Atom Arc 9018-B3L (AWS E9018-B3L) ............................................ 14

Estimating & 4.6.8 Atom Arc 10018 (AWS E10018-M) ................................................... 15
Comparing Weld
4.6.9 Atom Arc 10018MM (AWS E10018-D2) ........................................... 15
Metal Costs
4.6.10 Atom Arc 12018 (AWS E12018-M).................................................... 16
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
Lesson 2
LESSON IV- Con't
Common Electric
Arc Welding
4.6.11 Atom Arc "T" (AWS E11018-M) ......................................................... 16

Lesson 3
Covered Electrodes 4.6.12 Atom Arc 9018HT (AWS E9018G) .................................................... 17
for Welding 4.6.13 Atom Arc 4130 (No AWS Classification) ............................................ 17
Mild Steels
4.6.14 Atom Arc 4130 LN (No AWS Classification) ...................................... 17
Lesson 4 Appendix A Stick Electrode Data Charts - Atom Arc Electrodes .......................... 19
Covered Electrodes
for Welding Low Appendix B Glossary of Terms ............................................................................. 20
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON IV
Welding
COVERED ELECTRODES FOR WELDING
Lesson 2
LOW ALLOY STEELS
Common Electric
Arc Welding
Processes
4.1 LOW ALLOY STEELS
Lesson 3 Low alloy steels, as discussed in Lesson I, are those steels to that have small amounts of
Covered Electrodes
for Welding alloying elements added for specific purposes; i.e., to increase strength, toughness, corrosion
Mild Steels and rust resistance, or to alter the response to heat treatment. Nearly every steel manufacturer
makes a family of low alloy steels that are usually sold under trade names such as Maynari R,
Lesson 4 Cor-ten, Man-ten, and many others. Many of the steels are designed to develop their specific
Covered Electrodes properties such as high strength or toughness in the hot rolled and controlled cooling condition,
for Welding Low
Alloy Steels rather than by subsequent heat treatment. Other compositions of low alloy steels are designed
to develop specific properties following heat treatments. Examples of these types are U.S.
Steel T-1, Armco Steel SS-100, Great Lakes Steel NA XTRA 100, all of which are quenched
Lesson 5
and tempered to reach high strength with good toughness. Covered low alloy welding elec-
for Stainless Steels trodes are designed, in most cases, to match the properties of the low alloy steels rather than
to match the exact chemical composition of the steel. Exceptions to this are the chromium
molybdenum electrodes that need to contain about the same amounts of the alloy ingredients
Lesson 6 as the steel in order to match the properties of the steel.
Carbon & Low Alloy
GMAW,GTAW,SAW 4.2 CONSEQUENCE OF HYDROGEN IN LOW ALLOY STEEL
Lesson 7 One of the reasons that low alloy steels are becoming more popular is because of the exten-
Flux Cored Arc sive research that was conducted in the development of electrodes for welding them. Although
Electrodes Carbon
Low Alloy Steels special precautions and care are required in welding the low alloy steels, they can now be
joined with a high degree of reliability. But that was not always so. During World War II when
there was a dramatic increase in the use of high strength low alloy steel, there was also a
Lesson 8 corresponding increase in weld defects. It was quickly realized that hardenable steels could
Hardsurfacing
not be welded in the same manner and with the same electrodes as were then commonly used
Electrodes
for welding the lower strength mild steels. Through extensive research, it was found that en-
trapped hydrogen was the culprit in causing weld defects, and the term "hydrogen
Lesson 9 embrittlement" became synonymous with red flags warning of impending disaster.
Estimating &
Comparing Weld
4.2.0.1 When hydrogen bearing compounds such as water, minerals, or chemicals are
Metal Costs
present in the electrode coating, as is common with mild steel electrodes, the chemically
combined hydrogen is dissociated into atomic hydrogen by the heat of the welding arc. The
Lesson 10 molten weld metal has the capacity to dissolve the atomic hydrogen. However, as soon as the
Filler Metals

Lesson 1
Welding
weld metal solidifies, it loses the ability to hold the hydrogen in solution and the hydrogen is
either expelled into the atmosphere or moves throughout the weld zone. Steel and weld metal
Lesson 2 are not as solid as they appear to the naked eye, being filled with tiny submicroscopic pores.
Common Electric
Arc Welding The hydrogen atoms are smaller than the crystalline structure of the steel or the weld metal,
Processes and the hydrogen can move about somewhat freely in the steel, just as air can move through a
filter. The hydrogen atoms move out of the weld metal into the heat affected zone. The heat
affected zone (HAZ) is an area of critical importance in welding, especially in welding high
Lesson 3
Covered Electrodes strength steels.
for Welding
Mild Steels 4.2.0.2 The heat affected zone (See Figure 1) is that area of the weld joint that did not
become molten in the welding process, but underwent a microstructure change as a result of
Lesson 4 the heat induced by the arc. This
Covered Electrodes zone can become a weak link in
for Welding Low
Alloy Steels the normally very strong joint.
First of all, the grain struc- SOLIDIFIED WELD METAL
ture of the HAZ is less

Lesson 5 HEAT AFFECTED ZONE
refined and therefore,
for Stainless Steels weaker than the sur-
rounding unaffected UNAFFECTED BASE METAL
base metal or the once

Lesson 6 molten weld metal.
Carbon & Low Alloy
Steel Filler Metals - And secondly, if the
GMAW,GTAW,SAW HAZ is permitted to cool
too rapidly in certain steels,
Lesson 7 a hard brittle crystalline struc-
Flux Cored Arc ture, known as Marsenite, is locked HEAT AFFECTED ZONE
Electrodes Carbon
Low Alloy Steels in place. The relatively large pores of FIGURE 1
the heat affected zone are a natural collect-
ing place for atomic hydrogen. When two hydrogen atoms meet, they immediately unite to
Lesson 8 form molecular hydrogen. The resulting molecules are larger than the crystalline structure of
Hardsurfacing
Electrodes the metal and can no longer move about freely. As more and more hydrogen atoms come into
the pores, form molecules, and are trapped, tremendous pressure can develop. Mild steel and
lower strength steels are sufficiently plastic to move a little with the hydrogen pressure and not
Lesson 9 cause the steel to crack. Steels that have high hardness and high strength do not have suffi-
Estimating &
Comparing Weld cient plasticity to move with the pressure, and if enough hydrogen is present, cracking of the
Metal Costs steel occurs.
Lesson 10
Filler Metals

Lesson 1
Welding
4.2.0.3 This hydrogen caused defect, known as underbead cracking (See Figure 2), begins
in the HAZ making it particularly sinister since the crack is not immediately apparent to the
Lesson 2 eye. It occurs after the metal has cooled from about 400°F to room temperature, and it is
Common Electric
Arc Welding sometimes referred to as
WELD METAL
Processes "cold cracking". The defect
may occur immediately after HEAT AFFECTED ZONE
BASE METAL
cooling, or it may take hours,
Lesson 3
Covered Electrodes days, or even months before
for Welding it happens.
Mild Steels
4.2.1 Preheat - Steels
Lesson 4 that are highly hardenable by HYDROGEN INDUCED CRACKS

Covered Electrodes a rapid cooling in the heat
for Welding Low
Alloy Steels affected zone require pre- UNDERBEAD CRACKING
heat and interpass temperature control. FIGURE 2
As preheat is applied to the steel, the

Lesson 5
cooling rate of the steel from higher temperatures is slowed. Maintaining a constant tempera-
for Stainless Steels ture between each welding pass also helps to control this cooling. Slower cooling rates pre-
vent the steel from being excessively hardened and thus, minimizes the chance of underbead
cracking. When this technique is combined with the use of low hydrogen electrodes, a high
Lesson 6 degree of reliability can be expected from the welds.
Carbon & Low Alloy
GMAW,GTAW,SAW
4.3 MANUFACTURING LOW HYDROGEN ELECTRODES
Lesson 7 The discovery of hydrogen related weld defects initiated the development of low hydrogen
Flux Cored Arc electrodes. The functions of the coating with low hydrogen electrodes (i.e., shielding, arc
Electrodes Carbon
Low Alloy Steels stabilizers, alloy additions, etc.) are much the same as those listed in Lesson III for Mild Steel
Covered Electrodes, but the coating is formulated with ingredients that lack hydrogen in their
chemical composition. This is primarily accomplished by eliminating organic and chemical
Lesson 8 compounds high in moisture content. In fact, control of the moisture levels in the coating is
Hardsurfacing
Electrodes critical in the manufacture and use of low hydrogen electrodes.
4.3.0.1 In addition to eliminating hydrogen in the coating formula, the manufacturing process
Lesson 9 entails a high temperature bake cycle. After the coating is extruded onto the core in the same
Estimating & manner as a mild steel coated electrode, the low hydrogen electrodes are given an initial low
Comparing Weld
temperature bake (300-400°F), and then rebaked in a separate high temperature oven (800-
Metal Costs
900°F) for a specified period of time. This procedure practically eliminates all moisture, and
to guard against the reabsorbing of moisture that is naturally present in the atmosphere, the
Lesson 10
Filler Metals

Lesson 1
LESSON IV
The Basics of Arc
Welding
electrodes are immediately packaged in hermetically sealed metal containers following the
high temperature bake.
Lesson 2
Common Electric 4.3.1 Storage and Reconditioning - All low hydrogen electrodes will absorb some
Arc Welding
Processes moisture from the air after the electrode container is opened. Therefore, those electrodes that
are not intended for use within a given period of time must be stored in a vented oven and
maintained at a constant temperature.
Lesson 3
Covered Electrodes
for Welding 4.3.1.1 Various structural and military codes allow only specified times of exposure. These
Mild Steels may be anywhere from 30 minutes to 8 hours depending on the electrode alloy, the relative
humidity in the work area, and the critical nature of the application. If the low hydrogen elec-
Lesson 4 trodes are exposed to the atmosphere beyond these time limits, they must be scrapped or
Covered Electrodes reconditioned by rebaking in a vented oven for a specified time at a specific temperature.
for Welding Low
Alloy Steels
4.3.1.2 The recommended storage and rebake temperatures for Atom Arc low hydrogen
electrodes are follows:
Lesson 5 STORAGE RECONDITIONED
225-300°F 1 hr. @700°F
4.3.2 Moisture Resistant Coating - Moisture absorption is of special concern to end-
users such as shipbuilders and oil rig fabricators who are situated in areas of the world that
Lesson 6
Carbon & Low Alloy have a high level of relative humidity. As the temperature and relative humidity increase, the
Steel Filler Metals - chance of absorbing moisture in the low hydrogen coating is greatly increased. To combat this
GMAW,GTAW,SAW
possibility, major electrode manufacturers have in recent years developed low hydrogen
electrodes with moisture resistant coatings. These coatings low the rate of moisture absorp-
Lesson 7 tion in electrodes that have been exposed to the air for extended periods, thus adding an extra
Flux Cored Arc
Electrodes Carbon degree of reliability to low hydrogen electrodes.
Low Alloy Steels
4.3.2.1 The following graphs (figure 3) give an idea of the effectiveness of a moisture
resistant coating. The tests were conducted on Atom Arc 7018 electrodes. The method of
Lesson 8 moisture testing chosen by ESAB is that described in Section 25 of the AWS A5.5-96 Specifi-
Hardsurfacing
Electrodes cation. This method was chosen because it satisfies the AWS specifications and is sensitive
only to water, making it one of the most accurate and reliable methods of moisture determina-
tion currently in use.
Lesson 9
Estimating & 4.3.2.2 The AWS structural code and military specifications allow a maximum of 0.40% and
Comparing Weld
Metal Costs 0.20% moisture content, respectively, for E70XX low hydrogen electrodes. As shown on the
preceding graphs, the Atom Arc 7018 electrode satisfied this low moisture requirement for
exposure times beyond those normally allowed in field use.
Lesson 10
Filler Metals

Lesson 1
Welding
.40
70°F - 70% Relative Humidity
Lesson 2
.30
Common Electric
Arc Welding
.20
Processes
.10
Lesson 3 0
Covered Electrodes 1 2 4 8 12 24 36 48 96
for Welding Moisture at Exposure Time (hours)
Zero Hours .09
Mild Steels
.40
Lesson 4
Covered Electrodes .30
for Welding Low
Alloy Steels .20
.10
Lesson 5
Welding Filler Metals 01 2 4 8 12 24 36 48 96
for Stainless Steels Moisture at Exposure Time (hours)
Zero Hours .08
Lesson 6
Carbon & Low Alloy .40
GMAW,GTAW,SAW .30

.20
Lesson 7
.10
Flux Cored Arc
Electrodes Carbon
0
Low Alloy Steels 1 2 4 8 12 24
Moisture at
Exposure Time (hours)
Zero Hours .10
EFFECTIVENESS OF MOISTURE RESISTANT COATING - ATOM ARC 7018 ELECTRODES
Lesson 8
FIGURE 3
Hardsurfacing
Electrodes
4.4 AWS SPECIFICATION FOR LOW ALLOY
ELECTRODES A5.5-96
Lesson 9
Estimating &
Comparing Weld With very few exceptions, low alloy electrodes are made by adding the appropriate alloying
Metal Costs elements to the electrode coating rather than having a core wire that matches the low alloy
steel. Low alloy covered electrodes are classified according to the American Welding Society
filler metal specification A5.5-96. This specification contains the mechanical property require-
Lesson 10
Filler Metals

Lesson 1
Welding
ments and stress relieved condition, the chemical requirements, and the weld metal sound-
ness requirements. Electrodes are classified under this specification according to the me-
Lesson 2 chanical properties and chemical composition of the weld metal, the type of covering, and the
Common Electric
Arc Welding welding position of the electrode. The classification of the electrode is designated by the
Processes manufacturer according to the results of his own tests. The manufacturer, thereby, guarantees
his electrode to meet the requirements of the AWS specification.
Lesson 3
4.4.0.1 The letter-number designations for low alloy electrode classifications mean much
Covered Electrodes
for Welding the same as with mild steel electrodes, except that the major alloy composition is indicated by
Mild Steels a letter-number suffix. For example, E7018-A1 indicates an electrode (letter E); with a mini-
mum of 70,000 psi tensile strength (70); is weldable in all positions (1); is iron powder low
Lesson 4 hydrogen (8); and contains nominally 1/2% molybdenum (A1). The full list of nominal alloy
Covered Electrodes compositions for this specification is contained in Table 1.
for Welding Low
Alloy Steels
TABLE 1. Nominal Alloy Designations for AWS A5.5 Specification
Lesson 5 A1 1/2% Molybdenum

Welding Filler Metals B1 1/2% Chromium, 1/2% Molybdenum
for Stainless Steels B2 1-1/4% Chromium, 1/2% Molybdenum
B2L Low Carbon version of B2 type. Carbon content is 0.05% or less
B3 2-1/4% Chromium, 1% Molybdenum
Lesson 6 B3L Low Carbon version of B3 type. Carbon content is 0.05% or less
Carbon & Low Alloy
B4L 2% Chromium, 1/2% Molybdenum, low carbon (0.05% or less)
GMAW,GTAW,SAW B5 1/2% Chromium, 1.1% Molybdenum
C3 1% Nickel
C1 2% Nickel
Lesson 7 C2 3% Nickel
Flux Cored Arc
Electrodes Carbon D1 1-1/2% Manganese, 1/3% Molybdenum
Low Alloy Steels D2 1-3/4% Manganese, 1/3% Molybdenum
M Conforms to compositions covered by Military specifications.
G Needs only a minimum of one of the elements listed in the AWS A5.5 Table
Lesson 8 for Chemical Requirements.

Hardsurfacing
Electrodes
4.4.1 Effect of Alloying Elements

Lesson 9
Estimating & 4.4.1.1 Molybdenum - When mild steel weld metal is stress relieved, the yield point is
Comparing Weld lowered 3,000 psi or more and the tensile strength is also lowered 3,000 psi or more. When
Metal Costs
1/2% of molybdenum is added to the weld, both the yield point and the tensile strength remain
constant from the as-welded to the stress relieved condition. The presence of molybdenum
Lesson 10 also increases the tensile strength of the weld metal.

Filler Metals

Lesson 1
Welding
4.4.1.2 Chromium - When chromium is added to the weld metal, the corrosion and high
temperature scaling resistance are increased. The combination of chromium and molybde-
Lesson 2 num allows the weld metal to retain high strength levels at medium high temperatures.
Common Electric
Arc Welding
4.4.1.3 Nickel - Mild steel weld metal usually becomes brittle at temperatures below -20°F.
Processes
The addition of 1-3% nickel to the weld metal enables the weld metal to remain tough at con-
siderably lower temperatures. The presence of the nickel also makes the weld metal more
Lesson 3
resistant to cracking at room temperature.
Covered Electrodes
for Welding
Mild Steels 4.4.1.4 Manganese - The presence of 1-1/2% to 2% manganese in weld metal increases
the tensile strength and when 1/3% molybdenum is added in combination, the high strength
weld metal is crack resistant.
Lesson 4
Covered Electrodes
for Welding Low 4.4.1.5 It should be noted that the A5.5-96 specification covers not only the low alloy low
Alloy Steels hydrogen electrodes, but also low alloy versions of the cellulosic, titania, and iron oxide type
electrodes. A full list of all the electrodes covered by this specification is presented in Table 2.
Lesson 5
Welding Filler Metals TABLE 2. Electrode Classifications of AWS A5.5 Specification
E7010-A1 E8018-B2 E9015-B3L E11018-M
E7011-A1 E8018-B2L E9016-B3 E12018-M

Lesson 6
Carbon & Low Alloy E7015-A1 E8015-B4L E9018-B3
Steel Filler Metals - E7016-A1 E8016-B5 E9018-B3L EXX10-G
GMAW,GTAW,SAW
E7018-A1 E8016-C1 E9015-D1 EXX11-G
E7020-A1 E8018-C1 E9018-D1 EXX13-G

Lesson 7 E7027-A1 E8016-C2 E9018-M EXX15-G
Flux Cored Arc
Electrodes Carbon E8018-C2 EXX16-G
Low Alloy Steels E8016-B1 E8016-C3 E10015-D2 EXX18-G
E8018-B1 E8018-C3 E10016-D2 E7020-G
E8015-B2L E10018-D2
Lesson 8
Hardsurfacing E8016-B2 E9015-B3 E10018-M
Electrodes
4.4.2 Mechanical Properties (AWS A5.5-96) - Since many low alloy steels require
Lesson 9
Estimating & some post-weld heat treatment to relieve the internal stresses generated from the welding
Comparing Weld
process, physical testing on the weld metal of most low alloy electrodes is required to be
Metal Costs
performed after the specimen has been stress-relieved. Only the E8016-C3, E8018-C3,
E9018-M, E11018-M, and E12018-M types are permitted to be tested in the as-welded condi-
Lesson 10 tion for classification purposes.
Filler Metals

Lesson 1
Welding
4.4.3 Impact Properties - Since many low alloy steels are developed for low tempera-
Lesson 2 tures service, impact properties of the weld metal designed to join these steels are very impor-
Common Electric
Arc Welding tant. Except for those types already mentioned, all impact testing is performed on specimens
Processes after they have been stress-relieved. Table 3 lists the minimum charpy v-notch impacts re-
quired in the A5.5 specification.
Lesson 3
Covered Electrodes TABLE 3. Impact Requirements for AWS A5.5 Specification
for Welding
Mild Steels AS WELDED MINIMUM REQUIREMENT STRESS-RELIEVED
E8016-C3 )------- 20 ft.-lbs. @-40°F.
Lesson 4 E8018-C3 )
Covered Electrodes E9018-M ) ( E9015-D1
for Welding Low
Alloy Steels E10018-M ) ( E9018-D1
E11018-M )------- 20 ft.-lbs. @-60°F. -------- ( E10015-D2
E12018-M ) ( E10016-D2
Lesson 5
( E10018-D2
for Stainless Steels ( E8016-C1
20 ft.-lbs. @-75°F. -------- ( E8018-C1
( E8016-C2
Lesson 6 20 ft.-lbs. @-100°F.------- ( E8018-C2
Carbon & Low Alloy
Steel Filler Metals - Impact values for all other classifications are not required.
GMAW,GTAW,SAW
Lesson 7
4.5 SELECTING THE PROPER LOW ALLOY ELECTRODE
Flux Cored Arc
Electrodes Carbon As stated earlier, low alloy electrodes are often selected to match the properties of the steel to
Low Alloy Steels
be welded rather than matching the exact chemical composition of the steel. These properties
(i.e., strength, toughness, creep, and corrosion resistance) reflect the type of service for which
the steel is intended. The letter-number suffix of the electrode classification gives an indication
Lesson 8
Hardsurfacing of that service. Whenever possible, the electrode should be selected on the basis of the
Electrodes appropriate strength levels and the intended service of the weldment.
4.5.1 Service Conditions - The large family of "proprietary" steels that are sold in the as
Lesson 9 rolled, controlled, cooled condition have a 50,000 psi minimum yield point and 70,000 psi
Estimating &
Comparing Weld minimum tensile strength. Electrodes that deposit low hydrogen weld metal of those strength
Metal Costs levels are used to weld them.
Lesson 10
Filler Metals

Lesson 1
Welding
4.5.1.1 Some of the low alloy high strength steels are intended for use at subzero tempera-
tures. Nickel bearing low hydrogen electrodes (C1, C2, C3 types) are available for such low
Lesson 2 temperature applications.
Common Electric
Arc Welding
Processes 4.5.1.2 Chromium molybdenum low alloy steels are used for moderately high temperature
service. Piping, tubing, boilers, etc., that are used extensively in power generating plants, are
fabricated from these steels. Chrome-moly low hydrogen electrodes (B1, B2, B3, etc.) are
Lesson 3
produced to weld these steels.
Covered Electrodes
for Welding
Mild Steels 4.5.1.3 Many bridges and outdoor structures are constructed from "weathering" grade
steels. These are low alloy steels that, on exposure to the atmosphere, develop a thin, tightly
adhering layer of rust that prevents further rusting and eliminates the need for painting. Low
Lesson 4
Covered Electrodes alloy electrodes with additions of chromium and copper are available for welding these steels.
for Welding Low
Alloy Steels 4.5.1.4 Quenched and tempered low alloy steels usually develop high strength with good
toughness. These types are used where substantial savings in the weight of the structure is
Lesson 5 important. Quite often, but not exclusively, these steels are used by the military. One of the
Welding Filler Metals more exotic applications for quenched and tempered low alloy steels is in the fabrication of the
pressure hulls for nuclear submarines. The "M" series of high tensile low hydrogen electrodes
is intended to weld these steels.
Lesson 6 4.5.1.5 High tensile line pipe for the transmission of oil and gas is being used with greater
Carbon & Low Alloy
Steel Filler Metals - frequency today. Low alloy cellulosic electrodes of the 7010 and 8010 variety are used for
GMAW,GTAW,SAW field welding.
4.5.2 Joint Design - In fillet welding of high strength quenched and tempered steels, toe
Lesson 7
Flux Cored Arc cracking alongside the welds (see Figure 4) is frequently a problem. The toe cracking is
Electrodes Carbon caused by the high strength weld metal having a higher yield point and tensile strength than the
Low Alloy Steels
steel.
4.5.2.1 When the weld area shrinks on CRACK AT TOE

Lesson 8 BASE OF WELD
Hardsurfacing cooling from the welding temperature, something METAL
Electrodes must give, and because the yield and strength
levels of the steel are lower than those of the
weld metal, cracking occurs in the heat affected HEAT AFFECTED WELD METAL
Lesson 9 ZONE
Estimating & zone of the steel. The solution to this problem is
Comparing Weld to use a lower strength weld metal and increase
Metal Costs
the fillet size to meet the weld joint strength requirements. TOE CRACKING
FIGURE 4
Lesson 10
Filler Metals

Lesson 1
Welding
With a somewhat lower strength weld metal as the filler, the yield point of the weld metal is
reached during the shrinkage on cooling. The weld metal stretches without overloading in the
Lesson 2 heat affected zone of the steel and there is no cracking.
Common Electric
Arc Welding
Processes 4.5.3 Equipment - The electrode selected will operate only on the appropriate power
source. Table 4 lists the type of current for which each class of electrode is designed.
Lesson 3
Covered Electrodes
for Welding TABLE 4. Current Requirements for AWS Electrode Classes
Mild Steels
Electrode Class Current
EXX10-X* DCRP
Lesson 4 EXX11-X AC or DCEP
Covered Electrodes EXX13-X AC or DC either polarity
for Welding Low EXX15-X DCEP
Alloy Steels
EXX16-X AC or DCEP
EXX18-X AC or DCEP
EXX20-X AC or DCEN (horizontal fillet)
Lesson 5
AC or DC either polarity (flat)
for Stainless Steels EXX27-X AC or DCEN (horizontal fillet)
AC or DC either polarity (flat)
* "X" indicates a variable in the classification.
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
4.6 ESAB ATOM ARC LOW HYDROGEN IRON POWDER
Lesson 2 ELECTRODES - FEATURES AND DATA

Common Electric
Arc Welding
Processes
4.6.1 Atom Arc 7018 (AWS E7018) - Although this electrodes is really of the mild steel
category and classification, the mechanical properties of the weld metal are sufficient to meet
Lesson 3 the similar properties of the 50,000 psi yield and 70,000 psi tensile strength steels. Usually,
Covered Electrodes
for Welding preheat and interpass temperature control of those steels is not necessary when welding with
Mild Steels Atom Arc 7018, although heavier thicknesses of steel may require some preheat. Common
applications include: welding carbon steels, high sulfur steels, enameling steels, and some
low alloy, high tensile steels.
Lesson 4
Covered Electrodes
for Welding Low Typical Mechanical Properties of Weld Metal
Alloy Steels
As Welded Stress-Relieved
Yield Point, psi 68,500 62,000

Lesson 5 Tensile Strength, psi 75,000 72,000
for Stainless Steels % Elongation (2") 31 32
% Reduction 75.5 77
Charpy V-Notch Impact @72°F. 125 ft.-lbs. 130 ft.-lbs.
Lesson 6 @-20°F. 70 ft.-lbs. 75 ft.-lbs.
Carbon & Low Alloy
GMAW,GTAW,SAW Typical Chemical Composition of Weld Metal
C Mn Silicon
Lesson 7 0.06% 1.10% 0.50%

Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
4.6.2 Atom Arc 7018 Mo (AWS E7018-A1) - This electrode, which deposits 1/2%
Lesson 8 molybdenum weld metal, is useful in welding power piping and pressure vessels of
Hardsurfacing molybdenum bearing steels designed for use at elevated temperatures. Typical applications
Electrodes
include: welding of low carbon and carbon-moly tubes and piping, forged alloy steel pipe
flanges, fittings and valves for high temperature service, carbon-moly steel boiler and
Lesson 9 superheater tubes, manganese-moly and manganese-moly-nickel pressure vessel plates, high
Estimating & strength structural steel and steel castings for highway service.
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
Typical Mechanical Properties of Weld Metal
As Welded* Stress-Relieved*
Lesson 2 Yield Point, psi 73,500 71,000
Common Electric
Tensile Strength, psi 84,000 81,000
Arc Welding
Processes % Elongation (2") 30 30
@-10°F. 85 ft.-lbs. 85 ft.-lbs.
Lesson 3
Covered Electrodes @-40°F. 70 ft.-lbs. 70 ft.-lbs.
for Welding
Mild Steels
Typical Chemical Composition of Weld Metal
C Mn Ni
Lesson 4 0.04% 1.06% 2.37%
Covered Electrodes
for Welding Low
Alloy Steels
4.6.3 Atom Arc 8018N (AWS E8018-C2) - 8018N electrodes with 3% nickel are usually
Lesson 5
Welding Filler Metals used to weld 3% nickel steels for low temperature service. It has solved many weld cracking
problems by its weld crack resistance, as well as remaining tough at temperatures as low as -
100°F. Typical applications include: welding of piping for low temperature service, carbon and
low alloy steel forgings and ferritic steel castings for high pressures at low temperatures, high
Lesson 6
Carbon & Low Alloy strength steel castings for structural purposes, carbon steel forgings for railroad use and
Steel Filler Metals - concrete reinforcement bars.
GMAW,GTAW,SAW

Lesson 7 As Welded Stress-Relieved
Flux Cored Arc
Electrodes Carbon Yield Point, psi 83,000 80,500
Low Alloy Steels Tensile Strength, psi 94,000 90,500
% Elongation (2") 25 28
% Reduction of Area 55 74
Lesson 8
Hardsurfacing Charpy V-Notch Impacts @72°F. 110 ft.-lbs. 112 ft.-lbs.
Electrodes @0°F. 91 ft.-lbs. 93 ft.-lbs.
@-40°F. 73 ft.-lbs. 63 ft.-lbs.
@-100°F. 35 ft-lbs. 30 ft.-lbs.

Lesson 9
Estimating &
Comparing Weld Typical Chemical Composition of Weld Metal
Metal Costs
C Mn Si Ni
0.5% 0.84% 0.37% 3.30%
Lesson 10
Filler Metals

Lesson 1
Welding
4.6.4 Atom Arc 8018CM (AWS E8018-B2) - This 1-1/4% chrome, 1/2% moly electrode
deposits weld metal that retains high strength at temperatures up to 600°F. The 8018CM
Lesson 2 electrodes are used to weld the 1/2% chrome-1/2% moly, 1% chrome-1/2% moly steels, as
Common Electric
Arc Welding well as the 1-1/4% chrome-1/2% moly power piping, boiler tubing, plates and castings. Many
Processes of the fossil fired steam boilers in electric generating plants in the United States have been
welded with this electrode and its relative 9018CM.
Lesson 3
Covered Electrodes Typical Mechanical Properties of Weld Metal
for Welding Stress-Relieved Stress-Relieved
Mild Steels
8 hrs. @1150°F. 8 hrs. @1350°F.
Lesson 4 Tensile Strength, psi 100,000 78,300
Covered Electrodes
for Welding Low % Elongation (2") 23 32
Alloy Steels % Reduction of Area 60.7 79.1
Charpy V-Notch Impacts @30°F. 64 ft.-lbs. 127 ft-lbs.
Lesson 5
Welding Filler Metals Typical Chemical Composition of Weld Metal
C Mn Si Ni Mo
0.06% 1.10% 0.40% 1.00% 0.50%
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 4.6.5 Atom Arc 8018W (AWS E8018-G) - The balanced alloy combination of chromium,
GMAW,GTAW,SAW
nickel and copper of this electrode causes the weld metal to "weather" similarly to the
weathering grade steels when exposed to the atmosphere. The inform color blend of this weld
Lesson 7 metal with the weathered steel makes these electrodes the ideal choice when architectural
Flux Cored Arc
Electrodes Carbon appearance and weld integrity is important.
Low Alloy Steels
Typical Mechanical Properties of Weld Metal Stress-Relieved
As Welded 1 hr. @1025°F.
Lesson 8
Hardsurfacing Yield Point, psi 84,600 79,100
Electrodes Tensile Strength, psi 94,400 90,100
% Reduction of Area 68.8 72.3
Lesson 9
Estimating & Charpy V-Notch Impacts @-60°F. 63 ft-lbs. 44 ft.-lbs.
Comparing Weld
Metal Costs Typical Chemical Composition of Weld Metal
C Mn Si Ni Mo
Lesson 10 0.05% 1.11% 0.32% 1.70% 0.28%

Filler Metals

Lesson 1
Welding
4.6.6 Atom Arc 9018CM (AWS E9018-B3) - These 2-1/4% chrome - 1% moly electrodes
are used to weld and match the composition of the 2-1/4% chrome - 1% moly steels in
Lesson 2 pressure piping and power boilers. The chromium-molybdenum content of the weld metal
Common Electric
Arc Welding helps retain appreciable strength at temperatures up to 800°F.
Processes
Stress-Relieved Stress-Relieved
Lesson 3
Covered Electrodes 1 hr. @1275°F. 2 hrs. @1350°F.
for Welding Yield Point, psi 87,000 75,000
Mild Steels
Lesson 4 % Reduction of Area 67 70
Covered Electrodes
for Welding Low
Alloy Steels Typical Chemical Composition of Weld Metal
C Mn Si Ni Mo
Lesson 5 0.05% 0.75% 0.60% 2.20% 1.05%

4.6.7 Atom Arc 9018-B3L (AWS E9018-B3L) - The low carbon content of this 2-1/4%
Lesson 6
Carbon & Low Alloy chrome - 1% moly electrode makes the weld metal more crack resistant in heavy sections and
Steel Filler Metals - allows lower preheat and interpass temperatures to be used. Typical applications include:
GMAW,GTAW,SAW
high temperature power piping, boilers, heat-exchanger and condenser tubes, pressure vessel
plates and steel castings for high temperature pressure service.
Lesson 7
Flux Cored Arc
Electrodes Carbon Typical Mechanical Properties of Weld Metal
Low Alloy Steels Stress-Relieved Stress-Relieved
8 hrs. @1150°F. 8 hrs. @1350°F.
Lesson 8
Hardsurfacing Tensile Strength, psi 103,800 86,400
Electrodes % Elongation (2") 21 24
% Reduction of Area 67.6 73
Lesson 9
Estimating &
Metal Costs
C Mn Si Ni Mo
0.02% 0.74% 0.61% 2.47% 1.10%
Lesson 10
Filler Metals

Lesson 1
LESSON IV
The Basics of Arc
Welding
4.6.8 Atom Arc 10018 (AWS E10018-M) - The manganese-nickel-molybdenum
composition of Atom Arc 10018 is used mostly on thinner sections of quenched and tempered
Lesson 2 low alloy steels where 100,000 psi tensile strength, along with good ductility and toughness at
Common Electric
Arc Welding temperatures as low as -60°F, are required. This product is used primarily for military
Processes applications.
Typical Mechanical Properties of Weld Metal Stress-Relieved

Lesson 3
Covered Electrodes
Mild Steels
Lesson 4 % Reduction of Area 63.5 67
Covered Electrodes
for Welding Low Charpy V-Notch Impact @-60°F. 33 ft.-lbs. 22 ft.-lbs.
Alloy Steels
Lesson 5 C Mn Si Ni Mo
Welding Filler Metals 0.05% 1.58% 0.40% 1.50% 0.30%
4.6.9 Atom Arc 10018MM (AWS E10018-D2) - This electrode, with its combination of
Lesson 6
Carbon & Low Alloy manganese and molybdenum, was originally developed during World War II to repair and
Steel Filler Metals - fabricate manganese-molybdenum castings and armor plate. It is used to weld similar
GMAW,GTAW,SAW
composition low alloy steels, as well as heat treatable steels comparable to hardenable steels.
Lesson 7 Typical Mechanical Properties of Weld Metal

Flux Cored Arc
Electrodes Carbon Stress-Relieved
Low Alloy Steels As Welded 2 hrs. @1100°F.

Lesson 8
Hardsurfacing % Elongation (2") 22 26
Electrodes % Reduction of Area 51 68
Charpy V-Notch Impacts @72°F. 83 ft.-lbs. 73 ft.-lbs.
@0°F. 55 ft.-lbs. 50 ft.-lbs.
Lesson 9
Estimating & @-40°F. 38 ft.-lbs. 34 ft.-lbs.
Comparing Weld
Metal Costs Typical Chemical Composition of Weld Metal
C Mn Si Mo
Lesson 10 0.09% 1.77% 0.68% 0.35%

Filler Metals

Lesson 1
LESSON IV
The Basics of Arc
Welding
4.6.10 Atom Arc 12018 (AWS E12018-M) - This electrode deposits high strength weld
metal in both the as welded and stress-relieved conditions, which is required for welding many
Lesson 2 of the high strength quenched and tempered steels. It is used to weld steels with 120,000 psi
Common Electric
Arc Welding tensile strength in applications, such as welding carbon and high strength alloy steel forgings
Processes for railroad equipment, high strength steel castings for structural work, and steel castings for
highway bridges.
Lesson 3
Covered Electrodes Typical Mechanical Properties of Weld Metal Stress-Relieved
for Welding As Welded 1 hr. @1025°F.
Mild Steels
Lesson 4 % Elongation (2") 20 22
Covered Electrodes
for Welding Low % Reduction of Area 56 60
Alloy Steels Charpy V-Notch Impacts @72°F. 52 ft.-lbs. 54 ft.-lbs.
@-60°F. 32 ft.-lbs. 31 ft.-lbs.
Lesson 5
Welding Filler Metals Typical Chemical Composition of Weld Metal
C Mn Si Cr Ni Mo
0.05% 1.90% 0.25% 0.85% 2.00% 0.50%
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
4.6.11 Atom Arc "T" (AWS E11018-M) - Atom Arc "T" electrodes were developed for
welding U.S. Steels T-1 steel, which is quenched and tempered to high strength and ductility. It
Lesson 7 has since been used to weld all of the quenched and tempered steels, including HY-80, the
Flux Cored Arc
Electrodes Carbon steel used for the pressure hulls of nuclear submarines.
Low Alloy Steels
Stress-Relieved
Lesson 8
Hardsurfacing
Electrodes Yield Point, psi 103,000 102,000
Lesson 9
Estimating & % Reduction of Area 62 63
Comparing Weld Charpy V-Notch Impacts @72°F. 80 ft.-lbs. 73 ft.-lbs.
Metal Costs
@0°F. 55 ft.-lbs. 50 ft.-lbs.
@-40°F. 48 ft.-lbs. 42 ft.-lbs.
Lesson 10 @-60°F. 41 ft.-lbs. 26 ft.-lbs.

Filler Metals

Lesson 1
Welding
C Mn Si Cr Ni Mo
Lesson 2 0.06% 1.53% 0.27% 0.31% 1.88% 0.43%
Common Electric
Arc Welding
Processes
4.6.12 Atom Arc 9018HT (AWS E9018G) - As the HT indicates, this electrode is intended
for heat treated applications. It deposits weld metal with properties that match chromium-
Lesson 3
Covered Electrodes molybdenum steel castings and is also useful in the repair and rebuilding of hot forging dies.
for Welding
Mild Steels
Quenched @1700°F. Quenched @1600°F.
Lesson 4 Tempered @1275°F. Tempered @900°F.
Covered Electrodes
for Welding Low Yield Point, psi 78,000 133,000
Alloy Steels Tensile Strength, psi 98,000 180,000
% Elongation (2") 20 12.5
Lesson 5 % Reduction of Area 57.5 27

for Stainless Steels Typical Chemical Composition of Weld Metal
C Mn Si Cr Mo
0.14% 0.80% 0.65% 2.30% 1.00%
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
4.6.13 Atom Arc 4130 (No AWS Classification) - This composition was developed to
weld heat treatable steels such as SAE4130, providing a weld metal that responds similarly to
Lesson 7 the heat treatment.
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels Typical Mechanical Properties of Weld Metal
Quenched @1600°F. Quenched @1600°F.
Tempered @1150°F. Tempered @950°F.
Lesson 8
Hardsurfacing Yield Point, psi 121,000 152,000
Electrodes Tensile Strength, psi 138,000 163,000
Lesson 9
Estimating &
Metal Costs
C Mn Si Cr Ni Mo
0.18% 1.25% 0.40% 2.50% 1.28% 0.20%
Lesson 10
Filler Metals

Lesson 1
Welding
4.6.14 Atom Arc 4130 LN (No AWS Classification) - This alloy combination has less
than 1% nickel so that it may be used safely to weld oil field equipment that handles "sour"
Lesson 2 (high sulfur) crude oil. The weld metal is hardenable by quenching and tempering similar to
Common Electric
Arc Welding SAE4130 steel.
Processes
Lesson 3 Quenched @1600°F. Quenched @1600°F.

Covered Electrodes Tempered @1200°F. Tempered @900°F.
Mild Steels
Lesson 4 % Reduction of Area 58.6 44.6
Covered Electrodes
for Welding Low
Alloy Steels Typical Chemical Composition of Weld Metal
C Mn Si Cr Ni Mo
Lesson 5 0.26% 1.25% 0.47% 0.49% 0.80% 0.16%

4.6.15 Additional information on Atom Arc Low Hydrogen, Low Alloy electrodes is
Lesson 6
Carbon & Low Alloy contained in the Atom Arc product catalog and the Atom Arc handbook for welding low alloy
Steel Filler Metals - high tensile steels, published by ESAB.
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
APPENDIX A
Lesson 2
STICK ELECTRODE DATA CHARTS
Common Electric
Arc Welding ATOM ARC ELECTRODES
Processes
Lesson 3
Covered Electrodes DEPOSITION EFFICIENCY DATA-LOW ALLOY, IRON POWDER ELECTRODES
for Welding TYPES E7018, E8018, E9018, E10018, E11018, AND E12018
Mild Steels
ELECTRODE DEPOSITION EFFICIENCYELECTRODE DEPOSITION EFFICIENCY
DIAMETER AMPS RATE lbs/hr % DIAMETER AMPS RATE lbs/hr %
3/32 70 1.37 70.50 3/16 200 4.85 76.40

Lesson 4
90 1.65 66.30 250 5.36 74.60
Covered Electrodes
for Welding Low 110 1.73 64.40 300 5.61 70.30
Alloy Steels 1/8 120 2.58 71.60 7/32 250 6.50 75.00
140 2.74 70.90 300 7.20 74.00
160 2.99 68.10 350 7.40 73.00
Lesson 5 5/32 140 3.11 75.00 1/4 300 7.72 78.00
Welding Filler Metals 170 3.78 73.50 350 8.67 77.00
200 4.31 73.00 400 9.04 74.00
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - CHART TO CONVERT ENGLISH
STUB"LOSS CORRECTION TABLE FOR COATED
GMAW,GTAW,SAW ELECTRODE DIMENSIONS TO METRIC
ELECTRODE EFFICIENCY INCLUDING STUB LOSS
EQUIVALENTS
ELEC. DEPOSITION 2" 3" 4" 5"
Lesson 7 LENGTH EFFICIENCY STUB STUB STUB STUB DIAMETER LENGTH

Flux Cored Arc 60% 50.0% 45.0% 40.0% 35.0%
Electrodes Carbon 65% 54.2% 48.7% 43.3% 37.9% Inches mm Inches mm
Low Alloy Steels 12" 70% 58.3% 52.5% 46.6% 40.8%
3/32 2.4 12 300
75% 62.5% 56.2% 50.0% 43.7%
1/8 3.2 14 350
80% 66.6% 60.0% 53.3% 46.6% 5/32 4.0 14 350
Lesson 8 60% 51.4% 47.1% 42.8% 38.5% 3/16 4.8 14/18 350/450
Hardsurfacing 65% 55.7% 51.1% 46.4% 41.8% 7/32 5.6 18 450
Electrodes 14" 70% 60.0% 55.0% 50.0% 45.0% 1/4 6.4 18 450
5/16 8.0 18 450
75% 64.3% 58.9% 53.6% 48.2%
80% 68.5% 62.8% 57.1% 51.4%
60% 53.3% 50.0% 46.6% 43.3%
Lesson 9
Estimating & 65% 57.7% 54.2% 50.5% 46.9%
Comparing Weld 18" 70% 62.2% 58.3% 54.4% 50.5%
Metal Costs 75% 66.6% 62.5% 58.3% 54.2%
80% 71.1% 66.6% 62.2% 57.7%
Lesson 10
Filler Metals

Lesson 1
Welding
APPENDIX B
Lesson 2 LESSON IV - GLOSSARY OF TERMS

Common Electric
Arc Welding
Processes Quench - The rapid cooling of steel from a temperature above the transformation
temperature. This results in hardening of the steel.
Lesson 3 Temper - Reheating of steel to a temperature below the transformation temperature

Covered Electrodes following the quenching of steel. This usually lowers the hardness and
for Welding strength and increases the toughness of the steel.
Mild Steels
Stress - The reheating of a weldment to a temperature below the transformation

Lesson 4 Relieved temperature and holding it for a specified period of time. A frequently used
Covered Electrodes
temperature and time is 1150°F. for 1 hr. per inch of thickness. This
for Welding Low
Alloy Steels reheating removes most of the residual stresses put in the weldment by the
heating and cooling during welding.
Lesson 5 Transformation - The temperature at which the crystal structure of the steel changes,
Temperature usually about 1600°F.
Heat Affected - The area of the base metal that did not become molten in the welding
Lesson 6 Zone process, but did undergo a microstructure change as a result of the heat
Carbon & Low Alloy induced into that area. If the HAZ in hardenable steels is cooled rapidly, the
GMAW,GTAW,SAW area becomes excessively brittle.
Underbead - A weld defect that starts in the heat affected zone and is caused by
Lesson 7
Cracking excessive molecular hydrogen trapped in that region. It is sometimes
Flux Cored Arc
Electrodes Carbon referred to as cold cracking, since it occurs after the weld metal has cooled.
Low Alloy Steels
Low Hydrogen - Stick electrodes that have coating ingredients that are very low in
Electrodes hydrogen content. The low hydrogen level is achieved primarily by keeping
Lesson 8 the moisture content of the coating to a bare minimum.
Hardsurfacing
Electrodes
Weathering - Low alloy steel that is specially formulated to form a thin tightly adhering
Steel layer of rust. This initial layer prevents further rusting and thus, the need to
Lesson 9 paint the steel is eliminated. The main alloys in this steel are copper and
Estimating & chromium.
Comparing Weld
Metal Costs
Toe - A weld defect that occurs at the toe of the weld metal. The cracking
Cracking occurs when the weld metal does not stretch with the base metal because
Lesson 10 the yield and tensile strength of the weld metal is greater than the steel.
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
for Welding WELDING FILLER METAL
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Lesson 5
Lesson 6 LESSON V
Carbon & Low Alloy
Steel Filler Metals - WELDING FILLER METALS
GMAW,GTAW,SAW
FOR STAINLESS STEELS
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON V
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON V
Lesson 2
Common Electric WELDING FILLER METALS
Arc Welding
Processes FOR STAINLESS STEELS
Lesson 3 5.1 INTRODUCTION TO STAINLESS STEEL ...................................... 1

Covered Electrodes
for Welding 5.2 DIFFERENCES IN STAINLESS AND CARBON STEELS .............. 3
Mild Steels
5.3 STAINLESS STEEL TYPES ............................................................ 5
Lesson 4 5.4 AUSTENITIC STAINLESS STEELS ................................................ 6

Covered Electrodes
for Welding Low 5.4.1 Carbide Precipitation ........................................................................ 6
Alloy Steels 5.4.2 Ferrite in Austenitic Stainless Steels .................................................. 7
5.5 CALCULATION OF FERRITE CONTENT IN STAINLESS STEEL . 8

Lesson 5
Welding Filler Metals 5.6 SPECIAL FERRITE REQUIREMENT IN STAINLESS STEEL
ELECTRODES ................................................................................. 10
5.7 MARTENSITIC STAINLESS STEELS ............................................. 10

Lesson 6
Carbon & Low Alloy 5.8 FERRITIC STAINLESS STEELS ..................................................... 11
GMAW,GTAW,SAW
5.9 DUPLEX STAINLESS STEELS ...................................................... 12
Lesson 7 5.10 ELECTRODE SELECTION ............................................................. 12

Flux Cored Arc
Electrodes Carbon 5.11 WELDING DISSIMILAR STEELS .................................................... 13
Low Alloy Steels
5.12 STAINLESS STEEL ELECTRODES AND FILLER METALS ......... 16
5.12.1 Covered Stainless Electrodes............................................................ 16
Lesson 8 5.12.2 Arcaloy Lime Coated Electrodes ....................................................... 17
Hardsurfacing
Electrodes 5.12.3 Arcaloy AC-DC Titania Coated Electrodes ........................................ 17
5.12.4 Arcaloy Plus Electrodes ..................................................................... 17
Lesson 9 5.13 ARCALOY COVERED ELECTRODE PROPERTIES

Estimating & AND APPLICATIONS ....................................................................... 18
Comparing Weld
Metal Costs 5.13.1 Arcaloy 308L and 308L Plus .............................................................. 18
5.13.2 Arcaloy 309L and 309L Plus .............................................................. 18
5.13.3 Arcaloy 309 Cb.................................................................................. 18
Lesson 10
Filler Metals

Lesson 1 LESSON V
The Basics of Arc
Welding
TABLE OF CONTENTS
Lesson 2 LESSON V - Con't.
Common Electric
Arc Welding
Processes 5.13.4 Arcaloy 309MoL ................................................................................ 19
5.13.5 Arcaloy 310 ....................................................................................... 19
5.13.6 Arcaloy 310 Cb.................................................................................. 19
Lesson 3
Covered Electrodes 5.13.7 Arcaloy 310Mo .................................................................................. 19
for Welding 5.13.8 Arcaloy 312 ....................................................................................... 19
Mild Steels
5.13.9 Arcaloy 316L and 316L Plus .............................................................. 19
5.13.10 Arcaloy 316LF5 ................................................................................. 20
Lesson 4 5.13.11 Arcaloy 317L and 317L Plus .............................................................. 20
Covered Electrodes
for Welding Low 5.13.12 Arcaloy 318 ....................................................................................... 20
Alloy Steels 5.13.13 Arcaloy 320 and 320LR ..................................................................... 20
5.13.14 Arcaloy 347 and 347 Plus .................................................................. 21
Lesson 5 5.13.15 Arcaloy 410 ....................................................................................... 21

for Stainless Steels 5.14 ARCALOY BARE STAINLESS STEEL ELECTRODES ................. 21
5.15 APPLICATIONS AND COMPOSITIONS OF ARCALOY
Lesson 6 BARE STAINLESS ELECTRODES ................................................ 22

Carbon & Low Alloy 5.15.1 Arcaloy ER308L ................................................................................ 22
5.15.2 Arcaloy ER308LSi ............................................................................. 22
GMAW,GTAW,SAW
5.15.3 Arcaloy ER309L ................................................................................ 22
5.15.4 Arcaloy ER310 .................................................................................. 22
Lesson 7
5.15.5 Arcaloy ER312 .................................................................................. 23
Flux Cored Arc
Electrodes Carbon 5.15.6 Arcaloy ER316L ................................................................................ 23
Low Alloy Steels 5.15.7 Arcaloy ER316LSi ............................................................................. 23
5.15.8 Arcaloy ER347 .................................................................................. 23
Lesson 8
5.16 CORE-BRIGHT STAINLESS STEEL FLUX CORED
Hardsurfacing
Electrodes ELECTRODES ................................................................................. 23
5.17 CORE-BRIGHT STAINLESS STEEL FLUX CORED

Lesson 9 ELECTRODE APPLICATIONS AND PROPERTIES ....................... 24
Estimating & 5.17.1 Core-Bright 307................................................................................. 24
Comparing Weld
Metal Costs 5.17.2 Core-Bright 308 Mo ........................................................................... 24
5.17.3 Core-Bright 308LTo ........................................................................... 24
5.17.4 Core-Bright 309L ............................................................................... 25
Lesson 10 5.17.5 Core-Bright 316L ............................................................................... 25
Filler Metals

Lesson 1 LESSON V
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON V - Con't.
Lesson 2
Common Electric
Arc Welding
Processes
5.17.6 Core-Bright 347................................................................................. 25
Lesson 3 5.18 FERRITE CONTENT OF CORE-BRIGHT WELD METALS ............ 25

Covered Electrodes
for Welding 5.19 SHIELD-BRIGHT & SHIELD-BRIGHT X-TRA
Mild Steels
STAINLESS STEEL FLUX CORED ELECTRODES ...................... 26
Lesson 4 5.20 SHIELD-BRIGHT & SHIELD-BRIGHT X-TRA STAINLESS STEEL

Covered Electrodes FLUX CORED ELECTRODE APPLICATIONS & PROPERTIES ... 26
for Welding Low
5.20.1 Shield-Bright 308L ............................................................................. 26
Alloy Steels
5.20.2 Shield-Bright 309L ............................................................................. 27
5.20.3 Shield-Bright 309LMo ........................................................................ 27
Lesson 5 5.20.4 Shield-Bright 316L ............................................................................. 27
for Stainless Steels 5.20.5 Shield-Bright 317L ............................................................................. 28
5.20.6 Shield-Bright 347............................................................................... 28
Lesson 6 5.21 ARCALOY NICKEL ALLOY COVERED WELDING ELECTRODES -

Carbon & Low Alloy FEATURES AND DATA .................................................................... 29
5.21.1 Arcaloy 9N10 Nickel-Copper ............................................................. 29
GMAW,GTAW,SAW
5.21.2 Arcaloy 8N12 Nickel-Chromium-Iron .................................................. 29
5.21.3 Arcaloy Ni-9 ....................................................................................... 30
Lesson 7
5.21.4 Arcaloy Ni-12 ..................................................................................... 31
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 5.22 ELECTRODES FOR WELDING CAST IRON .................................. 32
5.22.1 Nickel-Arc 55 ..................................................................................... 32
5.22.2 Nickel-Arc 550................................................................................... 33
Lesson 8 5.22.3 Nickel-Arc 99 ..................................................................................... 33
Hardsurfacing
Electrodes 5.22.4 Nicore 55 .......................................................................................... 33
5.22.5 Cupro Nickel Electrodes .................................................................... 34
Lesson 9 Appendix A - GLOSSARY OF TERMS .................................................................. 35

Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
WELDING FILLER METALS FOR

Lesson 2
Common Electric STAINLESS STEELS
Arc Welding
Processes
5.1 INTRODUCTION TO STAINLESS STEEL
Lesson 3 Stainless steel, introduced commercially during the early 1930's, presented industry with a new
Covered Electrodes "wonder metal" with its shiny surface and ability to resist rust and corrosion. This new steel
for Welding
Mild Steels alloy also presented welding problems that had not been previously encountered. It took many
years of research and experimentation to develop successful welding filler metals and welding
procedures for this "rustless iron" as it was then called.
Lesson 4
Covered Electrodes
for Welding Low 5.1.0.1 Most of us think of stainless as an attractive metal used for trim on our stoves and
Alloy Steels automobiles, or as bright, easy-to-clean cooking utensils and cutlery. Besides being used for
its corrosion resisting properties, however, stainless steel is used for low temperature applica-
tions, and for applications where its resistance to scaling at high temperatures is important.
Lesson 5
for Stainless Steels 5.1.0.2 Stainless steel is basically an alloy of iron and chromium. As the amount of chro-
mium added to a steel alloy is increased, the corrosion resistance increases until the amount
of chromium reaches 11% to 12%, at which point it is considered a stainless steel. The graph
Lesson 6 in Figure 1 shows how the amount of chromium affects the rate of corrosion in a semi-rural,
Carbon & Low Alloy
Steel Filler Metals - outdoor air environment. Corrosion rate will vary with the corrosive media to which the stain-
GMAW,GTAW,SAW less steel is exposed and with the type of stainless employed.
Lesson 7 .001 MILD STEEL

Flux Cored Arc
Electrodes Carbon
.0008
Low Alloy Steels
.0006
Lesson 8 .0004
Hardsurfacing STAINLESS STEEL
Electrodes
.0002
Lesson 9 2 4 6 8 10 12 14
Estimating & PERCENT CHROMIUM

Comparing Weld
CORROSION RATE VERSUS PERCENT CHROMIUM
Metal Costs OUTDOOR ATMOSPHERE, SEMI-RURAL ENVIRONMENT
FIGURE 1
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.1.0.3 The mechanism by which chromium imparts corrosion resistance to steel has been
well established. Essentially, the chromium combines with oxygen of the atmosphere to form a
Lesson 2 stable non-metallic oxide film on the surface of the steel. This film protects the steel by acting
Common Electric
Arc Welding as a protective coating. As the chromium content of the steel increases, the tenacity, imper-
Processes meability and strength of this film increases, imparting greater and greater corrosion resis-
tance. This film is too thin to be seen. What we do see is the shiny, unoxidized steel just below
this film.
Lesson 3
Covered Electrodes
for Welding 5.1.0.4 In Lesson I we learned that the application of heat to metals can change the micro-
Mild Steels structure and thereby, the properties of that metal. The fabricator of ordinary carbon steel
understands that successful welds depend upon how that material behaves under the heat of
Lesson 4 the arc. With that information as a guide, welds can be produced that satisfy the mechanical
Covered Electrodes requirements of the welded joint. With stainless steel, however, other aspects such as preser-
for Welding Low
Alloy Steels vation of corrosion resistance and heat resistance must also be considered.
5.1.0.5 Stainless steel may be welded by most of the common arc welding processes.
Lesson 5 Shielded metal-arc welding with coated electrodes is still probably the most widely used
process. Other commonly used processes are flux cored arc welding, gas metal-arc welding,
gas tungsten-arc welding and submerged arc welding as discussed in Lesson II.
5.1.0.6 The cost of stainless steel is approximately six times that of mild steel. For this
Lesson 6
Carbon & Low Alloy reason, it is important that the proper electrodes or filler metals are selected and the proper
Steel Filler Metals - welding procedures are followed to minimize rework or scrap losses due to faulty welds. An
GMAW,GTAW,SAW
understanding of the peculiarities of the four types of stainless steel, and how they compare to
mild or carbon steels, will help to avoid costly mistakes.
Lesson 7
Flux Cored Arc 5.1.0.7 There are four primary grades of stainless steel: austenitic, martensitic, ferritic, and
Electrodes Carbon
Low Alloy Steels duplex. The names are metallurgical terms derived from the crystal structure of the steel at
room temperature and will be covered in more detail later in this lesson. Figure 2 shows the
basic differences and the composition of the four types.
Lesson 8
Hardsurfacing
Electrodes TYPE RANGE OF ALLOYING ELEMENTS
CHROMIUM NICKEL
AUSTENITIC 16 - 30% 8 - 40%

Lesson 9 MARTENSITIC 11 - 18% 0 - 5%
Estimating & FERRITIC 11 - 30% 0 - 4%
Comparing Weld DUPLEX 18 - 28% 4 - 8%
Metal Costs
MAJOR STAINLESS STEEL ALLOYING ELEMENTS
FIGURE 2
Lesson 10
Filler Metals
© COPYRIGHT 2000 THE ESAB GROUP,

Lesson 1
LESSON V
The Basics of Arc
Welding
5.1.0.8 That group of stainless steels that contain both chromium and nickel (austenitic
grade) is more readily and satisfactorily welded than those that contain less than 5% nickel
Lesson 2 (martensitic and ferritic grades). Weld joints produced in austenitic stainless steels are strong,
Common Electric
Arc Welding ductile and tough in their as-welded condition. They do not normally require preheat or post
Processes weld heat treatment. On the other hand, the martensitic and ferritic stainless steels are charac-
terized by hardness or brittleness after welding, and preheat and post-heating is necessary to
improve their properties.
Lesson 3
Covered Electrodes
for Welding 5.1.0.9 Austenitic stainless is commonly referred to as the "chrome-nickel" type and the
Mild Steels martensitic and ferritic steels are commonly called the "straight chrome" types.
Lesson 4 5.2 DIFFERENCES IN STAINLESS AND CARBON

Covered Electrodes
for Welding Low STEELS
Alloy Steels
The behavior of stainless steel in the heat of the arc differs from that of mild steel. Figure 3
shows that the rate of expansion of the chromium-nickel types is about 50% greater than that
Lesson 5
Welding Filler Metals of carbon steel. This means that distortion from warping must be compensated for to a
for Stainless Steels greater extent.
Lesson 6
Carbon & Low Alloy CARBON
Steel Filler Metals - STEEL
GMAW,GTAW,SAW
CHROMIUM-
NICKEL
Lesson 7 TYPES
Flux Cored Arc
Electrodes Carbon STRAIGHT
Low Alloy Steels CHROMIUM
TYPES
.020 .040 .060 .080 .100 .120

Lesson 8 INCHES EXPANSION PER FOOT
Hardsurfacing 1000°F TEMPERATURE RISE
Electrodes
RATE OF EXPANSION
FIGURE 3
Lesson 9
Estimating & 5.2.0.1 When welding an austenitic stainless steel to a carbon steel, the different rates of
Comparing Weld expansion can cause cracking due to internal stresses unless the proper electrode and weld-
Metal Costs
ing procedure is used. The expansion of the straight chromium types is about the same as or
slightly less than that of carbon steels.
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.2.0.2 The melting temperature of all stainless steels are lower than that of carbon steel as
shown in Figure 5, and both chrome-nickel and straight chrome types are much more fluid in
Lesson 2 the melted state. Therefore, less heat (welding current) is required to weld stainless steels
Common Electric
compared to carbon steels.
Arc Welding
Processes
CARBON
STEEL
Lesson 3
Covered Electrodes
CHROMIUM-
for Welding
NICKEL
Mild Steels
TYPES
STRAIGHT
Lesson 4 CHROMIUM
Covered Electrodes TYPES
for Welding Low
Alloy Steels 2000 2250 2500 2750 3000
DEGREES FAHRENHEIT
MELTING TEMPERATURES
Lesson 5
Welding Filler Metals FIGURE 4
5.2.0.3 The electrical resistance of both the chrome-nickel and the straight chrome types is
considerably higher than that of the plain carbon steels as shown in Figure 5. This higher
Lesson 6 resistance creates more resistance heating in the stainless steel electrode and in the base
Carbon & Low Alloy plate. Lower welding current or amperage is required to avoid overheating the electrode. The
GMAW,GTAW,SAW
CARBON
Lesson 7 STEEL
Flux Cored Arc
Electrodes Carbon CHROMIUM-
Low Alloy Steels NICKEL
TYPES
STRAIGHT
Lesson 8 CHROMIUM
Hardsurfacing TYPES
Electrodes
MICROHMS/SQ 10 20 30 40 50 60 70 80
CM/CM AT 20° C.
ELECTRICAL RESISTANCE
Lesson 9
Estimating & FIGURE 5
Comparing Weld
Metal Costs
electrical resistance of the chrome-nickel alloys is about six times that of carbon steel and may
be substantially higher if the stainless is cold-worked. The straight chrome types have electri-
Lesson 10 cal resistances varying from three to six times that of carbon steel.
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.2.0.4 The chrome-nickel stainless alloys conduct heat only 40% to 50% as fast as carbon
steel and in the straight chrome types, heat conductivity is 50% to 65% that of carbon steel as
Lesson 2 shown in Figure 6. This means that the heat remains in the vicinity of the arc for a longer
Common Electric
Arc Welding period of time instead of being dispersed throughout the weldment rapidly, as it does when
Processes welding materials of high thermal conductivity. This is another reason that lower amperages
are required to weld these steels.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CARBON
STEEL
Lesson 4 CHROMIUM-
Covered Electrodes NICKEL
for Welding Low
TYPES
Alloy Steels
STRAIGHT
CHROMIUM
Lesson 5 TYPES
AT 20° - 100° C .020 .040 .060 .080 .100 .120
CAL/SEC/SQ CM
THERMAL CONDUCTIVITY
Lesson 6 FIGURE 6
Carbon & Low Alloy
GMAW,GTAW,SAW 5.3 STAINLESS STEEL TYPES
As already mentioned, there are three principal categories of stainless steels: austenitic,
Lesson 7
Flux Cored Arc martensitic, and ferritic. The names are derived from the crystalline structure of the steel
Electrodes Carbon normally found at room temperature. When low carbon steel is heated above 1550°F, the
Low Alloy Steels
atoms of the steel are rearranged from the structure called ferrite at room temperatures to the
crystal structure called austenite. On cooling, the low carbon steel atoms return to their original
Lesson 8 structure — ferrite. The high temperature structure, austenite, is non-magnetic, plastic and has
Hardsurfacing lower strength and greater ductility than the room temperature form of ferrite.
Electrodes
5.3.0.1 When more than 17% chromium and 7% nickel are added to the steel, the high
temperature crystalline structure of the steel — austenite, is stabilized so that it persists at all
Lesson 9
Estimating & temperatures from the very lowest to almost melting. This alloy combination is the basis for the
Comparing Weld austenitic category of stainless steels . Many alloy additions are made to that base as modifi-
Metal Costs
cations for different service requirements.
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON V
Welding
5.3.0.2 When certain alloy steels are cooled rapidly from above the transformation tempera-
ture, a very hard brittle phase occurs. This phase is called martensite. Steels that contain 5-
Lesson 2 15% chromium have this special characteristic. Unless special care is used in welding such
Common Electric
Arc Welding steels, they become crack sensitive. These are the martensitic stainless steel alloys.
Processes
5.3.0.3 When more than 16% chromium is added to the steel, the room temperature crystal-
line structure, ferrite, is stabilized and the steel remains in the ferritic condition at all tempera-
Lesson 3
tures. Hence the name, ferritic stainless steel is applied to this alloy base.
Covered Electrodes
for Welding
Mild Steels
5.4 AUSTENITIC STAINLESS STEELS
Lesson 4 Austenitic Stainless Steels are designated by a series of 300 numbers according to the Ameri-
Covered Electrodes can Iron & Steel Institute (AISI). Nominal compositions of some of the more important types
for Welding Low
Alloy Steels are shown in Figure 7. About 80% of the stainless steel welded is of the austenitic type.
AISI No. Chromium % Nickel % Molybdenum % Columbium %

Lesson 5
301 17 7
302 18 9
for Stainless Steels 304 19 10
309 23 13
310 25 20
316 17 12 2.5
317 19 13 3.5
Lesson 6 347 18 11 1
Carbon & Low Alloy
Steel Filler Metals - MOST COMMON TYPES OF AUSTENITIC STAINLESS STEELS
5.4.1 Carbide Precipitation - Many of the austenitic stainless steels are subject to the
Lesson 7
Flux Cored Arc phenomenon of carbide precipitation. At elevated temperatures in the range of 800-1600°F,
Electrodes Carbon the carbon content in excess of 0.02% migrates to the grain boundaries of the austenitic
Low Alloy Steels
structure where it reacts with chromium to form chromium carbide. If the chromium is tied up
with the carbon, it is not available for corrosion resistance. Thus, when the steel with carbide
Lesson 8 precipitation is exposed to a corrosive environment, intergranular corrosion results, allowing

Hardsurfacing the grain boundaries to be eaten away. Figure 8 shows how intergranular corrosion may take
Electrodes
place in a tank holding a corrosive liquid. Notice that the corrosion takes place only in the heat
affected zone on the inside where the corrosive media is located, and there is no evidence of
Lesson 9 failure on the outside.

Estimating &
Comparing Weld 5.4.1.1 Carbide precipitation has no other effect on the steel, however, other than loss of
Metal Costs
corrosion resistance in the heat affected zone. During welding, the heat-affected zones along
the sides of the weld in austenitic stainless steel are exposed to the temperatures that cause
Lesson 10 carbide precipitation.

Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
HEAT
INSIDE OF AFFECTED
TANK ZONES
Lesson 2
Common Electric
Arc Welding
Processes
WELD
METAL
INTERGRANULAR CORROSION
Lesson 3
for Welding
Mild Steels
5.4.1.2 If the weldment is to be used in corrosive service, the carbide precipitation and
resultant intergranular corrosion must be eliminated. Three dependable methods of controlling
Lesson 4 this problem are defined below:
Covered Electrodes
for Welding Low
Alloy Steels a. Carbide precipitation is a function of the carbon content. Keeping the carbon content
as low as possible in the steel (0.04% maximum) and welding it with low carbon elec-
trodes is one solution.
Lesson 5
Welding Filler Metals b. If the carbon of the steel and weld metal are tied up by an element that has a stronger
affinity for carbon than does chromium, carbide precipitation cannot occur. Columbium
and titanium are alloys that have a stronger affinity for carbon. Steels with columbium or
Lesson 6 titanium, and covered electrodes with columbium present, are made for this purpose.
Carbon & Low Alloy
Steel Filler Metals - c. Another method, although not as practical, is to heat the finished weldment to at least
GMAW,GTAW,SAW
1850°F allowing all of the precipitated carbides to go back into solution. The weldment
is then rapidly cooled and quenched so that it passes through the critical temperature
Lesson 7 (1200°F) very quickly, allowing little or no carbides to reform. However, stainless steel
Flux Cored Arc
Electrodes Carbon weldments heated to such high temperatures would be subject to warping, sagging and
Low Alloy Steels other loss of dimension as well as being covered with heavy scale.
5.4.2 Ferrite in Austenitic Stainless Steel - Stainless weld metal that is fully austenitic is
Lesson 8 non-magnetic and has a relatively large grain structure. This results in the weld being crack-
Hardsurfacing
sensitive. By controlling the balance of the alloying elements in the electrode, small amounts of
Electrodes
another phase, ferrite, can be introduced in the weld metal. The ferrite phase causes the
austenitic grains to be much finer and the weld becomes more crack-resistant.
Lesson 9
Estimating & 5.4.2.1 Certain alloying elements used in stainless steels and weld metals behave as
Comparing Weld
austenite stabilizers and others as ferrite stabilizers. Among the austenite stabilizers are
Metal Costs
nickel, carbon, manganese and nitrogen. The ferrite stabilizers are chromium, silicon, molyb-
denum and columbium. It is the balance between the two types of alloying elements that
Lesson 10 controls the quantity of ferrite in the weld metal.
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.4.2.2 The amount of ferrite in austenitic stainless steel weld metal may be measured by
magnetic devices because the ferrite is magnetic. A small amount of ferrite in austenitic
Lesson 2 stainless weld metal is good, because it prevents weld cracking. If the weldment is to be in
Common Electric
Arc Welding very low temperature service, however, large amounts of ferrite should be avoided because
Processes ferrite is not tough at low temperatures. Also, if the weldment is to be used in high temperature
(higher than 1000°F) service, the ferrite should be maintained at low levels because the ferrite
becomes brittle at those temperatures.
Lesson 3
Covered Electrodes
for Welding
Mild Steels 5.5 CALCULATION OF FERRITE CONTENT IN
STAINLESS STEEL
Lesson 4 Several simple, yet accurate, methods have been developed for determining the balance
Covered Electrodes
for Welding Low between the austenite and ferrite forming elements in iron. When the chemical composition of
Alloy Steels the weld metal is known, the Schaeffler or WRC-1992 diagrams can be used. See Figures 9
and 10.
Lesson 5
5.5.0.1 The purpose of these diagrams is to calculate the nickel and chromium equivalent of
for Stainless Steels the weld metal in question and plot the point on the appropriate diagram. The nickel equiva-
lent is the sum of the nickel content and all other austenite formers, multiplied by coefficients
representing their austenite forming effect as compared to that of nickel. The chromium
Lesson 6 equivalent is calculated in the same manner. In both diagrams, the nickel equivalent is the
Carbon & Low Alloy
Steel Filler Metals - vertical axis, and the chromium equivalent is the horizontal axis. The WRC-1992 diagram has
GMAW,GTAW,SAW an advantage since it also takes the nitrogen content into consideration. Nitrogen is a power-
ful austenite forming element. If the nitrogen content is not known, we assume 0.06% for
Lesson 7 GTAW and SMAW electrodes and, 0.08% for GMAW and FCAW filler metals.
Flux Cored Arc
Electrodes Carbon 5.5.0.2 When chemical composition is not available, two common instruments can also be
Low Alloy Steels
used to determine ferrite content. Since ferrite at room temperature is magnetic and austenite
is not, a relationship between magnetic response and ferrite content can be established. The
Lesson 8 more magnetic response to the instrument, the more ferrite present in the metal. The two
Hardsurfacing commercially available instruments that use this principal to measure ferrite content are the
Electrodes
Magne gage and the Severn gage. The Magne gage is a laboratory instrument, while the
Severn gage is a pocket-size instrument designed for on-site readings.
Lesson 9
Estimating & 5.5.0.3 In the past, ferrite was expressed as a volume percent of the metal. However,
Comparing Weld because of non-standard calibration, conflicting and inaccurate results often occurred. To
Metal Costs
eliminate this problem, the ferrite volume percent was changed to a standardized expression
known as the ferrite number (FN) and has been adopted by the Welding Research Council
Lesson 10 (WRC), the American Welding Society (AWS), and other agencies. Ferrite numbers (FN) are
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low SHAEFFLER CONSTITUTION DIAGRAM FOR STAINLESS STEEL WELD METAL
Alloy Steels
FIGURE 9
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
WRC-1992 DIAGRAM FOR STAINLESS STEEL WELD DATA
Lesson 8 FIGURE 10
Hardsurfacing
Electrodes
the same as the volume percent numbers in the range of 0-7%. At higher contents, FN values
Lesson 9 become increasingly higher than the previous percent ferrite values. The DeLong diagram
Estimating & shows this comparison.
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.6 SPECIAL FERRITE REQUIREMENT IN STAINLESS
STEEL ELECTRODE
Lesson 2
Common Electric In order to meet the AWS classification of a stainless steel electrode, a specific chemical
Arc Welding
Processes range must be followed by the electrode manufacturers. Since ferrite content is mainly con-
trolled by chemical composition, the ferrite content will also fall into certain ranges depending
on the particular electrode in question. However, some users of stainless steel require the
Lesson 3
ferrite content be above or below the normal ranges as found in typical chemical analyses. An
Covered Electrodes
for Welding example of this is the SMAW 316 electrode. Normally, a 316 stick electrode has a FN in the 0-
Mild Steels 2 range, but a specially formulated 316 stick electrode could have a minimum of 5 FN, if
needed. Since these electrodes require special chemical formulations, they must be ordered
Lesson 4 on a special request basis from most manufacturers.
Covered Electrodes
for Welding Low
Alloy Steels 5.7 MARTENSITIC STAINLESS STEEL
Martensitic stainless steels fall into the 400 number series according to the American Iron and
Lesson 5
Steel Institute. They are magnetic and contain from 11.5% to 18% chromium. As previously
for Stainless Steels noted, they get the name martensite because of the crystalline structure of the steel at room
temperature. With a lower alloy content than the austenitic steels, they are lower in cost than
the austenitic types. They have adequate corrosion resistance in many environments because
Lesson 6 they form the characteristic chromium oxide surface film. They also have a high hardenability
Carbon & Low Alloy
Steel Filler Metals - characteristic.
GMAW,GTAW,SAW
5.7.0.1 Other chromium bearing heat resistant steels that have only 4% to 10% chromium
(not a true stainless steel by the 11.5% minimum chrome requirement) have similar
Lesson 7
Flux Cored Arc hardenability characteristics. These steels are designated by the 500 series numbers accord-
Electrodes Carbon ing to the American Iron and Steel Institute and from a welding standpoint, may be considered
Low Alloy Steels
in the same grouping as the martensitic stainless steels. Nominal compositions of these types
are shown in Figure 11.
Lesson 8 Carbon Chromium Molybdenum

AISI No.
Hardsurfacing 5.7.0.2 These steels are frequently in a hard- %* %* %*
Electrodes 403 0.15 11.5 - 13
ened state meaning they have low ductility. If 410 0.15 11.5 - 13.5
heat is applied suddenly, as in arc welding, to a 501 0.10 min 4-6 0.40 - 0.65
502 0.10 4-6 0.40 - 0.65
localized area and it then is allowed to cool
Lesson 9 * Maximum unless otherwise noted.
Estimating & suddenly, cracking may occur. The heated area
NOMINAL COMPOSITION-MARTENSITIC STAINLESS
Comparing Weld contracts on cooling and the lack of ductility in STEELS AND CHROMIUM HEAT RESISTANT STEELS
Metal Costs
the parent metal prevents it from following along. FIGURE 11
This type of cracking can be prevented by pre-
Lesson 10 heating the steel, since preheating lowers the thermal difference between the weld area and
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
the base metal. This allows the weld area to cool more slowly and as a result, the steel in the
heat affected zone will not be hardened as severely.
Lesson 2
Common Electric 5.7.0.3 The preheating temperature used is in the range of 350°F to 500°F and should be
Arc Welding
Processes maintained during the entire welding operation. Upon completion of welding, the weldment
should be cooled slowly, preferably furnace cooled, allowing gradual temperature change.
Lesson 3 5.7.0.4 The mechanical properties of martensitic stainless steels are affected by welding
Covered Electrodes
since they harden intensely, even on relatively slow cooling from high temperatures. The weld
for Welding
Mild Steels deposit and the steel that surrounds the weld deposit is hard and brittle. Heat treatment of the
weldment is necessary to improve these physical properties.
Lesson 4 5.7.0.5 If preheating or postweld heat treatment is not practical, it may be necessary to use
Covered Electrodes
for Welding Low a higher alloy austenitic stainless steel electrode (such as 309) that deposits tough, ductile
Alloy Steels weld metal without cracking. This solution would depend on the required properties of the
weldment and is not recommended in all cases. Martensitic stainless steels make up about
Lesson 5 15% of the stainless steels that are welded.

5.8 FERRITIC STAINLESS STEELS
Ferritic stainless steels are straight chrome alloys in the AISI 400 series. They are magnetic
Lesson 6
Carbon & Low Alloy and have varying ranges of chromium content as shown in Figure 12.
GMAW,GTAW,SAW 5.8.0.1 All ferritic stainless steels have the room temperature crystal structure of ferrite
stabilized to all temperatures. The higher chromium content provides good resistance to high
Lesson 7 temperature scaling. For this reason, the ferritic stainless steels are used to make heat treat-
Flux Cored Arc ing containers, jigs, and fixtures.
Electrodes Carbon
Low Alloy Steels
5.8.0.2 Welding the ferritic high chromium
AISI No. Carbon %* Chromium %* Other %*
stainless steels, however, is difficult. The steels
405 0.08 11.5 - 14.5 Aluminum
Lesson 8 have rapid rates of grain growth at temperatures 0.10 - 0.30
Hardsurfacing over 1700°F. The large grains absorb the 430 0.12 16.0 - 18.0 --
Electrodes 446 0.20 23.0 - 27.0 Nitrogen
smaller grains and grow larger. The resultant 0.25
* Maximum unless otherwise noted.
coarse grain structures are very crack sensitive.
NOMINAL COMPOSITION-FERRITIC STAINLESS STEELS
Lesson 9 Grain growth is a time and temperature function.
FIGURE 12
Estimating & To keep the time of high welding temperature as
Comparing Weld
short as possible, these steels should be mildly preheated to about 300°F, welded with small
Metal Costs
diameter electrodes and with the lowest possible welding current, thereby limiting the heat
input. About 5% of the stainless steels welded are of the ferritic category.
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.9 DUPLEX STAINLESS STEELS
Lesson 2 Duplex means "two". Duplex stainless steels consist of the two "building stones" (microstruc-
Common Electric ture phases) ferrite and austenite and are often termed ferritic-austenitic stainless steels.
Arc Welding
Typically, duplex stainless steels have a microstructure consisting of approximately 50% ferrite
Processes
and 50% austenite.
Lesson 3 5.9.0.1 In simple terms, the ferrite could be said to give high strength and some resistance
Covered Electrodes to stress corrosion cracking, the austenite provides good toughness, and the two phases in
for Welding
Mild Steels combination give the duplex steels their attractive corrosion resistance.
5.9.0.2 The most important alloying elements of duplex stainless steels are Cr, Ni, Mo and
Lesson 4 N. These elements largely govern the properties of the steels. Some grades also contain
Covered Electrodes
for Welding Low additions of copper (Cu) or tungsten (W).
Alloy Steels
5.9.0.3 A wide range of different versions of duplex stainless steel is currently available
on the market. At present, the 22% chromium (Cr), 5% nickel (Ni), 3% molybdenum (Mo),
Lesson 5
0.15% nitrogen (N) grade (commonly called 2205) is the most common type of duplex stain-
for Stainless Steels less steel and is used in a wide range of applications. Higher alloyed duplex steels, the so-
called super duplex stainless steels, have also been introduced into the market. The 25%
chromium (Cr), 7% nickel (Ni), 4% molybdenum (Mo), 0.25% nitrogen (N) grade (commonly
Lesson 6 called 2507) is one example of a modern high alloy super duplex stainless steel. These steels
Carbon & Low Alloy
Steel Filler Metals - are designed for use in demanding applications where even greater corrosion resistance or
GMAW,GTAW,SAW higher strength is required.
Lesson 7 5.10 ELECTRODE SELECTION

Flux Cored Arc
Electrodes Carbon
Low Alloy Steels There are a great many AISI grades of stainless steel, and in many cases there is a matching
electrode for the AISI type. For instance, if both members of a weldment are AISI type 316, the
electrode to be used would be 316 also. It is not necessary to have a matching electrode for
Lesson 8 every type of stainless steel, however, because some electrodes produce satisfactory welds
Hardsurfacing
even though the chemical analysis of the steel may be slightly different.
Electrodes
5.10.0.1 Type 308 stainless steel electrodes may be used for welding AISI 201 and 202 that
Lesson 9 have a lower nickel content and a high manganese content. Type 308 electrodes may also be
Estimating & used to weld types 301, 302, 304, 305 and of course, 308 itself. Even though their chromium-
Comparing Weld
nickel contents vary slightly, all of these steel types may be considered as one family of alloys.
Metal Costs
The chart in Figure 13 shows the proper Arcaloy electrode to be used for the various types of
AISI steels.
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON V
Welding
Lesson 2
Common Electric Arcaloy Electrodes to Weld AISI Steels
Arc Welding Chemical Analyses of Stainless Steels, percent*
Processes AISI** Other Weld with
Type Number Carbon Manganese Silicon Chromium Nickel Elements Arcaloy Type
Austenitic
Lesson 3 201 0.15 5.5/7.5 1.00 16.00/18.00 3.50/5.50 N 0.25 Max. 308/308 ELC
Covered Electrodes 202 0.15 7.5/10.0 1.00 17.00/19.00 3.50/5.50 N 0.25 Max. 308/308 ELC
for Welding 301 0.15 2.00 1.00 16.00/18.00 6.00/8.00 --- 308/308 ELC
Mild Steels 302 0.15 2.00 1.00 17.00/19.00 8.00/10.00 --- 308/308 ELC
302B 0.15 2.00 2.00/3.00 17.00/19.00 8.00/10.00 --- 308/308 ELC
303 0.15 2.00 1.00 17.00/19.00 8.00/10.00 S 0.15 Min.*** 312
303Se 0.15 2.00 1.00 17.00/19.00 8.00/10.00 Se 0.15 Min. 312
Lesson 4
304 0.08 2.00 1.00 18.00/20.00 8.00/12.00 --- 308/308 ELC
Covered Electrodes
304L 0.03 2.00 1.00 18.00/20.00 8.00/12.00 --- 308 ELC
for Welding Low 305 0.12 2.00 1.00 17.00/19.00 10.00/13.00 --- 308/308 ELC
Alloy Steels 308 0.08 2.00 1.00 19.00/21.00 10.00/12.00 --- 308/308 ELC
309 0.2 2.00 1.00 22.00/24.00 12.00/15.00 --- 309
309S 0.08 2.00 1.00 22.00/24.00 12.00/15.00 --- 309
310 0.25 2.00 1.50 24.00/26.00 19.00/22.00 --- 310
Lesson 5
310S 0.08 2.00 1.50 24.00/26.00 19.00/22.00 --- 310
Welding Filler Metals 314 0.25 2.00 1.50/3.00 23.00/26.00 19.00/22.00 --- 310/312
for Stainless Steels 316 0.08 2.00 1.00 16.00/18.00 10.00/14.00 Mo 2.00/3.00 316/316 ELC
316L 0.03 2.00 1.00 16.00/18.00 10.00/14.00 Mo 2.00/3.00 316 ELC
317 0.08 2.00 1.00 18.00/20.00 11.00/15.00 Mo 3.00/4.00 317/317 ELC
321 0.08 2.00 1.00 17.00/19.00 9.00/12.00 Ti 5 x C Min. 308 ELC/347
Lesson 6 347 0.08 2.00 1.00 17.00/19.00 9.00/13.00 Cb + Ta 10 x C Min. 308 ELC/347
Carbon & Low Alloy 348 0.08 2.00 1.00 17.00/19.00 9.00/13.00 Cb + Ta 10 x C Min. 308 ELC/347
Steel Filler Metals - Ta 0.10 Max.
GMAW,GTAW,SAW 20Cb-3 0.06 2.00 1.00 19.00/21.00 32.50/35.00 Cb + Ta 8 x C min. 320LR
1.00% Max.
Martensitic
403 0.15 1.00 0.50 11.50/13.00 --- --- 309
Lesson 7
410 0.15 1.00 1.00 11.50/13.50 --- --- 309
Flux Cored Arc
414 0.15 1.00 1.00 11.50/13.50 1.25/2.50 --- 309/410
Electrodes Carbon 0.15 1.25 1.00 12.00/14.00 --- S 0.15 Min.*** 312/410
416
Low Alloy Steels 416Se 0.15 1.25 1.00 12.00/14.00 --- Se 0.15 Min. 312/410
420 Over 0.15 1.00 1.00 12.00/14.00 --- --- 309/410
431 0.2 1.00 1.00 15.00/17.00 1.25/2.50 --- 309/430
CA6NM 0.06 1.00 1.00 11.50/14.00 3.5/4.5 Mo 0.4-1.0 410NiMo
Lesson 8
Hardsurfacing Ferritic
Electrodes 0.08 1.00 1.00 11.50/14.50 --- Al 0.10/0.30 309/410
405
430 0.12 1.00 1.00 14.00/18.00 --- --- 309/430
430F 0.12 1.25 1.00 14.00/18.00 --- S 0.15 Min.*** 312/430
430Se 0.12 1.25 1.00 14.00/18.00 --- Se 0.15 Min. 312/430
Lesson 9 442 0.2 1.00 1.00 18.00/23.00 --- --- 309/310
Estimating & 446 0.2 1.50 1.00 23.00/27.00 --- N 0.25 Max. 309/310
Comparing Weld
Metal Costs * Single Values are Maximums Except as Noted. If service allows
** According to AISI Steel Products Manual, Stainless and Heat Resisting Steels. Not regarded as weldable
*** Molybdenum Content of up to 0.60% Permissible and is optional with the Producer.
Lesson 10 STAINLESS STEEL SELECTION CHART

Filler Metals FIGURE 13

Lesson 1
LESSON V
The Basics of Arc
Welding
5.11 WELDING DISSIMILAR STEELS
Lesson 2
Stainless steels are expensive and the higher the alloy content of the steel, the higher the cost.
Common Electric
Arc Welding The most efficient design of a structure calls for the use of the higher alloy steels only where
Processes
they are needed. Such a design may call for several different steels to be used. As mentioned
above, there is no problem of electrode selection when welding stainless steels or any steel to
Lesson 3
a steel of the same type. Simply match the electrode to the steels. When a change from one
Covered Electrodes
for Welding type of steel to another (called a transition weld) is made, care must be given to the selection
Mild Steels
of the electrode used.
Lesson 4 5.11.0.1 There are two general conditions and rules for electrode selection to weld dissimilar
Covered Electrodes
for Welding Low steels.
Alloy Steels
a. When the steels are similar metallurgically but dissimilar chemically, match the
Lesson 5 electrode to the lower chemical composition or less expensive steel. For example, type 310
Welding Filler Metals steel (25% chromium, 20% nickel) is sometimes welded to type 304 steel (19% chromium,
10% nickel). Both types are austenitic. Type 304 steel, which is welded with 308 electrodes,
is less expensive, so that weld would be made with type 308 electrodes rather than type 310
Lesson 6 electrodes.
Carbon & Low Alloy
GMAW,GTAW,SAW b. When the steels to be jointed are different metallurgically and chemically, the
electrode is selected to provide a tough, crack resistant weld between the two steels. For
Lesson 7 example, 304 stainless steel is frequently welded to mild structural steel. Corrosion resistance
Flux Cored Arc
cannot be part of the problem because mild steel is on one side of the joint with practically no
Electrodes Carbon
Low Alloy Steels corrosion resistance compared to the stainless steel. If this weld is made with mild steel
electrodes to match the mild steel side of joint, the weld metal would be enriched by the wash-
in of chromium and nickel from the stainless side. This intermediate chrome-nickel is usually
Lesson 8
Hardsurfacing hard and crack sensitive. If the weld is made with type 308 electrodes to match the stainless
Electrodes
steel side of the joint, the chromium and nickel contents of the weldment are diluted by the mild
steel side of the joint to an intermediate level that would again probably be hard and crack
Lesson 9 sensitive. When welding mild steel to stainless steel, a proportion of 18% chromium and 8%
Estimating &
Comparing Weld nickel is desirable in the weld deposit to produce sound welds, with 17% chromium and 7%
Metal Costs nickel being the minimum allowable amounts.
5.11.0.2 The following examples in Figure 14 show the results of making a transition weld of
Lesson 10
Reliability of Welding mild steel to 304 stainless steel with three different electrodes.
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
60% ELECTRODE
Lesson 2
Common Electric
Arc Welding
Processes 20% 20%
Lesson 3
Covered Electrodes 304 MILD
for Welding STEEL
Mild Steels 308 ELECTRODE
ELECTRODE X 60% 304 X 20% MILD WELD

STEEL X 20% METAL
Lesson 4
CHROMIUM 19.5 11.7 18.0 3.6 0 0 15.3
Covered Electrodes NICKEL 9.5 5.7 8.0 1.6 0 0 7.3
for Welding Low
Alloy Steels The composition of 15.3% chromium and 7.3% nickel does not meet the minimum 17-7%
proportion. The weld metal will be mostly martensitic with a very small amount of ferrite.
This structure is quite brittle.
310 ELECTRODE
Lesson 5
Welding Filler Metals ELECTRODE X 60% 304 X 20% MILD WELD
for Stainless Steels STEEL X 20% METAL
CHROMIUM 26.0 15.6 18.0 3.6 0 0 19.2

NICKEL 21.0 12.6 8.0 1.6 0 0 14.2
Lesson 6 The composition of 19.2% chromium and 14.2% nickel is not near the 18/8 proportion.
The weld metal would be fully austenitic and crack sensitive.
Carbon & Low Alloy
Steel Filler Metals - 309 ELECTRODE
GMAW,GTAW,SAW
ELECTRODE X 60% 304 X 20% MILD WELD
STEEL X 20% METAL
CHROMIUM 23.0 13.8 18.0 3.6 0 0 17.4

Lesson 7 NICKEL 13.0 7.8 8.0 1.6 0 0 9.4
Flux Cored Arc
Electrodes Carbon The composition of 17.4% chromium and 9.4% nickel is close to the 18/8 proportion. The
Low Alloy Steels weld metal will be austenitic with some ferrite and a small amount of martensite to keep
the weld metal from being tough and crack resistant. 309 is the best choice.
ELECTRODE SELECTION - 304 STAINLESS TO MILD STEEL
Lesson 8 FIGURE 14
Hardsurfacing
Electrodes 5.11.0.3 Normally the most severe dilution of the weld metal by the base metal is 40%. Thus,
the weld metal in the joint is comprised of 60% from the electrode and 40% from the base
metal as shown in Figure 14. In the case of butt joints between dissimilar steels, half of the
Lesson 9
Estimating & dilution comes from each side of the joint, or 20% from each base metal.
Comparing Weld
Metal Costs 5.11.0.4 Many times, type 310 and 312 electrodes are used erroneously for welding stain-
less to mild or low alloy steel. In many cases, not only can more dependable welds be made
with 309 electrodes, but appreciable savings can be achieved because of their lower cost.
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.11.0.5 Another common use of stainless steel filler metals is the overlaying or cladding of
less expensive steels with a layer of stainless. Mild steel tanks designed to hold corrosive
Lesson 2 liquids may be lined with stainless steel in this manner. Usually, continuous bare or flux cored
Common Electric
Arc Welding electrodes are used with an automated welding setup. Current and penetration must be
Processes controlled closely to limit dilution with the base metal. Sometimes it is necessary to deposit
more than one layer to assure the correct analysis of the deposit.
Lesson 3
5.11.0.6 The welding of stainless clad plate (produced by some steel mills) should also be
Covered Electrodes
for Welding mentioned. Thicker sections may be welded with both mild steel and stainless electrodes, and
Mild Steels thinner sections may be welded only with stainless electrodes. Joint preparation, welding
procedure and electrode selection will vary with the thickness and type of clad plate being
Lesson 4 welded. Welding of clad plate is a specialized area of dissimilar metal welding and beyond
Covered Electrodes the scope of this course.
for Welding Low
Alloy Steels
5.12 STAINLESS STEEL ELECTRODES AND FILLER METALS
Lesson 5
There are several different forms of stainless steel electrodes: covered, continuous solid bare,
continuous flux cored and cut length bare welding rods.
Lesson 6 5.12.1 Covered Stainless Electrodes - Arcaloy covered stainless steel electrodes are
Carbon & Low Alloy
Steel Filler Metals - classified according to the American Welding Society Filler Metal Specification A-5.4-92. As
GMAW,GTAW,SAW defined by that specification, the electrodes are classified by weld metal composition and type
of welding current. For example, the AWS designation E308-15 means electrode (E), AISI
Lesson 7 type 308 steel (20% chrome, 10% nickel) and direct current electrode positive (-15). If the
Flux Cored Arc classification reference were E308-16, it would indicate an electrode (E), AISI type 308 steel
Electrodes Carbon
Low Alloy Steels (308) and AC-DC electrode positive operation (-16 & -17). Arcaloy lime coated electrodes
have the DC suffix -15, Arcaloy AC-DC electrodes have the suffix -16, and Arcaloy Plus elec-
trodes use the -17 suffix.
Lesson 8
Hardsurfacing 5.12.1.1 Arcaloy high alloy stainless steel covered electrodes are produced by extruding
Electrodes carefully formulated and mixed coating material on a stainless steel core wire, thus ensuring
constant weld metal properties and composition.
Lesson 9
5.12.1.2 Arcaloy stainless steel electrodes have been among the leaders in the stainless
Estimating &
Comparing Weld electrode industry for many years. The strict purchase specifications for the core wire and the
Metal Costs covering materials, and the rigid quality control under which the Arcaloy electrodes are manu-
factured, have resulted in this position of leadership.
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
5.12.2 Arcaloy lime coated electrodes were among the earliest stainless steel elec-
trodes developed in the United States. Designed for welding with direct current, reverse
Lesson 2 polarity only, the coating contains considerable amounts of limestone and fluorspar producing
Common Electric
Arc Welding a fast freezing slag that facilitates welding in the vertical and overhead positions. The weld
Processes bead is slightly convex and moderately rippled. (See Figure 15).
5.12.2.1 Characterized by a strong globular arc, a moderate amount of spatter and slag
Lesson 3
removal that is somewhat difficult, the lime type is not the most popular with the welding opera-
Covered Electrodes
for Welding tors. However, it is the easiest to use stainless electrode for out-of-position welding. Also, the
Mild Steels convex bead can provide the necessary margin of safety in highly stressed joints in many
cases.
Lesson 4
Covered Electrodes 5.12.3 Arcaloy AC-DC Titania coated electrodes were the first such electrodes to
for Welding Low receive wide acceptance in this country. Designed to operate on alternating current as well as
Alloy Steels
direct current, the coating contains dominant amounts of rutile (titania), medium amounts of
limestone, and limited amounts of fluorspar. By far, the AC/DC type is the most popular of the
Lesson 5 coated stainless electrodes. Welders like to use it because of the smoother arc action, low
amount of fine spatter and easy slag removal. Also, the bead is relatively flat, finely rippled and
has good side-wall fusion (See Figure 15). Although used in all positions, vertical and over-
head welding requires slightly more operator skill than with the lime types because the slag
Lesson 6 does not freeze as quickly.
Carbon & Low Alloy
Steel Filler Metals - 5.12.4 Arcaloy "Plus" electrodes display characteristics not found in the conventional
GMAW,GTAW,SAW
lime and AC-DC Titania coatings. Designed to operate on DCEP or AC, this coating is
specially formulated to operate on a broad range of current settings, and most significantly,
Lesson 7 these electrodes perform their best at high heat inputs where conventional AC-DC electrodes
Flux Cored Arc
Electrodes Carbon tend to break down.
Low Alloy Steels
5.12.4.1 When operating at high currents, Arcaloy Plus electrodes deposit weld metal at
exceptional speeds with a smooth spray transfer. The bead profile is finely rippled, concave,
Lesson 8 and evenly feathered (See Figure 15). Spatter is minimal. The molten slag does not edge
Hardsurfacing
Electrodes into the weld puddle, thereby assuring easy visibility of the arc transfer.
5.12.4.2 Arcaloy Plus electrodes were developed for applications on dairy and food pro-
Lesson 9 cessing equipment and chemical containers, to name a few, where the weld radius must be
Estimating & smooth and concave to prevent particle entrapment. When welding in the flat and horizontal
Comparing Weld
Metal Costs fillet positions, the concave deposit and absence of surface irregularities make it ideal for
applications where cosmetic appearance, speed, and final finishing are factors.
Lesson 10
Filler Metals

Lesson 1
LESSON V
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes (-15) (-16) (-17)
LIME AC-DC PLUS
CONVEX FLAT CONCAVE
MODERATE RIPPLE LOW RIPPLE MININUM RIPPLE
Lesson 3
Covered Electrodes WELD BEAD SHAPE ARCALOY COATED ELECTRODES
for Welding
Mild Steels FIGURE 15
Lesson 4 5.12.4.3 The weld metal properties are similar for each of the three coating types: lime, AC-
Covered Electrodes DC and AC-DC Plus.
for Welding Low
Alloy Steels
Lesson 5 5.13 ARCALOY COVERED ELECTRODE PROPERTIES

for Stainless Steels AND APPLICATIONS
5.13.1 Arcaloy 308L (AWS E308/308L-15 & -16), Arcaloy 308L Plus (AWS E308/308L-
Lesson 6 17) - This extra low carbon composition is intended to weld Type 304L steels to prevent car-
Carbon & Low Alloy
Steel Filler Metals - bide participation. It can also be used to weld Types 321 and 347 steels. Typical chemical
GMAW,GTAW,SAW composition of weld metal is:
Carbon 0.03% Chromium 19.1%

Lesson 7 Nickel 9.7% Manganese 1.6%
Flux Cored Arc
Silicon 0.4% Ferrite No. 8
Electrodes Carbon
Low Alloy Steels
5.13.2 Arcaloy 309L (AWS E309L-15 & -16), Arcaloy 309L Plus (AWS E309/309L-17)
- The low carbon content of Arcaloy 309 L weld metal makes it useful to weld low carbon
Lesson 8
overlay on carbon or low alloy steel to control carbide precipitation in the overlay. The chemi-
Hardsurfacing
Electrodes cal composition of the weld metal is the same as that of Arcaloy 309 except that the carbon
content is 0.04% and the typical ferrite no. is 8.
5.13.3 Arcaloy 309 Cb (AWS 309Cb-15 & -16) - The addition of columbium to Type 309
Lesson 9
Estimating & weld metal improves its high temperature performance. It is also useful in welding Types 321
Comparing Weld and 347 clad steels. The weld metal composition is the same as Type 309, except that 0.80%
Metal Costs
columbium is added and the ferrite no. is 8.
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
for Welding
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Lesson 5
LESSON VI
Lesson 6
Carbon & Low Alloy
CARBON AND
GMAW,GTAW,SAW LOW ALLOY STEEL
FILLER METALS
Lesson 7
Flux Cored Arc
Electrodes Carbon
FOR THE GMAW, GTAW AND
Low Alloy Steels SAW WELDING PROCESSES
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
©COPYRIGHT 2000 ESAB WELDING & CUTTING PRODUCTS

Lesson 1
The Basics of Arc LESSON VI
Welding
TABLE OF CONTENTS
Lesson 2
LESSON VI
Common Electric CARBON & LOW ALLOY STEEL FILLER
Arc Welding
Processes METALS FOR THE GMAW, GTAW, AND SAW
WELDING PROCESSES
Lesson 3
Covered Electrodes
for Welding Section Nr. Section Title Page
Mild Steels
6.1 Introduction ............................................................................................. 1

Lesson 4
Covered Electrodes 6.2 Manufacturing ......................................................................................... 2
for Welding Low
Alloy Steels 6.3 Wire Selection for Gas Shielded Arc Welding ........................................ 3
6.4 AWS Specification A5.18-93
Carbon Steel Filler Metals for Gas Shielded Arc Welding ....................... 6
Lesson 5
Welding Filler Metals 6.5 Individual Filler Metal Characteristics ..................................................... 8
6.5.1 ER70S-2 ................................................................................................. 8
6.5.2 ER70S-3 ................................................................................................. 8

Lesson 6
6.5.3 ER70S-4 ................................................................................................. 8
Carbon & Low Alloy
Steel Filler Metals - 6.5.4 ER70S-5 ................................................................................................. 8
GMAW,GTAW,SAW
6.5.6 ER70S-6 ................................................................................................. 8
6.5.6 ER70S-7 ................................................................................................. 9

Lesson 7
Flux Cored Arc 6.5.7 ER70S-G ................................................................................................ 9
Electrodes Carbon
Low Alloy Steels 6.6 ESAB Bare Solid Carbon Steel Wires .................................................... 9
6.6.1 SPOOLARC 65 ....................................................................................... 9
6.6.2 SPOOLARC 29S .................................................................................... 10

Lesson 8
Hardsurfacing 6.6.3 SPOOLARC 85 ....................................................................................... 10
Electrodes
6.6.4 SPOOLARC 86 ...................................................................................... 11
6.6.5 SPOOLARC 87HP .................................................................................. 11

Lesson 9
Estimating & 6.7 AWS Specification AWS A5.28-96
Comparing Weld Low Alloy Steel Filler Metals for Gas Shielded Arc Welding ................... 12
Metal Costs
6.7.1 The Chromium-Molybdenum Types........................................................ 12
6.7.2 The Nickel Alloy Types ............................................................................ 13

Lesson 10
Filler Metals

Lesson 1
Welding
TABLE OF CONTENTS
LESSON VI - Con't.
Lesson 2
Common Electric
Processes
6.7.3 The Manganese-Molybdenum Types ........................................................ 14

Lesson 3 6.7.4 SPOOLARC 83 ....................................................................................... 15
Covered Electrodes
for Welding 6.7.5 SPOOLARC Hi-84 .................................................................................. 15
Mild Steels
6.7.6 All Other Low Alloy Types ......................................................................... 16
6.7.7 SPOOLARC 95 and 120 ......................................................................... 17

Lesson 4
Covered Electrodes 6.8 Wires and Fluxes for Submerged Arc Welding of Carbon Steels ........... 18
for Welding Low
6.8.1 Equipment............................................................................................... 18
Alloy Steels
6.8.2 Welding Filler Metals .............................................................................. 19
6.8.3 Fluxes for Carbon Steel Electrodes ........................................................ 19

Lesson 5
Welding Filler Metals 6.9 AWS Specification A5.17-89
Carbon Steel Electrodes and Fluxes for Submerged Arc Welding ......... 21
6.10 ESAB Wires and Fluxes for Carbon Steel Submerged Arc Welding ...... 23
Lesson 6 6.10.1 SPOOLARC 81 ....................................................................................... 23
Carbon & Low Alloy
Steel Filler Metals - 6.10.2 SPOOLARC 29S .................................................................................... 23
GMAW,GTAW,SAW
6.10.3 SPOOLARC 80 ....................................................................................... 24
6.10.4 UNIONMELT 231 .................................................................................... 24

Lesson 7
Flux Cored Arc 6.10.5 UNIONMELT 429 .................................................................................... 25
Electrodes Carbon
Low Alloy Steels 6.10.6 UNIONMELT 282 .................................................................................... 25
6.10.7 UNIONMELT 50 ...................................................................................... 26
6.10.8 UNIONMELT 80 ...................................................................................... 26

Lesson 8
Hardsurfacing 6.11 Electrodes and Fluxes for Submerged Arc Welding of the
Electrodes
Low Alloy Steels ...................................................................................... 27
6.11.1 Electrodes and Fluxes for Welding the Alloys......................................... 27

Lesson 9 6.12 AWS Specification A5.23-90
Estimating &
Comparing Weld Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding ...... 28
Metal Costs
6.12.1 Composition Requirements for Solid Low Alloy Electrodes .................... 29
6.13 Spoolarc Low Alloy Wires for Submerged Arc Welding .......................... 31
Lesson 10
Filler Metals

Lesson 1
Welding
TABLE OF CONTENTS
LESSON VI - Con't.
Lesson 2
Common Electric
Processes
6.13.1 Manganese-Molybdenum Wires .............................................................. 31

Lesson 3 6.13.2 Chromium-Molybdenum Wires ................................................................. 31
Covered Electrodes
for Welding 6.13.3 Nickel Wire .............................................................................................. 31
Mild Steels
6.13.4 High Strength Wires................................................................................. 31
6.13.5 Special Purpose Wires ............................................................................ 31

Lesson 4
Covered Electrodes 6.14 Unionmelt Fluxes for Welding Low Alloy Steels ...................................... 32
for Welding Low
6.14.1 Unionmelt 429......................................................................................... 32
Alloy Steels
6.14.2 Unionmelt 439......................................................................................... 32
6.14.3 Unionmelt 656......................................................................................... 32

Lesson 5
Welding Filler Metals 6.15 Alloy Shield Composite Electrodes for Submerged Arc
Welding of the Low Alloy Steels .............................................................. 32
6.15.1 Alloy Shield B1S ..................................................................................... 32

Lesson 6 6.15.2 Alloy Shield B2S ..................................................................................... 33
Carbon & Low Alloy
Steel Filler Metals - 6.15.3 Alloy Shield B3S ..................................................................................... 34
GMAW,GTAW,SAW
6.15.4 Alloy Shield Ni1S .................................................................................... 34
6.15.5 Alloy Shield Ni2S .................................................................................... 35

Lesson 7
Flux Cored Arc 6.15.6 Alloy Shield M2S..................................................................................... 35
Electrodes Carbon
Low Alloy Steels 6.15.7 Alloy Shield M3S..................................................................................... 36
6.15.8 Alloy Shield WS ...................................................................................... 36
6.15.9 Alloy Shield F2S ..................................................................................... 37

Lesson 8
Hardsurfacing 6.15.10 Alloy Shield 420SB ................................................................................. 37
Electrodes
Appendix A Glossary of Terms ................................................................................... 39
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
CARBON AND LOW ALLOY STEEL FILLER
Lesson 2
METALS FOR THE GMAW, GTAW AND SAW
Common Electric
Arc Welding WELDING PROCESSES
Processes
6.1 INTRODUCTION
Lesson 3
Covered Electrodes
for Welding
Mild Steels 6.1.0.1 During the early part of the 20th century, some welding was done using bare steel
wires or rods. The weld quality was poor because of the oxides and nitrides found in the weld
metal. Even after the advent of the extruded coated electrode in 1927, automated welding
Lesson 4
Covered Electrodes using bare wires (or lightly coated wires) continued to be used, despite the poor qualities of
for Welding Low the welds, because this method allowed more rapid deposition of the weld metal. Critical
Alloy Steels
welds, however, were made with coated electrodes.
6.1.0.2 The advantages of using an inert gas to shield the arc were known during the 20’s
Lesson 5
Welding Filler Metals and 30’s, but the inert gases, such as helium and argon, were too expensive to produce.
6.1.0.3 In 1935, submerged arc welding (then known as submerged melt welding) was
introduced and provided a method of producing quality welds at greater welding speeds than
Lesson 6 were obtainable with coated electrodes.
Carbon & Low Alloy
GMAW,GTAW,SAW 6.1.0.4 During World War II, the aircraft industry needed a reliable process for welding
magnesium engine parts and as a result, gas tungsten arc welding (GTAW), using a bare filler
wire and a helium gas shield, was developed.
Lesson 7
Flux Cored Arc
Electrodes Carbon 6.1.0.5 Economical methods of producing the inert gases were ultimately developed,
Low Alloy Steels leading to the use of solid wire with a helium or argon gas shield in the 1940’s. This process
became known as metal inert gas (MIG) welding.
Lesson 8 6.1.0.6 In the early 1950’s, it was realized that a more economical shielding gas, such as
Hardsurfacing
Electrodes carbon dioxide, could be used if the wire chemistry was adjusted to neutralize the oxidizing
effect of this gas. Since carbon dioxide (CO2) is not an inert gas, the name MIG welding
actually did not apply to this process since CO2 is a reactive gas. As a result, the American
Lesson 9 Welding Society has standardized on the term GMAW (Gas Metal Arc Welding) to include the
Estimating &
Comparing Weld inert gases, active gases, and gas mixtures as covered in Lesson II. In Europe, the term MIG
Metal Costs (Metal Inert Gas) welding still applies to the process if an inert gas or mixtures of inert and
active gases are used, and the term MAG (Metal Active Gas) is used if straight CO2 is em-
ployed as the shielding gas.
Lesson 10
Filler Metals
®COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.1.0.7 Although carbon steel, low alloy steels, stainless steels, magnesium, copper, copper
alloys, titanium and other metals may be welded by one or all of the processes described
Lesson 2 above, this Lesson will be confined to the filler metals for welding mild or carbon steels, and
Common Electric
Arc Welding low alloy high strength steels with the GMAW and GTAW processes.
Processes
6.2 MANUFACTURING
Lesson 3
Covered Electrodes
for Welding
Mild Steels 6.2.0.1 The manufacture of solid welding wires for GMAW or GTAW differs from the manu-
facture of coated or flux cored electrodes in that the deoxidizers and alloying elements that
contribute to the purity and mechanical properties of the weld metal, must be included in the
Lesson 4
wire chemistry rather than in the flux. Therefore, the raw material must be ordered from the
Covered Electrodes
for Welding Low supplier to exact specifications. When received, a sample from both ends of each coil of the
Alloy Steels hot rolled rod is analyzed by the manufacturer to ensure that the “hot rod”, as it is called, meets
these specifications.
Lesson 5
Welding Filler Metals 6.2.0.2 The hot rod is cleaned to remove mill scale or rust and drawn to an intermediate
for Stainless Steels diameter. At this stage, the wire has “work hardened” which necessitates that it be annealed
before it is copper plated, drawn down to final size, spooled and packaged.
Lesson 6 6.2.0.3 Close quality checks must be made throughout the manufacturing process to insure
Carbon & Low Alloy
that the end product is a smooth finished, uniform diameter wire, that will feed easily through
GMAW,GTAW,SAW the end user’s wire feeding equipment and welding gun. The wire is copper plated and/or
otherwise coated to retard oxidation or rusting of the wire, to decrease contact tip wear, and to
Lesson 7 assure good electrical conductivity. The plating or coating must not flake off or leave a residue
Flux Cored Arc that will clog the wire feed cable or the welding gun. If copper coated, the layer of copper must
Electrodes Carbon
be kept to a low level to minimize copper welding fumes and flaking.
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.3 WIRE SELECTION FOR GAS SHIELDED ARC
WELDING
Lesson 2
Common Electric
6.3.0.1 When selecting the wire or filler metal for either the GMAW or GTAW process,
Arc Welding
Processes several things must be considered.
1. Mechanical Properties - The wire chosen must produce weld metal having approxi-
Lesson 3 mately the same mechanical properties as the base metal whether it is carbon steel or
Covered Electrodes
for Welding low alloy high tensile steel.
Mild Steels
2. Shielding Gas - In Lesson II, we learned that the shielding gases used in GTAW of
carbon steel are pure argon or argon helium mixtures. In GMAW, shielding gases may
Lesson 4
Covered Electrodes be pure CO2, or mixtures of argon, helium, CO2 and oxygen. The gas mixtures contain-
for Welding Low
ing oxygen or CO2 will exhibit oxidizing characteristics which, if they combine with
Alloy Steels
carbon, will form carbon monoxide gas porosity in the weld metal.
a. The most common shielding gases used for welding mild and low alloy steels may
Lesson 5
Welding Filler Metals be classified in terms of their oxidizing effect as shown in Figure 1.
Pure Argon or 98% Argon 75% Argon

Lesson 6 Argon - Helium 2% O2 25% CO2 Pure CO2
Carbon & Low Alloy Mixtures
GMAW,GTAW,SAW Process GTAW GMAW GMAW GMAW
Degree of Non- Slightly More Most

Lesson 7
Oxidation Oxidizing Oxidizing Oxidizing Oxidizing
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels OXIDATION POTENTIAL OF COMMONLY USED SHIELDING GASES
FIGURE 1
Lesson 8
Hardsurfacing b. Each of the following variables should be considered when selecting the proper gas
Electrodes for a specific job:
• MATERIAL TYPES • WELD METAL MECHANICAL

Lesson 9
- Carbon, Stainless, Aluminum, etc. PROPERTIES
Estimating &
Comparing Weld • MATERIAL CONDITION • JOB REQUIREMENT
Metal Costs
- Rusty, Oily, Primed, etc. - Fit-Up
• TYPES OF METAL TRANSFER - Penetration
Lesson 10 - Short Circuit, Spray, Pulse, etc. - Spatter Levels
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
3. Wire Chemistry - In order to provide specific characteristics, it may be necessary to
have a filler metal that matches the base plate chemistry. The most common examples
Lesson 2 are requirements to weld 1-1/4 Cr - 1/2 Mo steel with ER80S-B2(L) or 2-1/4 Cr - 1 Mo
Common Electric
Arc Welding steel with ER90S-B3(L) providing matching high temperature strength and scaling
Processes resistance.
a. To minimize the oxidizing effect of the various shielding gases, elements that are
Lesson 3
called deoxidizers are included in the wire in varying amounts. These deoxidizers,
Covered Electrodes
for Welding usually silicon and manganese, and to a lesser extent titanium, aluminum, and zirco-
Mild Steels nium, will combine with the oxygen in preference to reacting with the carbon and will
form very small amounts of harmless glass-like slag islands on the weld surface.
Lesson 4
Covered Electrodes b. In the case of GTAW of steels where inert gases such as argon or argon-helium
for Welding Low mixtures are used, there will be little or no loss of the deoxidizers.
Alloy Steels
c. In GMAW, where shielding gases of different mixtures are used and welds of the
Lesson 5 highest quality are required, the filler wire must be selected to allow for the degree of
Welding Filler Metals oxidation of the shielding gas. When welding carbon or low alloy steels with a 98%
argon - 2% oxygen mixture, wires containing low amounts of manganese and silicon
may be used. If welding carbon or low alloy steels with a 75% argon - 25% CO2 shield-
ing gas, wires with a higher amount of deoxidizers may be necessary to maintain the
Lesson 6
Carbon & Low Alloy proper manganese and silicon content in the weld metal. When welding with straight
CO2 as a shielding gas, wires with an even greater amount of deoxidizers may be
GMAW,GTAW,SAW
necessary.
Lesson 7 4. Base Metal - The type of steel in the base metal will influence the type of wire selected.
Flux Cored Arc Rimmed steel (see Lesson I), which involve the least oxidation during manufacture, will
Electrodes Carbon
Low Alloy Steels require that the filler wire contain a higher level of deoxidizers than semi-killed steel that
is partially deoxidized. Killed steels that are fully deoxidized when manufactured may
be welded with wires with a lower deoxidizer content.
Lesson 8
Hardsurfacing 5. Rust and Mill Scale - which are actually iron oxide (FeO) are a further source of oxy-
Electrodes
gen that is detrimental to the weld metal unless a wire containing sufficient deoxidizers
is selected. Cold rolled steel, that is devoid of mill scale and is reasonably rust free,
Lesson 9 may be welded with a wire having lower amounts of silicon and manganese. Hot rolled
Estimating & steel, that is characterized by having some amount of mill scale on the surface, requires
Comparing Weld
Metal Costs a wire containing greater amounts of deoxidizers to produce sound welds.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6. Bead Geometry - Bead geometry (or bead shape) is influenced by both the amount of
deoxidizers in the wire and by the specific selection of shielding gas. Increasing the
Lesson 2 silicon and manganese content of the wire will produce flatter beads and better side
Common Electric
Arc Welding wall fusion (wetability) because the puddle is more fluid. See Figure 2.
Processes
a. The choice of shielding gas like-
wise influences bead shape. CO2 LOW SILICON-
HIGH SILICON-
Lesson 3 MANGANESE
MANGANESE
produces more spatter and a higher CONTENT
Covered Electrodes CONTENT
for Welding crown or more convex bead.
Mild Steels
Argon-CO2 and argon-O2 gas mixtures
provide smoother metal transfer, less
Lesson 4 spatter, and better bead appearance. SILICON-MANGANESE EFFECT ON BEAD SHAPE
Covered Electrodes Figure 2
for Welding Low 7. Welding Current - When welding at
Alloy Steels
high current for greater weld metal deposition, the weld puddle becomes larger, mean-
ing that more of the base metal has been melted and will stay molten for a longer pe-
Lesson 5 riod, allowing more time for oxidation and resultant porosity to take place. Also, high
currents produce a greater amount of heat in the arc area and will cause greater
amounts of an oxidizing shielding gas to be dissociated, thereby releasing more oxy-
gen in the area of the molten pool. For these reasons, a wire with higher levels of
Lesson 6 deoxidizing elements should be selected for high current operation.
Carbon & Low Alloy
Steel Filler Metals - 6.3.0.2 To summarize, the above 7 factors must be properly considered in order to produce
GMAW,GTAW,SAW
top quality welds. The economics of your decision should never compromise the need to
deposit the highest weld metal integrity possible. The result of your decision will only lead to
Lesson 7 most cost effective choice of welding materials. The following are economic considerations:
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 1. The cost of the wire increases with the percentage of deoxidizers and alloying elements
such as silicon, manganese, chromium, molybdenum, nickel, etc. in the welding wire.
Lesson 8 2. The cost of pure carbon dioxide is approximately one-fourth that of argon and
Hardsurfacing argon-CO2 or argon-O2 mixtures.
Electrodes
3. The deposition efficiency of solid wires is very high, but it varies with the shielding gas
and welding current being used. Figure 3 shows the average efficiency when using the
Lesson 9
Estimating & more common shielding gases. The differences in efficiency are due to spatter loss,
Comparing Weld and are proportional to the amount of argon in the gas mixture. CO2 produces more
Metal Costs
weld spatter and therefore a lower deposition efficiency.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Shielding Gas Efficiency Range Average Efficiency
Lesson 2
Pure CO2 88% - 95% 93%
Common Electric
Arc Welding
75% Ar - 94% - 98% 96%
Processes
25% CO2
98% Ar - 2% 2O 97% - 98.5% 98%

Lesson 3
Covered Electrodes DEPOSITION EFFICIENCIES - GAS METAL ARC WELDING
for Welding CARBON AND LOW ALLOY STEEL WIRES
Mild Steels
FIGURE 3
Lesson 4 4. The deposition rate of solid wires is very high when compared to that of coated elec-
Covered Electrodes
for Welding Low trodes, but is somewhat lower than the deposition rate of flux cored electrodes.
Alloy Steels
6.4 AWS SPECIFICATION A5.18-93

Lesson 5
6.4.0.1 This AWS specification is entitled Specification for Carbon Steel Filler Metals for
Gas Shielded Arc Welding. It covers bare carbon steel solid wires for use with the GMAW
Lesson 6 and GTAW processes. It differs from the AWS specifications in the previous lessons in that it
Carbon & Low Alloy classifies the chemical composition of the wire rather than that of the weld metal. It does,
however, classify the mechanical properties of the weld metal in the as-welded condition using
GMAW,GTAW,SAW
the gas metal arc welding process.
Lesson 7 6.4.0.2 The chemical composition requirements are based on the chemical analysis of the
Flux Cored Arc
as-manufactured wire or filler metal and include the elements in the coating or copper plating
Electrodes Carbon
Low Alloy Steels applied by the manufacturer.
ELECTRODE OR WELDING ROD
6.4.0.3 The letter-number designations MIN. TENSILE STRENGTH X 1000 psi
Lesson 8 in this specification are shown in Figure 4.

ERXXS-X
Hardsurfacing For example, ER70S-3 indicates an
Electrodes
electrode or welding rod (ER) that will CHEMICAL COMPOSITION
BARE SOLID ELECTRODE OR ROD
produce weld metal of a minimum 70,000
Lesson 9 psi tensile strength (70); is a solid bare
LETTER - NUMBER DESIGNATIONS
Estimating & wire or welding rod (S); of a specific CARBON AND LOW ALLOY STEEL WIRES
Comparing Weld FIGURE 4
Metal Costs chemical composition (3) as shown in
Figure 5. For a complete chemical
composition of these wires, see AWS A5.18-93.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
MAJOR ALLOYING ELEMENTS - % BY WEIGHT
AWS CLASS CARBON MANGANESE SILICON TITANIUM ZIRCONIUM ALUMINUM
ER70S-2 0.07 0.90 - 1.40 0.40 - 0.70 0.05 - 0.15 0.02 - 0.12 0.05 - 0.15
Lesson 2
Common Electric ER70S-3 0.06 - 0.15 0.90 - 1.40 0.45 - 0.70 — — —
Arc Welding ER70S-4 0.07 - 0.15 1.00 - 1.50 0.65 - 0.85 — — —
Processes ER70S-5 0.07 - 0.19 0.90 - 1.40 0.30 - 0.60 — — 0.50 - 0.90
ER70S-6 0.07 - 0.15 1.40 - 1.85 0.80 - 1.15 — — —
ER70S-7 0.07 - 0.15 1.50 - 2.00 0.50 - 0.80 — — —
Lesson 3
Covered Electrodes ER70S-G NO CHEMICAL REQUIREMENTS
for Welding
Mild Steels CHEMICAL COMPOSITION - CARBON STEEL BARE WIRES
FIGURE 5
Lesson 4 6.4.0.5 Tensile strength requirements of the weld metal produced by the filler metals in this
Covered Electrodes
classification are shown in Figure 6.
for Welding Low
Alloy Steels
Tensile Yield
Shielding Strength Strength Elongation
AWS Class Gas PSI PSI in 2" - % Min.
Lesson 5
for Stainless Steels ER70S-2
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
ER70S-3
ER70S-4
ER70S-5
ER70S-6
ER70S-7
ER70S-G
} CO2
*
72,000
72,000
60,000
60,000
* As agreed upon between supplier and purchaser
22
22
Lesson 7 WELD METAL TENSILE REQUIREMENTS

Electrodes Carbon
Low Alloy Steels
6.4.0.6 Although Figure 6 shows CO2 as the shielding gas, the specification does not
restrict the use of argon-CO2 or
Minimum
Lesson 8 argon-mixtures. It states that a filler metal AWS Class Impact Properties
Hardsurfacing
classified with CO2 will also meet
Electrodes ER70S-2 20 ft-lb @ -20° F
specification requirements when used with ER70S-3 20 ft-lb @ 0° F
the above gas mixtures. ER70S-4 Not Required
Lesson 9 ER70S-5 Not Required

Estimating & 6.4.0.7 Impact properties, according to ER70S-6 20 ft-lb @ -20° F
Comparing Weld the Charpy V-notch test as listed in the ER70S-7 20 ft-lb @ -20° F
Metal Costs ER70S-G As agreed between
specification, are shown in Figure 7. supplier & purchaser
WELD METAL IMPACT PROPERTIES

Lesson 10 FIGURE 7
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.5 INDIVIDUAL FILLER METAL CHARACTERISTICS
Lesson 2
Common Electric 6.5.1 ER70S-2 - This classification covers filler metals that contain small amounts of
Arc Welding
Processes titanium, zirconium, and aluminum, in addition to the normal deoxidizing elements of manga-
nese and silicon. These wires are commonly referred to as “triple deoxidized wires”. They will
produce sound welds in all types of carbon or mild steels. They are especially suited for
Lesson 3
Covered Electrodes welding carbon steels that are rusty or have mill scale on the surface. Weld integrity will vary
for Welding
with the amount of oxides on the surface of the steel. They may be used with CO2, argon-CO2,
Mild Steels
or argon-O2 shielding gas mixtures. They work well in the short-circuiting mode for
out-of-position welding.
Lesson 4
Covered Electrodes 6.5.2 ER-70S-3 - Filler metals of this classification contain a relatively low percentage of
for Welding Low
Alloy Steels deoxidizing elements; however, they are one of the most widely used GMAW wires. They
produce welds of fair quality when used to weld rimmed steels (steels with high oxygen con-
tent) using argon-O2 or argon-CO2 as a shielding gas. The use of straight CO2 is not recom-
Lesson 5 mended when welding rimmed steels. Sound welds may be made when welding semi-killed
for Stainless Steels (low oxygen) and killed (fully deoxidized) steels using argon-O2, argon-CO2, or straight CO2.
6.5.2.1 Wires of this classification may be used for out-of-position welding in the
Lesson 6 short-circuiting transfer mode using argon-CO2 or CO2 shielding gas.

Carbon & Low Alloy
Steel Filler Metals - 6.5.2.2 When CO2 shielding gas is used, high welding currents should be avoided because
GMAW,GTAW,SAW
welds produced may not meet the minimum tensile and yield strengths of this specification.
6.5.3 ER70S-4 - Containing slightly higher silicon and manganese contents than the
Lesson 7
Flux Cored Arc ER70S-3 type, these filler metals will produce weld metal of higher tensile strength. Primarily
Electrodes Carbon
Low Alloy Steels used for CO2 shielding gas applications where a higher degree of deoxidization is necessary.
6.5.4 ER70S-5 - The filler metals in this classification contain aluminum as well as silicon
Lesson 8 and manganese as deoxidizers. The addition of aluminum allows these wires to be used at
Hardsurfacing higher welding currents with CO2 as the shielding gas. Not used for out-of-position
Electrodes short-circuiting type transfer because of high puddle fluidity. Can be used for welding rusty or
dirty steels with a slight loss of weld quality.
Lesson 9 6.5.5 ER70S-6 - Wires in this classification contain the highest combination of deoxidiz-
Estimating &
Comparing Weld ers in the form of silicon and manganese. This allows them to be used for welding all types of
Metal Costs
carbon steel, even rimmed steels, using CO2 as a shielding gas. They produce smooth, well
shaped beads, and are particularly well suited for welding sheet metal. This filler metal is also
useable for out-of-position welding with short-circuiting transfer. Moderately rusted or scaled
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
steels may be welded successfully with this wire. The weld quality depends on the degree of
surface impurities. This wire may be used for high current, high deposition welding using
Lesson 2 argon mixed with 5-10% oxygen or carbon dioxide.
Common Electric
Arc Welding 6.5.6 ER70S-7 - This wire is similar to the ER70S-3 classification, but it has a higher
Processes
manganese content which provides better wetting action and bead appearance. The tensile
and yield strengths are slightly higher, and welding speed may be increased compared to the
Lesson 3
Covered Electrodes ER70S-3 type. This filler metal is usually recommended for use with argon-O2 shielding gas
for Welding mixtures, although argon-CO2 and straight CO2 may be used. The weld metal will be slightly
Mild Steels harder than that of the ER70S-3 types, but not as hard as an ER70S-6 deposit.
6.5.7 ER70S-G - This classification may be applied to solid filler metals that do not fall
Lesson 4
Covered Electrodes into any of the preceding classes. It has no specific chemical composition or shielding gas
for Welding Low requirements, but must meet all other requirements of the AWS A5.18-93 specification.
Alloy Steels
6.6 ESAB BARE SOLID CARBON STEEL WIRES

Lesson 5
6.6.1 Spoolarc 65 (AWS Class ER70S-2) - Spoolarc 65 is a cut length electrode avail-
able for a variety of tig and oxy-fuel gas welding applications. In addition to the standard
Lesson 6 deoxidizers, ER70S-2 also contains additional cleaners such as aluminum, titanium, and
Carbon & Low Alloy
zirconium. This electrode is often used on out-of-position welding of pipe joints. The ends of
GMAW,GTAW,SAW the 36" electrode can be flag tagged for identification purposes.
A. Typical Chemical Analysis of the Wire

Lesson 7
Flux Cored Arc Carbon 0.08% Phosphorus 0.011%
Electrodes Carbon
Low Alloy Steels Manganese 1.00% Sulfur 0.009%
Silicon 0.40%
B. Typical Mechanical Properties of the Weld Metal
Lesson 8 As Welded Stress Relieved*
Hardsurfacing
Electrodes
Lesson 9 % Reduction of Area 73 78
Estimating &
Charpy V-Notch Impacts
Comparing Weld
Metal Costs ft.-lbs. @-20°F 170 160
* 8 hrs. at 1150°F
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.6.2 Spoolarc 29S (AWS Class ER70S-3) - Spoolarc 29S is a copper coated wire for
general purpose welding with the gas-metal arc process. It contains sufficient deoxidizers to
Lesson 2 produce sound welds on killed and semi-killed steels and adequate welds on rimmed steels.
Common Electric
Arc Welding Carbon dioxide or argon-CO2 shielding gas mixtures may be used. The smaller diameters (up
Processes to .045") are especially useful for welding light gauge mild steel in all positions. Among the
many applications for which Spoolarc 29S may be used are farm equipment, metal furniture,
iron work, trailers, truck bodies, metal fixtures, light vessels, and hoppers.
Lesson 3
Covered Electrodes
for Welding A. Typical Chemical Analysis of the Wire
Mild Steels Carbon 0.08% Phosphorus 0.007%
Manganese 0.62% Sulfur 0.009%
Lesson 4 Silicon 0.27%
Covered Electrodes
for Welding Low
Alloy Steels B. Typical Mechanical Properties of the Weld Metal Using CO2 Shielding Gas
Yield Point, psi 60,100
Tensile Strength, psi 75,000
Lesson 5
% Elongation (2") 32
for Stainless Steels Charpy V-Notch Impacts 95 ft.-lbs. @0°F
Lesson 6 6.6.3 Spoolarc 85 (AWS Class ER70S-4) - Spoolarc 85 is a copper plated gas-metal
Carbon & Low Alloy
Steel Filler Metals - arc welding wire. This wire contains more manganese and silicon for greater deoxidation than
GMAW,GTAW,SAW ER70S-3 wire. The additional levels of deoxidizers provides more improved rust and mill
scale tolerance, while improving bead cosmetics.
Lesson 7
Flux Cored Arc A. Typical Chemical Analysis of the Wire
Electrodes Carbon
Low Alloy Steels Carbon 0.07% Phosphorus 0.004%
Silicon 0.39% Copper 0.16%
Lesson 8
Hardsurfacing Typical Mechanical Properties of the Weld Metal Using CO2 Shielding Gas
B.
Electrodes
Lesson 9 % Elongation (2") 26
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.6.4 Spoolarc 86 (AWS Class ER70S-6) - Spoolarc 86 is a copper plated gas-metal
arc welding wire. Containing a high level of deoxidizers, it produces sound welds in all carbon
Lesson 2 steels using CO2 shielding gas, argon/CO2 and argon/O2 mixtures. The arc is quiet and very
Common Electric
Arc Welding stable. High speed, high deposition welds can be made with argon-oxygen gas mixtures.
Processes Ideal for welding sheet metal where smooth weld beads with good wetting action are desir-
able. It may be used to weld carbon steels that have a moderate amount of rust or mill scale.
Spoolarc 86 can also be used for out-of-position welding with the short-circuit transfer method,
Lesson 3
Covered Electrodes making it ideal for pipe welding. Other applications are for bridges, building construction,
for Welding boiler and pressure vessels, storage tanks, auto parts, and construction equipment.
Mild Steels
Lesson 4 Carbon 0.09% Phosphorus 0.012%

Covered Electrodes Manganese 1.18% Sulfur 0.011%
for Welding Low
Alloy Steels Silicon 0.57%
B. Typical Mechanical Properties of the Weld Metal Using CO2 Shielding Gas
Lesson 5
for Stainless Steels Tensile Strength, psi 81,600
Charpy V-Notch Impacts 31 ft.-lbs. @-20°F
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW 6.6.5 Spoolarc 87HP (AWS Class ER70S-7) - Spoolarc 87HP is a high manganese
carbon steel wire. It features an optimized manganese to silicon ratio to produce excellent
Lesson 7 appearing welds over a wide range of welding parameters. It also produces excellent weld
Flux Cored Arc metal mechanical properties and welds over moderate amounts of rust and scale.
Electrodes Carbon
Low Alloy Steels
Carbon 0.11% Phosphorus 0.015%
Lesson 8 Manganese 1.75% Sulfur 0.014%

Hardsurfacing Silicon 0.65%
Electrodes
B. Typical Mechanical Properties of the Weld Metal Using 75% Ar/25% CO2
Lesson 9 Tensile Strength, psi 79,100

Estimating & % Elongation (2") 29
Comparing Weld
Metal Costs Charpy V-Notch Impacts 62 ft.-lbs. @-20°F
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Lesson 2
Common Electric 6.7.0.1 This specification is entitled Specification for Low Alloy Steel Filler Metal for Gas
Arc Welding
Processes Shielded Arc Welding. It covers the solid bare wires for welding those steels commonly re-
ferred to as the chromium-molybdenum (chrome-molys), manganese-molybdenum
(manganese-molys), nickel alloy and other low alloy steels. The wires referred to in this lesson
Lesson 3
Covered Electrodes are for use with the gas-metal arc welding process and also may be used as filler metals for
for Welding the GTAW process.
Mild Steels
6.7.0.2 The letter-number designations have the same significance as those used in the
Lesson 4 carbon steel specification shown in Figure 4. Using ER80S-B2 as an example, the letters ER
Covered Electrodes indicate that it is an electrode or a welding rod; will produce weld metal of 80,000 psi tensile
for Welding Low
strength (80); is a solid bare wire (S) of a specific chemical composition (B2) as described in
Alloy Steels
Figure 8.
Major Alloying Elements - % By Weight
Lesson 5 AWS Class Carbon Chromium Molybdenum

Welding Filler Metals ER80S-B2L *0.05 1.20 - 1.50 0.40 - 0.65
for Stainless Steels ER80S-B2 0.07 - 0.12 1.20 - 1.50 0.40 - 0.65
ER80S-B3L 0.05 2.30 - 2.70 0.90 - 1.20
ER80S-B3 0.07 - 0.12 2.30 - 2.70 0.90 - 1.20
Lesson 6 * Single figure denotes maximum

Carbon & Low Alloy
Steel Filler Metals - CHEMICAL COMPOSITION CHROMIUM-MOLYBDENUM SOLID BARE WIRES
6.7.1 The Chromium-Molybdenum Types (Cr-Mo) - The letter “B” designates a Cr-Mo
Lesson 7
Flux Cored Arc wire to be used for welding the Cr-Mo pressure vessel steels, and the number that follows desig-
Electrodes Carbon
Low Alloy Steels nates the chemical composition of the filler metal. If the last number is followed by an “L”, it
indicates that the wire has a low carbon content.
6.7.1.1 Figure 8 shows only the major chemical composition requirements for these filler
Lesson 8
Hardsurfacing metals. For complete requirements, see AWS A5.28-96 Filler Metal Specification.
Electrodes
6.7.1.2 Figure 9 shows the mechanical property requirements for the Cr-Mo weld metal.
Lesson 9 6.7.1.3 Filler metals of the preceding classifications are used to weld the 1/2 Cr-1/2 Mo, 1
Estimating & Cr-1/2 Mo, 1-1/4 Cr-1/2 Mo, and 2-1/4 Cr-1 Mo steels that are used in welding high tempera-
Comparing Weld
Metal Costs ture piping and pressure vessels. They provide a degree of corrosion resistance and are
used for welding dissimilar grades of Cr-Mo steels and carbon steels.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Tensile Yield
Strength Strength Elongation Impact
AWS Class psi psi in 2", % Properties
Lesson 2 ER80S-B2 80,000 68,000 19 Not Required
Common Electric
ER80S-B2L 80,000 68,000 19 Not Required
Arc Welding
Processes ER90S-B3 90,000 78,000 17 Not Required
ER90S-B3L 90,000 78,000 17 Not Required
All values are mininums
Lesson 3 MECHANICAL PROPERTIES OF Cr - Mo WELD METAL
for Welding
Mild Steels 6.7.1.4 These filler metals may be used with all GMAW metal transfer modes. The AWS
mechanical properties and impact properties are established using argon plus 1-5% oxygen
Lesson 4 as a shielding gas. Straight CO2 and argon-CO2 mixtures may be used. These mixtures will
Covered Electrodes produce welds with deeper penetration, although impact properties will be somewhat lower.
for Welding Low
Alloy Steels
6.7.1.5 Welding low alloy high strength steels with the GMAW process requires that pre-
heat, interpass, and post-weld temperatures be closely controlled to prevent cracking. The low
Lesson 5 carbon filler metals designated by the letter “L” will provide greater resistance to cracking, and
are more suitable when post-weld heat treatment is not practical or possible.
6.7.2 The Nickel Alloy Types (Ni) - The letters
“Ni” designate that the filler metal is a nickel alloy Nickel

Lesson 6 AWS Class % by Weight
Carbon & Low Alloy wire for welding the nickel alloy steels. The number
ER80S-Ni1 0.80 - 1.10
Steel Filler Metals - following the letters designates the chemical
GMAW,GTAW,SAW ER80S-Ni2 2.00 - 2.75
composition of the wire. Figure 10 shows only the ER80S-Ni3 3.00 - 3.75
amount of nickel required in the wire under this
Lesson 7 specification. For complete chemical NICKEL REQUIREMENTS
Flux Cored Arc NICKEL ALLOY SOLID BARE WIRES
Electrodes Carbon requirements, see AWS A5.28-96 Filler Metal
FIGURE 10
Low Alloy Steels Specification.
6.7.2.2 Figure 11 shows the mechanical property requirements for nickel alloy weld metals.
Lesson 8
Hardsurfacing
Electrodes Tensile Yield
AWS Class psi psi in 2", Min. Properties
Lesson 9 ER80S-Ni1 20 ft-lb @ -50°F

Estimating &
Comparing Weld
ER80S-Ni2
ER90S-Ni3
} 80,000 68,000 24 20 ft-lb @ -80°F
20 ft-lb @ -100°F
Metal Costs All values are mininums
MECHANICAL PROPERTIES OF NICKEL ALLOY WELD METALS
FIGURE 11
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.7.2.3 Nickel alloy wires are used for welding the nickel alloy steels that are employed in
applications requiring 80,000 psi tensile strength and good toughness at low temperatures.
Lesson 2 The ER80S-Ni1 wire deposits weld metal containing a nominal 1% nickel, similar to an
Common Electric
Arc Welding E8018C3 coated electrode. The ER80S-Ni2 deposits weld metal containing a nominal 2-1/
Processes 2% nickel, similar to an E8018C1 coated electrode and the ER80S-Ni3 deposits weld metal
containing a nominal 3-1/2% nickel, similar to an E8018C2 coated electrode.
Lesson 3
6.7.2.4 The weld metal deposit will have a chemical composition similar to the chemical
Covered Electrodes
for Welding composition of the wire when argon-O2 shielding gas is used. If CO2 is used as a shielding
Mild Steels gas, the deoxidizing elements, such as manganese and silicon, will be considerably reduced
in the weld metal. The recommended shielding gas is argon plus 1.0 to 5.0% oxygen. Weld-
Lesson 4 ing the nickel alloy steels usually requires that the weldment be preheated before welding, and
Covered Electrodes the interpass temperature controlled. It may also be necessary to subject the weldment to post
for Welding Low
Alloy Steels weld heat treatment, depending on the alloy and thickness of the material.
Lesson 5
Welding Filler Metals 6.7.3 The Manganese-Molybdenum Types ”Mn-Mo” - The suffix letter “D” designates
a manganese-molybdenum wire to be used for welding the manganese-molybdenum steels.
The number that follows designates the chemical composition of the wire.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 6.7.3.1 There is only one manganese-moly wire in this classification. It is designated as
GMAW,GTAW,SAW ER80S-D2 and was formerly classified as E70S-1B in AWS Specification A5.18-89 (since
updated to A5.18-93).
Lesson 7
Flux Cored Arc A. Chemical Composition Requirements for ER80S-D2 Bare Solid Wire
Electrodes Carbon Carbon 0.07-0.12% Nickel 0.15% max.
Low Alloy Steels
Manganese 1.60-2.10% Copper 0.50% max.
Silicon 0.50-0.80% Phosphorus0.025% max.
Lesson 8 Molybdenum 0.40-0.60% Sulfur 0.025% max.

Hardsurfacing
Electrodes
B. Mechanical Property Requirements ER80S-D2 Weld Metal
Yield Strength, psi 60,000

Comparing Weld
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.7.3.2 This wire is suitable for welding a large variety of low alloy and carbon steels. It is
excellent for out-of-position work and contains molybdenum for increased strength. Argon-O2
Lesson 2 and argon-CO2 gas mixtures are recommended for maximum mechanical properties, but
Common Electric
Arc Welding welds made with CO2 shielding gas will still deliver mechanical properties within the specifica-
Processes tion limits due to the high level of manganese and silicon in the wire. The high level of deoxi-
dizers allows this wire to be used over moderate amounts of rust and mill scale.
Lesson 3
Covered Electrodes
for Welding
Mild Steels 6.7.4 Spoolarc 83 (AWS Class ER80S-D2) - Spoolarc 83 is a small diameter copper
coated solid wire for gas metal arc welding. Because of the additional alloys, manganese,
and molybdenum, the deposit is adequate for high strength low alloy steels. In addition, the
Lesson 4
Covered Electrodes higher levels of deoxidizers provide improved rust and mill scale tolerance, as well as
for Welding Low out-of-position capabilities. This wire is most commonly used on pressure vessel and gas
Alloy Steels
transmission line applications.

Lesson 5
Welding Filler Metals Carbon 0.10% Phosphorus 0.005%
Silicon 0.27% Molybdenum 0.38%
Lesson 6
Carbon & Low Alloy B. Typical Mechanical Properties of the Weld MetalUsing CO2 Shielding Gas
Steel Filler Metals - Yield Strength, psi 77,000
GMAW,GTAW,SAW
Lesson 7 % Reduction of Area 66.8
Flux Cored Arc
Electrodes Carbon Charpy V-Notch Impacts 44 ft.-lbs. @-20°F
Low Alloy Steels
6.7.5 Spoolarc Hi-84 (AWS Class ER80S-D2) - Spoolarc Hi-84 is a 1/2% Mo wire that
has been microalloyed to produce exceptional impact toughness at temperatures as low as
Lesson 8
Hardsurfacing -50°F. The weld metal deposit produces a high strength weld with good tolerance of rust and
Electrodes mill scale.

Lesson 9 Carbon 0.11% Nickel 0.15%
Estimating &
Comparing Weld Manganese 1.90% Chromium 0.08%
Metal Costs Silicon 0.60% Ti and Zr 0.017%
Molybdenum 0.50%
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
B. Typical Mechanical Properties of the Weld MetalUsing 98% Ar/2% O2
Shielding Gas
Lesson 2 Yield Strength, psi 99,000
Common Electric
Arc Welding Tensile Strength, psi 111,500
Processes % Elongation (2") 20
Charpy V-Notch Impacts 65 ft.-lbs. @-20°F
51 ft.-lbs. @-50°F
Lesson 3
Covered Electrodes 6.7.6 All Other Low Alloy Types
for Welding
Mild Steels
6.7.6.1 Solid wires for welding the low alloy high tensile steels that do not fit into the com-
mon Cr-Mo, Ni alloys and Mn-Mo types, fall into the “all other” category. They produce welds
Lesson 4 with very high strength and very good notch toughness. These alloys are designated by the
Covered Electrodes
for Welding Low numbers “1”, “2”, or "G" as shown in Figure 12.
Alloy Steels
6.7.6.2 Only the major alloying elements for these wires are shown above. For complete
chemical composition requirements, see AWS Filler Metal Specification A5.28-96.
Lesson 5
Major Alloying Elements - % By Weight
AWS Class Carbon Manganese Nickel Chromium Molybdenum
ER100S-1 0.08* 1.25 - 1.80 1.40 - 2.10 0.30 0.25 - 0.55
Lesson 6 ER100S-2 0.12 1.25 - 1.80 0.80 - 1.25 0.30 0.20 - 0.55
Carbon & Low Alloy
ER110S-1 0.09 1.40 - 1.80 1.90 - 2.60 0.50 0.25 - 0.55
GMAW,GTAW,SAW ER120S-1 0.10 1.40 - 1.80 2.00 - 2.80 0.60 0.30 - 0.65
ERXXS-G As agreed between supplier and purchaser
*Single values are maximums.
Lesson 7
Flux Cored Arc CHEMICAL COMPOSITION - OTHER LOW ALLOYS - SOLID BARE WIRE
Electrodes Carbon FIGURE 12
Low Alloy Steels
6.7.6.3 The mechanical requirements for the weld metal deposited in this classification are
shown in Figure 13.
Lesson 8
Hardsurfacing
Tensile Yield
Electrodes
AWS Class psi psi in 2", Min. Properties
ER100S-1 100,000 88,000 - 102,000 16

Lesson 9
Estimating &
Comparing Weld
Metal Costs
ER100S-2
ER110S-1
ER120S-1
100,000
110,000
120,000
88,000 - 102,000
95,000 - 107,000
105,000 - 122,000
16
15
14
} 50 ft-lb @ -60°F
ERXXS-G * As agreed between supplier and purchaser

* Ultimate tensile strength must meet value placed after "ER"
WELD METAL MECHANICAL PROPERTIES REQUIREMENTS - OTHER LOW ALLOYS
Lesson 10
Reliability of Welding FIGURE 13
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.7.6.4 The wires in this category were originally developed for the high strength steels in
military applications. Today, they are used in structural and other applications requiring tensile
Lesson 2 strengths in excess of 100,000 psi and toughness at low temperatures. Common types of
Common Electric
Arc Welding steels welded with these wires are the T-1, HY-80, HY-100, NAXtra100 and others.
Processes
6.7.7 Spoolarc 95 and 120 (AWS Class ER100S-1 and ER120S-1) - Spoolarc 95 and
120 are Military grade high strength wires designed for welding HY-80 and HY-100 steels.
Lesson 3
Both wires produce excellent mechanical properties and low temperature toughness. They
Covered Electrodes
for Welding can be used for nonmilitary applications requiring high strength and low temperature tough-
Mild Steels ness.

Lesson 4
Covered Electrodes Spoolarc 95 Spoolarc 120
for Welding Low Carbon 0.07% 0.07%
Alloy Steels
Manganese 1.40% 1.30%
Silicon 0.35% 0.35%
Lesson 5 Molybdenum 0.35% 0.45%
Chromium 0.20% 0.40%
Nickel 1.80% 2.60%
Lesson 6 B. Typical Mechanical Properties of the Weld Metal Using 98% Ar/
Carbon & Low Alloy 2% O2 Shielding Gas
GMAW,GTAW,SAW Spoolarc 95 Spoolarc 120
Yield Strength, psi 95,000 112,000
Lesson 7
Flux Cored Arc % Elongation (2") 23 19
Electrodes Carbon Charpy V-Notch Impacts
Low Alloy Steels
ft.-lbs. @-0°F 93 100
ft.-lbs. @-60°F 65 75
Lesson 8
Hardsurfacing The suffix letter “G” applies to solid wire electrodes and welding rods that do not fall into any of
Electrodes
the other classes in this specification. They must have at least one of the following: 0.50%
nickel, 0.30% chromium, or 0.20% molybdenum. They must pass the radiographic soundness
Lesson 9 test for porosity or inclusions, and also the weld metal tensile tests that are spelled out in detail
Estimating & in this specification.
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.8 WIRES AND FLUXES FOR SUBMERGED ARC
Lesson 2 WELDING OF CARBON STEELS

Common Electric
Arc Welding
Processes
6.8.0.1 In submerged arc welding (SAW), the weld metal quality, mechanical properties and
bead shape are the result of the electrode* (or wire) and flux combination used in a particular
Lesson 3 application. Unlike coated electrodes, where the core wire and flux coating are inseparable,
Covered Electrodes
for Welding various fluxes may be used with a given wire to produce the desired results. The weld area is
Mild Steels shielded by this blanket of flux. When molten, the flux forms a protective layer above the molten
weld metal that not only provides for specific mechanical properties, but also gives the bead
Lesson 4 some shape.

Covered Electrodes
for Welding Low Note - * The American Welding Society has standardized on the term “electrode” when referring to the wires used in
SAW since these wires always carry the welding current. In this Lesson, the terms wire and electrode will be used
Alloy Steels interchangeably and will have the same meaning.
6.8.0.2 The advantages for using SAW are numerous. They include:
Lesson 5
a. High rates of travel.
for Stainless Steels b. High deposition rates.
c. Superior weld metal integrity.
d. Reduce edge preparations.
Lesson 6 e. Improved operator comfort and safety.
Carbon & Low Alloy
GMAW,GTAW,SAW 6.8.1 Equipment - The SAW process can utilize either an AC or DC power supply. DC is
most often chosen because it provides the following advantages:
Lesson 7 a. Good control over bead shape and penetration.
Flux Cored Arc b. Best arc starting characteristics on either electrode positive (+) or
Electrodes Carbon
Low Alloy Steels electrode negative (-).
c. DCEN offers 10-15% higher deposition rates than AC.
d. DCEP offers better bead shape control and deeper penetration.
Lesson 8 e. Lowest cost to purchase.
Hardsurfacing
Electrodes
6.8.1.1 AC, on the other hand, provides features as well. They include:
a. Reduced arc blow (especially when amperage exceeds 800 amps or when
Lesson 9 welding on heavy sections).
Estimating &
Comparing Weld b. Increased flexibility when used in combination with multiple wires (DC-AC,
Metal Costs AC-AC, or AC-AC-AC).
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.8.2 Welding Filler Metals - A continuous bare electrode is fed into a blanket of granular
flux that covers the weld joint. Once current is applied to the electrode, usually ranging in size
Lesson 2 from 1/16" to 1/4" diameter, an arc is established and the base metal, the electrode, and the
Common Electric
Arc Welding flux melt to form a molten puddle. The solid electrode is usually copper coated, except for
Processes certain nuclear applications, to minimize contact tip wear and assure good current transfer to
the wire. The molten flux flows to the surface to form a slag while the metallic components
Lesson 3 create a weld.

Covered Electrodes
for Welding 6.8.2.1 Since high currents are usually applied to the electrode, extremely high deposition
Mild Steels
rates are possible with SAW. The current and voltage ranges reflected in Figure 14 will pro-
vide information on the deposition capability of SAW.
Lesson 4
Covered Electrodes Deposition Rate*
for Welding Low Wire Diameter Current Ranges Volts lbs./hr.
Alloy Steels
1/16" (1.6 mm) 150 - 500 19 - 27 5-17 (2.27- 7.71 Kg)
5/64" (2.0 mm) 200 - 600 20 - 28 6-22 (2.72- 9.98 Kg)
Lesson 5
Welding Filler Metals 3/32" (2.4 mm) 250 - 700 22 - 30 8-24 (3.63-10.89 Kg)
1/8" (3.2 mm) 300 - 900 23 - 32 8-28 (3.63-12.70 Kg)
5/32" (4.0 mm) 400 - 1000 25 - 34 9-30 (4.08-13.61 Kg)
3/16" (4.8 mm) 500 - 1100 27 - 36 12-34 (5.44-15.42 Kg)
Lesson 6
Carbon & Low Alloy 7/32" (5.6 mm) 600 - 1200 30 - 37 20-44 (9.07-19.96 Kg)
1/4" (6.4 mm) 700 - 1600 30 - 38 18-56 (8.16-25.40 Kg)
GMAW,GTAW,SAW
OPERATING RANGES AND DEPOSITION RATES

Lesson 7 (DCEP - ESO AVERAGE 8 X WIRE DIAMETER)
Flux Cored Arc
Electrodes Carbon FIGURE 14
Low Alloy Steels
6.8.2.2 Composite submerged electrodes, as described in Lesson II, are not normally used
for welding carbon steel. They are, however, used in welding low alloy high strength materials.
Lesson 8
Current and voltage ranges will differ, along with their respective deposition rates. These
Hardsurfacing
Electrodes electrodes will be discussed late in this lesson.
6.8.3 Fluxes for Carbon Steel Electrodes - The granular powder, referred to as “flux”,
Lesson 9 under which the welding takes place, shields the molten puddle from the atmosphere, cleans
Estimating &
the weld metal, and influences the mechanical properties and shape of the weld bead. The flux
Comparing Weld
Metal Costs also acts as a barrier preventing the heat from escaping, permitting the desired depth of
penetration (this can vary with current and polarity). Fluxes differ as a result of the method
used to manufacture them.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.8.3.1 Fluxes are classified as either “bonded” or “fused” based on the manufacturing
methods. When manufacturing a bonded flux, fine particles of various ingredients are dry
Lesson 2 mixed and bonded together with a sodium silicate or other similar compound. The wet
Common Electric
Arc Welding bonded mix is pelletized and baked at relatively low temperatures. The pellets are then broken
Processes into smaller pieces and screened into proper sizes and packaged for shipment.
6.8.3.2 The advantages of “bonded” fluxes are that additional deoxidizers and alloying
Lesson 3
elements can be added. Secondly, this type of flux generally has a lower consumption rate.
Covered Electrodes
for Welding The major disadvantage of a bonded flux is their inherent moisture pick-up, especially when
Mild Steels opened, bags are allowed to remain exposed to the atmosphere.
6.8.3.3 “Fused” fluxes are manufactured under different conditions. The raw materials are
Lesson 4
Covered Electrodes mixed together and then melted at very high temperatures in a furnace. The molten mixture is
for Welding Low cooled either by pouring it onto a chill table and allowed to cool, or shooting the molten mixture
Alloy Steels
with a stream of water. The glass-like material is crushed, then screened to a particular par-
ticle size and packaged for shipment.
Lesson 5
Welding Filler Metals 6.8.3.4 “Fused” fluxes offer several advantages to the user, including much less moisture
pick-up than bonded fluxes. Secondly, the user has better control of weld metal properties
after recycling used flux. The major disadvantage with fused fluxes is the inability to add
additional deoxidizers and alloys during manufacturing.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 6.8.3.5 Fluxes are also described as “active” or “neutral”, depending on the amount of
GMAW,GTAW,SAW alloying elements or deoxidizers (especially manganese or silicon) that are transferred to the
weld metal.
Lesson 7
Flux Cored Arc a. Active Fluxes - contain manganese and silicon. Active fluxes are readily trans-
Electrodes Carbon ferred to the weld metal. The amount transferred depends on the amount of flux consumed per
Low Alloy Steels
unit of wire. Excessively high manganese and silicon transferred to the weld can cause weld
metal cracking. Active fluxes are recommended for single pass or limited multipass welding
Lesson 8 applications. Changes in arc voltage can greatly effect the flux consumption per unit of wire
Hardsurfacing and the weld metal properties. It is, therefore, crucial to adhere to the manufacturer’s sug-
Electrodes
gested welding parameters.
b. Neutral Fluxes - produce little significant change in weld metal properties as a

Lesson 9
Estimating & result of arc voltage. The primary purpose for neutral fluxes is that they can be used on multi-
Comparing Weld pass weldments, especially those that exceed one inch thickness. The disadvantage for
Metal Costs
neutral fluxes is their low tolerance to rust and mill scale. Generally speaking, active fluxes are
used with carbon steel electrodes, while neutral fluxes are recommended for both carbon and
Lesson 10 low alloy steels.

Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Lesson 2
Common Electric 6.9.0.1 This AWS specification is entitled Specification for Carbon Steel Electrodes and
Arc Welding
Processes Fluxes for Submerged Arc Welding. It classifies the electrodes on the basis of their chemical
composition as shown in Figure 15A. The fluxes are classified on the basis of the mechanical
properties of the weld metal they deposit with a particular classification of electrode as shown
Lesson 3
Covered Electrodes in Figure 15B.
for Welding
Mild Steels Electrode When Used, Indicates Electrode Made
From Silicon-Killed (Deoxidized) Steel.
Lesson 4 EXXXK
Covered Electrodes
for Welding Low
Alloy Steels
Percent Percent
Manganese Carbon
By Weight By Weight
Lesson 5
Welding Filler Metals L = 0.25 - 0.60 8 = 0.10 Max.
for Stainless Steels M = 0.80 - 1.40 12 = 0.05 - 0.15
H = 1.70 - 2.20 13 = 0.07 - 0.19
14
15 =
=
} 0.10 - 0.20
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - ELECTRODE DESIGNATIONS FOR SUBMERGED ARC WELDING CARBON STEEL
GMAW,GTAW,SAW FIGURE 15A
Lesson 7
Flux Cored Arc Flux A = As Welded
Electrodes Carbon P = Postweld Heat Treatment
Low Alloy Steels 1150° for 1 Hour
FXXX
Lesson 8
Hardsurfacing F6XX F7XX Impact Requirements
Electrodes Tensile 60,000 70,000 Charpy V-Notch
Strength to to Z No Requirement
psi 80,000 95,000 0 0° F
Lesson 9
Estimating &
Comparing
Costs
Weld
Metal Costs
Yield
Strength
psi
Elongation
% in 2"
48,000
Min.
22
Min.
58,000
Min.
22
Min.
}
2
4
5
6
8
20 ft-lbs @
-20 °F
-40 °F
-50 °F
-60 °F
-80 °F
FLUX DESIGNATIONS FOR SUBMERGED ARC WELDING CARBON STEEL

Lesson 10 FIGURE 15B
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.9.0.2 For example, when a manufacturer assigns the AWS classification EM12K to a
given wire or electrode, he certifies that his product is an electrode (E); containing a medium
Lesson 2 manganese content of 0.80 to 1.40% (M); containing a carbon content of 0.05 to 0.15% (12);
Common Electric
Arc Welding and is made from a heat of silicon-killed steel (K).
Processes
6.9.0.3 When classifying a flux as to mechanical properties, it is necessary to also specify
the electrode or wire with which these properties are obtained. As an example, the classifica-
Lesson 3
tion F7P6-EM12K certifies that the product is a submerged arc flux (F); will provide weld metal
Covered Electrodes
for Welding of 70,000 to 95,000 psi tensile strength, a minimum of 58,000 psi yield strength and a mini-
Mild Steels mum of 22% elongation in two inches after the weldment has been subjected to a postweld
heat treatment of 1150°F for one hour (P); and will have a minimum charpy V-notch impact of
Lesson 4 20 ft.-lbs. at -60°F when used with an EM12K wire.
Covered Electrodes
for Welding Low 6.9.0.4 The eleven types of carbon steel electrodes listed in AWS A5.17-89 are as follows:
Alloy Steels
A. Low Manganese Steel Electrodes
Lesson 5 1) EL8
Welding Filler Metals 2) EL8K
3) EL12
B. Medium Manganese Steel Electrodes
1) EM12
Lesson 6
Carbon & Low Alloy 2) EM12K
Steel Filler Metals - 3) EM13K
GMAW,GTAW,SAW
4) EM14K
5) EM15K
Lesson 7 C. High Manganese Steel Electrodes
Flux Cored Arc
Electrodes Carbon 1) EH11K
Low Alloy Steels 2) EH12K
3) EH14
Lesson 8
Hardsurfacing
Electrodes 6.9.0.5 The carbon and manganese content of these wires are shown in Figure 15. For
complete chemical composition of these wires, see AWS Filler Metal Specification A5.17-89.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.10 ESAB WIRES AND FLUXES FOR CARBON STEEL
SUBMERGED ARC WELDING

Lesson 2
Common Electric
Arc Welding 6.10.1 Spoolarc 81 (AWS Class EM12K) - Spoolarc 81 is a general purpose submerged
Processes
arc wire for moderately clean material. Applications include low and medium structural carbon
steel, longitudinal and circumferential welds on low to medium strength pressure vessel steels
Lesson 3
and some offshore and ship fabrication.
Covered Electrodes
for Welding
Mild Steels A. Typical Chemical Analysis of the Wire

Lesson 4 Manganese 0.956% Sulfur 0.008%
Covered Electrodes Silicon 0.22% Copper 0.34%
for Welding Low
Alloy Steels
B. Typical Mechanical Properties (* See note following Unionmelt 80)
Weld UTS YS % CVN (ft-lbs) AWS/ASME
Lesson 5 Flux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class
for Stainless Steels 231 AW 82-90 75-80 25-29 24-29 F7A2-EM12K
429 AW 75-82 65-72 25-30 35-45 F7A2-EM12K
SR(a) 70-75 58-64 25-30 35-45 @-40°F F7P4-EM12K
Lesson 6 80 AW 70-75 60-65 27-31 35-45 F6A2, F7A2-EM12K
Carbon & Low Alloy
Steel Filler Metals - (a) Stress-Relieved @1150°F - 1 hr.
GMAW,GTAW,SAW
6.10.2 Spoolarc 29S (AWS Class EM13K) - Spoolarc 29S has increased amounts of sili-
Lesson 7 con for both improved puddle fluidity and rust and mill scale tolerance. This wire is not recom-
Flux Cored Arc mended for material greater than 1" thickness. Applications include single pass high speed
Electrodes Carbon
Low Alloy Steels fillets on both low and medium carbon steels.

Hardsurfacing
Electrodes Manganese 0.98% Sulfur 0.012%
Lesson 9 B. Typical Mechanical Properties (* See note following Unionmelt 80)

Estimating &
Comparing Weld Weld UTS YS % CVN (ft-lbs) AWS/ASME
Metal Costs Flux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class
231(a) AW 85-94 77-83 25-29 25-30 @ 0°F. F7A0-EM13K
429 AW 80-85 66-73 25-30 28-35 @-20°F. F7A2-EM13K
Lesson 10 (a) This combination of flux and wire is only recommended for single pass welding.
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.10.3 Spoolarc 80 (AWS Class EL12) - Spoolarc 80 has the least amount of manganese
and silicon and is therefore intended for clean material. The major advantage of this wire is the
Lesson 2 improved ductility, ease of machining and improved crack resistance. Applications include high
Common Electric
Arc Welding speed fillets on axle housings and wheel rims and thick heavy sections on highly restrained
Processes multipass weldments.

Lesson 3
Covered Electrodes Carbon 0.10% Phosphorus 0.003%
for Welding
Mild Steels Manganese 0.44% Sulfur 0.014%
Lesson 4 B. Typical Mechanical Properties

Covered Electrodes
for Welding Low Weld UTS YS % CVN (ft-lbs) AWS/ASME
Alloy Steels Flux Cond. (ksi) (ksi) Elong. @-20°F SFA 5.17 Class
231(a) AW 71-77 60-69 26-31 15-25 @ 0°F. F7AZ-EL12

429 AW 64-69 55-60 26-32 45-55 @-20°F. F6A2-EL12
Lesson 5
Welding Filler Metals (a) This combination of flux and wire is only recommended for single pass welding.
6.10.4 Unionmelt 231 - Unionmelt Flux 231 is an active flux that is limited to a maximum
Lesson 6
Carbon & Low Alloy plate thickness of one inch or less and operated at less than 36 volts. Applications include single
and multipass flat and horizontal fillets over rust and mill scale. This flux can be used with Spoolarc
GMAW,GTAW,SAW
81, 29S and 80.
Lesson 7 A. Typical Deposit Chemistry

Flux Cored Arc AWS/ASME
Electrodes Carbon Wire Material C Mn Si Cu SFA 5.17
Low Alloy Steels
81 A516 0.08 1.20 0.55 0.11 F7A2-EM12K
29S(a) A285 0.08 1.30 0.70 0.10 F7A0-EM13K
Lesson 8 80 A36 0.07 0.90 0.40 0.11 F7AZ-EL12

Hardsurfacing
Electrodes B. Typical Mechanical Properties (* See note following Unionmelt 80)
Spoolarc Weld UTS YS % CVN

Material Wire Condition (ksi) (ksi) Elong. (ft.-lbs.)
Lesson 9
Estimating & A516 81 AW 82-90 75-80 25-29 24-29 @-20°F
Comparing Weld
A285 29S(a) AW 85-94 77-83 25-29 25-30 @ 0°F
Metal Costs
A36 80 AW 71-77 60-69 26-31 15-25 @ 0°F
(a) Unionmelt Flux 231 and Spoolarc 29S are recommended for single pass welding only.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.10.5 Unionmelt 429 - Unionmelt Flux 429 is a neutral bonded flux designed for multipass
welding. Weld metal chemistries are excellent both as-welded and stress-relieved. Applica-
Lesson 2 tions include deep groove multipass welds found on pressure vessels and offshore oil fabrica-
Common Electric
Arc Welding tion. Commonly used with hand-held semi-automatic equipment. This flux can be used with
Processes Spoolarc 81 and 29S.
A. Typical Deposit Chemistry

Lesson 3 AWS/ASME
Covered Electrodes Wire Material C Mn Si Cu SFA 5.17
for Welding
Mild Steels 81 A36 0.07 1.25 0.50 0.14 F7A2-EM12K
29S A285 0.06 1.28 0.70 0.12 F7A2-EM13K
Lesson 4 B. Typical Mechanical Properties (* See note following Unionmelt 80)

Covered Electrodes
for Welding Low Spoolarc Weld UTS YS % CVN
Alloy Steels
A36 81 AW 75-90 75-80 25-29 24-29 @-20°F
SR(a) 70-75 58-64 25-30 35-45 @-40°F
Lesson 5
A285 29S AW 80-85 66-73 25-30 28-35 @-20°F
for Stainless Steels (a) Stress-Relieved @1150°F - 1 hr.
Lesson 6 6.10.6 Unionmelt 282 - Unionmelt Flux 282 is an active bonded flux designed for high speed
Carbon & Low Alloy
Steel Filler Metals - single pass welding on thin gauge material. The weld metal fluidity and high travel speeds make
GMAW,GTAW,SAW this flux extremely versatile. Applications include longitudinal welds on structural steel, as well as
circumferential seams on spiral pipe. This flux is best used with Spoolarc 81 and 29S.
Lesson 7
Flux Cored Arc A. Typical Mechanical Properties (* See note following Unionmelt 80)
Electrodes Carbon
Low Alloy Steels Spoolarc Wire Tested Per AWS A5.17-89
Spoolarc 81 Conforms to F7A0-EM12K (20 ft.-lbs. @ 0°F)
Spoolarc 29SConforms to F7A0-EM13K (20 ft.-lbs. @ 0°F)

Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.10.7 Unionmelt 50 - Unionmelt Flux 50 is a neutral fused flux developed for high speed
welding of thin gauge material (usable on relatively clean steel only). In addition, this flux works
Lesson 2 equally well for surfacing and build-up applications. Because this flux is a fused type, it is particu-
Common Electric
Arc Welding larly resistant to moisture pick-up. Applications include propane cylinders and hot water tanks.
Processes This flux can be used with Spoolarc 81 and 80.
A. Typical Deposit Chemistry

Lesson 3 Spoolarc AWS/ASME
Covered Electrodes Material Wire C Mn Si SFA 5.17
for Welding
Mild Steels A36 81 0.05 0.93 0.30 F7A2-EM12K
Stress-Relieved F6P4-EM12K
A36 80 0.05 1.17 0.42 F6A2-EL12
Lesson 4
Covered Electrodes B. Typical Mechanical Properties (* See note following Unionmelt 80)
for Welding Low
Alloy Steels Spoolarc Weld UTS YS % CVN
A36 81 AW 70-75 60-65 24-28 25-40 @-20°F

Lesson 5
SR(a) 65-70 50-55 25-29 75-80 @-20°F
for Stainless Steels A36 80 AW 65-70 55-60 24-28 30-40 @-20°F
(a) Stress-Relieved @1150°F - 8 hrs.
6.10.8 Unionmelt 80 - Unionmelt Flux 80 is a neutral fused flux for multipass, heavy plate
Lesson 6
Carbon & Low Alloy welding applications. Superior mechanical properties on clean material is available in both
as-welded and stress-relieved conditions. The low moisture pick-up of this flux helps reduce the
GMAW,GTAW,SAW
handling and storage casts. Applications include carbon and low alloy steels used to fabricate
pressure vessels. This flux can be used with Spoolarc 81 and 80.
Lesson 7
Flux Cored Arc A. Typical Deposit Chemistry
Electrodes Carbon
Low Alloy Steels Spoolarc AWS/ASME
Material Wire C Mn Si SFA 5.17
A36 81 0.06 1.0 0.50 F6A2, F7A2-EM12K

Lesson 8 A36 80 0.05 0.60 0.40 F6A2-EL12
Hardsurfacing
Electrodes B. Typical Mechanical Properties *
Spoolarc Weld UTS YS % CVN
Lesson 9 A36 81 AW 70-75 60-65 26-30 35-45 @-20°F

Estimating &
A36 80 AW 65-70 55-60 26-30 45-55 @-20°F
Comparing Weld
Metal Costs * NOTE: The data listed for both the deposit chemistry and mechanical properties are based on laboratory tests.
Results may vary according to your specific welding parameters or base metal conditions. It is,
therefore, important that the user run tests that closely duplicate their actual production conditions.
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.11 ELECTRODES AND FLUXES FOR SUBMERGED ARC
Lesson 2 WELDING OF THE LOW ALLOY STEELS

Common Electric
Arc Welding
Processes
6.11.0.1 In an earlier lesson, we learned that most low alloy coated electrodes have a mild or
carbon steel core wire, and the alloying elements, that produce the higher tensile strengths or
Lesson 3 improved impact properties, are in the electrode coating. In the case of stainless steel coated
Covered Electrodes
for Welding electrodes, a stainless steel core wire is used, and the elements that determine the specific
Mild Steels analysis of the weld metal are included in the coating. In submerged arc welding, the choice
exists as to the wire-flux combination that will produce the required end result.
Lesson 4
6.11.1 Electrodes and Fluxes for Welding the Alloys - Electrodes for welding the low
Covered Electrodes
for Welding Low alloy steels are available as low alloy solid wires or composite electrodes. Composite elec-
Alloy Steels
trodes are similar to flux cored electrodes, but since they are used with a granular flux, the core
contains mostly the necessary alloying elements. The outer sheath may be a carbon or alloy
Lesson 5 steel. Submerged arc wires are available in diameters ranging from 1/16" to 1/4" diameter.
for Stainless Steels 6.11.1.1 Welding the low alloy steels with the submerged arc process may be accomplished
in several different manners. They are:
Lesson 6 a. A solid wire that has a sufficient amount of alloying elements included in the chemistry
Carbon & Low Alloy
Steel Filler Metals - of the wire as manufactured, and a neutral flux that shields the weld and influences bead
GMAW,GTAW,SAW shape, but has a minimal affect on weld metal chemistry.
b. A composite wire that contains the necessary alloying elements in the core and/or the
Lesson 7
Flux Cored Arc steel sheath, used in conjunction with a neutral flux.
Electrodes Carbon
Low Alloy Steels c. A solid carbon steel wire may be used, such as an EM12K type, in combination with a
flux that contains the necessary alloying elements to produce the desired low alloy weld
metal.
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Lesson 2
Common Electric 6.12.0.1 This AWS specification is entitled Specification for Low Alloy Steel Electrodes and
Arc Welding
Processes Fluxes for Submerged Arc Welding. Since there are two types of welding wires, solid and
composite, each must be considered in a different manner. Solid wires are classified by their
as manufactured chemical analysis, but this is not possible with composite wires because the
Lesson 3
Covered Electrodes outer steel sheath and the core ingredients combine to produce the resultant weld metal.
for Welding Therefore, composite wires are classified as to the weld metal chemical composition as are
Mild Steels
coated electrodes.
Lesson 4 6.12.0.2 The fluxes for welding low alloys with the submerged arc process are classified by
Covered Electrodes the weld metal mechanical properties they produce with a given wire or electrode. Figure 16
for Welding Low
shows the classification of fluxes and electrodes under this specification.
Alloy Steels
Tensile Yield Impact Requirements

Lesson 5 Strength Strength Elongation Charpy V-Notch
Welding Filler Metals psi psi % in 2" Z No Requirement
for Stainless Steels F7XX 70,000 - 95,000 58,000 22 0 0° F
}
F8XX 80,000 - 100,000 68,000 20 2 -20 °F
F9XX 90,000 - 110,000 78,000 17 4 -40 °F
5 -50 °F
F10XX 100,000 - 120,000 88,000 16 20 ft-lbs @
6 -60 °F
F11XX 110,000 - 130,000 98,000 15 8 -80 °F
Lesson 6 F12XX 120,000 - 140,000 108,000 14 10 -100 °F
Carbon & Low Alloy 15 -150 °F
Steel Filler Metals - 1 or 2 Digits
GMAW,GTAW,SAW
FXXX
Lesson 7
Flux Cored Arc A = As Welded
Flux
Electrodes Carbon P = Postweld Heat Treatment
Low Alloy Steels Time & Temp. per AWS A5.17-89
FLUX DESIGNATIONS
Lesson 8 Classification of Electrode -

Hardsurfacing Indicates Composite Electrode. 2, 3, or 4 Numbers or Letters.
Electrodes Omission Indicates Solid Wire
Chemical Composition of Weld Metal -
Electrode 1, 2, or 3 Numbers or Letters
ECXXXN-XNHX
Lesson 9
Estimating & Used Only for Some Nuclear Requirements
Optional Diffusable
Hydrogen Designator
Comparing Weld
Metal Costs ELECTRODE DESIGNATIONS
FLUX AND ELECTRODE DESIGNATIONS FOR SUBMERGED ARC WELDING - LOW ALLOY STEELS
Lesson 10 FIGURE 16
Filler Metals
®COPYRIGHT 2000 THE ESAB GROUP, IN

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.12.1 Composition Requirements for Solid Low Alloy Electrodes - The listing in
Figure 17 indicates only the major alloying elements of each electrode type. For complete
Lesson 2 chemical composition requirements, see AWS A5.23-90.

Common Electric
Arc Welding C = Carbon Ni = Nickel
Processes
Mn = Manganese Mo = Molybdenum
Cr = Chromium
Lesson 3
Covered Electrodes
for Welding
Mild Steels ELECTRODE
CLASSIFICATION C Mn Cr Ni Mo Si
Carbon Steel
Lesson 4 EL12 0.04 - 0.14 0.25 - 0.60 — — — 0.10
EM12K 0.05 - 0.15 0.80 - 1.25 — — — 0.10 - 0.35
Covered Electrodes
for Welding Low Carbon-Molybdenum
EA1 0.07 - 0.17 0.65 - 1.00 — — 0.45 - 0.65 0.20
Alloy Steels
EA2 0.07 - 0.17 0.95 - 1.35 — — 0.45 - 0.65 0.20
EA3 0.10 - 0.18 1.65 - 2.15 — — 0.45 - 0.65 0.20
EA3K 0.07 - 0.12 1.60 - 2.10 — — 0.40 - 0.60 0.50 - 0.80
Lesson 5 EA4 0.07 - 0.17 1.20 - 1.70 — — 0.45 - 0.65 0.20
Welding Filler Metals Chromium Molybdenum
for Stainless Steels EB1 0.10 0.40 - 0.80 0.40 - 0.75 — 0.45 - 0.65 0.05 - 0.30
EB2 0.07 - 0.15 0.45 - 0.80 1.00 - 1.75 — 0.45 - 0.65 0.05 - 0.30
EB2H 0.28 - 0.33 0.45 - 0.65 1.00 - 1.50 — 0.40 - 0.65 0.55 - 0.75
EB3 0.05 - 0.30 0.40 - 0.80 2.25 - 3.00 — 0.90 - 1.10 0.05 - 0.30
Lesson 6 EB5 0.18 - 0.23 0.40 - 0.70 0.45 - 0.65 — 0.90 - 1.20 0.40 - 0.60
Carbon & Low Alloy EB6 0.10 0.35 - 0.70 4.50 - 6.50 — 0.45 - 0.65 0.05 - 0.50
Steel Filler Metals - EB6H 0.25 - 0.40 0.75 - 1.00 4.80 - 6.00 — 0.45 - 0.65 0.25 - 0.50
EB8 0.10 0.30 - 0.65 8.00 - 10.50 — — 0.05 - 0.50
GMAW,GTAW,SAW
Nickel Steel
ENi1 0.12 0.75 - 1.25 0.15 0.85 - 1.25 0.30 0.05 - 0.30
ENi2 0.12 0.75 - 1.25 — 2.10 - 2.90 — 0.05 - 0.30
Lesson 7 ENi3 0.13 0.60 - 1.20 0.15 3.10 - 3.80 — 0.05 - 0.30
Flux Cored Arc ENi4 0.12 - 0.19 0.60 - 1.00 — 1.60 - 2.10 0.10 - 0.30 0.10 - 0.30
Electrodes Carbon ENi1K 0.12 0.80 - 1.40 — 0.75 - 1.25 — 0.40 - 0.80
Low Alloy Steels Other Low Alloy Steel
EF1 0.07 - 0.15 0.90 - 1.70 — 0.95 - 1.60 0.25 - 0.55 0.15 - 0.35
EF2 0.10 - 0.18 1.70 - 2.40 — 0.40 - 0.80 0.40 - 0.65 0.20
EF3 0.10 - 0.18 1.70 - 2.40 — 0.70 - 1.10 0.45 - 0.65 0.30
Lesson 8 EF4 0.16 - 0.23 0.60 - 0.90 0.40 - 0.60 0.40 - 0.80 0.15 - 0.30 0.15 - 0.35
Hardsurfacing EF5 0.10 - 0.17 1.70 - 2.20 0.25 - 0.50 2.30 - 2.80 0.45 - 0.65 0.20
Electrodes EF6 0.07 - 0.15 1.45 - 1.90 0.20 - 0.55 1.75 - 2.25 0.40 - 0.65 0.10 - 0.30
EM2 0.10 1.25 - 1.80 0.30 1.40 - 2.10 0.25 - 0.55 0.20 - 0.60
EM3 0.10 1.40 - 1.80 0.55 1.90 - 2.60 0.25 - 0.65 0.20 - 0.60
EM4 0.10 1.40 - 1.80 0.60 2.00 - 2.80 0.30 - 0.65 0.20 - 0.60
Lesson 9 EW 0.12 0.35 - 0.65 0.50 - 0.80 0.40 - 0.80 — 0.20 - 0.35
Estimating & EG No Requirements
Comparing Weld Single Figures are Maximums
Metal Costs
MAJOR CHEMICAL COMPOSITION REQUIREMENTS
SOLID WIRE SUBMERGED ARC WELDING ELECTRODES. AWS A5.23-90
FIGURE 17
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.12.1.1 Figure 17 lists two carbon steel wires (EL12 and EM12K) that are the same as
those listed in AWS A5.17-89, the specification for mild and carbon steels. They appear here
Lesson 2 only because they can be used with fluxes that contain sufficient alloying elements to deposit a
Common Electric
Arc Welding low alloy weld metal.
Processes
6.12.1.2 Although all of the low alloy electrodes in AWS Specification A5.23-90 are listed
here, a complete knowledge of their uses and applications are beyond the scope of this
Lesson 3
course. They are presented here so that you will be familiar with the various AWS designa-
Covered Electrodes
for Welding tions.
Mild Steels
6.12.1.3 As an example, a manufacturer of a solid wire electrode may assign the AWS
classification EB3. Under this specification, he certifies that this wire is an electrode (E), the
Lesson 4
Covered Electrodes chemical composition is a chrome-moly type (B) containing a nominal 2-1/2% chromium and
for Welding Low 1% molybdenum, and it meets the other chemical requirements (3).
Alloy Steels
6.12.1.4 The specification also lists the chemical composition of the weld metal which differs
Lesson 5 slightly from the chemical requirements for the wire. The same designations are used for the
Welding Filler Metals weld metal as for the electrode classification in Figure 17 except that the letter “E” is deleted.
For example, the weld metal is designated as A2, B3, Ni2, F2, N3, etc. Since classification of
the composite electrodes is based on the weld metal composition, the letters “EC” are placed
before the weld metal classification and the electrode designation for composite electrodes
Lesson 6
Carbon & Low Alloy would be ECA2, ECB3, ECNi2, etc.
GMAW,GTAW,SAW 6.12.1.5 An example of a complete flux electrode designation would be as follows:
F8P10-ECNi2-Ni2. This designation refers to a flux (F) that will produce weld metal of a
Lesson 7 minimum 80,000 psi tensile strength (8), when postweld heat treated (P), and satisfies a
Flux Cored Arc
charpy V-notch impact strength test of at least 20 ft.-lbs. at -100°F (10) when used with a
Electrodes Carbon
Low Alloy Steels composite electrode (EC) of a nickel type (Ni) containing a nominal 2-1/2% nickel (2) and will
produce weld metal of the chemical composition specified under Ni2 in AWS Specification
A5.23-90 (Ni2).
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding 6.13 SPOOLARC LOW ALLOY WIRES FOR SUBMERGED ARC WELDING
Lesson 2
Common Electric
Arc Welding 6.13.1 Manganese-Molybdenum Wires
Processes
6.13.1.1 Spoolarc 40A, 40B, and 40 (AWS Class EA1, EA2, and EA3) - These (Mn-Mo)
wires are designed for pressure vessel fabrication requiring postweld heat treatment and weld
Lesson 3
Covered Electrodes metal tensile strength of 60 ksi, 70 ksi, and 80 ksi. They are generally used with Unionmelt 80,
for Welding 124, and 429 fluxes.
Mild Steels
6.13.2 Chromium-Molybdenum Wires
Lesson 4
Covered Electrodes 6.13.2.1 Spoolarc U515 and U521 (AWS Class EB2 and EB3) - Spoolarc U515 and
for Welding Low U521 wires are designed for welding 1-1/4% Cr - 1/2% Mo and 2-1/2% Cr - 1% Mo pressure
Alloy Steels
vessels. They can be used with Unionmelt 80, 124, and 709-5 fluxes.
6.13.3 Nickel Wire

Lesson 5
for Stainless Steels 6.13.3.1 Spoolarc ENi4 (AWS Class ENi4) - Spoolarc ENi4 is designed for single or
multipass welding on high strength steels and produces good low temperature toughness. It is
usable with Unionmelt 429, 439, 709-5, and 656 flux.
Lesson 6
Carbon & Low Alloy 6.13.4 High Strength Wires
GMAW,GTAW,SAW
6.13.4.1 Spoolarc 44 (AWS Class EF2) - Spoolarc 44 is designed for single or multipass
welding on high strength steels of 80 ksi. The addition of nickel helps it produce good low
Lesson 7 temperature toughness. It is usable with Unionmelt 709-5 and 656 fluxes.
Flux Cored Arc
Electrodes Carbon
6.13.4.2 Spoolarc 95, 100, and 120 wires (AWS Class EM2, EM5, and EF4) - Spoolarc
Low Alloy Steels
95, 100, and 120 are military grade, high strength, low temperature impact wires designed for
welding HY-80 and HY-100 steels. They are usable with Unionmelt 709-5 and 656 fluxes.
Lesson 8
Hardsurfacing 6.13.5 Special Purpose Wires
Electrodes
6.13.5.1 Spoolarc WS (AWS Class EW) - Spoolarc WS is designed for single and multi-
pass welding on weathering grade steels such as A588 and Cor-Ten. The weld chemistry
Lesson 9
produces good “color match”, “weathering resistance”, and meets fracture critical code re-
Estimating &
Comparing Weld quirements. It is usable with Unionmelt 429, 439, 709-5, and 656 fluxes.
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.14 UNIONMELT FLUXES FOR WELDING LOW
Lesson 2 ALLOY STEELS

Common Electric
Arc Welding 6.14.1 Unionmelt 429 Flux - Unionmelt 429 flux is a bonded flux developed for single or
Processes multipass butt and fillet welding on pressure vessel and structural steel fabrication. It operates
on either AC or DC, single or multiple wire operation. It has good performance in the as
Lesson 3 welded or stress relieved condition on carbon and low alloy steels.
Covered Electrodes
for Welding 6.14.2 Unionmelt 439 Flux - Unionmelt 439 flux has similar performance to 429 flux but
Mild Steels
will give higher toughness properties.
6.14.3 Unionmelt 656 Flux - Unionmelt 656 operates similar to 439 flux, but has less
Lesson 4
Covered Electrodes tolerance for rust. It should be used on clean material. It will produce excellent low tempera-
for Welding Low
Alloy Steels ture toughness, better than 439 flux.
Lesson 5
for Stainless Steels 6.15 ALLOY SHIELD COMPOSITE ELECTRODES FOR
SUBMERGED ARC WELDING OF THE LOW ALLOY STEELS
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 6.15.0.1 ESAB produces a line of composite electrodes for welding several varieties of the
GMAW,GTAW,SAW
low alloy steels. These electrodes carry the brand name Alloy Shield and are used with a
neutral flux since the alloying elements are in the electrode core.
Lesson 7
Flux Cored Arc 6.15.0.2 Alloy Shield electrodes are available in 3/32" - 5/32" diameters. Each size is
Electrodes Carbon
Low Alloy Steels available on 60 lb. coils and for maximum productivity, 500 lb. pay-off packs.
6.15.1 Alloy Shield B1S (No AWS Class) - Alloy Shield B1S is an electrode for welding
Lesson 8 the 1/2% Chrome - 1/2% Molybdenum steels. These steels are used principally in power
Hardsurfacing piping, boiler work and other moderately high temperature applications. Recommended flux is
Electrodes
Unionmelt Flux 80. If other fluxes are used, the weld deposit analysis may vary.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
A. Typical Chemical Analysis of the Weld Metal

Lesson 2 Manganese 1.03% Chromium 0.50%
Common Electric
Arc Welding Silicon 0.39% Molybdenum 0.53%
Processes
Sulfur 0.025%

Lesson 3
Covered Electrodes Stress Relieved 1 Hr. @1275°F
for Welding
Mild Steels Yield Point, psi 70,000

Covered Electrodes
Charpy V-Notch Impacts 30 ft.-lbs. @72°F
for Welding Low
Alloy Steels 20 ft.-lbs. @32°F
Lesson 5 6.15.2 Alloy Shield B2S (AWS A5.23 F8PZ-ECB2-B2) - Alloy Shield B2S is an electrode
Welding Filler Metals for welding the 1% chromium - 1/2% molybdenum and the 1-1/4% chromium - 1/2% molybde-
num steels for high temperature applications such as power piping, boiler work and tubes,
plate forgings and castings covering a wide variety of ASTM steels. Recommended flux is
Lesson 6 Unionmelt Flux 80. If other fluxes are used, weld deposit analysis may vary.
Carbon & Low Alloy
Steel Filler Metals - A. Typical Chemical Analysis of the Weld Metal
GMAW,GTAW,SAW
Manganese 0.96% Chromium 1.25%
Lesson 7 Silicon 0.37% Molybdenum 0.55%
Flux Cored Arc
Electrodes Carbon Sulfur 0.024%
Low Alloy Steels
Stress Relieved 1 Hr. @1150°F
Lesson 8
Hardsurfacing
Electrodes Tensile Strength, psi 90,000
Charpy V-Notch Impacts 22 ft.-lbs. @70°F
Lesson 9
16 ft.-lbs. @30°F
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.15.3 Alloy Shield B3S (AWS A5.23 F9PZ-ECB3-B3) - Alloy Shield B3S is an electrode
for welding 1% chromium - 1% molybdenum and the 2-1/4% chromium - 1% molybdenum
Lesson 2 steels. Used for welding in high strength, high temperature applications, such as power pip-
Common Electric
Arc Welding ing, boiler, and turbine work. Recommended flux is Unionmelt Flux 80. If other fluxes are used,
Processes weld deposit analysis may vary.

Lesson 3
Covered Electrodes
for Welding Manganese 1.03% Chromium 2.28%
Mild Steels Silicon 0.50% Molybdenum 1.08%
Sulfur 0.023%
Lesson 4
Covered Electrodes B. Typical Mechanical Properties of the Weld Metal
for Welding Low
Alloy Steels Stress Relieved 1 Hr. @1275°F
Lesson 5
for Stainless Steels Charpy V-Notch Impacts 30 ft.-lbs. @70°F
20 ft.-lbs. @32°F
Lesson 6 6.15.4 Alloy Shield Ni1S (AWS Class A5.23 F7A6-ECNi1-Ni1) - Alloy Shield Ni1S is an
Carbon & Low Alloy
Steel Filler Metals - electrode for nominal 1% Ni weld metal where notch toughness is required in the weld deposit.
GMAW,GTAW,SAW Recommended flux is Unionmelt Flux 651VF. If other fluxes are used, weld deposit analysis
may vary.
Lesson 7
Flux Cored Arc A. Typical Chemical Analysis of the Weld Metal
Electrodes Carbon Carbon 0.06% Sulfur 0.019%
Low Alloy Steels
Manganese 1.18% Phosphorus 0.024%
Silicon 0.34% Nickel 0.86%
Lesson 8
Hardsurfacing B. Typical Mechanical Properties of the Weld Metal
Electrodes
As Welded

Comparing Weld
60 ft.-lbs. @-40°F
57 ft.-lbs. @-60°F
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.15.5 Alloy Shield Ni2S (AWS 5.23 F8A6, F8P10-ECNi2-Ni2) - Alloy Shield Ni2S is a
nickel alloy electrode for applications where good impact properties are necessary at tem-
Lesson 2 peratures as low as -100°F. The weld deposit contains 2-1/2% nickel. Recommended flux is
Common Electric
Unionmelt Flux 651VF. If other fluxes are used, weld metal analysis may vary.
Arc Welding
Processes
Carbon 0.07% Sulfur 0.021%
Lesson 3
Covered Electrodes
for Welding Silicon 0.28% Nickel 2.65%
Mild Steels
Lesson 4 As Welded
Covered Electrodes Yield Point, psi 68,000 74,000
for Welding Low
Alloy Steels Tensile Strength, psi 80,000 83,500
Charpy V-Notch Impacts
Lesson 5
88 ft.-lbs. @ -40°F 92 ft.-lbs. @ -40°F
for Stainless Steels 65 ft.-lbs. @ -60°F 72 ft.-lbs. @ -60°F
35 ft.-lbs. @-100°F 50 ft.-lbs. @-100°F
Lesson 6 6.15.6 Alloy Shield M2S (AWS A5.23 F11A6-ECM2-M2) - Alloy Shield M2S is an elec-
Carbon & Low Alloy
Steel Filler Metals - trode for welding the T-1 and other similar high strength steels. Despite its high strength, the
GMAW,GTAW,SAW weld metal has good impact properties. Recommended flux is Unionmelt Flux 651VF. If other
fluxes are used, the weld metal analysis may vary.
Lesson 7
Electrodes Carbon Carbon 0.06% Phosphorus 0.016%
Low Alloy Steels
Manganese 1.6% Nickel 1.83%
Silicon 0.64% Molybdenum 0.49%
Lesson 8 Sulfur 0.014%

Hardsurfacing B. Typical Mechanical Properties of the Weld Metal
Electrodes
As Welded
Estimating &
Comparing Weld % Elongation (2") 23
Metal Costs Charpy V-Notch Impacts 62 ft.-lbs. @ 0°F
27 ft.-lbs. @-60°F
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.15.7 Alloy Shield M3S (AWS A5.23 F11A4-ECM3-M3) - Alloy Shield M3S is an elec-
trode for welding T-1 and other similar high strength steels requiring tensile strengths of
Lesson 2 110,000 to 120,000 psi. It produces good low temperature impacts and is approved by the
Common Electric
Arc Welding American Bureau of Shipping. Recommended flux is Unionmelt Flux 651VF. If other fluxes are
Processes used, the weld metal analysis may vary.

Covered Electrodes
Manganese 1.10% Chromium 0.40%
for Welding
Mild Steels Silicon 0.39% Nickel 2.63%
Sulfur 0.017% Molybdenum 0.61%
Lesson 4
for Welding Low As Welded
Alloy Steels
for Stainless Steels Charpy V-Notch Impacts 44 ft.-lbs. @-40°F
37 ft.-lbs. @-60°F
Lesson 6 6.15.8 Alloy Shield WS (AWS Class A5.23 F7A2-ECW-W) - Alloy Shield WS is for
Carbon & Low Alloy
welding “weathering” grade steels. Weld deposit will color match to the weathering steel after
GMAW,GTAW,SAW exposure to the atmosphere. Recommended flux is Unionmelt Flux 651VF. If other fluxes are
used, the weld metal analysis may vary.
Lesson 7 Typical Chemical Analysis of the Weld Metal

A.
Flux Cored Arc
Electrodes Carbon Carbon 0.06% Phosphorus 0.017%
Low Alloy Steels Manganese 0.76% Chromium 0.54%
Silicon 0.31% Nickel 0.68%
Sulfur 0.013% Copper 0.49%
Lesson 8
Hardsurfacing
Electrodes B. Typical Mechanical Properties of the Weld Metal
As Welded
Lesson 9
Estimating & Tensile Strength, psi 77,000
Comparing Weld % Elongation (2") 28
Metal Costs
Charpy V-Notch Impacts 91 ft.-lbs. @ 72°F
32 ft.-lbs. @-20°F
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
6.15.9 Alloy Shield F2S (AWS A5.23 F10P2-ECF2-F2) - Alloy Shield F2S wire devel-
oped for welding SAE 4130 and similar hardenable steels. Retains excellent properties after
Lesson 2 stress relieving or quench and tempering. Good choice for oil field equipment requiring less
Common Electric
Arc Welding than 1% nickel. Recommended flux is Unionmelt Flux 709-5. If other fluxes are used, the weld
Processes metal analysis may vary.

Lesson 3
Covered Electrodes
for Welding Manganese 1.63% Nickel 0.69%
Mild Steels Silicon 0.52% Molybdenum 0.55%
Sulfur 0.012%
Lesson 4
for Welding Low
Stress-Relieved 12 hrs. @1150°F.
Alloy Steels
Lesson 5
for Stainless Steels Charpy V-Notch Impacts 67 ft.-lbs. @ 32°F
35 ft.-lbs. @-20°F
Lesson 6 6.15.10 Alloy Shield 420SB (No AWS Class) - Alloy Shield 420SB was specially devel-
Carbon & Low Alloy
Steel Filler Metals - oped to match the analysis for continuous caster roll found in the steel making industry. Rec-
GMAW,GTAW,SAW ommended flux is Unionmelt Flux S-420SB. If other fluxes are used, the weld metal analysis
may vary.
Lesson 7
Electrodes Carbon Carbon 0.28% Sulfur 0.010%
Low Alloy Steels
Silicon 0.20% Chromium 11.70%
Lesson 8
Hardsurfacing B. Hardness of Deposited Weld Metal
Electrodes
1 Layer on 1045 Steel - 54 Rockwell C
2 Layers on 1045 Steel - 51 Rockwell C
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
APPENDIX A
LESSON VI - GLOSSARY OF TERMS
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3 Composite
Covered Electrodes - A filler metal electrode used in arc welding, consisting of more than one metal
for Welding Electrode component combined mechanically. It may or may not include materials which
Mild Steels
protect the molten metal from the atmosphere, improve the properties of the
weld metal or stabilize the arc.
Lesson 4
Covered Electrodes Work Harden - The development of hardness in metals as a result of cold working such as
for Welding Low
forming, bending, or drawing.
Alloy Steels
Anneal - The process of heating a metal to a temperature below the critical range,
Lesson 5 followed by a relatively slow cooling cycle to induce softness and remove
Welding Filler Metals stresses.
Deoxidizers - Elements, such as manganese, silicon, aluminum, titanium, and zirconium,
used in welding electrodes and wires to prevent oxygen from forming harmful
Lesson 6
oxides and porosity in weld metal.
Carbon & Low Alloy
GMAW,GTAW,SAW Flux - Material used to prevent, dissolve, or facilitate removal of oxides and other
undesirable substances in welding, soldering, or brazing. In submerged arc
Lesson 7 welding, the flux shields the molten puddle from the atmosphere which helps
Flux Cored Arc to influence the mechanical weld metal deposit.
Electrodes Carbon
Low Alloy Steels
Bonded - Bonded fluxes are manufactured by binding an assortment of powder together
Fluxes and then baking at a low temperature. The major advantage is that addi-
Lesson 8
Hardsurfacing tional alloying ingredients can be added to the mixture.
Electrodes
Fused - Fused fluxes are melted ingredients which have been chilled and ground to a
Lesson 9 Fluxes particular particle size. The advantage of this type flux is the low moisture
Estimating &
Comparing Weld pick-up and improved recycling capabilities.
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VI
The Basics of Arc
Welding
Active - Active fluxes produce changes in weld metal chemistry when welding is
Lesson 2 Fluxes changed. Active fluxes are restricted to single or minimal multipass welding.
Common Electric
Arc Welding
Processes
Neutral - Neutral fluxes produce little change to mechanical properties when adjusting
Fluxes the voltage. Best utilized when welding on plate thickness of one inch or
Lesson 3 more.
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
for Welding
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Lesson 5
Lesson 6 LESSON VII

Carbon & Low Alloy
GMAW,GTAW,SAW
FLUX CORED ARC WELDING
ELECTRODES FOR CARBON
Lesson 7
Flux Cored Arc & LOW ALLOY STEELS
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
©COPYRIGHT 2000 ESAB WELDING & CUTTING PRODUCTS

Lesson 1
LESSON VII
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON VII
Lesson 2 FLUX CORED ARC WELDING ELECTRODES
Common Electric
Arc Welding
FOR CARBON & LOW ALLOY STEELS
Lesson 3
Covered Electrodes Part I - Flux Cored Arc Welding Electrodes for
for Welding Carbon and Low Alloy Steels ............................................................. 1
Mild Steels
7.1 INTRODUCTION ................................................................................ 1

Lesson 4
Covered Electrodes 7.2 MANUFACTURING FLUX CORED ELECTRODES........................... 1
for Welding Low
Alloy Steels 7.3 FEATURES OF FLUX CORED ELECTRODES ................................. 3
7.3.1 Functions of the Flux Ingredients ........................................................ 3
7.3.2 Slag Systems ...................................................................................... 4
Lesson 5
for Stainless Steels 7.4 GAS SHIELDED TYPES .................................................................. 4
7.4.1 Joint Design ...................................................................................... 4
7.4.2 Shielding Gas ................................................................................... 6
Lesson 6 7.4.3 Electrode Extension .......................................................................... 7
Carbon & Low Alloy
7.4.4 All-Position Electrodes ...................................................................... 7
GMAW,GTAW,SAW 7.4.5 Mild Steel Electrodes ........................................................................ 7
7.4.6 Low Alloy Electrodes ......................................................................... 7
Lesson 7
7.5 SELF-SHIELDED ELECTRODES .................................................... 7
Flux Cored Arc
Electrodes Carbon 7.5.1 Electrode Extension .......................................................................... 8
Low Alloy Steels 7.5.2 All-Position Electrodes ...................................................................... 8
7.5.3 High Deposition Types ...................................................................... 8
Lesson 8 7.6 AWS SPECIFICATION A5.20-95 ...................................................... 9

Hardsurfacing
Electrodes 7.6.1 Tensile Strength and Elongation ....................................................... 9
7.6.2 Usability and Performance................................................................ 10
7.6.3 Chemical Composition Requirements .............................................. 10
Lesson 9
Estimating & 7.7 INDIVIDUAL ELECTRODE CHARACTERISTICS ........................... 11
Comparing Weld
7.7.1 EXXT-1 & EXXT-1M .......................................................................... 11
Metal Costs
7.7.2 EXXT-2 ............................................................................................. 12
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
Lesson 2
TABLE OF CONTENTS
Common Electric LESSON VII - Con't.
Arc Welding
7.7.3 EXXT-3 ............................................................................................. 12

Lesson 3
Covered Electrodes 7.7.4 EXXT-4 ............................................................................................. 12
for Welding 7.7.5 EXXT-5 ............................................................................................. 12
Mild Steels
7.7.6 EXXT-6 ............................................................................................. 13
7.7.7 EXXT-7 ............................................................................................. 13
Lesson 4 7.7.8 EXXT-8 ............................................................................................. 13
Covered Electrodes
for Welding Low 7.7.9 EXXT-9 & EXXT-9M ......................................................................... 13
Alloy Steels 7.7.10 EXXT-10 ........................................................................................... 13
7.7.11 EXXT-11 ........................................................................................... 13
Lesson 5 7.7.12 EXXT-12 & EXXT-12M ..................................................................... 13

Welding Filler Metals 7.7.13 EXXT-G ............................................................................................ 14
7.7.14 EXXT-GS .......................................................................................... 14
Part II - Individual Dual Shield Flux Cored Wires For

Lesson 6
Carbon & Low Alloy Welding Carbon Steels .................................................................................... 15
GMAW,GTAW,SAW 7.8 ELECTRODE SELECTION .............................................................. 15
7.9 AWS E70T-1 ELECTRODES ........................................................... 15

Lesson 7
Flux Cored Arc 7.9.1 DUAL SHIELD ARC 70 ..................................................................... 15
Electrodes Carbon
7.9.2 DUAL SHIELD 111A-C ...................................................................... 16
Low Alloy Steels
7.9.3 DUAL SHIELD 111HD ....................................................................... 16
7.9.4 DUAL SHIELD R-70 ULTRA ............................................................. 16
Lesson 8
Hardsurfacing 7.10 COREWELD METAL CORED WIRES ............................................. 17
Electrodes 7.10.1 COREWELD 70 ................................................................................ 17
7.10.2 COREWELD ULTRA ........................................................................ 18
Lesson 9 7.11 AWS E70T-2 ELECTRODES ........................................................... 18

Estimating &
7.11.1 DUAL SHIELD 110............................................................................ 19
Comparing Weld
Metal Costs 7.11.2 DUAL SHIELD SP............................................................................. 19
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON VII
Welding
TABLE OF CONTENTS
LESSON VII - Con't.
Lesson 2
Common Electric
Arc Welding

Lesson 3 7.12.1 DUAL SHIELD T-5 & T-75 ................................................................. 20
Covered Electrodes
for Welding
7.13 ALL-POSITION ELECTRODES....................................................... 20
Mild Steels
7.13.1 DUAL SHIELD 7000 ......................................................................... 20
7.13.2 DUAL SHIELD 7100 ULTRA ............................................................. 21
Lesson 4 7.13.3 DUAL SHIELD FC-717 ..................................................................... 21
Covered Electrodes
for Welding Low 7.13.4 DUAL SHIELD II 70 ULTRA & DUAL SHIELD II 71 ULTRA ................ 22
Alloy Steels
7.14 CORESHIELD SELF-SHIELDED FLUX CORED WIRES .............. 23
Lesson 5 7.15 AWS E70T-4 ELECTRODES ........................................................... 23

Welding Filler Metals 7.15.1 CORESHIELD 40 .............................................................................. 23
7.16.1 CORESHIELD 7 ................................................................................ 23
Lesson 6
Carbon & Low Alloy
7.17 AWS E70T-10 ELECTRODES ......................................................... 24
GMAW,GTAW,SAW 7.17.1 CORESHIELD 10 .............................................................................. 24
7.18 AWS E70T-11 ELECTRODES ......................................................... 24

Lesson 7 7.18.1 CORESHIELD 11 .............................................................................. 24
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 7.19 AWS E71T-GS ELECTRODES ........................................................ 25
7.19.1 CORESHIELD 15 .............................................................................. 25
Lesson 8 7.20 AWS SPECIFICATION A5.29-80 ...................................................... 25

Hardsurfacing
Electrodes 7.21 AWS DESIGNATIONS...................................................................... 25
7.22 USABILITY AND PERFORMANCE ................................................. 26

Lesson 9
Estimating & 7.23 MECHANICAL PROPERTIES REQUIREMENTS ........................... 27
Comparing Weld
Metal Costs 7.24 WELD METAL CHEMICAL COMPOSITION REQUIREMENTS...... 27
7.24.1 Carbon-Molybdenum ......................................................................... 27
7.24.2 Chromium-Molybdenum ..................................................................... 27
Lesson 10
7.24.3 Nickel Steel Electrodes ..................................................................... 28
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
TABLE OF CONTENTS
Lesson 2
LESSON VII - Con't.
Common Electric
Arc Welding
7.24.4 Manganese-Molybdenum................................................................... 28
Lesson 3
Covered Electrodes 7.24.5 All Other Low Alloy Steel Electrodes .................................................. 29
for Welding
Mild Steels 7.25 IMPACT PROPERTIES .................................................................... 30
7.26 SELECTING THE PROPER LOW ALLOY ELECTRODE ............... 31

Lesson 4
Covered Electrodes 7.26.1 Dissimilar Steels ............................................................................... 31
for Welding Low 7.26.2 Welding Procedures .......................................................................... 32
Alloy Steels
7.27 ADVANCED DEVELOPMENTS IN FLUX CORED ELECTRODES 32
Lesson 5 7.28 DUAL SHIELD SELECTOR GUIDE ................................................ 33

APPENDIX A - GLOSSARY OF TERMS ............................................................... 38
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
FLUX CORED ARC WELDING ELECTRODES
Lesson 2 FOR CARBON AND LOW ALLOY STEELS
Common Electric
Arc Welding
Processes 7.1 INTRODUCTION
Lesson 3 Gas shielded flux cored electrodes for welding carbon steels were developed in the early
Covered Electrodes 1950’s and were made commercially available in 1957. This process was developed to
for Welding
combine the best features of submerged arc welding and CO2 welding. The combination of
Mild Steels
the fluxing ingredients in the core and the external CO2 gas shield produce high quality
welds and a stable arc with a low spatter level. Initially, these electrodes were available
Lesson 4 only in the larger diameters (5/64"-5/32") and were for use in the flat or horizontal positions
Covered Electrodes
for Welding Low on heavy weldments. In 1972, small diameter gas shielded flux cored electrodes for weld-
Alloy Steels ing in all positions were developed, and this greatly expanded the flux cored arc welding
field.
Lesson 5
Welding Filler Metals 7.1.0.1 Self shielded flux cored electrodes were made available shortly after the gas
for Stainless Steels shielded types were introduced and both have gained industry wide acceptance for specific
applications. The major differences of the two types were covered in Lesson II and should
be reviewed at this time.
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 7.2 MANUFACTURING FLUX CORED ELECTRODES
GMAW,GTAW,SAW
Manufacturing flux cored electrodes requires close controls. Since the weld metal is a
Lesson 7 combination of the metal sheath and the flux ingredients, both must be closely checked for
Flux Cored Arc size and chemical composition before fabrication begins.
Electrodes Carbon
Low Alloy Steels
7.2.0.1 Since the space within the wire is limited, particle size of the ingredients be-
comes very important, so that the particles will “nest” together. Flux ingredients must be
Lesson 8 totally mixed or blended and measures taken to prevent segregation of the elements before
Hardsurfacing fabrication.
Electrodes
7.2.0.2 Most flux cored electrodes are manufactured from a flat metal strip that is passed
through a mill where forming rolls progressively shape it into a U-shaped section. A me-
Lesson 9
Estimating & tered amount of granular flux is fed into the formed strip. It then passes through the closing
Comparing Weld rolls, forming the strip into a tube and tightly compressing the core material. See Figure 1.
Metal Costs
7.2.0.3 The tube is then pulled through a series of drawing dies that reduce it to its final
size, and further compress the flux to lock it in place within the tube.
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
STRIP STEEL
Lesson 2
Common Electric FLUX
Arc Welding HOPPER
Processes
"U" FORMING ROLLS

Lesson 3 FLUX FILL
Covered Electrodes
for Welding
TO
Mild Steels DRAWING
OPERATION
CLOSING
ROLLS
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels FLUX CORED ELECTRODE FORMING OPERATION
FIGURE 1
Lesson 5 7.2.0.4 During manufacture, close control to assure that flux voids do not occur through-
for Stainless Steels out the entire length of the wire is necessary. Also, the surface of the wire must be smooth
and free of contaminants that may be detrimental to feeding and welding current transfer to
the wire. The wire must be carefully wound on spools, coils, or into drums, so that kinks or
Lesson 6 bends do not occur. Spools and coils are usually packaged in plastic with some sort of
Carbon & Low Alloy
Steel Filler Metals - desiccant material to absorb moisture within the package, and are then placed in a card-
GMAW,GTAW,SAW board carton for protection.
7.2.0.5 Flux cored electrodes are manufactured in several different configurations. The
Lesson 7
Flux Cored Arc most common are shown in Figure 2. The butt type is used for electrodes where a rela-
Electrodes Carbon tively heavy steel strip is used, and the core ingredients can be lower in volume. Most of
Low Alloy Steels
the carbon steel and low alloy steel electrodes of 7/64" diameter and smaller are of this
configuration. Some of the larger diameters and electrodes for the high alloys, such as
stainless steel where it is necessary to include more alloying elements in the core, are of
Lesson 8
Hardsurfacing the lap or heart-shaped configuration.
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs BUTT LAP HEART SHAPED
FLUX CORED ELECTRODE CONFIGURATIONS
Lesson 10 FIGURE 2
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.3 FEATURES OF FLUX CORED ELECTRODES
Lesson 2 Flux cored electrodes combine the advantages of several of the welding processes we
Common Electric have discussed earlier. As with coated electrodes, the flux improves the weld metal chemi-
Arc Welding
cal composition and mechanical properties. As in gas metal arc welding and submerged
Processes
arc welding, productivity is increased because the electrode is continuous.
Lesson 3 7.3.0.1 Flux cored electrodes may be used for welding carbon steels, low alloy high
Covered Electrodes strength steels, and the high strength quenched and tempered steels. They are also used
for Welding
Mild Steels for welding stainless steels and abrasion resistant steels. These will be covered in subse-
quent lessons.
Lesson 4 7.3.1 Functions of the Flux Ingredients - As with coated ingredients, each manufac-
Covered Electrodes
for Welding Low turer has his own formulas for the flux ingredients. The composition of the flux core can be
Alloy Steels varied to provide electrodes for specific applications.
7.3.1.1 The basic functions of the flux ingredients are:

Lesson 5
Welding Filler Metals Deoxidizers and Denitrifiers - Since nitrogen and oxygen can cause porosity or
a)
brittleness, deoxidizers such as manganese and silicon are added. In the case of
self-shielded electrodes, denitrifiers such as aluminum are added. Both help to
Lesson 6 purify the weld metal.
Carbon & Low Alloy
Steel Filler Metals - b) Slag Formers - Slag formers such as oxides of calcium, potassium, silicon or so-
GMAW,GTAW,SAW
dium are added to protect the molten weld puddle from the atmosphere. The slag
aids in improving the weld bead shape and “fast freezing” slags help hold the weld
Lesson 7 puddle for out-of-position welding. The slag also retards the cooling rate, especially
Flux Cored Arc
Electrodes Carbon important when welding the low alloy steels.
Low Alloy Steels
c) Arc Stabilizers - Elements, such as potassium and sodium, help produce a smooth
arc and reduce spatter.
Lesson 8
Hardsurfacing d) Alloying Elements - Alloying elements, such as molybdenum, chromium, carbon,
Electrodes
manganese, nickel, and vanadium, are used to increase strength, ductility, hardness
and toughness.
Lesson 9
e) Gasifiers - Minerals, such as fluorspar and limestone, are usually used to form a
Estimating &
Comparing Weld shielding gas in the self-shielded type wires.
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.3.2 Slag Systems - The ingredients in the core determine the weldability of the
electrode and the mechanical properties of the weld metal. Electrodes that have a prepon-
Lesson 2 derance of flux components of an acidic nature produce an acid type slag. Those elec-
Common Electric
Arc Welding trodes that are composed of larger amounts of components of a basic nature are said to
Processes produce a basic type slag. Electrodes produced with an acid slag system have excellent
weldability. This means that the arc is smooth and spray-like with very little spatter, and
these electrodes have high operator appeal. The mechanical properties are good and
Lesson 3
Covered Electrodes meet or exceed AWS specifications.
for Welding
Mild Steels 7.3.2.1 Electrodes having a basic slag system produce weld metal with excellent ductility
and notch toughness. The weldability is not as good as that of the acid slag types. Metal
Lesson 4 transfer is more globular, resulting in a bit more spatter. Figure 3 shows the characteristics
Covered Electrodes of the two slag systems.
for Welding Low
Alloy Steels
7.3.2.2 Some low alloy electrodes are now being produced utilizing a recent develop-
ment in slag systems, that combines the excellent weldability of the acid slag types with the
Lesson 5 excellent mechanical properties of the basic slag types.
SLAG MECHANICAL
SYSTEMS WELDABILITY PROPERTIES
Lesson 6
Acid Excellent Good
Carbon & Low Alloy
Steel Filler Metals - Basic Fair Excellent
GMAW,GTAW,SAW Rutile Basic Excellent Excellent
SLAG SYSTEM CHARACTERISTICS
Lesson 7 FIGURE 3
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
7.4 GAS SHIELDED TYPES
Lesson 8 Gas shielded flux cored electrodes are available in diameters of .035" to 1/8" and utilize
Hardsurfacing
Electrodes reverse polarity (electrode positive) welding current, resulting in high deposition rates, deep
penetration, and a relatively smooth arc. High deposition rates mean that the weld metal
can be deposited more quickly, saving labor and overhead costs, the largest part of the
Lesson 9 total welding cost.
Estimating &
Comparing Weld 7.4.1 Joint Design - Another factor that influences the cost of deposited weld metal is
Metal Costs
the joint design. Figure 4 shows the single-vee joints suggested by the American Welding
Society for producing sound welds with the least amount of weld metal for the SMAW and
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2 2.691 2.354 1.721

Common Electric lbs./ft. lbs./ft. lbs./ft.
Arc Welding 1" 1" 1"
Processes
1/4" 3/8" 3/16"

Lesson 3
Covered Electrodes SHIELDED SELF SHIELDED GAS SHIELDED
METAL ARC FLUX CORED FLUX CORED
for Welding
Mild Steels FLUX CORED ARC WELDING VERSUS SHIELDED METAL ARC WELDING
WEIGHT OF WELD METAL PER FOOT OF JOINT
FIGURE 4
Lesson 4
the FCAW processes. SMAW requires a larger included angle and a considerable root
Covered Electrodes
for Welding Low opening on vee joints, so that the larger diameter of the coated electrode can reach down
Alloy Steels into the joint to assure a good root pass. Because of the smaller diameter of the flux cored
electrodes, the included angle may be smaller, and in the case of the CO2 gas shielded
Lesson 5 types that have very deep penetration, the required root opening may be very small or in
Welding Filler Metals some cases eliminated. Figure 4 shows the calculated weight of the weld metal per foot of
weld for each joint. The self-shielded flux cored joint requires .337 lbs (13%) less weld
metal than the shielded metal arc joint. The gas shielded flux cored joint requires .970 lbs
Lesson 6 (36%) less than the shielded metal arc joint.

Carbon & Low Alloy
Steel Filler Metals - 7.4.1.1 Comparable savings in the quantity of filler metal can be achieved in fillet welds
GMAW,GTAW,SAW
made with the gas shielded flux cored process. Conventionally, fillet welds are specified
and measured by the leg length of the largest triangle that can be inscribed in the
Lesson 7 cross-section of the weld. The load carrying dimension, the one that determines the
Flux Cored Arc
strength of the weld, is the throat dimension. Figure 5A shows a sketch of a typical fillet
Electrodes Carbon
Low Alloy Steels weld made with E7018 electrodes. The 1/2" leg weld that results in a throat dimension of
0.35", has a cross-sectional area of 0.125 square inches. This weld requires 0.425 pounds
Lesson 8
Hardsurfacing .35 THROAT .35 THROAT
Electrodes
Lesson 9
Estimating &
Comparing Weld 1/2 LEG 3/8 LEG
Metal Costs A E7018 B GAS SHIELDED FLUX
CORED
FILLET WELD SIZE COMPARISON - SMAW vs. GAS SHIELDED FCAW
Lesson 10 FIGURE 5
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
of filler metal per foot of weld. Figure 5B shows a sketch of a typical fillet weld made with
the flux cored CO2 shielded process. The leg length of this weld measures only 3/8". The
Lesson 2 deep penetration of the process results in a throat dimension equal to that in Figure 5A,
Common Electric
Arc Welding 0.35". The cross-sectional area of this fillet weld is 0.070 square inches and requires 0.239
Processes pounds of weld metal per foot of weld. This results in a savings of 0.186 pounds per foot of
weld, or a savings of 44% in weld metal volume. It should be remembered that not only is
the cost of the weld metal saved, but also the cost of the labor and overhead that would be
Lesson 3
Covered Electrodes
for Welding
WELD METAL
Mild Steels FILLET SIZE CU. IN/IN % INCREASE
1/4 .031
Lesson 4
Covered Electrodes 58%
for Welding Low 5/16 .049
Alloy Steels
43%
3/8 .070
Lesson 5
Welding Filler Metals 78.5%
for Stainless Steels 1/2 .125
Lesson 6
Carbon & Low Alloy COST OF OVERWELDING
Steel Filler Metals - FIGURE 6
GMAW,GTAW,SAW
spent in depositing the extra metal. The chart in Figure 6 shows the increase in volume of
Lesson 7 weld metal required as the fillet size increases. It shows that if a 5/16" fillet weld is made
Flux Cored Arc where a 1/4" fillet would suffice, more than half (58%) of the amount of weld metal is
Electrodes Carbon
Low Alloy Steels wasted.
7.4.2 Shielding Gas - Gas shielded flux cored electrodes require that an adequate
Lesson 8 gas shield be present at all times. Gusty or high velocity winds cannot be tolerated and in
Hardsurfacing such instances, it may be necessary to place a curtain or other wind screen around the
Electrodes
operator. Light breezes will not affect the gas shield. Inadequate gas shielding will be
evidenced by porosity on the surface of the weld metal.
Lesson 9
Estimating & 7.4.2.1 CO2 is the most common shielding gas used; however, Argon-CO2 mixtures may
Comparing Weld be recommended for some types. The gas shield effectively protects the arc from atmo-
Metal Costs
spheric oxygen and nitrogen but some oxygen will be present from the dissociation of the
shielding gas. The deoxidizers in the core materials allow the electrodes to tolerate these
Lesson 10 small amounts of oxygen. The need to denitrify the weld metal is of less importance be-
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
cause the shielding gas keeps atmospheric nitrogen from the weld zone. The
manufacturer’s shielding gas recommendation should be followed. Shielding gas flow
Lesson 2 rates of 30 to 45 cubic feet per hour are used depending on the electrode size, electrode
Common Electric
Arc Welding extension, and other welding conditions.
Processes
7.4.3 Electrode Extension - Electrode extension is the length of an electrode protrud-
ing beyond the end of the contact tip during welding. This dimension is commonly referred
Lesson 3
to as “electrical stickout” and is relatively short when using gas shielded flux cored elec-
Covered Electrodes
for Welding trodes (3/4" to 1-1/2"). This short electrical stickout with a relatively high welding current
Mild Steels produces narrow, deep penetrating welds.
7.4.4 All-Position Electrodes - Gas shielded, all-position flux cored electrodes con-
Lesson 4
Covered Electrodes tain ingredients in the core that produce a fast freezing slag, and the proper puddle fluidity
for Welding Low for vertical, overhead, or other out-of-position welding. They are available in .045", .052",
Alloy Steels
and 1/16" diameters. Since the slag helps hold the puddle, the welding voltage and current
may be relatively high, resulting in high deposition rates. The deep penetration of these
Lesson 5 electrodes limits the minimum material thickness to 1/8" in the vertical position, and 3/16" in
the flat or horizontal position.
7.4.5 Mild Steel Electrodes - Gas shielded mild steel electrodes are available for
general purpose welding, welding through rust and mill scale of varying degrees,
Lesson 6
Carbon & Low Alloy out-of-position welding, and for applications when high mechanical properties or high
Steel Filler Metals - impact values are necessary. Electrodes designed for high deposition rates and high
GMAW,GTAW,SAW
deposition efficiency are also available. Most of the mild steel electrodes utilize CO2 as the
shielding gas; however, some may use Argon/CO2 mixtures.
Lesson 7
Flux Cored Arc 7.4.6 Low Alloy Electrodes - Gas shielded flux cored electrodes are widely used for
Electrodes Carbon
Low Alloy Steels welding the low alloy, high strength steels. They are available for welding the
carbon-molybdenum, chromium-molybdenum, nickel, manganese-molybdenum and the
high strength quenched and tempered steels. The combination of an external gas shield
Lesson 8 and the fluxing elements in the core produce high purity weld metal.
Hardsurfacing
Electrodes
7.5 SELF-SHIELDED ELECTRODES
Lesson 9 Self-shielded electrodes rely solely on the materials in the core of the wire for shielding the
Estimating &
Comparing Weld arc from the atmosphere, purifying the weld metal and providing the slag formers neces-
Metal Costs sary to protect the molten weld puddle. These electrodes do not rely on gas shielding as
the gas shielded types do; therefore, they can operate more effectively in outdoor environ-
ments without a windscreen.
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.5.0.1 Self-shielded electrodes are extensively used in mild steel welding applications.
A few electrodes are available containing 1% nickel for improved strength and impact
Lesson 2 properties.
Common Electric
Arc Welding
Processes 7.5.0.2 Being a continuous welding process, self-shielded electrodes are capable of
higher deposition rates than coated electrodes, and are designed for specific applications
such as general purpose welding, assembly and repair welding, out-of-position welding,
Lesson 3
and high deposition welding. Some electrodes are specifically designed for welding lighter
Covered Electrodes
for Welding gauge materials (.047" to 3/16" thickness) at high speeds. Self-shielded electrodes are
Mild Steels available in diameters ranging from .030" to 5/32".
7.5.1 Electrode Extension - Self-shielded flux cored electrodes utilize a longer elec-
Lesson 4
Covered Electrodes trode extension than the gas shielded types. The electrode extension ranges from 1/2" to
for Welding Low 3-3/4" depending on the electrode type, and the application. The longer length of wire
Alloy Steels
beyond the contact tip decreases the arc voltage, since the additional wire acts as a resis-
tance. It causes the wire to heat and is accompanied by a lower welding current (amper-
Lesson 5 age). This lower voltage and amperage results in a narrow, shallow weld bead that does
not melt as much of the base metal, allowing the process to be used on welding thinner
material and for poor fit-up applications. If the welding current and voltage are increased,
the deposition rate will increase, and to a lesser degree, so will the penetration. It is impor-
Lesson 6 tant that the manufacturer’s recommendations for each type and size of electrode are
Carbon & Low Alloy followed.
GMAW,GTAW,SAW
7.5.2 All-Position Electrodes - The self-shielded all-position electrodes utilize direct
current, straight polarity (electrode negative). Penetration is low, making them suitable for
Lesson 7 bridging gaps in poor fit-up applications. Optimum welding current and amperage settings
Flux Cored Arc
Electrodes Carbon are lower than those with the gas shielded types. The .068" and 5/64" diameters are most
Low Alloy Steels commonly used for out-of-position work, although the 3/32" may be used in some cases.
Electrical stickout between 1/2" to 1" is recommended for these wires.
Lesson 8 7.5.3 High Deposition Types - The high deposition types of self-shielded wires utilize
Hardsurfacing
Electrodes long electrical stickout (1-1/2" to 3-3/4") and most use reverse polarity (electrode positive).
Designed for use in the flat or horizontal positions only, they are commonly available in the
5/64", 3/32", 7/64", and .120" diameters.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2 This American Welding Society (AWS) Specification is entitled Specification For Carbon
Common Electric Steel Electrodes For Flux Cored Arc Welding. It prescribes the requirements for classifying
Arc Welding
flux cored electrodes for welding carbon steels or low alloy steels.
Processes
7.6.0.1 The following requirements will be covered in this text:

Lesson 3
Covered Electrodes 1. Whether gas shielded or self-shielded
for Welding 2. Single pass or multiple pass
Mild Steels
3. Type of welding current
4. Welding position
Lesson 4 5. As-welded mechanical properties of the weld metal
Covered Electrodes
for Welding Low 6. Chemical composition of the weld metal
Alloy Steels
7.6.0.2 The letter-number designations in this specification are shown in Figure 7.
Lesson 5
Electrode
for Stainless Steels Min. Tensile Strength X 10,000 psi
0: Flat and Horizontal
1: All Position
Lesson 6
EX X T - X
Carbon & Low Alloy
GMAW,GTAW,SAW Usability, Performance & Impacts
Tubular or Flux Cored
Lesson 7 CARBON STEEL FLUX CORED ELECTRODE DESIGNATIONS

Flux Cored Arc
FIGURE 7
Electrodes Carbon
Low Alloy Steels
7.6.0.3 As an example, the designation E71T-1 indicates an electrode (E) that will pro-
Lesson 8 duce weld metal of a minimum 72,000 psi ultimate tensile strength (7), may be used for
Hardsurfacing welding in all positions (1), is a flux cored electrode (T), is a multipass gas shielded type for
Electrodes
operation on direct current, reverse polarity (electrode positive), and must have a minimum
Charpy V-notch value of 20 ft.-lbs at 0°F (Figure 9).
Lesson 9
7.6.1 Tensile Strength and Elongation - The specification has only two tensile
Estimating &
Comparing Weld strength classifications. They are shown in Figure 8.
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
TENSILE YIELD* ELONGATION*
AWS STRENGTH STRENGTH PERCENT IN
Lesson 2 CLASSIFICATION psi. psi. 2 INCHES
Common Electric
Arc Welding E6XT-X 62,000 50,000 22
Processes E7XT-X 72,000 60,000 22
* E6XT-GS, E7XT-2, E7XT-3, E7XT-10 and E7XT-GS have no yield strength or elongation requirements.
Lesson 3 WELD METAL MECHANICAL PROPERTIES OF CARBON STEEL

Covered Electrodes FLUX CORED ELECTRODES
for Welding
Mild Steels FIGURE 8
7.6.2 Usability and Performance - The number of passes, shielding gas require-
Lesson 4
ments, type of welding current and the impact requirements, are all specified by the last
Covered Electrodes
for Welding Low digit or letter in the electrode designation. The significance of the last digit or letter is
Alloy Steels shown in Figure 9.
AWS Classification Shielding Gas Current and Polarity V-notch impact

Lesson 5
Welding Filler Metals EXXT-1 Multiple Pass CO 2
DCEP 20 ft.-lbs. @0°F*
EXXT-1M Multiple Pass 75-80%Ar/bal CO DCEP 20 ft.-lbs. @0°F*
for Stainless Steels 2
EXXT-2 Single Pass CO 2

DCEP Not Specified
EXXT-2M Single Pass 75-80%Ar/bal CO 2
DCEP Not Specified
EXXT-3 Single Pass None DCEP Not Specified
EXXT-4 Multiple Pass None DCEP Not Specified
Lesson 6 EXXT-5 Multiple Pass CO 2
DCEP or DCEN 20 ft.-lbs. @-20°F*
Carbon & Low Alloy EXXT-5M Multiple Pass 75-80%Ar/bal CO 2
DCEP or DCEN 20 ft.-lbs. @-20°F*
Steel Filler Metals - EXXT-6 Multiple Pass None DCEP 20 ft.-lbs. @-20°F*
GMAW,GTAW,SAW EXXT-7 Multiple Pass None DCEN Not Specified
EXXT-8 Multiple Pass None DCEN Not Specified
EXXT-9 Multiple Pass CO 2
DCEP 20 ft.-lbs. @-20°F*
EXXT-9M Multiple Pass 75-80%Ar/bal CO 2
Lesson 7 EXXT-10 Single Pass None DCEN Not Specified
Flux Cored Arc EXXT-11 Multiple Pass None DCEN Not Specified
Electrodes Carbon EXXT-12 Multiple Pass CO 2
EXXT-12M Multiple Pass 75-80%Ar/bal CO DCEP 20 ft.-lbs. @-20°F*
Low Alloy Steels 2
EXXT-G Multiple Pass Not Specified Not Specified Not Specified

EXXT-GS Single Pass Not Specified Not Specified Not Specified
* "J" Designation indicates V-notch impact values of 20 ft.-lbs. @-40°F
Lesson 8
USABILITY, PERFORMANCE AND IMPACT VALUES
Hardsurfacing FLUX CORED ELECTRODE DESIGNATIONS
Electrodes
FIGURE 9
7.6.3 Chemical Composition Requirements - The chemical requirements of the weld

Lesson 9
Estimating & metal are specified only for the multipass electrodes, since the single pass types would
Comparing Weld show high dilution from the base metal and would be meaningless. Weld metal chemical
Metal Costs
composition requirements for the multipass types are:
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
Maximum Percent by Weight
(as determined)
Lesson 2
Common Electric E7XT-1; E7XT-1M E7XT-4; E7XT-6
Arc Welding E7XT-5; E7XT-5M E7XT-7; E7XT-8
Processes Element E7XT-9; E7XT-9M E7XT-11 E7XT-12; E7XT-12M
Carbon 0.18 Reported 0.15

Lesson 3
Covered Electrodes Manganese 1.75 1.75 1.60
for Welding Silicon 0.90 0.60 0.90
Mild Steels
Sulfur 0.03 0.03 0.03
Phosphorus 0.03 0.03 0.03
Lesson 4 Chromium 0.20* 0.20* 0.20*
Covered Electrodes
for Welding Low Nickel 0.50* 0.50* 0.50*
Alloy Steels Molybdenum 0.30* 0.30* 0.30*
Vanadium 0.08* 0.08* 0.08*
Aluminum -- 1.8 --
Lesson 5
Welding Filler Metals Copper 0.35 0.35 0.35
* The amounts of these elements shall be reported only if intentionally added.
Single pass types EXXT-2, EXXT-3, EXXT-10 and EXXT-GS have no chemical require-
Lesson 6 ments.
Carbon & Low Alloy
GMAW,GTAW,SAW
7.7 INDIVIDUAL ELECTRODE CHARACTERISTICS
Lesson 7 The electrodes in this specification may be grouped by their suffix i.e., T-1, T-2, T-3, etc.,
Flux Cored Arc as having similar flux components that give them similar usability characteristics and are
Electrodes Carbon
Low Alloy Steels briefly described here.
7.7.1 EXXT-1 & EXXT-1M - Electrodes of the T-1 classification are gas shielded types,
Lesson 8 and the properties required in this specification are listed using CO2 as the shielding gas.
Hardsurfacing Argon-CO2 gas mixtures may be used for the electrodes specified for all-position welding.
Electrodes
These are usually the smaller wires of .045", .052", and 1/16" diameter. Using an
Argon-CO2 gas mixture will diminish the amount of oxygen present and cause the weld
Lesson 9 metal to have a higher manganese and silicon content. This will increase the tensile
Estimating & strength and may improve the impact properties. The manufacturer’s recommendation for
Comparing Weld
Metal Costs the type of shielding gas should be followed. Those electrodes specified for flat and hori-
zontal fillet welding usually use a CO2 gas shield and will range from 1/16" to 1/8" in
diameter.
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.7.1.1 These electrodes may be used for single or multiple pass welding. The elec-
trodes in this group have a rutile (acid) slag that is characterized by a spray-like transfer,
Lesson 2 little spatter and good weld bead contour that is flat to slightly convex.
Common Electric
Arc Welding 7.7.2 EXXT-2 - These electrodes are classified as single pass electrodes because they
Processes
contain higher amounts of deoxidizers (manganese and silicon) for welding through rust or
mill scale. Since the rust or mill scale is iron oxide (FeO), the manganese and silicon will
Lesson 3
combine with the oxygen in the FeO and float to the slag surface as harmless manganese
Covered Electrodes
for Welding oxide or silicon dioxide. If no rust or mill scale is present, or if multiple passes are made
Mild Steels over the preceding passes, the manganese and silicon will become alloying elements in the
weld metal. This can change the mechanical properties drastically, and possibly cause
Lesson 4 cracking. These electrodes are for welding in the flat and horizontal positions, and the arc
Covered Electrodes characteristics and deposition rates are similar to those of the T-1 types. Running one
for Welding Low
Alloy Steels pass on each side of butt welds can be considered a single pass. There are no chemical
composition requirements for the weld metal produced by these electrodes since it would
be severely diluted with the base metal on single pass welds. They are, however, required
Lesson 5
to meet the minimum tensile strength specified in a transverse tensile test as specified in
for Stainless Steels AWS A5.20-95. These electrodes can be used for welding plate with heavy rust and mill
scale, and still produce X-ray quality welds.
Lesson 6 7.7.3 EXXT-3 - These electrodes require no external shielding gas and are for making
Carbon & Low Alloy high speed, automatic single pass welds on thin material up to 3/16" thickness. Welding
GMAW,GTAW,SAW current is DC electrode positive (+). They are for use in the flat and horizontal positions,
and up to 20° downhill welding. These electrodes are limited to 3/16" metal thickness and
single pass welding; otherwise, the welds may become hard and crack sensitive. They
Lesson 7
Flux Cored Arc have a spray-like metal transfer.
Electrodes Carbon
Low Alloy Steels 7.7.4 EXXT-4 - These are self-shielded electrodes designed for high deposition rates,
and they operate on DC electrode positive (+). The metal transfer is globular and the slag
system desulfurizes the weld metal, making it resistant to cracking. Penetration is low,
Lesson 8
Hardsurfacing allowing the weld metal to bridge gaps caused by poor fit-up. These electrodes are for
Electrodes single or multipass welding in the flat and horizontal positions.
7.7.5 EXXT-5 - These are gas shielded electrodes for flat and horizontal fillet welds.
Lesson 9 They have a basic slag system that provides excellent impact properties when compared to
Estimating &
Comparing Weld the T-1 and T-2 acid slag types. Spatter level is slightly higher than the T-1 and T-2 elec-
Metal Costs trodes. Argon-CO2 gas mixtures are recommended by some manufacturers for the 1/16"
diameter sizes, for a spray-like metal transfer and high deposition rates. CO2 shielding gas
is usually recommended for 5/64" diameters and up, and the metal transfer is more globu-
Lesson 10
lar. They may be used for single and multipass welds.
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.7.6 EXXT-6 - These self-shielded electrodes operate on direct current, electrode
positive (+). Penetration is relatively good, and the metal transfer is spray-like. Deposition
Lesson 2 rate is high, and the weld metal has good low temperature impact properties. They are
Common Electric
Arc Welding used for single and multiple pass welds in the flat and horizontal positions.
Processes
7.7.7 EXXT-7 - These are self-shielded electrodes for welding with direct current,
electrode negative (-). The smaller diameters may be used for all-position welding. The
Lesson 3
larger diameters, 3/32" and up, produce high deposition rates in the flat and horizontal
Covered Electrodes
for Welding positions. The weld metal is relatively crack resistant. These electrodes may be used for
Mild Steels single and multiple pass welding.
7.7.8 EXXT-8 - These are self-shielded electrodes for welding with direct current,
Lesson 4
Covered Electrodes electrode negative (-). They are intended for all-position welding where good impact prop-
for Welding Low erties are necessary. The slag system is such that it desulfurizes the weld metal that helps
Alloy Steels
to resist cracking. They may be used for single or multiple pass welds.
7.7.9 EXXT-9 & EXXT-9M - Electrodes in the T-9 classification are gas shielded types,
Lesson 5
Welding Filler Metals and the properties required in this specification are listed using CO2 as the shielding gas for
EXXT-9 and argon-CO2 gas mixtures for EXXT-9M electrodes. The arc transfer, welding
characteristics, deposition rates and welding parameters will be similar to those electrodes
classified under EXXT-1 and EXXT-1M. Electrodes classified as EXXT-9 and EXXT-9M are
Lesson 6
Carbon & Low Alloy essentially EXXT-1 and EXXT-1M electrodes that deposit weld metal with improved impact
Steel Filler Metals - properties, meeting 20 ft.-lbs at -20°F.
GMAW,GTAW,SAW
7.7.10 EXXT-10 - Electrodes of this classification are self-shielded and operate on
Lesson 7 direct current, electrode negative (-). They are single pass electrodes for welding at high
Flux Cored Arc travel speeds in the flat, horizontal, and downhill (up to 20°) position.
Electrodes Carbon
Low Alloy Steels
7.7.11 EXXT-11 - These electrodes are self-shielded and operate on direct current,
electrode negative (-). They are general purpose electrodes for single and multiple pass
Lesson 8 welding in all-positions. The arc is relatively smooth and spray-like.

Hardsurfacing
Electrodes 7.7.12 EXXT-12 & EXXT-12M - These electrodes are essentially EXXT-1 and EXXT-1M
electrodes that have been modified to meet lower manganese requirements of the A-1
Analysis Group in the ASME Boiler & Pressure Vessel Code, Section IX. Therefore, EXXT-
Lesson 9
Estimating & 12 and EXXT-12M electrodes will have a decrease in tensile strength and hardness, and
Comparing Weld impact properties meeting 20 ft.-lbs at -20°F. The arc transfer, welding characteristics,
Metal Costs
deposition rates, and welding parameters will be similar to EXXT-1 and EXXT-1M elec-
trodes.
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.7.13 EXXT-G - This classification is for new multipass electrodes that do not fit into
any of the above categories. They may or may not require a gas shield, and their proper-
Lesson 2 ties may be any combination of those covered by these specifications.
Common Electric
Arc Welding 7.7.14 EXXT-GS - This classification is for new single pass electrodes that do not fit into
Processes
any of the above categories. They may or may not require a gas shield, and their proper-
ties may be any combination of those covered by this specification.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
INDIVIDUAL DUAL SHIELD FLUX CORED WIRES
Lesson 2 FOR WELDING CARBON STEELS
Common Electric
Arc Welding
Processes 7.8 ELECTRODE SELECTION
ESAB has a wide variety of flux cored electrodes for welding the mild or medium carbon
Lesson 3 steels. For example, there are six electrodes that meet the E70T-1 AWS classification.
Covered Electrodes
for Welding Slight formula variations may make one of them more suitable for particular applications
Mild Steels than another. Features such as tensile strength, impact properties, deposition rate, bead
shape and arc characteristics can vary within this group. Another factor in electrode selec-
Lesson 4 tion is whether or not the electrode meets the required code or specification for the particu-
Covered Electrodes lar job.
for Welding Low
Alloy Steels
7.8.0.1 The following is a brief description of each of ESAB’s E70T-1 electrodes cur-
rently available. Only the distinguishing points of each type are covered here to help in
Lesson 5 selecting the proper electrode. See the Dual Shield catalog for more complete details and
Welding Filler Metals code or specification approvals.
7.9 AWS E70T-1 ELECTRODES

Lesson 6
Carbon & Low Alloy These electrodes are all multiple pass, CO2 shielded types for DC electrode positive opera-
GMAW,GTAW,SAW tion. They are for use in the flat and horizontal positions only.
7.9.1 DUAL SHIELD ARC 70 - The very smooth metal transfer produces minimum
Lesson 7 spatter and has a very good bead appearance. Slag is easily removed. The plate material
Flux Cored Arc
Electrodes Carbon should be reasonably clean.
Low Alloy Steels
A. Typical Weld Metal Properties and Chemical Composition
Yield Point 76,700 psi

Lesson 8 Tensile Strength 90,200 psi
Hardsurfacing
Electrodes Elongation in 2" 26%
Charpy V-notch Impact 30 ft-lbs @0°F
Carbon 0.07%
Lesson 9 Manganese 1.36%
Estimating &
Comparing Weld Silicon 0.65%
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.9.2 DUAL SHIELD 111A-C - is one of the most widely used E70T-1 types. The plate
should be reasonably clean, although the relatively high level of deoxidizers will tolerate
Lesson 2 some amount of rust or scale. Good spray-like metal transfer with very little spatter. This
Common Electric
Arc Welding electrode has been widely used in fabricating earth moving equipment, bridges, pressure
Processes vessels, construction, shipbuilding and in welds governed by structural, shipbuilding and
nuclear codes and applications. Weld beads are flat to slightly convex.
Lesson 3 Typical Weld Metal Properties and Chemical Composition

A.
Covered Electrodes
for Welding Yield Point 77,400 psi
Mild Steels
Tensile Strength 88,900 psi
Elongation in 2" 26%
Lesson 4 Reduction of Area 59%
Covered Electrodes
for Welding Low Charpy V-notch Impact 25 ft-lbs @0°F
Alloy Steels Carbon 0.07%
Manganese 1.45%
Silicon 0.48%
Lesson 5
for Stainless Steels 7.9.3 DUAL SHIELD 111HD - This electrode retains good mechanical properties and
operating characteristics of the 111A-C with the added advantage of high deposition rates.
The 3/32" diameter will deposit weld metal at the rate of 18 lbs per hour, at the optimum
Lesson 6
Carbon & Low Alloy parameters of 475 amps, 31 volts. The deposition efficiency is 88-90%. The steel should
Steel Filler Metals - be reasonably clean; however, small amounts of rust or scale are tolerable.
GMAW,GTAW,SAW
Lesson 7 Yield Point 72,000 psi

Flux Cored Arc
Electrodes Carbon
Low Alloy Steels Elongation in 2" 26%
Reduction of Area 59%
Lesson 8 Carbon 0.07%
Hardsurfacing
Electrodes Manganese 1.33%
Silicon 0.58%
Lesson 9
7.9.4 DUAL SHIELD R-70 Ultra - A newly reformulated electrode allows for greater
Estimating &
Comparing Weld tolerance of mill scale and surface oxides while generating lower welding fumes than other
Metal Costs
similar electrodes in the E70T-1 class. The as-welded tensile strength and notch tough-
ness are the highest in this group. The weld bead is smooth and flat. This electrode has
found extensive use in railcar, heavy equipment, and general fabrication.
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding

Common Electric
Arc Welding Elongation in 2" 25%
Processes Reduction of Area 52%
Covered Electrodes Manganese 1.60%
for Welding
Mild Steels Silicon 0.79%
Lesson 4 7.10 COREWELD METAL CORED WIRES

Covered Electrodes
for Welding Low
Alloy Steels Metal cored electrodes are fabricated tubular wires having a metallic sheath with the core
ingredients predominantly iron powder. Iron powder serves to increase the electrodes
deposition efficiency, while improving the speed of travel. Because the slagging ingredients
Lesson 5
have been replaced with iron powder, the slag residue makes up less than 5% of the de-
for Stainless Steels posit. This feature provides the user the capability to multipass without deslagging. These
wires are now classified to AWS A5.18-93.
Lesson 6 7.10.1 COREWELD 70 - E70C-6M (.035" - 3/32" diameters). The spray-like transfer
Carbon & Low Alloy produces deposition rates over 20 lbs/hr. at 90-97% efficiency. It is usable on a variety of
GMAW,GTAW,SAW low and carbon steels in a variety of positions. This electrode is ideally suitable for auto-
matic and robotic equipment.
Lesson 7 A. Typical Weld Metal Properties and Chemical Composition

Flux Cored Arc
Electrodes Carbon 75 Ar/25 CO2 90 Ar/10 CO2
Low Alloy Steels Shielding Shielding
Yield Point 75,500 psi 72,800 psi
Lesson 8 Tensile Strength 83,300 psi 86,000 psi

Hardsurfacing Elongation in 2" 27 28
Electrodes Charpy V-notch Impacts 40 ft-lbs @0°F 42 ft-lbs @0°F
Carbon 0.034% 0.038%
Lesson 9 Manganese 1.250% 1.350%

Estimating & Silicon 0.750% 0.800%
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.10.2 COREWELD ULTRA - E70C-6M (.045" - 1/16" diameters) provides the latest in
technology in production of metal cored wires. Coreweld Ultra provides excellent mechani-
Lesson 2 cal properties, smooth spray transfer, low spatter, and extremely low fumes.
Common Electric
Arc Welding Typical Weld Metal Properties and Chemical Composition
A.
Processes
75 Ar/25 CO2 92 Ar/8 CO2
Shielding Shielding
Lesson 3
Covered Electrodes Yield Point 63,700 psi 65,000 psi
for Welding Tensile Strength 77,000 psi 79,000 psi
Mild Steels
Elongation in 2" 28 29
Lesson 4 Charpy V-notch Impacts 37 ft-lbs @0°F 31 ft-lbs @0°F
Covered Electrodes
for Welding Low 32 ft-lbs @-20°F 28 ft-lbs @-20°F
Alloy Steels Carbon 0.030% 0.031%
Silicon 0.62% 0.69%
Lesson 5
for Stainless Steels 7.11 AWS E70T-2 ELECTRODES
Electrodes of this classification are all gas shielded for single pass welding, and operate on
Lesson 6 direct current reverse polarity (electrode positive). They are considered as single pass
Carbon & Low Alloy electrodes because the flux contains higher levels of deoxidizers than the T-1 types for
GMAW,GTAW,SAW welding on carbon steels with mill scale and rust on the surface. This deoxidation may be
shown by the following reactions:
Lesson 7
Mn + FeO MnO + Fe Si + 2FeO SiO2 + Fe
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 7.11.0.1 The manganese combines with the oxygen to form manganese-oxide that floats
to the surface of the puddle and is harmlessly trapped in the slag. The iron becomes part
of the weld metal. The silicon reaction shows that the silicon reacts with the oxygen in the
Lesson 8 rust to form silicon dioxide, which floats to the surface of the puddle and again is trapped in
Hardsurfacing
the slag. The iron becomes part of the weld metal.
Electrodes
7.11.0.2 If used on clean plate, or if used for multiple pass welding where there is no
Lesson 9 oxide coating for the manganese and silicon to combine with, these elements become part
Estimating & of the weld metal. As a result, the tensile strength may increase to over 100,000 psi and
Comparing Weld
cracking may occur. These electrodes may also be used for welding the rimmed steels
Metal Costs
(steels that are not deoxidized).
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.11.0.3 Since these are considered single pass electrodes, the AWS Specification does
not require an all-weld metal tensile test because single pass welds would be highly diluted
Lesson 2 with the base metal. Instead, the specification only requires a transverse tension test. This
Common Electric
Arc Welding is a 1/4" thick by 1-1/2" wide bar of a minimum 72,000 psi tensile strength material. It is
Processes welded with a single pass on each side of a square butt joint. The welds are ground flush
with the bar, and the specimen is pulled until failure in a tensile testing machine. A speci-
men that breaks in the base plate is considered satisfactory to meet the 72,000 psi mini-
Lesson 3
Covered Electrodes mum.
for Welding
Mild Steels 7.11.0.4 There are no requirements in AWS A5.20-79 for weld metal chemical composi-
tion for the E70T-2 types, since a single pass weld would be highly diluted from the base
Lesson 4 plate. We publish the carbon, manganese and silicon content of the undiluted welding
Covered Electrodes metal for information purposes to indicate the relative amount of the deoxidizers in each
for Welding Low
Alloy Steels electrode. All of the E70T-2 types require CO2 shielding gas and have no AWS impact
requirements.
Lesson 5 7.11.1 DUAL SHIELD 110 - This electrode contains the highest amount of deoxidizers
in the group and is for use on carbon steel plate, that is heavily scaled or rusted. Bead
shape is flat to convex, and the thin slag is easily removed. Meets the 72,000 psi minimum
tensile strength requirements for this classification.
Lesson 6
Carbon & Low Alloy A. Undiluted Weld Metal Analysis (For Information Only)
GMAW,GTAW,SAW Carbon 0.07%
Manganese 2.30%
Silicon 1.50%
Lesson 7
Flux Cored Arc
Electrodes Carbon 7.11.2 DUAL SHIELD SP - This electrode contains a lesser amount of deoxidizers than
Low Alloy Steels
Dual Shield 110 and is for use on carbon steel plate, that has a considerable amount of mill
scale and rust. The bead contour is very good, and the slag is almost self-removing.
Lesson 8 Meets the AWS minimum tensile strength of 72,000 psi.

Hardsurfacing
Electrodes A. Undiluted Weld Metal Analysis (For Information Only)
Carbon 0.06%
Manganese 1.70%
Lesson 9
Estimating & Silicon 1.25%
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.12 AWS E70T-5
7.12.1 DUAL SHIELD T-5 & T-75 - A high quality electrode of the basic slag type. It
Lesson 2
Common Electric produces weld metal of excellent impact properties. The weld metal is resistant to cracking
Arc Welding
and the deposition efficiency and deposition rates are high. This electrode has the ap-
Processes
proval for use on structural work, heavy equipment, shipbuilding, and military work under
many codes and specifications.
Lesson 3
Covered Electrodes
7.12.1.1 CO2 shielding gas is recommended for the 3/32" and 7/64" diameters. Ar-
for Welding
Mild Steels gon-25% CO2 is recommended for .045" and 1/16" diameters, producing a spray-like
smooth metal transfer. May be used for high current, high deposition welding.
Lesson 4
Covered Electrodes 7.13 ALL-POSITION ELECTRODES
for Welding Low
Alloy Steels
ESAB was the originator of gas shielded, all-position flux cored wires. These electrodes
have gained wide usage because they provide the most rapid method of depositing deep
Lesson 5 penetrating, sound welds in all positions, thus eliminating costly setup time and expensive
Welding Filler Metals fixturing. Available in .035", .045", .052", and 1/16" diameters, they may be used on plate
thicknesses as thin as 3/16" in the vertical position, and 1/8" in the flat or horizontal. They
have been used for multipass welding on 3" thick material in many nuclear power plant
Lesson 6 applications. The shielding gas may be straight CO2 or Argon-25% CO2 as indicated below.
Carbon & Low Alloy
Steel Filler Metals - 7.13.1 DUAL SHIELD 7000 (E71T-1/E71T-1M & E71T-9/E71T-9M) - This is the original
GMAW,GTAW,SAW
all-position electrode and was designed to be used with either straight CO2 or Argon-25%
CO2 shielding gas. Using the Argon-CO2 mixture will improve the arc characteristics, in-
Lesson 7 crease the wetting action, and decrease penetration slightly. The fast freezing slag is easily
Flux Cored Arc
Electrodes Carbon removed and holds the weld puddle for rapid vertical-up and overhead welding. Performs
Low Alloy Steels well over normal mill scale and rust.
A. Typical Weld Metal Mechanical Properties (As Welded)

Lesson 8 Yield Point 76,000 psi
Hardsurfacing
Electrodes Tensile Strength 86,000 psi
Elongation in 2" 27%
Lesson 9 Charpy V-notch Impact 32 ft-lbs @0°F
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
B. Typical Weld Metal Analysis
Carbon 0.06%
Common Electric
Arc Welding Silicon 0.60%
Processes
7.13.2 DUAL SHIELD 7100 ULTRA (E71T-1/E71T-1M & E71T-9/E71T-9M) - This newly
Lesson 3 developed electrode is designed for optimum performance with straight CO2 shielding while
Covered Electrodes
generating lower welding fumes. Ar/CO2 mixes up to 75% Ar may be used for better arc
for Welding
Mild Steels characteristics. Fillet weld beads are flat to slightly convex and have uniform side wall
fusion or wetting. Welds produced are of X-ray quality. This electrode produces a lower
cost per pound of deposited weld metal than any other welding consumable, especially in
Lesson 4
Covered Electrodes the vertical-up and overhead positions.
for Welding Low
Alloy Steels A. Typical Weld Metal Mechanical Properties (As Welded)

Welding Filler Metals Elongation in 2" 27%
Lesson 6
Carbon & Low Alloy B. Typical Weld Metal Analysis
GMAW,GTAW,SAW Carbon 0.06%
Manganese 1.40%
Silicon 0.70%
Lesson 7
Flux Cored Arc
Electrodes Carbon 7.13.3 DUAL SHIELD FC-717 (E71T-1/E71T-1M & E71T-9/E71T-9M) - This all-position
Low Alloy Steels
flux cored wire is a lower cost alternative that produces low spatter, smooth stable arc and
a flat to slightly convex bead shape. Shielding gas can be CO2 or Argon/CO2 mixtures up to
Lesson 8 75% Argon.
Hardsurfacing
Electrodes A. Typical Weld Metal Mechanical Properties (As Welded)
CO2 75%Ar/25%CO2
Lesson 9 Shielding Shielding
Estimating & Yield Point 73,000 psi 76,500 psi
Comparing Weld
Metal Costs Tensile Strength 82,900 psi 87,500 psi
Elongation in 2" 27% 27%
Charpy V-notch Impact 50 ft-lbs @0°F 70 ft-lbs @0°F
Lesson 10 30 ft-lbs @-20°F 50 ft-lbs @-20°F
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
B. Typical Weld Metal Analysis
CO2 75%Ar/25%CO2
Lesson 2 Shielding Shielding
Common Electric
Arc Welding Carbon 0.050% 0.055%
Processes Manganese 1.10% 1.10%
Silicon 0.44% 0.55%
Lesson 3
Covered Electrodes 7.13.4 DUAL SHIELD II 70 ULTRA (E71T-1 & E71T-12M) and
for Welding
DUAL SHIELD II 71 ULTRA (E71T-1 & E71T-12)
Mild Steels
Dual Shield II 70 Ultra and Dual Shield II 71 Ultra provide all-position welding with excellent
Lesson 4 impact toughness and low hydrogen deposits. Arc characteristics are some of the best
Covered Electrodes
for Welding Low found in a flux cored wire with fume generation rates being extremely low. Available in
Alloy Steels 0.035" to 1/16" diameters, Dual Shield II 70 Ultra and Dual Shield II 71 Ultra are excellent
choices for critical applications.
Lesson 5 A. Typical Weld Metal Mechanical Properties (As Welded)

for Stainless Steels II 70 Ultra II 71 Ultra
Yield Point 72,300 psi 71,500 psi
Tensile Strength 81,100 psi 79,500 psi
Lesson 6
Elongation in 2" 29% 28%
Carbon & Low Alloy
Steel Filler Metals - % Reduction in Area 75% 77%
GMAW,GTAW,SAW Charpy V-notch Impact 117 ft-lbs @0°F 96 ft-lbs @0°F
70 ft-lbs @-20°F 40 ft-lbs @-20°F
Lesson 7
Flux Cored Arc B. Typical Weld Metal Analysis
Electrodes Carbon
Low Alloy Steels II 70 Ultra II 71 Ultra
Carbon 0.028% 0.019%
Lesson 8
Hardsurfacing Silicon 0.30% 0.30%
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.14 CORESHIELD SELF-SHIELDED FLUX CORED WIRES
Lesson 2 Self-shielded flux cored wires contain the necessary ingredients within the core to protect
Common Electric the molten weld metal from atmospheric contaminates. Typically, these products are used
Arc Welding
in windy or outdoor environments. Dependent on their specific AWS designation, they are
Processes
classed as either single or multipass electrodes. Mechanical properties, especially impact
toughness, is restrictive with the self-shielded electrodes.
Lesson 3
Covered Electrodes
for Welding 7.15 AWS E70T-4
Mild Steels
7.15.1 CORESHIELD 40 - This electrode is a self-shielded, horizontal and flat position
Lesson 4 weld wire, designed for high deposition welding. The penetration is not as deep as that of
Covered Electrodes the gas shielded types, making it more suitable for weld joints with poor fit-up.
for Welding Low
Alloy Steels Typical Weld Metal Mechanical Properties
A.

for Stainless Steels Elongation in 2" 26%
B. Typical Weld Metal Chemical Composition

Carbon & Low Alloy
Steel Filler Metals - Manganese 0.35%
GMAW,GTAW,SAW Silicon 0.35%
Aluminum 1.10%
Lesson 7
Flux Cored Arc
Electrodes Carbon 7.16 AWS E70T-7
Low Alloy Steels
7.16.1 CORESHIELD 7 - is a multipass wire for flat and horizontal position welding.
This specially developed formulation permits faster travel speeds as compared to
Lesson 8
Hardsurfacing Coreshield 40.
Electrodes
A. Typical Mechanical Properties

Lesson 9 Yield Strength 67,000 psi
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
A. Typical Chemical Properties
Carbon 0.26%
Common Electric
Arc Welding Silicon 0.10%
Processes Aluminum 1.55%
Lesson 3
Covered Electrodes 7.17 AWS E70T-10
for Welding
Mild Steels 7.17.1 CORESHIELD 10 - Ideally suited for thin gauge and galvanized steels. This
electrode performs well on high speed, single pass robotic applications.
Lesson 4
A. Typical Weld Metal Mechanical Properties
Covered Electrodes
for Welding Low Transverse Tensile Strength 95,900 psi
Alloy Steels
Longitudinal Guided Bend Test
(Aged 210°F for 48 hrs., bent 180° over 3/4" radius)
Lesson 5
for Stainless Steels 7.18 AWS E71T-11
7.18.1 CORESHIELD 11 - is an all-position single or multipass electrode for use in mild
Lesson 6 steel applications. The versatility of this electrode makes it an ideal choice for structural
Carbon & Low Alloy
Steel Filler Metals - steel applications.
GMAW,GTAW,SAW
A. Typical Mechanical Properties
Lesson 7 Yield Strength 62,500 - 65,000 psi

Flux Cored Arc Tensile Strength 88,500 - 91,200 psi
Electrodes Carbon
Low Alloy Steels Elongation in 2" 22 - 24
A. Typical Weld Metal Composition

Hardsurfacing
Manganese 0.65%
Electrodes
Silicon 0.40%
Aluminum 1.65%
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.19 AWS E71T-GS
7.19.1 CORESHIELD 15 - is an all-position single pass electrode for thin gauge galva-
Lesson 2
Common Electric nized or mild steel application. This electrode is available in .030" - 5/64" diameters.
Arc Welding
Processes A. Typical Mechanical Properties

Lesson 3 Longitudinal Guided Bend Passed
Covered Electrodes
for Welding
Mild Steels A. Typical Chemical Properties
Carbon 0.25%
Covered Electrodes
for Welding Low Silicon 0.40%
Alloy Steels Aluminum 2.40%
Lesson 5
This American Welding Society (AWS) Specification is entitled "Specification for Low
Alloy Steel Electrodes for Flux Cored Arc Welding". It prescribes the classification
Lesson 6 requirements for low alloy steel flux cored electrodes for welding carbon and low alloy
Carbon & Low Alloy steels. Among the requirements prescribed in the specification are test procedures, wind-
GMAW,GTAW,SAW ing requirements, spool and coil standards, packaging standards, and the items listed
below that will be covered in this text.
Lesson 7
Flux Cored Arc 1. Whether gas shielded or self-shielded
Electrodes Carbon 2. Type of welding current
Low Alloy Steels
3. Welding position
4. Chemical composition of the weld metal
Lesson 8 5. Mechanical properties of the weld metal
Hardsurfacing
Electrodes
7.21 AWS DESIGNATIONS
Lesson 9 The letter-number designations used in this specification are shown in Figure 10.
Estimating &
Comparing Weld
Metal Costs 7.21.0.1 As an example, the designation E81T1-Ni2 indicates an electrode (E) that will
produce weld metal of a minimum 80,000 psi tensile strength (8), may be used in welding
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
in all positions (1), is a flux cored electrode (T), is a multipass, gas shielded type for opera-
tion on direct current, electrode positive (1), and will produce weld metal containing ap-
Lesson 2 proximately 2% nickel (Ni2).
Common Electric
Arc Welding Electrode
Processes Min. Tensile Strength x 10,000 psi
0: Flat and Horizontal
1: All Position
Lesson 3
Covered Electrodes
for Welding EXX T X - X
Mild Steels
Chemical Composition
Usability and Performance
Lesson 4 Tubular or Flux Cored
Covered Electrodes
for Welding Low
Alloy Steels LOW ALLOY STEEL FLUX CORED ELECTRODE DESIGNATIONS
FIGURE 10
Lesson 5
7.22 USABILITY AND PERFORMANCE
The low alloy types have five classifications based on usability and performance. They are
Lesson 6
Carbon & Low Alloy T1, T4, T5, T8, and TX-G. There are two classifications for the gas shielded electrodes,
Steel Filler Metals - two classifications for the self-shielded electrodes, and one general classification for new
GMAW,GTAW,SAW
electrodes that do not fit into any of the categories defined in the A5.29-80 specification.
All of the electrodes in this specification may be used for single or multipass welds. Briefly,
Lesson 7 the usability characteristics are:
Flux Cored Arc
Electrodes Carbon
EXXT1-X CO2 Shielded DC, Electrode Positive
Low Alloy Steels
EXXT4-X Self-Shielded DC, Electrode Positive
EXXT5-X CO2 Shielded DC, Electrode Positive
Lesson 8 EXXT8-X Self Shielded DC, Electrode Negative
Hardsurfacing EXXTX-G Not Specified Not Specified
Electrodes
A more complete description of the usability and performance may be found in Section 7.7,
Lesson 9 INDIVIDUAL ELECTRODE CHARACTERISTICS. They are the same as those specified
Estimating & for the carbon steel electrodes in Specification A5.20-95.
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
7.23 MECHANICAL PROPERTIES REQUIREMENTS
Lesson 2 Figure 11 lists the mechanical property requirements for this specification.
Common Electric
Arc Welding
TENSILE MIN. YIELD MIN. PERCENT
Processes
AWS STRENGTH STRENGTH ELONGATION
CLASSIFICATION psi. psi. IN 2 INCHES
Lesson 3 E6XTX-X 60,000 - 80,000 50,000 22

Covered Electrodes E7XTX-X 70,000 - 90,000 58,000 20
for Welding E8XTX-X 80,000 - 100,000 68,000 19
Mild Steels E9XTX-X 90,000 - 110,000 78,000 17
E10XTX-X 100,000 - 120,000 88,000 16
E11XTX-X 110,000 - 130,000 98,000 15
E12XTX-X 120,000 - 140,000 108,000 14
Lesson 4 EXXXTX-G As agreed by Manufacturer and Purchaser
Covered Electrodes
for Welding Low For those electrodes using a shielding gas, properties must be attained using CO2.
Alloy Steels
WELD METAL MECHANICAL PROPERTY REQUIREMENTS
LOW ALLOY FLUX CORED ELECTRODES
Lesson 5 FIGURE 11
7.24 WELD METAL CHEMICAL COMPOSITION
REQUIREMENTS
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - In this section, we will be referring to the elements by their chemical symbols. The Glos-
GMAW,GTAW,SAW sary of Terms at the end of this lesson defines these symbols.
7.24.1 Carbon-Molybdenum Steel Electrodes - The carbon-moly electrodes are used

Lesson 7
Flux Cored Arc for moderately high tensile and moderately high temperature applications. Electrodes of
Electrodes Carbon this classification have the suffix A1 (EXXTX-A1). Chemical composition requirements of
Low Alloy Steels
the weld metal are listed below and the single figures indicate maximum allowable
amounts.
Lesson 8
Element % by Weight Element % by Weight
Hardsurfacing
Electrodes C 0.12 Mo 0.40 - 0.60
Mn 1.25 P 0.03
Si 0.80 S 0.03
Lesson 9
Estimating &
Comparing Weld 7.24.2 Chromium-Molybdenum Steel Electrodes - The “chrome-moly” types, as they
Metal Costs
are commonly referred to, are used in applications requiring strength and resistance to
oxidation (scaling) at elevated temperatures. Their chemical composition requirements are
Lesson 10 shown in Figure 12.

Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
AWS Chemical Composition %
Class. C Mn Si Cr Mo
Lesson 2 EXXTX-B1 0.12 1.25 0.80 0.40 - 0.65 0.40 - 0.65

Common Electric
EXXTX-B2L 0.05 1.25 0.80 1.00 - 1.50 0.40 - 0.65
Arc Welding
Processes EXXTX-B2 0.12 1.25 0.80 1.00 - 1.50 0.40 - 0.65
EXXTX-B2H 0.10 - 0.15 1.25 0.80 1.00 - 1.50 0.40 - 0.65
EXXTX-B3L 0.05 1.25 0.80 2.00 - 2.50 0.90 - 1.20
EXXTX-B3 0.12 1.25 0.80 2.00 - 2.50 0.90 - 1.20
Lesson 3
Covered Electrodes EXXTX-B3H 0.10 - 0.15 1.25 0.80 2.00 - 2.50 0.90 - 1.20
for Welding
Mild Steels All Classifications: P - 0.03%, S - 0.03%
WELD METAL CHEMICAL COMPOSITION REQUIREMENTS
CHROMIUM - MOLYBDENUM FLUX CORED ELECTRODES
Lesson 4 FIGURE 12
Covered Electrodes 7.24.3 Nickel Steel Electrodes - The nickel steel electrodes are used for low tempera-
for Welding Low
Alloy Steels ture applications where good impacts are necessary. As the amount of nickel is increased,
the low temperature impact properties increase. Figure 13 shows the chemical composi-
tion requirements for these electrodes.
Lesson 5
Welding Filler Metals AWS Chemical Composition %
for Stainless Steels Class. C Mn Si P S Ni Cr Al*
EXXTX-Ni1 0.12 1.50 0.80 0.03 0.03 0.80 - 1.10 0.15 1.8
Lesson 6 EXXTX-Ni2 0.12 1.50 0.80 0.03 0.03 1.75 - 2.75 - 1.8
Carbon & Low Alloy EXXTX-Ni3 0.12 1.50 0.80 0.03 0.03 2.75 - 3.75 - -
GMAW,GTAW,SAW *Self shielding types only
NICKEL-STEEL FLUX CORED ELECTRODES
Lesson 7
Electrodes Carbon
Low Alloy Steels 7.24.4 Manganese-Molybdenum Steel Electrodes - The manganese-moly steels are
used in high strength applications in the 90,000 to 100,000 psi tensile strength range.
Figure 14 shows the chemical composition requirements for these electrodes.
Lesson 8
Hardsurfacing
Electrodes AWS Chemical Composition %
Class. C Mn Si Mo P S
EXXT1-D1 0.12 1.25 - 2.00 0.80 0.25 - 0.55 0.03 0.03

Lesson 9
EXXT1-D2 0.12 1.65 - 2.25 0.80 0.25 -0.55 0.03 0.03
Estimating &
Comparing Weld EXXT1-D3 0.12 1.00 - 1.75 0.80 0.40 - 0.65 0.03 0.03
Metal Costs

MANGANESE - MOLYBDENUM STEEL FLUX CORED ELECTRODES
Lesson 10
FIGURE 14.
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2
3.1 Development of Covered Electrodes
Common Electric 7.24.5 All Other Low Alloy Steel Electrodes - Low alloy steels that do not fit into any of the previous
Arc Welding categories are in this category, with the suffix letter K, G, or W. Notice that in the weld metal chemical composition
Processes of the carbon-molybdenum, chromium molybdenum, nickel and manganese-molybdenum steels, only one or two alloyi
were added or changed. In this group, the carbon content is slightly higher, and all of the classifications have varying
amounts of manganese, nickel, chromium and molybdenum. Also, vanadium has been added to all but two of the elect
Lesson 3 7.24.5.1 The EXXXTX-K category includes electrodes for welding many of the trade name high strength steels, such as
Covered Electrodes USS T1, HY-80, HY-90, HY-100 and many others. Electrodes for welding the ASTM high strength steels, and the AISI-
for Welding heat treatable steels are in this group.
Mild Steels
7.24.5.2 The W suffix indicates an electrode for welding the weathering grades of steel. These are steels that corrode o
point where te oxide coating becomes impervious to further corrosion.
Lesson 4 7.24.5.3 Figure 15 shows the weld metal composition for these electrodes.
Covered Electrodes
for Welding Low
Alloy Steels AWS
Class. Chemical Composition % a
Lesson 5 C Mn Si Ni Cr Mo V Alb Cu
0.80- 0.80- 0.20-
for Stainless Steels EXXTX-K1 0.15 0.80 0.15 0.05 3/4 3/4
1.40 1.10 0.65
0.50- 0.80-
EXXTX-K2 0.15 0.80 0.15 0.35 0.05 1.8 3/4
1.75 2.00
Lesson 6
0.75- 1.25- 0.25-
Carbon & Low Alloy EXXTX-K3 0.15 0.80 0.15 0.05 3/4 3/4
2.25 2.60 0.65
GMAW,GTAW,SAW EXXTX-K4 0.15
1.20-
0.80
1.75- 0.20- 0.30-
0.05 3/4 3/4
2.25 2.60 0.60 0.65
0.10- 0.60- 0.75- 0.20- 0.15-
Lesson 7 EXXTX-K5 0.80 0.05 3/4 3/4
0.25 1.60 2.00 0.70 0.55
Flux Cored Arc
Electrodes Carbon 0.50- 0.40-
EXXTX-K6 0.15 0.80 0.15 0.15 0.05 1.8 3/4
Low Alloy Steels 1.50 1.10
1.00- 2.00-
EXXTX-K7 0.15 0.80 3/4 3/4 3/4 3/4 3/4
1.75 2.75
Lesson 8 0.10
EXXTX-KG 3/4 1.0 c 0.80 0.50 c 0.30 c 0.20 c c 1.8 3/4
Hardsurfacing
Electrodes
0.50- 0.35- 0.40- 0.30-
EXXTX-W 0.12 3/4 3/4 3/4 3/4
1.30 0.80 0.80 0.75
(a) single values are maximum only
Lesson 9 (b) Self-shielded electrodes only
Estimating & (c) Minimum values. The weld metal need have the minimum of only one of the elements listed.
Comparing Weld
Metal Costs Figure 15
Weld Metal Chemical Composition Requirements
All Other Alloy Steel Electrodes
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.25 IMPACT PROPERTIES
The impact properties of the low alloy electrodes are listed in Figure 16.
Lesson 2
Common Electric
Arc Welding
Processes AWS Impact AWS Impact
Class Strength Class Strength
E80T1-A1 Not Required* E90T5-Ni3 20 ft-lb @ -100° F*

Lesson 3 E81T1-A1 Not Required* E91T1-D1 20 ft-lb @ -40° F*
Covered Electrodes E70T5-A1 20 ft-lb @ -20° F* E90T5-D2 20 ft-lb @ -60° F*
for Welding E81T1-B1 Not Required* E100T5-D2 20 ft-lb @ -40° F*
Mild Steels E81T1-B2 Not Required* E90T1-D3 20 ft-lb @ -20° F*
E80T1-B2 Not Required* E80T5-K1 20 ft-lb @ -40° F*
E80T5-B2 Not Required* E70T4-K2 20 ft-lb @ 0° F*
Lesson 4 E80T1-B2H Not Required* E71T8-K2 20 ft-lb @ -20° F*
Covered Electrodes E80T5-B2L Not Required* E80T1-K2 20 ft-lb @ -20° F*
for Welding Low E90T1-B3 Not Required* E90T1-K2 20 ft-lb @ 0° F*
Alloy Steels E91T1-B3 Not Required* E91T1-K2 20 ft-lb @ 0° F*
E90T1-B3L Not Required* E100T1-K3 20 ft-lb @ 0° F*
Lesson 5 E90T1-B3H Not Required* E110T1K3 20 ft-lb @ 0° F*
Welding Filler Metals E71T8-Ni1 20 ft-lb @ -20° F E100T5-K3 20 ft-lb @ -60° F*
for Stainless Steels E80T1-Ni1 20 ft-lb @ -20° F E110T5-K3 20 ft-lb @ -60° F*
E81T1-Ni1 20 ft-lb @ -20° F E110T5-K4 20 ft-lb @ -60° F*
E80T5-Ni1 20 ft-lb @ -60° F E111T1-K4 20 ft-lb @ -60° F*
R71T8-Ni2 20 ft-lb @ -20° F E120T5-K4 20 ft-lb @ -60° F*
Lesson 6 E80T1-Ni2 20 ft-lb @ -40° F E120T1-K5 Not Required
Carbon & Low Alloy E81T1-Ni2 20 ft-lb @ -40° F E61T8-K6 20 ft-lb @ -20° F*
Steel Filler Metals - E80T5-Ni2 20 ft-lb @ -75° F E71T8-K6 20 ft-lb @ -20° F*
GMAW,GTAW,SAW E90T1-Ni2 20 ft-lb @ -40° F E101T1-K7 20 ft-lb @ -60° F*
E91T1-Ni2 20 ft-lb @ -40° F E80T1-W 20 ft-lb @ -20° F*
E80T5-Ni3 20 ft-lb @ -100° F EXXXTX-G **
Lesson 7 * Require post weld heat treatment. All others are as welded.
Flux Cored Arc ** As agreed between manufacturer and purchaser.
Electrodes Carbon
Low Alloy Steels IMPACT REQUIREMENTS LOW ALLOY STEEL FLUX CORED ELECTRODES
FIGURE 16.
Lesson 8
Hardsurfacing Notice that the impact requirement for the E80T5-Ni1 is 20 ft-lbs at -60°F., while the impact
Electrodes requirement for the E80T1-Ni1 is 20 ft-lbs at -20°F. The T-5 electrode has a basic slag
system, and the T-1 electrode has an acid slag system. As pointed out earlier, electrodes
with basic slag systems provide improved impact properties; however, they are limited to
Lesson 9
Estimating & flat and horizontal fillet welding only.
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.26 SELECTING THE PROPER LOW ALLOY ELECTRODE
Lesson 2 When welding low alloy steels, the tensile strength, yield strength, elongation, and impact
Common Electric properties of the weld metal should match those of the material being welded as closely as
Arc Welding
possible. The chemical composition of the weld metal should match that of the steel also,
Processes
although this may not always be possible. The mechanical properties and chemical com-
positions published in the electrode manufacturer’s literature are based on undiluted weld
Lesson 3 metal. Welds made on the job will be diluted with the base metal, and composition and
Covered Electrodes
for Welding strength level may be somewhat different than the published data. In most cases, how-
Mild Steels ever, matching strength and composition as closely as possible works out well.
7.26.0.1 Choosing an electrode that produces weld metal of slightly greater strength than
Lesson 4
Covered Electrodes the base material is allowable as long as ductility and service requirements are compatible.
for Welding Low In some cases, it may be necessary to use an electrode that produces weld metal of lower
Alloy Steels
strength than the base metal. This can be beneficial, as long as the strength is sufficient
for the application, since lower strength steels are usually more ductile and less likely to
Lesson 5 cause toe-cracking in the base metal. Conversely, gross overmatching of the electrode to
the base material can increase the cracking potential.
7.26.0.2 The wide variety of low alloy steels available today can make electrode selection
a complex problem. In some cases, low alloy steels of the same chemical composition will
Lesson 6
Carbon & Low Alloy have different mechanical properties depending on whether they have been rolled, hot or
Steel Filler Metals - cold worked, cast or forged. For this reason, the American Society for Testing Materials
GMAW,GTAW,SAW
(ASTM) has published several volumes of standards and classifications for the various
forms of ferrous metal products (See Lesson I, "Specifications"). Steel manufacturers and
Lesson 7 fabricators assign these classification numbers to their products such as steel sheet, plate,
Flux Cored Arc
Electrodes Carbon bar, pipe, castings, forgings, and others. Electrode manufacturers usually provide a list of
Low Alloy Steels some of the more common ASTM specifications for which their electrodes are suited. See
your Atom Arc and Dual Shield catalogs for suggested applications.
Lesson 8 7.26.1 Dissimilar Steels - Dissimilar steels with similar metallurgical structure can be
Hardsurfacing
Electrodes satisfactorily welded with electrodes matching the composition or behavior of the lower
alloys or lower cost electrode. Nothing is gained by using electrodes that match the higher
alloy or higher cost material because the lower composition steel is on one side of the joint
Lesson 9 immediately adjacent to the weld metal. As an example, 2-1/4% Cr-1% Mo steel is best
Estimating &
Comparing Weld welded to 1-1/4% Cr-1/2 Mo steel with an electrode producing weld metal of 1-1/4% Cr-1/2
Metal Costs Mo composition.
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Welding steels of dissimilar metallurgical structure requires a knowledge of welding metal-
lurgy, and when in doubt, the Technical Service Department of the electrode or steel manu-
Lesson 2 facturer should be consulted.
Common Electric
Arc Welding 7.26.2 Welding Procedures - Procedures for welding the low alloy high strength steels
Processes
are more stringent than those used for welding the carbon steels. Preheat, interpass
temperature control and post weld treating are necessary in many cases and will vary
Lesson 3
depending on the material thickness. In some cases, hammer peening between passes
Covered Electrodes
for Welding may be necessary to relieve stresses and prevent subsequent cracking, or to reduce distor-
Mild Steels tion. Proper joint design and qualified welding procedures for the various alloys must be
adhered to.
Lesson 4
Covered Electrodes
for Welding Low 7.27 ADVANCED DEVELOPMENTS IN CORED WIRES
Alloy Steels
Leading the industry in cored wire technology advancements has long been a tradition with
Lesson 5 ESAB Welding & Cutting Products. Since they first introduced flux cored wires to the
Welding Filler Metals market in 1957, ESAB has continued to bring innovation to the industry. Consider some of
the advancements in cored wire technology ESAB is proud of introducing:
1957 First flux cored wire introduced

Lesson 6
Carbon & Low Alloy 1965 First basic slag flux cored wire introduced for improved mechanical properties
GMAW,GTAW,SAW 1972 First small diameter, all-position flux cored wire
1984 Dual Shield II Series of Second Generation flux cored wires with good impact
Lesson 7 properties and low hydrogen
Flux Cored Arc
Electrodes Carbon 1985 First .030" diameter flux cored wire introduced
Low Alloy Steels
1988 First "Ultra Series" low fume and low spatter flux cored wire introduced
1997 New technology metal cored wire combining excellent weldability with low fume
Lesson 8
Hardsurfacing and exceptional mechanical properties
Electrodes
1998 "H4" Technology flux cored wires
The newest technology innovation is the introduction of the "H4 Technology" flux cored
Lesson 9
wires. These wires have the lowest diffusible hydrogen level of any acid slag flux cored
Estimating &
Comparing Weld wire, exhibiting less than 4 ml/100 gm weld metal of diffusible hydrogen. "H4 Technology"
Metal Costs cored wires are the Third Generation of a long series of flux cored wire technology ad-
vancements.
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
7.28 DUAL SHIELD SELECTOR GUIDE
The following is a listing of the standard available types of Dual Shield flux cored low alloy
Lesson 2
Common Electric electrodes. For more extensive information, see the ESAB Cored Wire Products catalog.
Arc Welding
Processes
DUAL SHIELD® LOW ALLOY FLUX CORED ELECTRODES SELECTOR GUIDE
Lesson 3 Dual Shield Typical Properties Weld Metal Typical

Shielding
Covered Electrodes Type Gas As Stress Weld Metal Description-Applications
Category
AWS Class Welded Relieved Analysis %
for Welding
7000-A1 CO Tensile Strength, psi 91,000 90,500 C - 0.07
Mild Steels 2 For all-position welding of 50,000 psi
or Yield Strength, psi 80,500 78,500 Mn - 1.02 minimum yield steels and .5% Mo steels.
AWS Argon-25% Elongation %-2" 23 24 Si - 0.57 For boilers, pressure vessels, pressure
piping and other applications.
E81T1-A1 CO Reduction of Area % 58 63 Mo - 0.51
Lesson 4 2
88CM Tensile Strength, psi 106,000 88,000 C - 0.07

Covered Electrodes
Yield Strength, psi 94,000 75,000 Mn - 0.74
for Welding Low For flat and horizontal position welding of
Alloy Steels AWS Elongation %-2" 14 22 Si - 0.34 the Cr-Mo steels. For welding plates,
E80T1-B2 Reduction of Area % 29 55 Cr - 1.25 tubes, castings and forgings.
Mo - 0.50
8000-B1 Argon-25% Tensile Strength, psi 103,700 99,700 C - 0.05
Lesson 5
CO Yield Strength, psi 91,700 86,800 Mn - 0.92
Welding Filler Metals 2
All-position chrome-moly designed to weld
AWS or CO Elongation %-2" 23 22 Si - 0.56
for Stainless Steels 2
1/2% chrome - 1/2% moly steels.
E81T1-B1 Reduction of Area % 60 64 Cr - 0.52
Mo - 0.53
8000-B2 Argon-25% Tensile Strength, psi 104,500 98,000 C - 0.05
An all-position Cr-Mo electrode for welding
Lesson 6 CO 2
Yield Strength, psi 93,000 87,000 Mn - 0.65 low alloy steels up to 1‰ Cr-‰ Mo. Similar
Carbon & Low Alloy AWS or CO 2
Elongation %-2" 20 21 Si - 0.58 to E8018-B2 manual electrodes. For
Steel Filler Metals - E81T1-B2 Reduction of Area % 53 60 Cr - 1.05 welding plate, pipe, tubes, castings or
GMAW,GTAW,SAW forgings to many ASTM specifications.
Mo - 0.55
T-85-B2 Argon- Tensile Strength, psi 103,000 92,000 C - 0.12
25% CO 2
Yield Strength, psi 87,000 77,000 Mn - 1.25 A basic slag electrode for the flat &
Lesson 7 AWS Elongation %-2" 23 24 Si - 0.80 horizontal positions. Optimum weld quality
Flux Cored Arc E80T5-B2 Reduction of Area % 58 67 P - 0.03
and resistance to cracking. For welding
Electrodes Carbon the low alloy steels up to 1… Cr-‰ Mo.
Charpy V-Notch 0 F 38 ft-lb 54 ft-lb S - 0.03 Made in .045" & 1/16" diameters. For high
Low Alloy Steels current, high deposition welding.
Cr - 1-1.5
Mo - .40-.65
98-CM CO 2
Tensile Strength, psi 128,000 96,000 C - 0.06
Lesson 8 Yield Strength, psi 109,500 82,500 Mn - 0.70 For flat & horizontal position welding of the
Hardsurfacing AWS Elongation %-2" 12 20 Si - 0.40 2… Cr-1 Mo steels. Weld metal is similar to
Electrodes E90T1-B3 Reduction of Area % 19 55 Cr - 2.21 E9018-B3 manual electrodes.
Mo - 1.04
9000-B3 CO 2
Tensile Strength, psi 120,000 96,000 C - 0.06 An all-position electrode for welding the
Yield Strength, psi 104,000 82,500 Mn - 0.70 2… Cr-1 Mo steels. Suitable for many
Lesson 9 ASTM specifications such as castings,
AWS Elongation %-2" 12 20 Si - 0.40
Estimating & boiler tubes, forgings and plate for high
E91T1-B3 Reduction of Area % 19 59 Cr - 2.21 temperature, high pressure container
Comparing Weld
Mo - 1.04 parts.
Metal Costs
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
DUAL SHIELD® LOW ALLOY FLUX CORED ELECTRODES SELECTOR GUIDE (Con't.)
Lesson 2
Common Electric
Arc Welding Dual Shield Shielding Typical Properties Weld Metal Typical
Processes Type Gas As Stress Weld Metal Description-Applications
AWS Class Category Welded Relieved Analysis %
T-95-B3 Argon- Tensile Strength, psi 124,000 98,000 C - 0.12 A basic slag electrode for the 2… Cr-1 Mo
25% CO Yield Strength, psi 106,000 82,000 Mn - 1.25 steels. For flat & horizontal position
Lesson 3 2
welding only. Optimum weld quality and
Covered Electrodes AWS Elongation %-2" 20 22 Si - 0.80
resistance to cracking. Made in .045" and
for Welding E90T5-B3 Reduction of Area % 48 66 Cr - 2-2.5 1/16" diameters for high current, high
Mild Steels Charpy V-Notch 0 F 16 ft-lb 31 ft-lb Mo - .9-1.2 deposition welding.
Coreweld 70 Argon-25% Tensile Strength, psi (75/25) C - 0.039
Ni1 CO or
2
Yield Strength, psi 76,400 Mn - 1.21
Lesson 4 Argon-8% Elongation %-2" 64,200 Si - 0.67
Covered Electrodes AWS CO 2
Reduction of Area % 31 Cr - 0.57 Metal cored wire with 1% addition of nickel
for Welding Low E80C-Ni1 2% O Charpy Impacts 72 Ni - 0.67 alloy. Improved impacts are possible.
2
Alloy Steels (75/25) (90/10) Cu - 0.59

- 4 F 86.2 85.5
-40 F 40.7 33
Lesson 5 88-C3 CO 2
Welding Filler Metals Yield Strength, psi 70,000 67,000 Mn - 0.95 For flat and horizontal position welding of
for Stainless Steels AWS Elongation %-2" 26 28 Si - 0.40 the 1% nickel steels. Good impacts at
E80T1-Ni1 Reduction of Area % 60 68 Ni - 1.03 -40 F. Weld metal properties similar to
E8018-C3 low hydrogen electrodes.
Charpy Impact 0 F 50 ft-lb 53 ft-lb
-40 F 25 ft-lb 22 ft-lb
Lesson 6 Dual Shield II Argon- Tensile Strength, psi 97,000 93,000 C - 0.05
Carbon & Low Alloy 80Ni-1 25% CO Yield Strength, psi 87,000 82,000 Mn - 1.46
Superior mechanical properties and
2
Steel Filler Metals - impacts. A 1% Nickel electrode which

Elongation %-2" 25 26 Si - 0.40 exceeds the impacts of most 2% Nickel
GMAW,GTAW,SAW types. all-position capabilities. Smooth
AWS Reduction of Area % 65 68 P - 0.02
E81T1-Ni1 Charpy Impact -40 F 61 ft-lb 38 ft-lb S - 0.01 spray transfer. Low nickel analysis well
suited for petrochemical applications. Ship
Ni - 0.95 building and heavy equipment.
Lesson 7
Flux Cored Arc
(A-25% CO (CO ) (A-25% CO )
Electrodes Carbon 2 2 2
Low Alloy Steels 8000-Ni2 Argon- Tensile Strength, psi 86,000 84,000 C - 0.05
25% CO 2
Widely used all-position electrode
AWS or CO 2
Elongation %-2" 28 28 Si - 0.35 producing 2‰% nickel weld metal. 75%
E81T1-Ni2 Reduction of Area % 68 67 Ni - 2.60 Argon/25% CO2 produces improved
Lesson 8 Charpy Impact 0 F 51 ft-lb 50 ft-lb weldability. Excellent electrode for ship
Hardsurfacing building and heavy equipment.
-20 F 43 ft-lb 43 ft-lb
Electrodes -40 F 30 ft-lb 30 ft-lb
85-C1 CO 2
Yield Strength, psi 71,000 77,000 Mn - 1.17 For flat & horizontal fillet positions. A basic
AWS Elongation %-2" 23 26 Si - 0.30 slag electrode which produces a 2‰%
Lesson 9 nickel deposit with excellent low
Estimating & E80T5-Ni2 Reduction of Area % 56 67 Ni - 2.75 temperature toughness and x-ray quality
Comparing Weld Charpy Impact 72 F 59 ft-lb 84 ft-lb welds.
Metal Costs -75 F 41 ft-lb 38 ft-lb
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2
Common Electric
T-90C1 CO 2
Lesson 3 Yield Strength, psi 82,000 84,000 Mn - 0.84

Covered Electrodes AWS Elongation %-2" 27 25 Si - 0.50 For flat & horizontal position welding of
for Welding E90T1-Ni2 Reduction of Area % 65 60 Ni - 2.65 2‰%-3 % nickel steels and castings.
Good sub-zero toughness.
Mild Steels Charpy Impact 0 F 35 ft-lb
-20 F 27 ft-lb
-50 F 23 ft-lb
Lesson 4 9000-C1 CO 2
Covered Electrodes Yield Strength, psi 101,000 93,000 Mn - 1.2 All-position electrode deposits nominal 2%
nickel weld metal similar to T-90C1. For
for Welding Low AWS Elongation %-2" 20 24 Si - 0.57
welding 2-3% nickel steels and castings
Alloy Steels E91T1-Ni2 Reduction of Area % 53 61 Ni - 2.30 requiring good toughness at subzero
Charpy Impact -20 F 37 ft-lb 25 ft-lb temperatures.
-40 F 20 ft-lb
Lesson 5 9000-D1 CO 2
Welding Filler Metals Yield Strength, psi 92,000 90,500 Mn - 1.37 All-position electrode for nominal 1‰% Mn-
for Stainless Steels AWS Elongation %-2" 23 23 Si - 0.73 ‰% Mo steels. For pressure vessel plates
and Mn-Mo steel castings.
E91T1-D1 Reduction of Area % 60 58 Mo - 0.45
Charpy Impact -20 F 27 ft-lb
150 CO 2
Carbon & Low Alloy AWS Elongation %-2" 16 17 Si - 0.38
Steel Filler Metals - For flat & horizontal position welding of Mn-
E90T1-D3 Reduction of Area % 30 35 Mo - 0.62 Mo steels of 100,000 psi tensile strength.
GMAW,GTAW,SAW
Charpy Impact 0 F 37 ft-lb
-25 F 30 ft-lb
-50 F 24 ft-lb
Lesson 7
85NM CO Tensile Strength, psi 98,500 85,000 C - 0.07
Flux Cored Arc 2
For flat & horizontal position welding Mn-Mo-

Electrodes Carbon Ni steels. Used largely for welding ASTM
Low Alloy Steels AWS Elongation %-2" 23 26 Si - -0.38
A533 (grade B) steel for nuclear pressure
E80T5-K1 Charpy Impact -10 F 60 ft-lb Mo - -0.96 vessels.
-60 F 34 ft-lb Ni - 0.50
98 CO 2
Lesson 8 Yield Strength, psi 85,000 84,500 Mn - 1.10 For flat & horizontal position welds 90,000
Hardsurfacing psi tensile steels. Also for ductile
AWS Elongation %-2" 20 23 Si - 0.30
attachment welds on T-1, HY-80, HY-90 &
Electrodes E90T1-K2 Reduction of Area % 63 61 Mo - 0.20 other high strength quenched & tempered
Charpy Impact 72 F 50 ft-lb 41 ft-lb Ni - 1.75 steels.
0 F 38 ft-lb 35 ft-lb
Lesson 9 9000M CO 2
Estimating & Yield Strength, psi 94,000 91,000 Mn - 1.10
For all-position welds on 90,000-100,000
Comparing Weld AWS Elongation %-2" 23 22 Si - 0.65
psi tensile strength steels. Properties
Metal Costs E91T1-K2 Reduction of Area % 62 60 Ni - 1.80 similar to Dual Shield 98.
Charpy Impact 72 F 43 ft-lb 32 ft-lb Mo - 0.25
0 F 30 ft-lb 20 ft-lb
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2
Common Electric
T-100 CO 2

Covered Electrodes AWS Elongation %-2" 23 24 Si - 0.50
For flat & horizontal welds on 100,000 psi
for Welding E100T1-K3 Reduction of Area % 60 60 Mo - 0.30
tensile strength steels.
Mild Steels Charpy Impact 72 F 45 ft-lb 40 ft-lb Ni - 2.00
-20 F 25 ft-lb 24 ft-lb
-60 F 22 ft-lb 20 ft-lb
Lesson 4 (HY-80) (Mild Steel)
Covered Electrodes Dual Shield Argon- Tensile Strength, psi 97,200 94,700 C - 0.058
for Welding Low II 101TM 25% CO 2
Yield Strength, psi 87,600 86,500 Mn - 1.13 All-position flux cored electrode with
Alloy Steels Elongation %-2" 24 24 Si - 0.37 excellent low temperature impact
AWS Reduction of Area % 64 64 Ni - 1.78 toughness. Developed specifically for
military applications.
E91T1-K2 Charpy Impacts 0 F 68 79
Lesson 5 -60 F 42 49
Welding Filler Metals Dual Shield Argon- Tensile Strength, psi 109,250 110,250 C - 0.05
for Stainless Steels II-100 25% CO 2
A significant new electrode with high
Elongation %-2" 21 22 Si - 0.38 strength and excellent ductility. An all-
AWS Reduction of Area % 60 61 Cr - 0.02 position electrode for welding the T-1 and
E100T1-K3 Charpy Impact 0 F 48 ft-lb 33 ft-lb Ni - 1.91 HY-80 steels. Excellent low temperature
Lesson 6 impacts.
-20 F 40 ft-lb 30 ft-lb Mo - 0.45
Carbon & Low Alloy -60 F 25 ft-lb 18 ft-lb
T-8 CO Tensile Strength, psi 117,000 113,000 C - 0.06
GMAW,GTAW,SAW 2
Yield Strength, psi 106,500 105,000 Mn - 1.45 For flat & horizontal welds on 110,000 psi
AWS Elongation %-2" 20 19 Si - 0.34 steels. For trade name steels such as
E110T1-K3 Reduction of Area % 45 48 Cr - 0.35 SSS 100, N-A-XTRA 110, JALLOY S110,
Lesson 7 USS T1 Type A and others.
Charpy Impact 72 F 42 ft-lb 35 ft-lb Ni - 1.85
Flux Cored Arc
Mo - 0.45
Electrodes Carbon
Low Alloy Steels Dual Shield Argon- Tensile Strength, psi 120,400 116,000 C - 0.05
II-110 25% CO 2
Elongation %-2" 19 19 Si - 0.35 Another Dual Shield II electrode with high
strength and excellent impact properties.
AWS Reduction of Area % 54 56 Cr - 0.03
For all-position welding of 110,000 psi
Lesson 8 E110T1-K3 Charpy Impact 0 F 40 ft-lb 25 ft-lb Ni - 2.14 steels such as HY-100, T1 and others.
Hardsurfacing -20 F 30 ft-lb 20 ft-lb Mo - 0.46
Electrodes -60 F 24 ft-lb
T-115 CO Tensile Strength, psi 113,000 109,000 C - 0.05
2
For flat & horizontal welds. A basic slag
(3/32") Argon- Yield Strength, psi 107,000 96,000 Mn - 1.75 electrode with excellent properties. Small
Lesson 9 (.045", 1/16") 25% CO 2
Elongation %-2" 24 23 Si - 0.47 diameters require Argon-CO mixture for
2
Estimating & Reduction of Area % 65 65 Ni - 2.00 high current, high deposition welding. For
welding T1, HY-80, HY-90, N-A-XTRA 90,
Comparing Weld AWS Charpy Impact -20 F 50 ft-lb 48 ft-lb Mo - 0.50
100 & 110 and the SSS 100 steels.
Metal Costs -60 F 36 ft-lb 32 ft-lb
Lesson 10
Filler Metals

Lesson 1 LESSON VII
The Basics of Arc
Welding
Lesson 2
Common Electric
T-4130 CO 2
SEE CATALOG C - 0.20
FOR COMPLETE Mn - 1.10 For flat and horizontal position welding of
Lesson 3 alloys such as A1S1 4130, 8630 and
Covered Electrodes AWS PROPERTIES Si - 0.29
comparable types. The heat treated
for Welding No Spec. Cr - 0.35 properties will match those of the base
Mild Steels Ni - 1.25 metal.
Mo - 0.22
4130LN Argon- SEE CATALOG C - 0.22
A basic slag electrode for flat and
Lesson 4 25% CO FOR COMPLETE Mn - 1.40
2
horizontal welding positions. Resists
Covered Electrodes AWS PROPERTIES Si - 0.52 cracking and welds are of highest quality.
for Welding Low No Spec. Cr - 0.56 For welding SAE 8630 and 4130 heat
Alloy Steels Ni - 0.88 treatable steels. Low nickel content meets
the standards of the National Association of
Mo - 0.18 Corrosion Engin
Lesson 5 88W CO 2
Welding Filler Metals Yield Strength, psi 68,000 70,000 Mn - 0.79
for Stainless Steels AWS Elongation %-2" 25 25 Si - 0.47
For flat and horizontal position welding of
E80T1-W Reduction of Area % 65.7 56.5 Cr - 0.51
the weathering grade steels such as Cor-
Charpy Impact 30 F 66 ft-lb 47 ft-lb Ni - 0.56 Ten or Mayari R.
0 F 42 ft-lb 35 ft-lb Cu - 0.55
Lesson 6 -20 F 32 ft-lb 23 ft-lb
Carbon & Low Alloy -44 F 20 ft-lb 20 ft-lb
Coreweld W Argon- Tensile Strength, psi 92,500 C - 0.031
GMAW,GTAW,SAW
6% CO 2
Yield Strength, psi 81,500 Mn - 1.33 Metal cored electrode for weathering grade
AWS Elongation %-2" 26 Si - 0.43 steels such as A588, A242, U.S.S. Cor-
E80C-G Charpy Impacts -20 F 38 Ni - 0.78 Tenfi , and Mayari Rfi .
Lesson 7
-60 F 23.5
Flux Cored Arc
8100W CO Tensile Strength, psi 96,500 C - 0.05
Electrodes Carbon 2
Low Alloy Steels Yield Strength, psi 89,500 Mn - 0.76

AWS Elongation %-2" 25 Si - 0.45 All-position flux cored electrode to provide
E80T1-W Reduction of Area % 61 color match for weathering grade steels.
Charpy Impacts 0 F 34
Lesson 8 -20 F 31
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VII
The Basics of Arc
Welding
APPENDIX A
Lesson 2
LESSON VII - GLOSSARY OF TERMS
Common Electric
Arc Welding Chemical symbols for the alloying elements commonly used in welding metallurgy:
Processes
C - Carbon S - Sulfur
Mn - Manganese B - Boron
Lesson 3 Si - Silicon Al - Aluminum
Covered Electrodes Cr - Chromium Cb - Columbium (Niobium)
for Welding Ni - Nickel Ti - Titanium
Mild Steels
Mo - Molybdenum W - Tungsten
V - Vanadium Co - Cobalt
Cu - Copper Pb - Lead
Lesson 4
Covered Electrodes P - Phosphorus N - Nitrogen
for Welding Low
Alloy Steels Flux Voids - Section of a flux cored electrode which contains no flux. Voids can
cause serious problems, especially in low alloy types.
Lesson 5 Mill Scale - The iron oxide (FeO) coating normally found on the surface of hot
Welding Filler Metals rolled steels.
- The temperature to which many of the low alloy steels must be
Preheat
Temperature heated before welding. Preheating retards the cooling rate, allowing
Lesson 6 more time for the hydrogen to escape, which minimizes underbead
Carbon & Low Alloy cracking. Preheat temperatures can vary from 10°F to 500°F on ½”
sections to 300°F to 600°F on heavy sections, depending upon the
GMAW,GTAW,SAW
alloy.
Interpass - The minimum temperature of the weldment between passes. It
Lesson 7 Temperature
is usually about the same as the preheat temperature.
Flux Cored Arc
Electrodes Carbon Peening - The mechanical working of metal by means of hammer blows to
Low Alloy Steels relieve stresses and reduce distortion. Peening is recommended for
thicker sections (over 1” or 2”) of some alloys on each successive
pass. Experience has shown that peening helps to reduce cracking.
Lesson 8
Hardsurfacing Peening may decrease the ductility and impact properties; however,
Electrodes the next pass will nullify this condition. For this reason, the last
surface layers should not be peened.
Post Weld - Reheating the weldment to 1100°F to 1350°F after welding
Lesson 9 Heat Treatment
Estimating & and holding at that temperature for a specified length of time. Heat
Comparing Weld treating allows additional hydrogen to escape, lowers the residual
Metal Costs
stresses due to welding, and restores toughness in the heat affected
zone.
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Lesson 5
Lesson 6 LESSON VIII

Carbon & Low Alloy
Steel Filler Metals - HARDSURFACING
GMAW,GTAW,SAW
ELECTRODES
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON VIII
Lesson 2
Common Electric HARDSURFACING ELECTRODES
Arc Welding
Processes

Lesson 3
Covered Electrodes 8.1 Introduction to Hardfacing ................................................................... 1
for Welding
Mild Steels 8.1.1 Definition and Purpose ........................................................................ 1
8.1.2 Buildup Alloys ...................................................................................... 2
Lesson 4 8.1.3 Hardfacing Alloys ................................................................................. 2

Covered Electrodes 8.1.4 Wear Factors ....................................................................................... 3
for Welding Low
Alloy Steels 8.1.5 Base Metals ......................................................................................... 7
8.2 Classification of Hardfacing Alloys ...................................................... 9
Lesson 5 8.2.1 Iron Base Alloys ................................................................................... 9

for Stainless Steels 8.2.2 Nickel Base Alloys ............................................................................... 9
8.2.3 Cobalt Base Alloys .............................................................................. 9
8.2.4 Tungsten Base Alloys .......................................................................... 10

Lesson 6
Carbon & Low Alloy 8.3 Methods of Hardfacing ........................................................................ 10
GMAW,GTAW,SAW 8.3.1 Oxyacetylene Surfacing....................................................................... 11
8.3.2 Shielded Metal Arc Surfacing .............................................................. 11
Lesson 7 8.3.3 Gas Tungsten Arc Surfacing ................................................................ 12

Flux Cored Arc
Electrodes Carbon 8.3.4 Flux Cored Arc Surfacing..................................................................... 12
Low Alloy Steels 8.3.5 Submerged Arc surfacing .................................................................... 12
8.3.6 Gas Metal Arc surfacing ...................................................................... 12
Lesson 8 8.4 Surfacing With Powders ...................................................................... 13

Hardsurfacing
Electrodes 8.4.1 Flame Spray Process .......................................................................... 13
8.4.2 Manual Torch Process ......................................................................... 13
8.4.3 Plasma Arc Spray and Plasma Arc Welding Process ......................... 13
Lesson 9
Estimating & 8.5 General Rules of Hardfacing ............................................................... 14
Comparing Weld
Metal Costs 8.6 Economics of Hardfacing .................................................................... 15
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON VIII
Lesson 2
Common Electric HARDSURFACING ELECTRODES
Arc Welding
Processes

Lesson 3
Covered Electrodes
for Welding
Mild Steels 8.7 ESAB Hardfacing Electrodes .............................................................. 16
8.7.1 Wear-Arc Coated Electrodes............................................................... 16
Lesson 4 8.7.2 Wear-O-Matic Open Arc Electrodes .................................................... 16

Covered Electrodes
8.7.3 Wear-O-Matic BR Wires ...................................................................... 16
for Welding Low
Alloy Steels 8.8 Hardfacing Alloy Selection Factors ...................................................... 17
8.8.1 Hardness ............................................................................................. 17

Lesson 5 8.8.2 Abrasion and Impact ........................................................................... 18
for Stainless Steels 8.9 Wear-Arc Covered Electrodes and Wear-O-Matic
Wires for Hardfacing ........................................................................... 21
8.9.1 Wear-Arc Covered Electrodes ............................................................. 22

Lesson 6
Carbon & Low Alloy 8.9.2 Wear-O-Matic Semiautomatic Cored Wires ........................................ 28
GMAW,GTAW,SAW Appendix A Glossary of Terms ....................................................................... 35
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON VIII
Welding
HARDSURFACING ELECTRODES
Lesson 2
Common Electric
Arc Welding
Processes
8.1 INTRODUCTION
Lesson 3 Hardfacing, or hard surfacing*, has been used as a method of reclaiming industrial parts
Covered Electrodes and equipment since the early 1920’s. At that time, it was found that a hard alloy deposit,
for Welding
Mild Steels properly applied to the surface of oil drilling bits, extended the life of those bits by more
than ten times. Since then, hardfacing has become universally accepted as an economical
and practical means of restoring plant and field equipment subjected to destructive wear.
Lesson 4
Covered Electrodes
8.1.1 Definition and Purpose - Hardfacing may be defined as the application of a
for Welding Low
Alloy Steels hard, wear resistant alloy to the surface of a softer metal to restore it dimensionally and
reduce wear caused by abrasion, impact, erosion, corrosion and heat.
Lesson 5 8.1.1.1 Lubrication of machine parts is an effective method of preventing abrasive wear;
for Stainless Steels however, in applications such as the external parts of farm and earth moving equipment, oil
drilling tools, engine valves, etc., lubrication is not possible. In these applications,
hardfacing has proven to be an effective means of extending part life by three to eight
Lesson 6 times.
Carbon & Low Alloy
GMAW,GTAW,SAW 8.1.1.2 In many cases, new parts which are destined for destructive wear, are hardfaced
before being put into service initially. Savings are effected by reclaiming worn parts, reduc-
ing maintenance and replacement costs, and permitting the use of relatively inexpensive
Lesson 7
Flux Cored Arc base metals.
Electrodes Carbon
Low Alloy Steels 8.1.1.3 Shops specializing in hardfacing are set up for automatic operation in many
cases. Jigs, fixtures, and rotating devices are often used for economical surfacing of large
numbers of parts. Parts which are large and costly to disassemble, such as power shovel
Lesson 8
buckets, can be hardsurfaced on site without dismantling the equipment, using semiauto-
Hardsurfacing
Electrodes matic or manual arc welding.
8.1.1.4 Various hardfacing and build-up alloys have been designed to perform specific
Lesson 9 functions with predictable results. The selection of the proper hardfacing alloys requires a
Estimating &
knowledge of:
Comparing Weld
Metal Costs
1. The wear factors under which it must operate.
2. The function of the part or equipment.
3. The base metal to which it must be applied.
Lesson 10
Reliability of Welding (Note: Hardfacing and hard surfacing are synonymous terms.)
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.1.2 Buildup Alloys - Buildup alloys are used for two purposes. They may serve as a
supporting base for a more wear resistant overlay, or they may serve as a moderately wear
Lesson 2 resistant alloy surface when it is necessary to machine the part to size. In some cases, the
Common Electric
Arc Welding buildup alloys may also be used for high strength attachment welds. The selection of the
Processes proper buildup alloy for parts worn beyond practical limits of hardfacing deposits is most
important, since the success of the hardfacing overlay depends upon the rigidity and defor-
mation resistance of the base metal. Experience has proven that in many cases where
Lesson 3
Covered Electrodes hardsurfacing overlays have failed, deformation of the base metal or buildup alloy took
for Welding place, causing spalling of the overlay alloy.
Mild Steels
8.1.2.1 Badly worn parts should be restored to within 3/16” to ¼” of their original size with
Lesson 4 a buildup alloy, which is compatible for welding to the base material and the hardfacing
Covered Electrodes alloy.
for Welding Low
Alloy Steels
8.1.3 Hardfacing Alloys - Hardfacing alloys are designed to provide maximum wear
resistance to a specific wear factor or a combination of wear factors. Performance of the
Lesson 5 overlay is in direct relationship to the amount of carbide forming elements - chromium,
molybdenum, tungsten, vanadium, and iron - in combination with carbon. Wear resisting
carbides are formed when one of these elements is allowed to react with carbon, and as a
result, is completely saturated forming a carbide consisting only of carbon and the element.
Lesson 6 The balance of the carbon remains in solution to form a semi-austenitic matrix (bonding
Carbon & Low Alloy metal) in which the hard, wear resistant carbides are evenly distributed. As the ratio of
GMAW,GTAW,SAW wear resistant carbides to alloy matrix increases, abrasion resistance increases. This
same increase reduces the toughness of the overlay, thereby lowering its impact value.
Figure 1 illustrates the effects of the carbide-to-matrix ratio.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
VERY HARD CARBIDES
Lesson 8 MATRIX
Hardsurfacing
Electrodes
Lesson 9 BETTER BETTER

Estimating & IMPACT RESISTANCE ABRASION RESISTANCE
Comparing Weld
Metal Costs
CARBIDES - MATRIX RATIO
FIGURE 1
Lesson 10
Filler Metals

Lesson 1 LESSON VIII
The Basics of Arc
Welding
Lesson 2
Common Electric 8.1.3.1 The pure carbides most commonly used in hardfacing alloys are listed below in order of descending
Arc Welding wear resistance.
Processes 1. Tungsten Carbide
2. Molybdenum Carbide
Lesson 3 3. Chromium Carbide

Covered Electrodes
for Welding 4. Iron Carbide
Mild Steels
8.1.3.2 Tungsten carbide is the hardest of the commercially available carbides within the price structure
feasible for hardfacing applications. It provides the maximum resistance to wear, although most hardfacing
alloy deposits contain mixtures of two or more of the carbide forming elements. This balanced combination of
Lesson 4 carbides provides a tougher structure, resulting in a more wear resistant deposit.
Covered Electrodes
for Welding Low 8.1.4 Wear Factors
Alloy Steels
8.1.4.1 Impact and Corrosion - These two wear factors can be discussed jointly because the
requirements of a hardfacing alloy to combat them are similar.
Lesson 5 8.1.4.1.1 Impact occurs when an object is struck by another object. Compression occurs in the form of weight
Welding Filler Metals or pressure. The material is said to have good resistance to impact or compressive loads when the yield
for Stainless Steels strength of the material exceeds that of the opposing force.
8.1.4.1.2 Weld metals for hardsurfacing or buildup applications must have the following characteristics
to successfully combat wear being caused by impact or compression.
Lesson 6
Carbon & Low Alloy 8.1.4.2 Buildup Alloys - When the force of a blow is less than the yield strength of the deposit weld
Steel Filler Metals - metal, the weld metal absorbs the force with no deformation. When the force of the blow exceeds the yield
GMAW,GTAW,SAW strength of the deposited weld metal, the weld metal deforms, resulting in roll over or upset.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.1.4.3 Hardfacing Alloys - Hardfacing alloys are designed to have very high compres-
sion resistance which usually results in low ductility and low shear strength. See Figure 3.
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding HIGH
LOW SHEAR
Mild Steels COMPRESSION LOW DUCTILITY
STRENGTH
RESISTANCE
PROPERTIES OF HARDFACING DEPOSIT

Lesson 4
for Welding Low
Alloy Steels 8.1.4.3.1 Because of these characteristics, hardfacing materials should always be applied
in the manner that allows impact to be absorbed as a compressive force. The term “good
Lesson 5 impact resistance” when applied to a hardfacing deposit, means that the deposit will not fail
Welding Filler Metals when impact is born as a compressive force as shown in Figure 4. Hardfacing alloys
should not be applied where only shear forces exist.
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7 POWER SHOVEL TOOTH

Flux Cored Arc PULVERIZING HAMMER
Electrodes Carbon
Low Alloy Steels These sketches illustrate good examples of
hardfacing applied so that impact is absorbed
as a compressive force.
Lesson 8
Hardsurfacing
Electrodes
ROLL CRUSHER
IMPACT AS A COMPRESSIVE FORCE
FIGURE 4
Lesson 9
Estimating &
Comparing Weld 8.1.4.3.2 The base metal over which a hardfacing deposit is to be made must have a high
Metal Costs yield strength to resist deformation. If the base metal has a low yield strength, it upsets
under impact and the hardsurfacing alloy is stressed in tension. As a result, the hardfacing
overlay breaks and spalling occurs as in Figure 5.
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
HARDFACING
Lesson 2
Common Electric
Arc Welding
Processes
BASE METAL
Lesson 3
MECHANICAL FAILURE DUE TO LOW YIELD BASE METAL
Covered Electrodes
for Welding FIGURE 5
Mild Steels
8.1.4.4 Abrasion - Abrasive wear occurs when hard particles or objects, such as sand,
Lesson 4 stone, or metallic particles, slide or roll over a surface under some amount of pressure. To
Covered Electrodes
for Welding Low scratch, scrape or gouge a surface, the abrasive particles must be harder than the surface
Alloy Steels they are in contact with. To prevent this surface damage, hardfacing supplies the logical
harder wear surface, although other factors such as toughness must also be considered.
Lesson 5 Abrasion may be considered three general types: scratching, grinding, and gouging.
for Stainless Steels 8.1.4.4.1 Scratching abrasion, or low stress abrasion, is the type of wear caused when the
abrasive particles slide over a surface, such as sand or gravel sliding down the chute, or a
plowshare working in sandy soil. The abrasive particles are not crushed. There are no
Lesson 6 large pieces impacting the surface.
Carbon & Low Alloy
GMAW,GTAW,SAW 8.1.4.4.2 Grinding abrasion, or high stress abrasion, is the wear caused when the abrasive
particles are under a compressive stress sufficient to cause them to be crushed. Cement
plant pulverizer parts and exposed drive sprockets on traced vehicles are examples of high
Lesson 7
Flux Cored Arc stress abrasion.
Electrodes Carbon
Low Alloy Steels 8.1.4.4.3 Gouging abrasion is caused by relatively large sized abrasive pieces which
cause grooves or visible gouges in a surface. Gouging abrasion is usually characterized by
high impact forces. Rock crushing mill hammers and shovel teeth are examples of parts
Lesson 8
Hardsurfacing which are subject to gouging abrasion. In some instances, it may be necessary to sacrifice
Electrodes some amount of abrasion resistance for better impact properties.
8.1.4.5 Hardness - Although hardness is a desirable factor in combatting wear, it is not a

Lesson 9 true criteria of abrasion resistance. As mentioned earlier, those alloys containing a greater
Estimating &
Comparing Weld percentage of carbide forming elements will have better abrasion resistance. Hardness, in
Metal Costs relation to abrasion resistance, is illustrated in the deposits of three alloys having equal
matrix hardness, but unequal alloy composition in Figure 6.
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
50 Rc 50 Rc 50 Rc
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3 HIGH CARBIDE TO LOW CARBIDE TO NO CARBIDES.

Covered Electrodes MATRIX RATIO. MATRIX RATIO. LEAST ABRASION
MOST ABRASION LESS ABRASION RESISTANT.
for Welding RESISTANT. RESISTANT.
Mild Steels
HARDNESS IN RELATION TO ABRASION RESISTANCE
FIGURE 6
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels 8.1.4.5.1 The three examples shown are equal in hardness (Rockwell 50 on the C scale)
but offer increased abrasion resistance as the carbide-to-matrix ratio is increased. As
mentioned in Lesson I, hardness of the metal is tested by measuring its resistance to
Lesson 5
Welding Filler Metals indentation. A Rockwell hardness tester produces a relatively large indentation or impres-
for Stainless Steels sion compared to the microscopic carbides suspended in the matrix, and the penetration
may simply displace the carbide particles. Measurement is more of an indication of the
hardness of the matrix than of the hard particles.
Lesson 6
Carbon & Low Alloy 8.1.4.6 Heat - High temperature causes a reduction of wear resistance in metals by
GMAW,GTAW,SAW softening, reducing the strength and causing oxidation and scaling. An oxide scale can
actually protect a surface from further oxidation in some cases, although in high tempera-
Lesson 7 ture wear applications, the scale is constantly worn away, permitting further rapid oxidation.
Flux Cored Arc Alloys are available which retain their hardness at high temperatures and resist scaling and
Electrodes Carbon
oxidation.
Low Alloy Steels
8.1.4.7 Corrosion - The corrosion caused by moisture is detrimental to hardfacing alloys
and if salts or acids are present in the water, corrosion will proceed at an accelerated rate.
Lesson 8
Hardsurfacing Many alloys derive some degree of corrosion resistance from a rapidly formed oxide coat-
Electrodes ing on the surface. However, in an abrasive application, this coating is constantly being
worn away, allowing corrosion to proceed at a rapid rate. By choosing the proper alloy, the
corrosion rate can be minimized.
Lesson 9
Estimating &
Comparing Weld 8.1.4.8 Many hardfacing applications will be subjected to a combination of the wear
Metal Costs factors discussed above. Selecting the proper alloy requires that the wear factors be
analyzed, and the alloy which most closely meets the needs is selected. As a simplified
example, we might consider a back-hoe bucket which is used for digging trenches for
Lesson 10
Filler Metals

Lesson 1
Welding
burying gas lines to homes in an area where the topsoil is a sandy loam, and the sub-soil is
a soft gumbo-like clay. For this application, only abrasion need be considered. If this
Lesson 2 back-hoe is moved to work in a new area where the soil contains shale and quartz rock in
Common Electric
Arc Welding small and large pieces, impact and abrasion must be considered.
Processes
8.1.5 Base Metals - Basically, there are three types of steel used in the manufacture
of equipment and parts subjected to heavy impact, compressive loads, and abrasive wear.
Lesson 3
These are the straight carbon steels, the low alloy high strength steels, and the austen-
Covered Electrodes
for Welding itic manganese steels. All of these steels possess good deformation resistance and lend
Mild Steels themselves well to the application of hardfacing alloys if the proper welding procedures are
followed.
Lesson 4
Covered Electrodes 8.1.5.1 Carbon Steels - If the base metal is a mild carbon steel with a carbon content of
for Welding Low .20% to .30%, preheat temperatures from 200°F to 300°F are recommended. If the carbon
Alloy Steels
content of the base metal ranges from .30% to .45%, preheating to 300°F for thin sections,
to 500°F for heavy sections, is necessary. For base metals to .45% to .80% carbon con-
Lesson 5 tent, preheat temperatures of 500°F for thin sections, to 800°F for heavy sections, are
necessary. High carbon tool steels containing carbon up to 1.7% are difficult to hardface
because they are prone to cracking. After hardfacing, parts should be allowed to cool
slowly.
Lesson 6
Carbon & Low Alloy 8.1.5.2 Low Alloy High Strength Steels - Low alloy steels may be hardfaced as long as
Steel Filler Metals - the proper welding procedure is followed. Preheat and postheat temperatures must be
GMAW,GTAW,SAW
maintained. In some alloys, stress relieving may be necessary. As a rule of thumb, the
welding procedure becomes more critical as the alloy and carbon content increases. Pre-
Lesson 7 heat temperatures of 100°F to 600°F are used for most alloys, although some low alloys
Flux Cored Arc
Electrodes Carbon with carbon content over .35% require preheat temperatures in the 800°F to 1100°F range.
Low Alloy Steels
8.1.5.3 Austenitic Manganese Steel - Austenitic manganese steel (known as Hadfield
steel) is a high alloy containing 11-14% manganese and approximately 1.2% carbon. It is
Lesson 8 non-magnetic, unless it has been work-hardened. It is characterized by high strength, high
Hardsurfacing
Electrodes ductility, and good wear resistance. It has no equal in its ability to work harden. It is widely
used in equipment and parts that are subjected to heavy impact and compressive loads.
These loads actually harden the new surface as the old is slowly worn away. It may actu-
Lesson 9 ally have a shorter service life when used in sand where there are no impact loads to work
Estimating &
Comparing Weld harden the surface.
Metal Costs
8.1.5.4 Unlike carbon and low alloy steels, preheating of high manganese steels is not
recommended. Temperatures above 500°F to 600°F will induce embrittlement if sustained
Lesson 10
Filler Metals

Up to 200
Lesson 1
LESSON VIII
The Basics of Arc
Welding
for long periods of time. The lowest welding current, which produces good fusion with the
base metal, should be used to minimize heat input. Welding in one area for long periods of
Lesson 2 time should be avoided. A skip-welding technique should be used. This means that each
Common Electric
succeeding pass should be made as far as possible from the preceding pass.
Arc Welding
Processes
8.1.5.5 Preheating should only be used when the weldment has been exposed to tem-
peratures below 50°F or when the weldment is massive. Then preheat temperatures of
Lesson 3 100°F should not be exceeded.
Covered Electrodes
for Welding
Mild Steels
Lesson 4 Preheat Preheat

Type of Steel % Carbon Temp. Type of Steel % Carbon Temp.
Covered Electrodes F F
for Welding Low PLAIN CARBON STEELS NICKEL-CHROMIUM STEELS
Alloy Steels Below 0.20 SAE 3115 0.15 200-400
0.20-0.30 200-300 SAE 3125 0.25 300-500
0.30-0.45 300-500 SAE 3130 0.30 400-700
0.45-0.80 500-800 SAE 3140 0.40 500-800
Lesson 5 CARBON-MOLYBDENUM STEELS SAE 3150 0.50 600-900
Welding Filler Metals 0.10-0.20 300-500 SAE 3215 0.15 300-500
for Stainless Steels 0.20-0.30 400-600 SAE 3230 0.30 500-700
0.30-0.35 500-800 SAE 3240 0.40 700-1000
MANGANESE STEELS SAE 3250 0.50 900-1100
Silicon Structural 0.35 300-500 SAE 3315 0.15 500-700
Medium Manganese 0.20-0.25 300-500 SAE 3325 0.25 900-1100
Lesson 6 SAE 1330 0.30 400-600 SAE 3435 0.35 900-1100
Carbon & Low Alloy SAE 1340 0.40 500-800 SAE 3450 0.50 900-1100
Steel Filler Metals - SAE 1350 0.50 600-900 LOW CHROMIUM-MOLYBDENUM STEELS
GMAW,GTAW,SAW 12% Manganese (Hadfield)* 1.25 Not Required 2.0% Cr, 0.5% Mo Up to 0.15 400-600
HIGH STRENGTH STEELS 2.0% Cr, 0.5% Mo 0.15-0.25 500-800
Manganese-Molybdenum 0.20 300-500 2.0% Cr, 1.0% Mo Up to 0.15 500-700
Chromium-Copper-Nickel 0.12 max. 200-400 2.0% Cr, 1.0% Mo 0.15-0.25 600-800
Lesson 7 Chromium-Manganese 0.40 400-600 MEDIUM CHROMIUM-MOLYBDENUM STEELS
Flux Cored Arc NICKEL STEELS 5.0% Cr, 0.5% Mo Up to 0.15 500-800
Electrodes Carbon SAE 2015 0.10-0.20 Up to 300 5.0% Cr, 0.5% Mo 0.15-0.25 600-900
Low Alloy Steels SAE 2115 0.10-0.20 200-300 8.0% Cr, 1.0% Mo 0.15 max. 600-900
Nickel Steel 0.10-0.20 200-400 STAINLESS CHROMIUM STEELS
SAE 2315 0.15 200-500 Type 410 300-500 300-500
SAE 2320 0.20 200-500 Type 430 300-500 300-500
SAE 2330 0.30 300-600 Type 446 300-500 300-500
Lesson 8 0.40 400-700
SAE 2340 STAINLESS CHROMIUM-NICKEL STEELS
Hardsurfacing MOLYBDENUM STEELS 18-8 Type 304 0.07
Electrodes SAE 4140 0.40 600-800 25-12 Type 309 0.07 Usually do
SAE 4340 0.40 700-900 25-20 Type 310 0.1 not require
SAE 4615 0.15 400-600 18-8 Columbium preheat but
SAE 4630 0.30 500-700 Type 347* 0.07 it may be
Lesson 9 SAE 4640 0.40 600-800 18-8 Molybdenum desirable to
Estimating & SAE 4820 0.20 600-800 Type 316* 0.07 heat to 32 F
Comparing Weld 18-8 Molybdenum
Type 317 0.07
Metal Costs
* When ambient temperature is below 50°F, preheat to 100°F.
Interpass temperatures over 500°F should be avoided.
RECOMMENDED PREHEAT TEMPERATURES

Lesson 10
Reliability of Welding FIGURE 7
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.1.5.6 The chart in Figure 7 lists the recommended preheat temperatures for welding
the various grades of steel with the proper welding electrode. In hardfacing, the deposit is
Lesson 2 quite different from the base metal and variations dictated by experience may be neces-
Common Electric
Arc Welding sary.
Processes
8.2 CLASSIFICATION OF HARDFACING ALLOYS
Lesson 3
Covered Electrodes Unlike the various electrodes, wires and filler metals in the previous lessons, hardfacing
for Welding electrodes and filler metals are frequently proprietary alloys made to each manufacturer’s
Mild Steels
specifications from formulas proven over the years. Very few of them are classified accord-
ing to an AWS specification. Hardfacing systems may be divided into four basic catego-
Lesson 4 ries: iron base, nickel base, cobalt base, and tungsten.
Covered Electrodes
for Welding Low
8.2.1 Iron Base Alloys - The iron base alloys as a group are the most widely used of
Alloy Steels
all the hardfacing systems, and include a wide range of alloy types. These range from low
alloy steels containing 2-12% alloying elements to high alloys containing 12-50% of these
Lesson 5
elements. This group includes a number of buildup alloys, as well as excellent hardfacing
for Stainless Steels alloys. The iron based alloys are characterized by excellent resistance to abrasion in
varying degrees or excellent resistance to impact, depending on alloy content. The higher
alloy versions afford good wear resistant properties up to 1,000°F. Filler metal is available
Lesson 6 as coated electrodes, bare electrodes for oxyacetylene welding or gas tungsten-arc weld-
Carbon & Low Alloy
Steel Filler Metals - ing, solid or cored wires for submerged arc welding, and cored wires for open arc welding.
GMAW,GTAW,SAW
8.2.1.1 When surfacing with the high chromium-iron base alloys or other brittle alloys, a
number of small cracks across the weld will appear. These cracks (known as checking or
Lesson 7
Flux Cored Arc check cracks) are not detrimental because they do not penetrate into the tougher base
Electrodes Carbon metal or buildup alloy. They are, in fact, helpful in relieving stress buildup which would
Low Alloy Steels
cause eventual longitudinal cracking in the fusion zone, leading to spalling of the
hardfacing material. On heavy weldments where heat buildup is great, check cracks may
Lesson 8 not appear. They should be induced by a light water spray or by an occasional hammer
Hardsurfacing blow on the weld surface.
Electrodes
8.2.1.2 The iron base alloys are the lowest in cost of the various hardfacing systems.
Lesson 9 8.2.2 Nickel Base Alloys - The nickel base alloys contain 70-80% nickel, 11-17%
Estimating &
Comparing Weld chromium, 2.50-3.70% boron, and 0.30-4.50% silicon. The forming of various carbides and
Metal Costs borides in the nickel matrix results in a deposit with excellent resistance to low temperature
abrasion, and makes these the best alloys for metal-to-metal wear. These alloys also have
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
good heat and corrosion resistance. They retain their hardness and temperatures up to
1200°F. The nickel base alloys lend themselves to flame spray and plasma arc applica-
Lesson 2 tions, and are available largely in powder form. The cost of nickel base alloys is approxi-
Common Electric
Arc Welding mately five to six times that of the iron base alloys.
Processes
8.2.3 Cobalt Base Alloys - The cobalt base alloys consist of 45-63% cobalt, 24-29%
chromium, 5.50-13.5% tungsten and 1.10-3.20% carbon. They are probably the most
Lesson 3
versatile of the hardfacing alloys because they resist heat, corrosion, abrasion, moderate
Covered Electrodes
for Welding impacts, galling, and metal-to-metal wear. Some alloys in this group remain substantially
Mild Steels hard at temperatures up to 1500°F. Applications would include hot work equipment such as
hot punches, valve parts, shear blades, etc.
Lesson 4
Covered Electrodes 8.2.3.1 In recent years, the price of cobalt has risen sharply since there are few sources
for Welding Low in the world. The price of cobalt alloys per pound exceed that of the iron base alloys by
Alloy Steels
approximately eighteen times.
8.2.4 Tungsten Base Alloys - The tungsten base alloys produce the most wear resis-
Lesson 5
Welding Filler Metals tant deposits of the hard surfacing materials. They consist of hard granules of tungsten
carbide distributed in a matrix of iron, carbon steel, cobalt alloy, or nickel alloy. The matrix,
being somewhat softer than the carbides, wears away to a degree, leaving the hard car-
bides protruding. This roughness of the deposit renders these alloys useless for
Lesson 6
Carbon & Low Alloy metal-to-metal applications, but ideal for applications such as rock drill bits and other min-
Steel Filler Metals - ing, quarrying and digging applications.
GMAW,GTAW,SAW
8.2.4.1 These rods or electrodes are usually supplied as carbon steel tubes filled with
Lesson 7 tungsten carbide granules by weight. The steel matrix produced is not soft by any means,
Flux Cored Arc because when the tube melts, it dissolves enough of the tungsten and carbon to form a
Electrodes Carbon
Low Alloy Steels hard matrix and is capable of supporting the carbide granules.
8.2.4.2 Despite their excellent abrasion resistance, tungsten carbide alloys can only
Lesson 8 withstand impacts that do not produce compressive stress above their yield strength.
Hardsurfacing Tungsten carbide alloys have low resistance to oxidation and low resistance to corrosion,
Electrodes
unless deposited in a nickel or cobalt matrix. Hardness at high temperatures is approxi-
mately equal to the higher alloy iron base alloys if the tungsten carbide granules are in an
Lesson 9 iron or steel matrix. If in a nickel or cobalt matrix, better hot hardness can be achieved.
Estimating &
Comparing Weld 8.2.4.3 The cost of rods or electrodes consisting of tungsten carbide granules in a car-
Metal Costs
bon steel matrix is approximately nine times that of the iron base alloys. If the matrix is a
nickel or cobalt base alloy, costs will be higher.
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.3 METHODS OF HARDFACING
Lesson 2 Hardfacing may be applied by a variety of methods and processes. The method chosen
Common Electric depends on a number of factors:
Arc Welding
Processes
a. Size and configuration of the part.
Lesson 3 b. End use of the hardfaced part.

Covered Electrodes
for Welding c. Depth of overlay required.
Mild Steels
d. Quality or smoothness of the overlay.
Lesson 4 e. Properties of the deposited overlay.

Covered Electrodes
for Welding Low f. Composition of the base metal.
Alloy Steels
g. Available forms of the filler metal.
h. Availability of the equipment necessary.

Lesson 5
i. Operator skill.
8.3.1 Oxyacetylene Surfacing - The oxyacetylene process, an early method of apply-

Lesson 6
Carbon & Low Alloy ing surfacing alloys, is still in use today. The equipment is low in cost and consists of a
Steel Filler Metals - torch, hoses, oxygen cylinder, acetylene cylinder, and two pressure regulators. Unlike
GMAW,GTAW,SAW
oxyacetylene welding, a thin surface layer of the part in the immediate area being
hardfaced, is brought to melting temperature. The hardfacing alloy is simultaneously
Lesson 7 melted into the molten area where it flows and spreads, and is fused to the surface in a thin
Flux Cored Arc
Electrodes Carbon smooth layer, with little dilution from the base metal. This method is commonly referred to
Low Alloy Steels as “sweating”.
8.3.1.1 The oxyacetylene process lends itself to servicing small parts, and fills grooves
Lesson 8 and recesses well. Other advantages are low dilution and low temperature gradients which
Hardsurfacing
Electrodes minimize stresses and subsequent cracking. The operator requires much skill, and the
deposition rate is very low. The process does not lend itself to automation, although some
automatic set-ups have been developed.
Lesson 9
Estimating & 8.3.2 Shielded Metal Arc Surfacing - SMAW, as described in Lesson II, is a versatile
Comparing Weld
method of depositing hardfacing materials. The electrode has a flux coating to assure weld
Metal Costs
cleanliness. The equipment is the same as for SMAW and consists of a power source,
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
weld cables, and an electrode holder. Surfacing may be performed in all positions and
although the deposition rate is low, this process is especially useful where many short
Lesson 2 welds are to be made. This method is used extensively for field repair and rebuilding of
Common Electric
Arc Welding equipment. The arc power may be either direct or alternating current. Dilution level is
Processes higher than in the oxyacetylene method, but can be kept to a minimum by using the proper
welding current, using a weaving bead instead of a stringer bead and keeping the electrode
in the puddle rather than on the base metal.
Lesson 3
Covered Electrodes
for Welding 8.3.3 Gas Tungsten Arc Surfacing - This process utilizes the same equipment and
Mild Steels procedures as GTAW as discussed in Lesson II. Deposition rate is low, but deposits are of
high quality as long as efforts are made to keep dilution to a minimum. Normal dilution is
Lesson 4 somewhat greater than in oxyacetylene surfacing. Although argon, helium or mixtures of
Covered Electrodes these gases may be used, dilution is the lowest when using pure argon. Gas Tungsten Arc
for Welding Low
Alloy Steels Surfacing is used for many of the same type of applications as the oxyacetylene process.
These are usually small wear surfaces which require a smooth high quality deposit.
Lesson 5 8.3.4 Flux Cored Arc Surfacing - Two types of continuous tubular electrodes are
available for hardsurfacing; self-shielded and those which require a gas shield.
8.3.4.1 The self shielded type are by far the more popular, and in the hardfacing field,
are known as “open arc wires”, indicating that they do not require externally applied granu-
Lesson 6
Carbon & Low Alloy lar flux or shielding gas. Deposits are comparable to those made with coated electrodes,
Steel Filler Metals - but there is no stub loss. Since no shielding gas or flux handling equipment are necessary
GMAW,GTAW,SAW
and the deposition rate is high, it is the most economical process for depositing hardfacing
materials. Portability of the equipment allows this process to be used for hardfacing heavy
Lesson 7 equipment in the field, as well as in the shop. Dilution is higher than that of coated elec-
Flux Cored Arc
Electrodes Carbon trodes, but lower than that of submerged arc welding.
Low Alloy Steels
8.3.4.2 The gas shielded cored wires are used to a lesser extent. The shielding gases
are used to reduce oxidation and minimize alloy loss. The use of CO2 as a shielding gas
Lesson 8 has a tendency to increase penetration and thereby, increase dilution. Shielding gas and
Hardsurfacing
Electrodes gas handling equipment also add to the deposition cost.
8.3.5 Submerged Arc Surfacing - Submerged arc welding utilizes both solid and
Lesson 9 tubular wires, and a granular flux. It lends itself to automatic operation and is used for
Estimating & production surfacing of large numbers of parts in shops. The deposition rate and travel
Comparing Weld
Metal Costs speeds are high, and the penetration is deep. Weld beads are smooth and of good quality.
Heat input is high and for this reason, this process is not recommended for use on austen-
itic manganese steels. The deep penetration causes the highest dilution (up to 50%) of all
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
of the processes, which makes it necessary to deposit three or more layers to attain the full
properties of the surfacing material.
Lesson 2
Common Electric 8.3.6 Gas Metal Arc Surfacing - Gas metal arc surfacing is not widely used for
Arc Welding
Processes hardfacing since most of the iron based alloys can be deposited more economically by
other methods. It is used somewhat for out-of-position surfacing where the low penetration
of the short circuiting transfer mode produces low dilution. It is also used for depositing
Lesson 3
non-ferrous alloys, such as aluminum-bronze, which cannot be applied by other methods.
Covered Electrodes
for Welding
Mild Steels
8.4 SURFACING WITH POWDERS
Lesson 4 The processes previously discussed utilized hardfacing alloys in the form of solid or tubular
Covered Electrodes rods and wires. Hardfacing alloys are also available in powdered form, and their method of
for Welding Low
Alloy Steels application is quite different from the standard welding methods. Hardsurfacing powders
are used for restoring worn surfaces and are widely used by original equipment manufac-
turers on new parts which require small hardened surfaces. The four major methods for
Lesson 5
applying powder metal hardfacing alloys are: flame spray, manual torch, plasma spray, and
for Stainless Steels plasma arc welding.
8.4.1 Flame Spray Process - The flame spray process is accomplished with a special
Lesson 6 gun-like apparatus which utilizes an oxyacetylene or oxyhydrogen flame. An air orifice
Carbon & Low Alloy aspirates the powder into the flame and deposits it on the surface. As the molten particles
GMAW,GTAW,SAW strike the surface, they flatten out and cool instantaneously. The bond is mechanical since
there is no fusion with the base metal. If desired, fusion can be accomplished in a subse-
quent fusing operation with an oxyacetylene burner.
Lesson 7
Flux Cored Arc
Electrodes Carbon 8.4.1.1 The process is very effective for shafts or small cylindrical parts which are rotated
Low Alloy Steels on a lathe while being surfaced. The surface must be cleaned and grit-blasted before
applying the powder for a good initial bond. Deposition thickness can range from 1/32 to 3/
32 inches.
Lesson 8
Hardsurfacing 8.4.2 Manual Torch Process - The manual torch process utilizes a special oxyacety-
Electrodes
lene torch which has a small hopper from which the surfacing powder is aspirated into the
fuel gas stream. Application of the surfacing powder and fusion to the base metal take
Lesson 9 place in one operation. Single pass deposit thickness can range from 0.030 to 0.050
Estimating &
Comparing Weld inches.
Metal Costs
8.4.3 Plasma Arc Spray and Plasma Arc Welding - These are two processes used
to deposit powdered metal surfacing alloys utilizing a plasma arc torch. The plasma arc
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
torch has a non-consumable tungsten electrode, the end of which is behind a small con-
stricting orifice. The electrode is surrounded by an inert gas such as argon. When the arc
Lesson 2 is established, either between the electrode and the constricting nozzle (non-transferred
Common Electric
Arc Welding arc) or between the electrode and the work (transferred arc), the gas becomes ionized in
Processes the arc, forms a plasma, which is forced through the orifice by the plasma gas and im-
pinges on the work piece. In plasma arc spraying, the non-transferred arc torch is used
and the metal powder is introduced into the plasma gas. It is projected at high velocity
Lesson 3
Covered Electrodes against the object being surfaced. Because the metal particles are fully molten and travel
for Welding at high velocity, the mechanical bond at the surface is very good and does not require
Mild Steels
subsequent fusing in most cases.
Lesson 4 8.4.3.1 In plasma arc welding, the transferred arc method is used, which is a higher
Covered Electrodes energy process. The base metal is actually melted, resulting in a fully fused surface. Both
for Welding Low
Alloy Steels plasma arc methods lend themselves to high production, automatic surfacing applications
requiring a thin overlay.
Lesson 5
Welding Filler Metals 8.5 GENERAL RULES FOR HARDFACING
Some general rules and precautions which will help to assure sound hardfacing deposits
are listed below:
Lesson 6
Carbon & Low Alloy a. Base Metal Identification - The base metal must be properly identified so that
GMAW,GTAW,SAW the proper buildup and/or hardfacing alloy can be selected. Also, base metal
type will help determine the proper preheat and interpass temperature. A magnet
will help to identify austenitic manganese steel since it is non-magnetic. The
Lesson 7
Flux Cored Arc magnet should be tried at several locations on the part because work hardened
Electrodes Carbon areas will be slightly magnetic.
Low Alloy Steels
b. Base Metal Preparation - The base metal must be cleaned with a grinding
wheel and be free of rust, oil, grease, or other foreign matter. Cracks, tears, or
Lesson 8
Hardsurfacing gouges must be repaired using the proper filler metal or buildup alloy.
Electrodes
c. Metal Removal - Rolled over and fatigued metal must removed. Work hardened
surfaces of austenitic manganese steel should be ground away before buildup or
Lesson 9 surfacing.
Estimating &
Comparing Weld Buildup - Buildup of badly worn parts to within approximately ¼” of their final
Metal Costs d.
size with an appropriate buildup alloy prior to hardfacing is necessary.
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
e. Preheat and Interpass Temperature - The importance of observing preheat and
interpass temperatures cannot be overstressed. Problems, such as spalling,
Lesson 2 cracking, and distortion can be minimized by proper preheating, interpass tem-
Common Electric
Arc Welding perature, and slow or retarded cooling.
Processes
f. Dilution - Dilution of the hardfacing deposits is expected in all cases where the
hardfacing alloy is fused to the base metal and should be kept to a minimum.
Lesson 3
Excessive dilution with the base metal will alter the hardness of the deposit and
Covered Electrodes
for Welding in part, is a result of the heat input. Heat input is a function of the heat (amper-
Mild Steels age and voltage) and deposition rate (travel speed).
Note: As an example, a coated electrode, which operates at 225 amps and has a low deposition rate,
Lesson 4 may put more heat into the workpiece than an open arc continuous electrode, which operates at
Covered Electrodes
400 amps but has a deposition rate three times higher than the coated electrode. The electrode
for Welding Low
Alloy Steels manufacturer’s recommended welding current should be used.
Dilution will be greater in stringer beads (straight) than in a weaving bead. A weaving bead is
recommended wherever possible.
Lesson 5
Welding Filler Metals Electrical stickout (the amount of wire between the contact tip and the arc) must be kept relatively
constant to control penetration in open arc welding. Long stickout decreases penetration and
thereby, the amount of dilution. Short stickout can drastically increase penetration and dilution.
Lesson 6 g. Hardfacing Thickness - Too much hardfacing can cause more problems than
Carbon & Low Alloy
Steel Filler Metals - too little. The hardfacing deposit should consist of no more than two layers and
GMAW,GTAW,SAW the total thickness should not exceed ¼” in most cases.
Lesson 7 8.6 ECONOMICS OF HARDFACING

Flux Cored Arc
Electrodes Carbon
Low Alloy Steels Hardfacing filler metals are quite costly as noted earlier. The iron based alloys are the
lowest in cost with the cobalt based alloys being the highest.
8.6.0.1 Consider a steel mill application requiring hardfacing on the guide blocks which
Lesson 8
Hardsurfacing will be subjected to abrasion and intermittent contact with hot billets at temperatures of
Electrodes approximately 1800-2000°F. Logically, one might choose a cobalt base surfacing alloy,
which will withstand continuously applied higher temperatures than the iron base types for
this application. However, since the guide blocks are in contact with the billets intermit-
Lesson 9
Estimating & tently for short periods of time, the constant operating temperature is well below 800°F.
Comparing Weld Iron base hardfacing alloys, which retain hardness at a constant 1000°F, are used in this
Metal Costs
application quite successfully at a considerable savings over the cobalt base types.
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.6.0.2 At today’s high labor and overhead rates, the process chosen to apply hardfacing
becomes of more importance. As an example, open arc cored electrodes can deposit
Lesson 2 metal three to five times faster than manual electrodes and should be used wherever
Common Electric
Arc Welding possible. The deposition efficiency of the open arc cored electrodes range from 87-95%,
Processes while the deposition efficiency of stick electrodes is only 55-70%, depending on stub loss.
If the cost of the coated hardfacing electrode is $1.00/lb., and the efficiency of that elec-
trode is 60%, the cost of the amount of electrode necessary to deposit 1 lb. of weld metal is
Lesson 3
Covered Electrodes $1.00 ÷ .60 = $1.67. If the cost of an open arc electrode is $1.47/lb., and the deposition
for Welding efficiency is 92%, the cost of the amount of electrode necessary to deposit 1 lb. of weld
Mild Steels
metal is $1.47 ÷ .92 = $1.60.
Lesson 4 8.6.0.3 The “more expensive” open arc wire results in a savings of 7¢ for each pound of
Covered Electrodes deposited weld metal. When all other factors, such as labor and overhead costs, deposi-
for Welding Low
Alloy Steels tion rate, and operating factor, are also taken into consideration, savings as high as 60%
can be realized by using open arc continuous electrodes instead of coated electrodes.
Lesson 5
Welding Filler Metals 8.7 ESAB HARDFACING ELECTRODES
ESAB hardfacing electrodes are all of the iron based alloy type, which is the most widely
used in the industry. They are available as Wear-Arc coated electrodes and as
Lesson 6 Wear-O-Matic continuous open arc electrodes.
Carbon & Low Alloy
8.7.1 Wear-Arc Coated Electrodes - Wear-Arc electrodes have a lower hydrogen iron
GMAW,GTAW,SAW
powder coating. The majority of the materials which are hard surfaced are steels which are
hardened by the heat of welding, and are susceptible to under bead cracking due to hydro-
Lesson 7
Flux Cored Arc gen, as covered in Lesson IV. The use of low hydrogen electrodes minimizes this problem.
Electrodes Carbon Proper preheating must still be maintained however; especially on massive parts or highly
Low Alloy Steels
restrained joints.
8.7.1.1 As with all low hydrogen types, Wear-Arc electrodes require that they be stored
Lesson 8
Hardsurfacing in a dry rod oven at 225-300°F after the hermetically sealed can is opened.
Electrodes
8.7.1.2 Properly balanced amounts of iron powder are added to these electrodes which
allow higher currents to be used without increasing the penetration and dilution. The higher
Lesson 9 welding current results in greater deposition rates. Wear-Arc electrodes allow welding in all
Estimating &
Comparing Weld positions.
Metal Costs
8.7.2 Wear-O-Matic Open Arc Wires - Wear-O-Matic continuous tubular electrodes
are internally stabilized, fluxed, and deoxidized. They require no shielding gas and repre-
Lesson 10 sent the most economical means of reclaiming worn equipment and parts.
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.7.3 Wear-O-Matic BR Wires - This is a gas shielded tubular, continuous electrode
designed for the repair and reclamation of railroad freight car bolster bowls. It requires a
Lesson 2 98% argon, 2% oxygen shielding gas (the full description appears in section 8.9.2.3).
Common Electric
Arc Welding
Processes 8.8 HARDFACING ALLOY SELECTION FACTORS
In order to select the proper Wear-Arc or Wear-O-Matic alloy, the controlling wear factors
Lesson 3
Covered Electrodes must be determined. Hardness of an overlay deposit is frequently considered as the prime
for Welding objective in the selection of a hard surfacing alloy. This might be true if all wear problems
Mild Steels
involved only straight abrasive wear. However, most wear conditions are complicated by
the addition of other wear factors which demand more than just hardness of a wear resis-
Lesson 4 tant alloy deposit, and the role of alloy content and balance becomes a prime factor. The
Covered Electrodes
for Welding Low importance of alloy content and balance to wear resistance is illustrated in the graphs that
Alloy Steels follow. Figure 8 shows the hardness for each Wear-Arc and Wear-O-Matic alloy.
Lesson 5 HARDNESS - ROCKWELL "C" SCALE

Welding Filler Metals 10 20 30 40 50 60 70 80 90
WEAR-ARC 3IP
WEAR-O-MATIC 3
Lesson 6 WEAR-ARC NICKEL MANGANESE
AS WELDED
Carbon & Low Alloy WORK HARDENED
Steel Filler Metals - WEAR-O-MATIC NICKEL MANGANESE
GMAW,GTAW,SAW WEAR-ARC WH
WEAR-O-MATIC WH
Lesson 7 WEAR-ARC 41P

Flux Cored Arc WEAR-ARC 51P
Electrodes Carbon
Low Alloy Steels WEAR-ARC 61P
WEAR-O-MATIC 6
WEAR-ARC 12IP
Lesson 8 WEAR-O-MATIC 12
Hardsurfacing
Electrodes WEAR-O-MATIC SUPER WH
WEAR-ARC 40
WEAR-O-MATIC 40
Estimating &
Comparing Weld WEAR-O-MATIC BR
Metal Costs WEAR-O-MATIC RAIL ARC
HARDNESS COMPARISON
Lesson 10
FIGURE 8
Filler Metals

Lesson 1
Welding
Lesson 2
WEAR-ARC 3IP
WEAR-O-MATIC 3
}
Common Electric WEAR-ARC NICKEL MANGANESE
Arc Welding
Processes WEAR-O-MATIC NICKEL MANGANESE
}
WEAR-ARC WH
WEAR-O-MATIC WH
}
Lesson 3
Covered Electrodes WEAR-ARC 41P
}
for Welding
WEAR-ARC 51P
Mild Steels
WEAR-ARC 61P
WEAR-O-MATIC 6
Lesson 4
WEAR-ARC 12IP
Covered Electrodes
for Welding Low WEAR-O-MATIC 12
Alloy Steels
WEAR-O-MATIC SUPER WH
Lesson 5
WEAR-ARC 40
WEAR-O-MATIC 40
}
WEAR-O-MATIC 15
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - RELATIVE RESISTANCE TO IMPACT AND COMPRESSION
GMAW,GTAW,SAW
FIGURE 9
8.8.1 Hardness - While constant hardness for various hard surfacing alloys is main-
Lesson 7
Flux Cored Arc tained, the particular hardness of any one alloy is a property resulting from the amount of
Electrodes Carbon alloying elements, including carbon, used to create the carbide formations necessary to
Low Alloy Steels
attain a desired amount of wear resistance. Succeeding graphs illustrate the importance of
alloy content in relation to hardness in the selection of overlay alloys for resistance to wear
Lesson 8 caused by abrasion, impact, compression, and heat.
Hardsurfacing
Electrodes 8.8.1.1 Figure 9 illustrates the relative resistance to impact and compressive force for
each alloy. Note that Wear-O-Matic 15, the hardest of the alloys in Figure 8, shows the
Lesson 9 least impact resistance. This is due to the high ratio of carbides to matrix of this alloy which
Estimating & provide little resistance to shock. Therefore, it is concluded that hardness alone is not a
Comparing Weld
Metal Costs reliable deciding factor in the choice of hard surfacing alloys.
8.8.1.2 Impact and compression are usually accompanied by other wear factors. In
Lesson 10 continuing this comparison of relative wear resistance of the various alloys to different wear
Filler Metals factor combinations, the charts show only those alloys which are practical from an eco-
nomic and application standpoint for the combination of wear factors involved.
Lesson 1
LESSON VIII
The Basics of Arc
Welding
WEAR-ARC 3IP
Buildup Carbon Steel
WEAR-O-MATIC 3
Lesson 2
Common Electric
WEAR-ARC NICKEL MANGANESE
Arc Welding Buildup Manganese Steel Only
WEAR-O-MATIC NICKEL MANGANESE
Processes
WEAR-ARC WH
Best for Overall Buildup - All Conditions
WEAR-O-MATIC WH
Lesson 3
Covered Electrodes WEAR-ARC 6IP
Wear-Arc 6IP Best for Out-of-position
for Welding WEAR-O-MATIC 6
Mild Steels
WEAR-O-MATIC SUPER WH Work Hardening Alloy - Severe Impact, Moderate Abrasion
WEAR-ARC 12IP
Lesson 4 Best for Overall Service - Heavy Impacts and Severe Abrasion
WEAR-O-MATIC 12
Covered Electrodes
for Welding Low
WEAR-ARC 40 Best for Medium Impact - Extreme Abrasion
Alloy Steels
WEAR-O-MATIC 40
Lesson 5 RELATIVE RESISTANCE TO ABRASION AND MEDIUM TO HEAVY IMPACT

FIGURE 10
8.8.2 Abrasion & Impact - When abrasion is combined with heavy impact, the alloy
best suited to render the ultimate in wear resistance must have the proper balance of
Lesson 6
Carbon & Low Alloy carbide forming elements in relation to matrix. The alloys shown in Figure 10 have this
Steel Filler Metals - structure and are the most suitable buildup and hard surfacing alloys for varying degrees of
GMAW,GTAW,SAW
impact and abrasion.
Lesson 7 8.8.2.1 Although Wear-O-Matic Super WH, Wear-Arc 12 IP, and Wear-O-Matic 12 show
Flux Cored Arc equal resistance to abrasion and impact in Figure 10, Wear-O-Matic Super WH would be
Electrodes Carbon
Low Alloy Steels the better choice if more severe impacts are expected. Wear-Arc 12 IP electrodes or
Wear-O-Matic 12 wires for semi-automatic open arc deposition should be used as a wear
resistant overlay in the majority of cases where heavy impact and severe abrasion are in
Lesson 8 combination. Wear-Arc 12 IP and Wear-O-Matic 12 provide an abrasion resistant chro-
Hardsurfacing
Electrodes mium carbide structure, in balance with a highly impact resistant matrix structure, providing
maximum wear resistance throughout the deposited overlay.
Lesson 9 8.8.2.2 Wear-Arc WH and Wear-O-Matic WH semi-automatic open arc wire are work
Estimating & hardening buildup alloys. Their high alloy nickel-chromium-manganese deposit is austen-
Comparing Weld
Metal Costs itic in structure and can be applied to carbon and austenitic manganese steel in any thick-
ness. Deposits, when subjected to impact, work harden on the skin surface to 48 Rockwell
C and provide wear resistance throughout the buildup deposit equal to that of Wear-Arc 12
Lesson 10 and Wear-O-Matic 12.
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.8.2.3 Overlaying a buildup deposit of WH alloy with the #12 alloy protects the WH
deposit until it has work hardened.
Lesson 2
Common Electric 8.8.2.4 Wear-Arc 6 IP and Wear-O-Matic 6 are illustrated as having good abrasion
Arc Welding
resistance under heavy impact loading. Wear-Arc 6 IP electrodes are designed especially
Processes
to be used for all-position applications.
Lesson 3 8.8.2.5 Figure 11 illustrates the relative wear resistant values of the alloys with the best
Covered Electrodes
abrasion resistance. Wear-O-Matic 15 provides the best resistance to straight abrasion;
for Welding
Mild Steels however, its impact resistance is low as can be seen in Figure 8. For this reason, Wear-Arc
40 or Wear-O-Matic 40 would be a better choice if medium impacts are involved. Both take
on a high polish and have a low coefficient of friction.
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels WEAR-ARC 40
WEAR-O-MATIC 40
RELATIVE RESISTANCE TO STRAIGHT ABRASION
FIGURE 11
Lesson 6
Carbon & Low Alloy 8.8.2.6 Figure 12 illustrates the ability of Wear-Arc 40 and Wear-O-Matic 40 hardfacing
alloys to retain their abrasion resistant properties at constant temperatures up to 1000°F.
GMAW,GTAW,SAW
Intermittently, temperatures up to 1800°F may be tolerated.
Lesson 7 60Rc
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 50Rc
Lesson 8
Hardsurfacing
Electrodes 40Rc
30Rc
Lesson 9
Estimating &
Comparing Weld 20Rc
200 300 400 500 600 700 800 900 1000 1100
Metal Costs
DEGREES FARENHEIT
HARDNESS IN RELATION TO TEMPERATURE RISE

Lesson 10
FIGURE 12
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.8.2.7 Figure 12 also shows that the Wear-Arc WH and Wear-O-Matic WH buildup
alloys will retain their hardness at elevated temperatures. The high chromium and nickel
Lesson 2 combination of this alloy imparts excellent high temperature properties and produces an
Common Electric
austenitic work hardening structure.
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels 8.9 WEAR-ARC COVERED ELECTRODES AND
WEAR-O-MATIC WIRES FOR HARDFACING
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
The following pages contain complete information on each of the individual buildup and
hardfacing alloys supplied by ESAB as they appear in the hardfacing catalog. Each of
Lesson 5 them should be studied since several of the test questions will be based on the information
for Stainless Steels contained on these pages.
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.9.1 Wear-Arc Covered Electrodes
Lesson 2 Introduction
Common Electric Surfacing is the application of wear-resistant alloys to metal parts subject to destructive wear caused by abrasion,
Arc Welding impact, compression, heat, or corrosion. The Wear-Arc electrodes are designed for manual arc welding for surfacing
parts. Two types of overlay alloys are recommended to correct destructive wear patterns:
Processes
Buildup Alloys
Because hardsurfacing alloys are limited by maximum thickness of deposit, badly worn parts must be built up prior to
Lesson 3 depositing the wear-resistant material. Wear-Arc 3 IP, Nickel Manganese, and WH are designed for buildup applica-
tions.
Covered Electrodes
These alloys possess good deformation resistance and provide a strong bond with the base metal. This helps to
for Welding prevent roll-over or spalling and provides a sound base for hardsurfacing.
Mild Steels
Hardsurfacing Alloys
Hardsurfacing alloys are designed to provide maximum resistance to specific wear factors or combination of wear
factors. The performance of these alloys is in direct relation to the amount of carbide forming elements present in
Lesson 4 combination with carbon. The carbon reacts with the carbide forming elements—chromium, tungsten, molybdenum,
Covered Electrodes etc.—creating hard carbides from which the overlay material derives its wear resistance. These carbides are evenly
for Welding Low distributed in a matrix and as the ratio of carbides to matrix increases, abrasion resistance increases and toughness or
ductility decreases. The chart below shows the relative impact resistance or “ductility” and the abrasion or wear
Alloy Steels resistance of the Wear-Arc line.
Relative Resistance to Impact and Abrasion

Lesson 5 Buildup Alloys Hardsurfacing Alloys
Wear-Arc 3IP Wear-Arc 4 IP
Lesson 6 Wear-Arc Nickel

Wear-Arc 5 IP
Carbon & Low Alloy Manganese
Steel Filler Metals - Wear-Arc 6 IP
GMAW,GTAW,SAW Wear-Arc WH
Wear-Arc 12 IP
Lesson 7 Wear-Arc 40
Flux Cored Arc
Electrodes Carbon Impact Resistance
Low Alloy Steels Abrasion Resistance
Welding Currents for Wear-Arc Electrodes

Lesson 8
Hardsurfacing Electrode 3 IP - 4 IP - 5 IP - 6 IP Nickel
Electrodes Diameter Flat Vertical Overhead 12 IP Manganese WH 40
1/8" (3.2 mm) 120-160 100-130 120-160 120-160 110-150 130-190 110-150
5/32" (4.0 mm) 150-200 120-150 140-190 150-200 140-190 170-250 140-190
3/16" (4.8 mm) 200-260 170-200 190-250 200-260 180-240 230-350 190-250
Lesson 9 1/4" (6.4 mm) 260-320 260-320 230-310 250-310
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.1.1 Wear-Arc 3 IP 8.9.1.2 Wear-Arc Nickel Manganese
No AWS Classification
Lesson 2 AC/DCEP (Electrode Positive) AWS Class EFeMn-A
Common Electric Electrode Imprint Marking: 3 IP AC/DCEP (Electrode Positive)
Arc Welding Buildup Alloy Electrode Imprint Marking: Ni Mn
Processes Carbon Steels Buildup Alloy
Low Alloy Steels Attachment Welding
Abrasion-Resistant Steels Manganese Steel
Lesson 3 Description: Severe Impact
Covered Electrodes Wear-Arc 3 IP weld metal provides excellent resistance Code and Specification Data:
for Welding to wear caused by heavy impact and compressive loads, AWS A5.13
Mild Steels and is most suitable as a base alloy for hardsurfacing
overlays. Description:
Wear-Arc 3 IP should be used where maximum machin- Wear-Arc Nickel Manganese weld deposit is crack
ability of a surface deposit is desired and as the final resistant and forms a ductile, high-strength fusion bond
on manganese steel. The austenitic structure of the weld
Lesson 4 overlay. The ductility and compressive strength of Wear-
provides excellent resistance to wear caused by heavy
Covered Electrodes Arc 3 IP weld metal is adequate for the wear problem of
many applications. Typical applications are: steel mill impact and compressive loads. Under conditions of
for Welding Low continuous impact, the deposit surface work hardens
wobblers and coupling boxes, bearing journals, steel
Alloy Steels mill roll necks and ends, forging hammer dies, and all to a BHN of 510.
carbon steel parts requiring buildup prior to Wear-Arc Nickel Manganese is best suited for applica-
hardsurfacing. tions where severe impact and compressive forces are
encountered continuously. Because of the sound, high-
Lesson 5 Procedure:
strength welds from this electrode, it should also be
Welding Filler Metals Wear-Arc 3 IP electrodes have superior welding charac- used for the attachment welding of wear plates, teeth,
teristics in all positions. Because of the iron powder in rounds, and shapes of manganese steel.
for Stainless Steels the coating, higher current settings may be used than
with conventional electrodes. Procedure:
Area Covered per Pound, 1/8" (3.2 mm) Depth— Wear-Arc Nickel Manganese electrodes require no
special technique of application. When welding manga-
24-25 in. (155-161 cm )
2 2
nese steel, these general recommendations should be
Lesson 6
Carbon & Low Alloy Typical Mechanical Properties followed:
Steel Filler Metals - As Welded 1. Weld only on sound, clean, unhardened base metal.
GMAW,GTAW,SAW Yield Strength, psi (MPa) 91,500 (631) 2. The use of preheat on manganese steel is not
Tensile Strength, psi (MPa) 101,750 (702) recommended. Avoid overheating the base metal by
% Elongation in 2" (51 mm) 24 using the lowest current which produces good metal
% Reduction in Area 64 transfer and arc characteristics. Keep austenitic
Lesson 7 Hardness 29 Rc* manganese steel below 600°F (316°C), interpass
*Two Layers weaving on 1020 Steel temperature.
Flux Cored Arc
Weld deposits can be cut with oxy-acetylene torch or by air
Electrodes Carbon carbon-arc cutting.
Typical Mechanical Properties
Low Alloy Steels As Welded
Typical Undiluted Weld Metal Analysis (%)
C Mn Si Cr Mo Yield Strength, psi (MPa) 62,000 (427)
Tensile Strength, psi (MPa) 116,000 (800)
0.20 Max. 0.09 0.70 2.30 1.10 % Elongation in 2" (51 mm) 45
Lesson 8 Hardness 90 Rb*
Properties of Deposited Weld Metal: Work-Hardened Hardness 48 Rc*
Hardsurfacing *Two Layers on Manganese Steel
Electrodes The chromium and molybdenum alloy balance imparts
impact and compression resistance, as well as consider- Weld deposits can be cut with oxy-acetylene torch or by air
able wear resistance to the weld metal in all thicknesses carbon-arc cutting.
of buildup. Deposits are machinable, forgeable, and Typical Undiluted Weld Metal Analysis (%)
respond to heat treatment.
C Mn Si Ni
Lesson 9 Standard Diameters and Packages
Estimating & 0.60 14.00 0.55 4.00
1/8" (3.2 mm) x 10# (4.5 kg) HSC
Comparing Weld 5/32" (4.0 mm) x 10# (4.5 kg) HSC Standard Diameters and Packages
Metal Costs 3/16" (4.8 mm) x 10# (4.5 kg) HSC 5/32" (4.0 mm) x 10# (4.5 kg) HSC
1/4" (6.4 mm) x 10# (4.5 kg) HSC 3/16" (4.8 mm) x 10# (4.5 kg) HSC
1/4" (6.4 mm) x 10# (4.5 kg) HSC
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
8.9.1.3 Wear-Arc WH Typical Mechanical Properties
No AWS Classification Wear-Arc 14%
AC/DCEP (Electrode Positive) WH Manganese
Lesson 2 Electrode Imprint Marking: WH Weld Metal Steel Plate
As Welded Heat Treated
Common Electric Buildup Alloy Yield Strength, psi (MPa) 77,000 (551) 50,000 (345)
Arc Welding High Strength Tensile Strength, psi (MPa) 97,500 (672) 86,000 (593)
Processes Manganese & Carbon Steels 120,000 (827)
% Elongation in 2" (51 mm) 36 35/45
Attachment Welding Hardness 23 Rc* 16 Rc
Severe Impact Work-Hardened Hardness 48.5 Rc* 48 Rc
Description: *Two Layers on 1020 Steel
Lesson 3 Weld deposits cannot be cut with oxy-acetylene torch or by air
Covered Electrodes The weld deposit of Wear-Arc WH is high in alloy
carbon-arc cutting.
content, extremely deformation resistant, and has 2-4
for Welding times greater wear resistance than work-hardened Typical Undiluted Weld Metal Analysis (%)
Mild Steels austenitic manganese steel. WH contains approximately C Mn Si Cr Ni
34% alloy, properly balanced to perform the dual
0.45 4.25 0.80 19.75 10.00
purpose of a work-hardening, wear-resistant buildup
alloy, and also a high strength welding alloy. The alloy is
Lesson 4 austenitic and produces tough, crack-resistant welds.
Covered Electrodes Wear-Arc WH produces a dependable bond to manga-
for Welding Low nese steel. Users of type 308, 309, 310, or 312 stainless
Alloy Steels steel electrodes for rebuilding and repair of equipment
constructed of manganese steel find Wear-Arc WH to be
a superior electrode for the job.
Deposits of Wear-Arc WH, when subjected to high
Lesson 5 impact and compressive loads, develop a surface
Welding Filler Metals hardness of 48-50 Rockwell C and still retain a tough,
for Stainless Steels resilient, deformation-resistant mass under the work-
hardened surface.
Procedure:
This chart illustrates a hardness probe of deposited
Wear-Arc WH electrodes are designed for welding with Wear-Arc WH weld metal after work-hardening by
Lesson 6 AC/DCEP (Electrode Positive) in all positions. When peening. Notice that although the outer skin of the
welding high-carbon steel, preheat to 300-400°F (149- deposit shows a hardness of 48 Rc, the metal
Carbon & Low Alloy 204°C). Do not preheat manganese steel. underneath retains the ductility necessary to resist
Hold the electrode at an angle of 15° in the direction of impact or compressive loads. This toughness
GMAW,GTAW,SAW travel with as short an arc as possible without allowing prevents spalling and overroll and provides an
the coating to touch the weld pool. Stringer beads are excellent base for harsurfacing overlays.
preferable. Weaving should be limited to 2-1/2 times the
Lesson 7 electrode diameter. Slag should be checked thoroughly
between passes.
Flux Cored Arc
For vertical welding, the electrode should be held
Electrodes Carbon
perpendicular to the plate using a very slight oscillation
Low Alloy Steels from side to side on the root bead. When welding in the
overhead position, hold a short arc with no oscillation
of the electrode.
Area Covered per Pound, 1/8" (3.2 mm)
Lesson 8 Depth—
Hardsurfacing 20-22 in. (129-142 cm )
2 2
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.1.5 Wear-Arc 5 IP
8.9.1.4 Wear-Arc 4 IP
No AWS Classification No AWS Classification
AC/DC AC/DCEP (Electrode Positive)
Lesson 2 Electrode Imprint Marking: 4 IP Coded Electrode Marking: 5 IP
Common Electric Hardsurfacing Alloy Hardsurfacing Alloy
Arc Welding Metal-to-Metal Wear High impact and moderate abrasion
Processes Impact & Abrasion Carbon steels and low alloy steels
Carbon Steels & Low Alloy Steels Description:
Description: Wear-Arc 5 IP is an all-position, low hydrogen
Lesson 3 Wear-Arc 4 IP is an all position, iron powder, low hardsurfacing composite electrode providing sound
hydrogen hardsurfacing electrode providing sound overlays on carbon and low alloy steels, as well as
Covered Electrodes many abrasion-resistant steels.
overlays on carbon and low alloy steels, as well as many
for Welding abrasion-resistant steels. The low hydrogen coating of Wear-Arc 5 IP is recommended for the reclamation of
Mild Steels this electrode promotes excellent fusion with the above parts subject to wear caused by moderate to high impact
steels and on buildup alloys without underbead crack- and moderate abrasion. Typical applications are:
ing.
Dipper Shovels
Wear-Arc 4 IP electrodes are designed to provide hard, Dipper Lips
Lesson 4 deformation-resistant, crack-free weld metal for resis-
Covered Electrodes Bulldozer Trunnions
tance to metal-to-metal wear involving impact, Drag Line Bucket Lips
for Welding Low compression, and abrasion. Typical applications are: Classifier Screens
Alloy Steels Dragline bucket pins & links Shovel rollers Bucket Pins
Dredge bucket lips Shovel latch pins Mud Pumps
Dredge driving tumblers and keepers Buckets and Impellers
Dredge spud points Tractor idlers Procedure:
Lesson 5 Can brake drums Tractor rollers
Wear-Arc 5 IP electrodes are designed for welding with
Welding Filler Metals Mill brake drums Wheels (Mine car,
Shovel idlers skip car, etc.) AC or DCEP. When welding out of position, DCEP is
for Stainless Steels preferred. A slight weaving technique may be used.
Cable sheaves Ditcher drive segments
Cable sheave shafts Ditcher rollers Typical Mechanical Properties:
Elevator bucket lips Shovel boom heels Deposits are non-machinable, but may be forged at red
Procedure: temperatures. The deposit is heat treatable and mag-
Lesson 6 The iron powder, low hydrogen coating of Wear-Arc 4 IP netic. Weld deposits can be cut with oxy-acetylene torch
Carbon & Low Alloy electrodes provides excellent arc characteristics and or by air carbon-arc cutting.
Steel Filler Metals - high deposition rates. A slight weaving technique may Hardness of Deposited Metal:
GMAW,GTAW,SAW be used. Deposit thickness should be limited to 3/8"
One layer on 1020 mild steel—50-55 Rockwell C
(9.5 mm) maximum.
Two layers on 1020 mild steel—58-60 Rockwell C
Area Covered per Pound, 1/8" (3.2 mm) Depth—
Typical Chemical Analysis of Weld Deposit
24-25 in. (155-161 cm. )
2 2
Lesson 7 (%)
Flux Cored Arc Typical Mechanical Properties: C Mn Si Cr Mo
Electrodes Carbon Wear-Arc 4 IP weld metal is characterized by its smooth 0.65 1.00 0.80 5.75 0.65
Low Alloy Steels appearance, high hardness, and high compressive
strength. The deposit is not machinable but may be
forged or heat treated. Weld deposits can be cut with
oxy-acetylene torch or by air carbon-arc cutting.
Lesson 8 Hardness of Deposited Metal:

Hardsurfacing Two layers, weave bead on 1020 steel—54-56 Rockwell C.
Electrodes Typical Undiluted Weld Metal Analysis (%)
C Mn Si Cr Mo
0.45 0.90 1.30 2.20 1.00
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.1.6 Wear-Arc 6 IP 8.9.1.7 Wear-Arc 12 IP
AC/DC AC/DC
Lesson 2 Electrode Imprint Marking: 6 IP Electrode Imprint Marking: 12 IP
Common Electric Hardsurfacing Alloy Hardsurfacing Alloy
Arc Welding High Abrasion & Light Impact High Impact & Good Abrasion Resistance
Processes Carbon Steels and Manganese Steels Carbon Steels and Manganese Steels
Description: Description:
The iron powder low hydrogen coating of Wear-Arc 6 IP In addition to heavy impact and good abrasion resis-
Lesson 3 electrodes promotes good bonds with manganese and tance, the high alloy content of Wear-Arc 12 IP also
carbon steels. provides good resistance to erosion and corrosion.
Covered Electrodes
for Welding Wear-Arc 6 IP is recommended for the reclamation of Wear-Arc 12 IP is recommended to prolong the service
parts subject to wear caused by abrasion and light life of new and worn parts subject to wear caused by
Mild Steels impact. This electrode is ideal for field work where parts abrasion and impact. Typical applications are:
cannot be positioned for downhand welding. Typical Dipper teeth and lips
applications are: Dragline bucket lips
Lesson 4 Shovel buckets and teeth Conveyor bucket lips
Covered Electrodes Dragline buckets and teeth Roll crushers
Pug mill paddles Gyratory crusher parts
for Welding Low Tamping tools Muller tires
Alloy Steels Screens Impactors
Asphalt mixer paddles Hammer mill parts
Crushing equipment Procedure:
Granulators
Lesson 5 Trunnions The iron powder, low hydrogen coating of Wear-Arc 12
Truck bodies IP electrodes provides excellent arc characteristics and
Welding Filler Metals high deposition rates in all positions using AC or DC,
for Stainless Steels Procedure: either polarity. Weaving technique or stringer beads may
The iron powder, low hydrogen coating of Wear-Arc 6 IP be used. Deposit thickness should be limited to two
electrodes provides excellent arc characteristics and passes or 1/4" (6.4 mm).
high deposition rates in all positions using AC or DC,
Area Covered per Pound, 1/8" (3.2 mm) Depth—
Lesson 6 either polarity. A weaving technique is recommended.
Deposit thickness should be limited to two passes or 1/ 22-24 in. (142-155 cm. )
2 2
Carbon & Low Alloy 4" (6.4 mm) maximum. Typical Mechanical Properties:
Steel Filler Metals - Check cracks may appear as the deposit stress relieves
GMAW,GTAW,SAW Area Covered per Pound, 1/8" (3.2 mm) Depth—
22-24 in. (142-155 cm. )
2 2
itself. These cracks do not impair the wear resistance of
the deposit, but do prevent warpage or distortion of the
Typical Mechanical Properties: base metal. Deposits are non-machinable and do not
Deposits are not machinable and are smooth, requiring respond to heat treatment. Weld deposits cannot be cut
Lesson 7 a minimum amount of grinding to bring them to shape. with oxy-acetylene torch or by air carbon-arc cutting.
Flux Cored Arc Deposits are not affected by heat treatment and can be
Hardness of Deposited Metal:
Electrodes Carbon forged at red heat. Weld deposits cannot be cut with
Two layers, weave bead on 1020 mild steel—
Low Alloy Steels oxy-acetylene torch or by air carbon-arc cutting.
54-56 Rockwell C
Two layers, weave bead on 1020 mild steel—
C Mn Si Cr Mo
56-59 Rockwell C
Lesson 8 Typical Undiluted Weld Metal Analysis (%) 3.50 2.70 1.80 13.00 1.10
Hardsurfacing C Mn Si Cr
Electrodes
3.00 0.80 1.80 6.50
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.1.8 Wear-Arc 40 Procedure:
No AWS Classification Wear-Arc 40 electrodes have good welding characteris-
AC/DCEP (Electrode Positive) tics in flat and vertical-up positions. These electrodes
Lesson 2 Electrode Imprint Marking: 40 operate on either AC or DCEP (Electrode Positive)
Common Electric welding current. Weaving technique or stringer beads
Hardsurfacing Alloy may be used. Limit deposit thickness to two passes.
Arc Welding Extreme Abrasion & Medium Impact
Processes Area Covered per Pound, 1/8" (3.2 mm) Depth—
Description: 20-24 in. (129-155 cm. )
2 2
Wear-Arc 40 is a coated electrode with a special core

Typical Mechanical Properties:
wire and the proper amount of alloys in the coating to
produce a deposit of highly abrasive resistant chrome The weld metal deposit of Wear-Arc 40 cannot be forged
Lesson 3 at any temperature and does not respond to heat
carbides in a matrix of iron and chromium. The use of a
Covered Electrodes special core wire gives much better arc action and also treatment. Weld deposits cannot be cut with oxy-
for Welding allows the electrode to operate at higher current acetylene torch or by air carbon-arc cutting.
Mild Steels settings. Deposits resist galling and seizing, and take a Hardness of Deposited Metal:
high polish when subject to sliding abrasive action. The Two layers on mild steel—57 Rockwell C
hardness and wear-resistant properties of this alloy are
retained at temperatures up to 1000°F (538°C) which Typical Undiluted Weld Metal Analysis (%)
Lesson 4 makes it suitable for many applications where intermit- C Mn Si Cr
Covered Electrodes tent high temperature service is involved.
4.50 0.30 1.80 30.00
for Welding Low Wear-Arc 40 is designed for use on steel mill twist
Alloy Steels guides, steel mill entry guides, wire guides, conveyor
chain, and agricultural tools. This electrode also gives
excellent service on certain crushing and quarrying
equipment where high abrasive wear is the primary
Lesson 5 wear factor.
Welding Filler Metals On many applications where heat and abrasion are the
prime wear factors, Wear-Arc 40 alloy may be the most
economical alloy. As illustrated in the temperature
hardness chart, this alloy has excellent hardness at
constant temperatures up to about 1000°F (538°C). In
considering this alloy for a heat and abrasion applica-
Lesson 6 tion, a constant operating temperature must be
Carbon & Low Alloy estimated. For example, a steel mill guide block surface
Steel Filler Metals - with Wear-Arc 40 withstands exposure to intermittent
contact with hot billets of bars at temperatures of 1800-
GMAW,GTAW,SAW 2000°F (982-1093°C). This is possible because
sufficient time elapses between contacts to prevent a
high temperature build-up.
Lesson 7 In this example, the constant operating temperature is
Flux Cored Arc only about 500°F (260°C).
Electrodes Carbon
Low Alloy Steels Temperature —Hardness
58 Rc
50 Rc
Lesson 8 40 Rc
Hardsurfacing 30 Rc
Electrodes 100 Rb
60 Rb
204 316 427 538 699 760 871
Temperature (°C)
Lesson 9 400 600 800 1000 1200 1400 1600
Temperature (°F)
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding
Lesson 2
Common Electric
8.9.2 Wear-O-Matic® Semiautomatic Cored Wires
Arc Welding
Processes Introduction
The Wear-O-Matic cored wires for welding, buildup, and hardsurfacing are designed to provide maximum versatility,
economy, and welder efficiency in their use. These 7/64" (2.8 mm) diameter wires may be used with either a constant
current power source and voltage sensing variable speed wire drive or a constant potential power source and a
Lesson 3 constant speed wire feeder. These wires combine the skill of the welder and the speed of automatically fed,
Covered Electrodes continuous wire welding.
for Welding The variety of electrodes available plus the speed, efficiency, and economy of the Wear-O-Matic process make it the
Mild Steels most economical means of reclaiming worn equipment parts.
When hard-surfacing with stick electrodes, a minimum of two inches (50 mm) of every 14-inch (350 mm) electrode are
thrown away as a stub end. This is a loss of nearly 15% of the total weight of the electrodes purchased by the user.
Lesson 4 This waste is a major contributing factor toward the low deposition efficiency (55 to 70%) normally obtained with stick
electrodes. The deposition efficiency of the open arc process is usually 87 to 95%.
Covered Electrodes
No flux dams are required. Expensive, time consuming flux handling is eliminated, as well as the cost of the
for Welding Low
submerged arc flux.
Alloy Steels
There are no shielding gases that have to be purchased, except for the Wear-O-Matic BR wires. Wires are internally
stabilized, fluxed, and deoxidized.
High current density and fast travel speed result in low heat input to the work, concentrated in a small area, when used
Lesson 5 with the 7/64" (2.8 mm) alloy wires. There is little slag and no flux blanket to hold heat in the weld area and cause
Welding Filler Metals overheating of the base metal. The total result is low penetration and less dilution of the weld metal. The higher alloy
deposits provide increased wear resistance, often superior to deposits of manual electrodes of similar analysis.
Most semiautomatic processes (submerged arc, inert gas) have limited use. The simplicity of open arc wire feed
equipment makes it extremely portable for field or shop use. All of the visibility and advantages of manual metal arc
welding are preserved. The operator can visually control the deposited metal and irregular contours can be followed
easily.
Lesson 6 Wear-O-Matic 7/64" (2.8 mm) cored wires for semiautomatic application are fabricated tubular electrodes, internally
Carbon & Low Alloy stabilized for good arc characteristics without the use of shielding gas or submerged arc granular flux. Each of the
Steel Filler Metals - grades available has a carefully balanced alloy content to produce specific properties in the deposited weld metal,
GMAW,GTAW,SAW providing the required wear resistance intended for each grade.
Relative Resistance to Impact and Abrasion

Lesson 7 Buildup Alloys Hardsurfacing Alloys
Flux Cored Arc

Electrodes Carbon Wear-O-Matic 3 Wear-O-Matic 6
Low Alloy Steels
Wear-O-Matic Wear-O-Matic 12
Nickel Manganese
Wear-O-Matic WH Wear-O-Matic
Lesson 8 Super WH
Hardsurfacing Wear-O-Matic Bolster
Electrodes Repair Wear-O-Matic 40
Wear-O-Matic 15
Lesson 9
Impact Resistance
Estimating & Abrasion Resistance
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.2.1 Wear-O-Matic 3 8.9.2.2 Wear-O-Matic Nickel
Manganese
DCEP or DCEN (Electrode Positive or Negative) No AWS Classification
Lesson 2 Open Arc—Buildup Alloy DCEP (Electrode Positive)
Common Electric High Impact Resistance Open Arc—Buildup Alloy
Arc Welding Carbon Steels; Low Alloy Steels Attachment Welding
Processes Description: Manganese Steel
Wear-O-Matic 3, a 7/64" (2.8 mm) diameter open-arc Description:
wire, is a buildup alloy for multiple layer application on Wear-O-Matic Nickel Manganese—7/64" (2.8 mm)
Lesson 3 all weldable carbon and low alloy steels. The weld diameter alloy wire for open arc, semiautomatic applica-
deposit is sound and machinable. tion provides the necessary high tensile and yield
Covered Electrodes
for Welding Wear-O-Matic 3 is recommended for the rebuilding of strength to permit this alloy to be used for both attach-
carbon and low alloy steel parts prior to hardsurfacing or ment welding and buildup applications on austenitic
Mild Steels for use where a machinable resurfacing alloy is re- manganese steel. The weld metal has excellent ductility
quired. and provides an ideal base for subsequent
Procedure: hardsurfacing overlays.
Lesson 4 The Wear-O-Matic 3 wire should be deposited with the Wear-O-Matic Nickel Manganese open arc wires are
open arc only, using direct current, straight or reverse recommended for the rebuilding and high strength
Covered Electrodes
polarity. The recommended amperage range is 225-350 welding of austenitic manganese steel parts and equipment.
for Welding Low
amperes at 30-40 arc volts. A weaving technique is
Alloy Steels recommended when a machinable deposit or multiple Procedure:
layer buildup is desired. Stringer beads may be used; Wear-O-Matic Nickel Manganese—7/64" (2.8 mm)
however, this produces a harder deposit and should be diameter wire should be deposited with the open arc
limited to three passes. only, using DCEP (Electrode Positive). The recom-
Lesson 5
Preheat is not required for weld metal. A 200°F (98°C) mended amperage range is 175-275 amperes at 30-35
Welding Filler Metals preheat is recommended to prevent excessive deposit arc volts.
for Stainless Steels hardness when a small deposit is to be applied to a Austenitic manganese steel should not be overheated
heavy section and the deposit is to be machined. The because loss of ductility may result. Use a skip-welding
requirement for preheat usually depends on the proper- technique to keep the manganese base metal below
ties of the base metal. The higher alloy steels generally 600°F (300°C).
Lesson 6 require some preheat.
Carbon & Low Alloy Typical Mechanical Properties:
Wear-O-Matic Nickel Manganese wire deposits high
Steel Filler Metals - The tough deposits of Wear-O-Matic 3, through the strength, ductile weld metal having excellent resistance
GMAW,GTAW,SAW addition of manganese and molybdenum in balance with to impact with moderate abrasion resistance. The weld
other alloying elements, produce a buildup structure for deposit improves with work-hardening, and is not
carbon and low-alloy steels which is highly resistant to machinable. It can be cut with an oxy-acetylene flame
deformation and impact. Although this alloy has high and by air carbon-arc cutting.
Lesson 7 compressive strength and excellent ductility, Wear-O-
Matic 3 is not appropriate for use as a high strength Hardness of Deposited Metal:
Flux Cored Arc
joining alloy. Two layer deposit on austenitic manganese steel:
Electrodes Carbon As Welded—90 Rockwell C
Low Alloy Steels Hardness of Deposited Metal:
Work-Hardened—48 Rockwell C
Two layer deposit on 1045 steel—weaving technique— Abrasion Resistance: Moderate—improves with cold
30 Rockwell C working
Stringer bead—36 Rockwell C Impact Resistance: Excellent
Abrasion Resistance: Moderate Machinability: Non-machinable. Finish by grinding.
Lesson 8 Impact Resistance: High Relief Checking: None
Hardsurfacing Compressive Strength: High Deposit Thickness: Multiple layers may be applied.
Electrodes Machinability: Excellent
Relief Checking: None Typical Undiluted Weld Metal Analysis (%)
C Mn Si Ni
C Mn Si Cr Mo 0.60 13.50 0.60 3.90
Lesson 9 0.07 2.00 2.00 0.50 0.50
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.2.3 Wear-O-Matic BR
Composite Metal Cored Wire
Lesson 2 DCEP (Electrode Positive)
Common Electric Gas Shielded-Buildup Alloy
Arc Welding Bolster Repair
Processes 1. Chamfer the total circumference of the female
Description: flange at a 45° angle-1/8" (3.2 mm) from the O.D. of the
The bolster wire is a gas shielded fabricated wire female flange to the bottom seat of the flange.
designed for the repair and reclamation of railroad
Lesson 3 freight car bolster bowls. This wire was designed to be
Covered Electrodes used with the Gas Metal Arc Welding process with a
98% argon/2% oxygen shielding gas mixture. With the
for Welding metal cored process and the argon/oxygen shielding, a
Mild Steels 98% deposition efficiency is possible. In addition, the
wire deposits a spatter-free, slag-free weld having a 35-
40 Rockwell C undiluted weld hardness. It offers
excellent abrasion resistance, but does not unduly
Lesson 4 impair machinability.
Covered Electrodes Wear-O-Matic BR is recommended for the 40 through
for Welding Low 100 ton bolsters of either grade “B” or “C” type castings.
Alloy Steels Another application is the rebuilding of railroad couplers.
The excellent combination between hardness and
ductility provides use where an unlimited layer buildup
wire is needed. Depending on the carbon content and 2. Clean all excess or loose slag residue left from the
material thickness, preheat may be necessary to prevent carbon-arc or flame cutting operation. If bolster is
Lesson 5 machined as above, cleaning is unnecessary.
cracking.
Procedure:
Wear-O-Matic BR is recommended to be used either in
the semiautomatic or full automatic welding mode using
a variable speed weld fixture to rotate the bolster. When
welding in the automatic mode, there are only two
Lesson 6 adjustments the operator must be concerned with; they
Carbon & Low Alloy are electrode “stick-out” and the horizontal adjustment
Steel Filler Metals - for overlapping of each weld.
GMAW,GTAW,SAW The first step in bolster repair is to chamfer the worn
area of the female lip by air carbon-arc cutting, prefer-
ably with a 5/8" x 3/16" x 12" (15.9 mm x 4.8 mm x 12.7
mm) flat electrode. The female lip of the center of the
Lesson 7 bolster should be beveled approximately 1/8" (3.2 mm)
Flux Cored Arc from the O.D. of the top of the raised area of the female,
Electrodes Carbon to approximately a 45° bevel to the bottom seat of the
center female section of the bolster. This will serve to 3. Place proper size bolster ring of either the 14" x 1-1/
Low Alloy Steels 8" (356 mm x 28.6 mm) or 14" x 1-3/8" (356 mm x 34.9
open up this area into a 45° square butt to the widest
point of wear across the top of the raised casting. The mm) size, using centering device from 2" (50.8 mm)
large amount of wear resistant weld metal from the top holding pin hole of the bolster; tack weld ring in place
of the buildup joint down to the root will serve to give using a 3 IP or E7018 electrode to the female bottom of
Lesson 8 much longer life to this very important part of the total the bolster casting.
Hardsurfacing bolster. It will especially counteract the upsetting or flow
Electrodes of metal common to the impacting of any force to an
edge of this kind.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding Wear-O-Matic BR (cont’d. from previous page)
4. Use approximately six (6) tack welds equally 1. The use of a fabricated wire permits precise control
spaced. Remove centering device used. The bolster ring of the weld metal composition.
Lesson 2 now serves as the inner wall or square portion of the 2. The use of the inert shielding gas permits a spray-
Common Electric groove to be built up with the wear material. type transfer having minimum penetration and
Arc Welding spatter. In addition, slag removal is completely
5. Preheat casting in the heavy center portion of the eliminated.
Processes bolster to be built up to 150°F (66°C) if a Grade “B”, 3. Costs of reclamation are reduced 60% over
250° (121°C) if Grade “C”. This will minimize the Shielded Metal Arc Welding and covered wires
possibility of cracking. through labor saved with the metal cored process.
4. A bolster bowl repaired with the Wear-O-Matic BR
Lesson 3 wire has 300-400% more longevity than the original
Covered Electrodes casting.
for Welding 5. The wire produces a weld that is more resistant to
Mild Steels metal roll-overs and metal upset caused by severe
impacting at the high speed the railroad industry
operates today.
6. The same wire can be used for building up pads on
bolster castings, along with a variety of other wear
Lesson 4 resistant applications in railroad maintenance
Covered Electrodes shops.
for Welding Low 7. Weld deposits can be cut with oxy-acetylene torch
Alloy Steels or by air carbon-arc cutting.
Hardness Typical
Range, Hardness
6. It is necessary to use only water-cooled equipment, Deposit Condition (Undiluted) Rc(1) Rc
Lesson 5 guns, water-circulating equipment, etc. Put in the first 37
pass at the root of the square butt joint using either the 3 layers on C1020, as welded 35 to 40
Welding Filler Metals 3 layers on C1020, stress relieved (2) 25 to 30 27
for Stainless Steels 1/16" (1.6 mm) or 5/64" (2.0 mm) Wear-O-Matic BR Undiluted, as welded 35 to 40 38
electrode with a lagging gun angle to assure proper gas Undiluted, stress relieved (2) 28 to 30 28
coverage. A 98% argon/2% oxygen, or 95% argon/5%
oxygen gas mix is recommended for use with this (1) Welded using 98% Argon/2% Oxygen Shielding Gas
electrode. Be sure to put in a shallow first pass if (2) Stress relieved for one (1) hour at 1150°F ± 25°F
Lesson 6 necessary with the same size wire. (621°C ± 14°C)
Carbon & Low Alloy 7. All consecutive buildup passes necessary should
Steel Filler Metals - be made using the 3/32" (2.4 mm) Wear-O-Matic BR Typical Undiluted Weld Metal Analysis (%)
GMAW,GTAW,SAW electrode with a lagging gun angle. This will speed C Mn Si Cr Mo
completion of building up this section of the bolster. The
0.12 1.60 0.37 2.50 0.55
last pass can be made to the inside edge of the bolster
ring to the outside edge of the female lip of the casting,
Lesson 7 making a finish pass over this entire surface.
Flux Cored Arc 8. A single 3/16" (4.8 mm) fillet weld should be made
Electrodes Carbon around the I.D. of the tack welded preplaced bolster
Low Alloy Steels ring, using the 3IP or the Wear-O-Matic BR alloy. This
will tend to give added wear in this area.
We recommend 25 to 40 cubic feet of gas per hour and

a water-cooled torch. The following amperes and volts
Lesson 8 for the three (3) size wires can be used as a guide:
Hardsurfacing 3/32" (2.4 mm) Wear-O-Matic BR 325/375 Ampere
Electrodes DCEP 29/31 Volts
5/64" (2.0 mm) Wear-O-Matic BR 275/300 Ampere
DCEP 28/29 Volts
1/16" (1.6 mm) Wear-O-Matic BR 225/250 Ampere
Lesson 9 DCEP 23/25 Volts
Typical Properties and Features:
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.2.4 Wear-O-Matic WH Hardness of Deposited Metal:
No AWS Classification Two layer deposit on 1045 steel:
DCEP (Electrode Positive) As Welded—18 Rockwell C
Lesson 2 Work-Hardened—41 Rockwell C
Open Arc—Buildup Alloy Typical Undiluted Weld Metal Analysis (%)
Common Electric Wear Resistant—Attachment Welding C Mn Si Cr Ni
Arc Welding Manganese and Low Alloy Steels
Processes 0.38 4.23 0.47 20.20 9.65
Description:
Wear-O-Matic WH alloy is a dual purpose wire for use of
the economic, semiautomatic open arc process when
Lesson 3 welding manganese to carbon steel and for buildup
Covered Electrodes applications involving severe impact or compressive
loads. The high alloy content of this fabricated wire is
for Welding balanced to perform a dual function, retaining the high
Mild Steels strength properties of a good attachment welding
material while also serving as an excellent work-
hardening, wear-resistant buildup material. The weld 8.9.2.5 Wear-O-Matic Super WH
metal is austenitic at room temperature.
Lesson 4
Procedure:
Covered Electrodes
Wear-O-Matic WH is manufactured in 7/64" (2.8 mm) No AWS Classification
for Welding Low diameter, designed for semiautomatic, open arc DCEP (Electrode Positive)
Alloy Steels application. Open Arc-Hardsurfacing Alloy
Operation: Open Arc only—DCEP (Electrode Positive) Severe Impact Resistance with some Abrasion
Amperage: 225 to 300 amps, at 30-35 volts Description:
Lesson 5 Wear-O-Matic Super WH deposits a tough, work-
Welding Filler Metals Attachment Welding: hardenable alloy weld metal.
for Stainless Steels Wear-O-Matic WH is suitable for production fabrication Wear-O-Matc Super WH is intended for the buildup or
of manganese steel and alloy steel parts which formerly overlay of objects subjected to severe impact or impact
required the use of a wire such as 308 stainless. Wear- with some abrasion. It may be used for multiple layer
O-Matic WH gives the user the added advantage of surfacing without cracking or spalling.
semiautomatic welding. The outstanding physical
Lesson 6 properties of Wear-O-Matic WH weld metal are valuable Procedure:
Carbon & Low Alloy in the field maintenance attachment welding of dipper Wear-O-Matic Super WH - 7/64" (2.8 mm) size should
Steel Filler Metals - teeth, tractor grousers, blade replacements, rounds and be welded by the open arc process only, using direct
GMAW,GTAW,SAW flats used as wear plates. current, reverse polarity. An electrode extension “stick-
out” of about two inches from the contact tip to the work
Typical Mechanical Properties: should be used with 300-450 amperes. Either weaving
or stringer bead technique may be used satisfactorily.
Wear-O-Matc WH weld metal is tough and resilient, and
Lesson 7 provides strong, crack-resistant welds. The surface of Typical Mechanical Properties:
Flux Cored Arc the deposit is work-hardenable, especially by impact. The tough alloy combination of the weld metal deposited
Electrodes Carbon However, the mass of material under this work-hardened by Wear-O-Matic Super WH gives it outstanding
Low Alloy Steels surface remains strong and tough, resisting upset, resistance to impact in service. The impacted surface of
overroll, and spalling. For this reason, Wear-O-Matic the weld metal work-hardens to the extent that it resists
WH is an excellent underlay for hardsurfacing alloys on wear from combined impact and abrasive service.
parts subject to heavy impact and compressive loads. Hardness of Deposited Metal:
Lesson 8 As Welded
Two layer deposit on 1045 steel:
Hardsurfacing As Welded—30 Rockwell C
Yield Strength, psi (MPa) 70,100 (483) Work-Hardened—46 Rockwell C
Electrodes Tensile Strength, psi (MPa) 102,900 (709) Six layer deposit on 1045 steel:
% Elongation in 2" (51 mm) 36
Fracture Test Sound
As Welded—30 Rockwell C
Fissures None Work-Hardened—47-49 Rockwell C
Lesson 9 Typical Undiluted Weld Metal Analysis (%)
Estimating & C Mn Si Cr Ni
Comparing Weld 1.10 15.00 0.65 17.00 1.40
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.2.6 Wear-O-Matic 6 8.9.2.7 Wear-O-Matic 12
DCEP or DCEN (Electrode Positive or Negative) DCEP (Electrode Positive)
Lesson 2 Open Arc-Hardsurfacing Alloy Open Arc-Hardsurfacing Alloy
Common Electric Severe Impact with Abrasion Heavy Impact and Severe Abrasion
Arc Welding Carbon Steel, Low Alloy Steel, Manganese Steel
Processes Description:
Description: Wear-O-Matic 12 - 7/64" (2.8 mm) diameter wire is a
Wear-O-Matic 6, a 7/64" (2.8 mm) diameter open-arc hardsurfacing alloy combining good compressive
wire, is a hardsurfacing alloy wire designed to provide strength and hardness to provide excellent resistance to
Lesson 3 impact and abrasion resistance. It may be applied to wear caused by heavy impact and abrasion.
carbon, low alloy and manganese steel parts.
Covered Electrodes Wear-O-Matic 12 is also recommended for power shovel
for Welding Wear-O-Matic 6 is recommended for applications and dragline bucket parts, dredge buckets, and
involving impact and abrasion on such parts as con- hammermill parts.
Mild Steels veyor buckets, dragline and power shovel bucket lips
and sides, scraper blades, and dredge bucket parts. Procedure:
Procedure: Wear-O-Matic 12 - 7/64" (2.8 mm) diameter wire should
be deposited with the open arc only, using direct current,
Lesson 4 Wear-O-Matic 6 - 7/64" (2.8 mm) diameter wire should reverse polarity. The recommended amperage range is
Covered Electrodes be deposited with the open arc only, using direct current, 175-300 amperes at 30-35 arc volts. A weaving tech-
for Welding Low straight or reverse polarity. The recommended amper- nique is recommended to develop maximum abrasion
age range is 250-400 amperes at 30-40 arc volts. and impact resistance. Application thickness should be
Alloy Steels Weaving beads are recommended to develop maximum limited to two passes or 1/4" (6.4 mm).
wear resistance in this alloy.
Preheat is not required for sound weld metal on two- The deposit of Wear-O-Matic 12 open-arc wire has good
Lesson 5 layer deposits. Where deposits over 1/4" (6.4 mm) in
thickness are desired, a preheat and interpass tempera- compressive strength. It is not machinable and cannot
Welding Filler Metals ture of at least 400°F (204°C) is recommended in order be forged. Relief checks may occur with this alloy but do
for Stainless Steels not impair its performance. Weld deposits cannot be cut
to achieve maximum impact and compressive wear with oxy-acetylene torch or by air carbon-arc cutting.
resistance.
Two layer deposit on 1045 steel—weaving technique—
Wear-O-Matic 6 open-arc wire is a chromium molybde- 50 Rockwell C
Lesson 6 num alloy combining exceptionally good compressive Abrasion Resistance: High
Carbon & Low Alloy strength with high hardness. Deposits may be heat Impact Resistance: Excellent
Steel Filler Metals - treated and are forgeable. Weld deposits can be cut with Compressive Strength: Excellent
GMAW,GTAW,SAW oxy-acetylene torch or by air carbon-arc cutting.
Hardness of Deposited Metal: Typical Undiluted Weld Metal Analysis (%)
C Mn Si Cr Mo
Two layer deposit on 1045 steel—weaving technique—
48 Rockwell C 2.30 0.30 1.00 17.00 0.80
Lesson 7 Abrasion Resistance: Moderate
Flux Cored Arc Impact Resistance: Very High
Electrodes Carbon Compressive Strength: High
Low Alloy Steels Machinability: Machinable with carbide tools
Relief Checking: None
C Mn Si Cr Mo
Lesson 8 0.65 2.60 0.20 3.00 0.50

Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON VIII
The Basics of Arc
Welding 8.9.2.8 Wear-O-Matic 15 8.9.2.9 Wear-O-Matic 40
DCEP or DCEN (Electrode Positive or Negative) DCEP (Electrode Positive)
Lesson 2 Open Arc-Hardsurfacing Alloy Open Arc-Hardsurfacing Alloy
Common Electric Severe Abrasion Resistance Severe Abrasion and Compression
Arc Welding
Description: Description:
Processes
Wear-O-Matic 15 - 7/64" (2.8 mm) diameter open arc Wear-O-Matic 40 - 7/64" (2.8 mm) diameter wire
wire is a hardsurfacing alloy with outstanding resistance is a hardsurfacing alloy with high chromium and carbon
to wear caused by severe abrasion. content. It is designed to provide outstanding resistance
Lesson 3 Wear-O-Matic 15 produces extremely high abrasion- to wear caused by abrasion in combination with com-
resistant qualities that make it an outstanding surface pression. These wear-resistant properties are retained
Covered Electrodes at temperatures up to 1000°F (538°C). Deposits take a
for Welding material for pug mill knives and augers, dry cement
pump screws, conveyor screws, and asphalt mixer high polish and do not gall or seize when subjected to
Mild Steels paddles and shanks. metal-to-metal wear.
Procedure: The unique wear-resistant properties of Wear-O-Matic
40 allow a wide variety of applications:
Wear-O-Matic 15 - 7/64" (2.8 mm) diameter wire should
Lesson 4 be deposited with the open arc only, using direct current, Crusher parts
Covered Electrodes straight or reverse polarity. Recommended amperage Hammermill parts
range, 175-300 amperes at 30-35 arc volts. Weaving Steel mill parts
for Welding Low Mill guides
Alloy Steels bead of 1-1/2" (38 mm) in width is recommended in
order to develop maximum abrasion-resistant qualities Procedure:
in the deposit. Deposit thickness should be limited to Wear-O-Matic 40 - 7/64" (2.8 mm) diameter wire should
two passes or 1/4" (6.4 mm). be deposited with the open arc only, using direct current,
Lesson 5 Typical Mechanical Properties: reverse polarity. The recommended amperage range is
The deposit of Wear-O-Matic 15 open-arc wire attains 175-300 amperes at 30-35 arc volts. A weaving bead
Welding Filler Metals of 1-1/2" (38 mm) in width is recommended. Deposit
for Stainless Steels maximum hardness as deposited and is unaffected by
heat treatment. In most cases, stress relief check cracks thickness should be limited to two passes or 1/4" (6.4 mm).
appear in the deposit but do not impair the abrasion Typical Mechanical Properties:
resistance or the ability of the deposit to take a high Wear-O-Matic 40 open-arc wire is a high alloy material
polish. Weld deposits cannot be cut with oxy-acetylene combining chromium and carbon with other alloying
Lesson 6 torch or by air carbon-arc cutting. elements to provide extremely high abrasion resistance
Carbon & Low Alloy Hardness of Deposited Metal: and good compressive strength. The deposit is not heat
Steel Filler Metals - Two layer deposit on 1045 steel—weaving technique— treatable and cannot be forged. Weld deposits cannot
GMAW,GTAW,SAW 60 Rockwell C be cut with oxy-acetylene torch or by air carbon-arc
Abrasion Resistance: Outstanding cutting.
Impact Resistance: Light Hardness of Deposited Metal:
Compressive Strength: High Two layer deposit on 1045 steel—weaving technique—
Lesson 7 Machinability: Non-machinable. Finish by grinding. 58 Rockwell C
Flux Cored Arc Abrasion Resistance: Excellent
Electrodes Carbon Typical Undiluted Weld Metal Analysis (%)
C Mn Si Cr Mo
Heat Resistance: Excellent up to 1000°F (538°C)
Low Alloy Steels Impact Resistance: Light
4.00 0.30 0.60 5.50 5.00 Compressive Strength: Good
Machinability: Non-machinable. Finish by grinding.
Relief Checking: A uniform pattern of check cracks
appears in the deposit as it cools, indicating the excel-
Lesson 8 lent stress-relief characteristics of this alloy. This check
Hardsurfacing crack pattern is necessary to prevent distortion in large
Electrodes parts when an alloy of this hardness and alloy content is
applied.

C Mn Si Cr Mo
Lesson 9
4.00 1.50 1.50 27.00 1.00
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
APPENDIX A
Lesson 2 LESSON VIII - GLOSSARY OF TERMS
Common Electric
Arc Welding
Processes
Spalling - The loss of particles or pieces from a surface due to cracking.
Lesson 3
Covered Electrodes Galling - The condition between rubbing surfaces where high spots or protrusions
for Welding on a surface become friction welded to the mating surface, resulting in
Mild Steels spalling and further deterioration.
Matrix - A crystalline phase of an alloy in which other phases are imbedded.

Lesson 4
Covered Electrodes
for Welding Low Shear - A force which causes deformation or fracture of a member by sliding one
Alloy Steels section against another in a plane or planes which are substantially
parallel to the direction of the force.
Lesson 5
for Stainless Steels Hadfield - The name sometimes used for austenitic manganese steel derived from
Steel its inventor.
Lesson 6
Carbon & Low Alloy Coefficient - A value used in engineering calculations which is an indicator of the
GMAW,GTAW,SAW of Friction ability of one material to slide on another. A low coefficient of friction
indicates a low rate of wear between sliding surfaces.
Lesson 7
Flux Cored Arc
Electrodes Carbon Stringer - A straight weld bead opposed to a weaving bead. In surfacing, the
Low Alloy Steels Bead weaving bead produces less dilution because the weld puddle is always
in contact with the part of the bead produced on the previous oscillation
rather than the base metal.
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
LESSON IX
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
ESTIMATING
AND COMPARING
Lesson 7
Flux Cored Arc WELD METAL COSTS
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON IX
Lesson 2
Common Electric ESTIMATING AND COMPARING WELD
Arc Welding
Processes METAL COSTS
Lesson 3
Covered Electrodes
for Welding 9.1 Introduction .................................................................................................. 1
Mild Steels
9.2 Factors For Cost Formulas ...................................................................... 2
Lesson 4 9.2.1 Labor & Overhead ......................................................................................... 2

Covered Electrodes 9.2.2 Deposition Rate ............................................................................................. 2
for Welding Low
9.2.3 Operating Factor ............................................................................................ 3
Alloy Steels
9.2.4 Deposition Efficiency .................................................................................... 4
9.2.5 Deposition Efficiency of Coated Electrodes .............................................. 4
Lesson 5 9.2.6 Efficiency of Flux Cored Wires ..................................................................... 6
for Stainless Steels 9.2.7 Efficiency of Solid Wires for GMAW ............................................................ 6
9.2.8 Efficiency of Solid Wires for SAW ............................................................... 7
9.2.9 Cost of Electrodes, Wires, Gases and Flux ................................................ 7
Lesson 6 9.2.10 Cost of Power ................................................................................................ 7
Carbon & Low Alloy
9.3 Deposition Data Tables ............................................................................. 8
GMAW,GTAW,SAW
9.4 Cost Calculations ....................................................................................... 12
Lesson 7 9.4.1 Calculating the Cost Per Pound of Deposited Weld Metal ....................... 12
Flux Cored Arc 9.4.2 Calculating the Cost Per Foot Of Deposited Weld Metal ......................... 14
Electrodes Carbon
Low Alloy Steels
9.5 Cost Calculations - Example 2 ................................................................ 15
9.6 Comparing Weld Metal Costs .................................................................. 17

Lesson 8
9.6.1 Example 3 ....................................................................................................... 19
Hardsurfacing
Electrodes
9.7 Other Useful Formulas .............................................................................. 20
9.8 Amortization of Equipment Costs .......................................................... 21

Lesson 9
Estimating &
Comparing Weld Appendix A Lesson IX Test Questions ......................................................................... 22
Metal Costs
Appendix B Problem 1 Worksheet ................................................................................ 26
Appendix C Problem 2 Worksheet ................................................................................ 27

Lesson 10
Filler Metals
Lesson 1
The Basics of Arc LESSON IX
Welding
ESTIMATING AND COMPARING WELD METAL COSTS
Lesson 2
Common Electric
Arc Welding
Processes 9.1 INTRODUCTION
Estimating the costs of depositing weld metal can be a difficult task because of the many
Lesson 3
Covered Electrodes variables involved. Design engineers must specify the type and size of weld joint to withstand
for Welding the loads that the weldment must bear. The welding engineer must select the welding process,
Mild Steels
and type of filler metal that will provide the required welds at the least possible cost. With
wages and the cost of operations rising, selection of the process that deposits weld metal
Lesson 4 most expediently must be carefully considered. Labor and overhead account for approxi-
Covered Electrodes
for Welding Low mately 85% of the total welding cost.
Alloy Steels
9.1.0.1 Welding costs may be divided into two categories; the “fixed” costs involved regard-
less of the filler metal or welding process selected, and those related to a specific welding
Lesson 5 process. Fixed costs entail material handling, joint preparation, fixturing, tacking, preheating,
for Stainless Steels weld clean-up and inspection. Although some of these items will be affected by the process
and filler metal chosen, they are a necessary part of practically all welding operations. Calcu-
lating these costs is best left to the manufacturer since they will depend upon his capabilities
Lesson 6 and equipment. The cost of actually depositing the weld metal however, will vary considerably
Carbon & Low Alloy
Steel Filler Metals - with the filler metal and welding process selected. This cost element is influenced by the
GMAW,GTAW,SAW user’s labor and overhead rates, deposition rate and efficiency of the filler metal, operating
factor, and cost of materials and power.
Lesson 7
Flux Cored Arc 9.1.0.2 This lesson will cover cost estimating for steel weldments produced by the four most
Electrodes Carbon common arc welding processes in use today: shielded metal-arc welding, gas metal-arc
Low Alloy Steels
welding, flux cored arc welding and submerged arc welding. Gas tungsten arc welding will not
be considered here because the variables, such as deposition rate and efficiency, are depen-
dent on operator technique, stub use, etc. The GTAW process is a relatively costly method of
Lesson 8
Hardsurfacing depositing weld metal, and is usually chosen for weld quality or material thickness and compo-
Electrodes sition limitations, rather than economy.
9.1.0.3 Large firms will frequently conduct their own deposition tests and time studies to
Lesson 9
determine welding costs, but many smaller shops do not know the actual cost of depositing
Estimating &
Comparing Weld weld metal.
Metal Costs
9.1.0.4 In estimating welding costs, all attempts should be made to work with accurate data,
which in some cases is difficult to secure. For this reason, this lesson contains charts, graphs
Lesson 10
Filler Metals

Lesson 1
Welding
and tables that provide average values that you may use. Electrode manufacturers will usually
supply the deposition data you need through their Technical Services Department, if it is not
Lesson 2 already published in their literature.
Common Electric
Arc Welding
Processes
9.2 FACTORS FOR COST FORMULAS

Lesson 3
Covered Electrodes
for Welding 9.2.1 Labor and Overhead - Labor and overhead may be considered jointly in your
Mild Steels calculations. Labor is the welder’s hourly rate of pay including wages and benefits. Overhead
includes allocated portions of plant operating and maintenance costs. Weld shops in manu-
Lesson 4 facturing plants normally have established labor and overhead rates for each department.
Covered Electrodes Labor and overhead rates can vary greatly from plant to plant, and also with location. Figure 1
for Welding Low
Alloy Steels shows how labor and overhead may vary and suggests an average value to use in your calcu-
lations when the actual value is unknown.
Lesson 5
Welding Filler Metals HOURLY WELDING LABOR & OVERHEAD RATES
Small Shops $10.00 to $25.00/hr.
Large Shops $25.00 to $50.00/hr
Average $30.00/hr.
Lesson 6
Carbon & Low Alloy APPROXIMATE LABOR AND OVERHEAD RATES
Steel Filler Metals - FIGURE 1
GMAW,GTAW,SAW
9.2.2 Deposition Rate - The deposition rate is the rate that weld metal can be deposited
Lesson 7
Flux Cored Arc by a given electrode or welding wire, expressed in pounds per hour. It is based on continuous
Electrodes Carbon operation, not allowing time for stops and starts caused by inserting a new electrode, cleaning
Low Alloy Steels
slag, termination of the weld or other reasons. The deposition rate will increase as the welding
current is increased.
Lesson 8
9.2.2.1 When using solid or flux cored wires, deposition rate will increase as the electrical
Hardsurfacing
Electrodes stick-out is increased, and the same amperage is maintained. True deposition rates for each
welding filler metal, whether it is a coated electrode or a solid or flux cored wire, can only be
established by an actual test in which the weldment is weighed before welding and then again
Lesson 9
after welding, at the end of a measured period of time. The tables in Figures 8-11 contain
Estimating &
Comparing Weld average values for the deposition rate of various types of welding filler metals. These are
Metal Costs based on welding laboratory tests and published data.
Lesson 10
Filler Metals

Lesson 1
LESSON IX
The Basics of Arc
Welding
9.2.3 Operating Factor - Operating factor is the percentage of a welder’s working day
that is actually spent welding. It is the arc time in hours divided by the total hours worked. A
Lesson 2 45% (.45) operating factor means that only 45% of the welder’s day is actually spent welding.
Common Electric
The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the
Arc Welding
Processes weldment, cleaning spatter from the welding gun, etc.
9.2.3.1 When using coated electrodes, (SMAW) the operating factor can range from
Lesson 3 15%-40% depending upon material handling, fixturing and operator dexterity. If the actual
Covered Electrodes
for Welding operating factor is not known, an average of 30% may be used for cost estimates when weld-
Mild Steels ing with the shielded metal arc welding process.
9.2.3.2 When welding with solid wires (GMAW) or metal cored welding (MCAW) using the
Lesson 4
Covered Electrodes semi-automatic method, operating factors ranging from 45%-55% are easily attainable. Use
for Welding Low 50% for cost estimating purposes.
Alloy Steels
9.2.3.3 For welds produced by flux cored arc welding (FCAW) semi-automatically, the
operating factor usually lies between 40%-50%. For cost estimating purposes, use a 45%
Lesson 5
Welding Filler Metals operating factor. The estimated operating factor for FCAW is about 5% lower than that of
for Stainless Steels GMAW to allow for slag removal time.
9.2.3.4 In semi-automatic submerged arc welding, slag removal and loose flux handling
Lesson 6 must be considered. A 40% operating factor is typical for this process.
Carbon & Low Alloy
GMAW,GTAW,SAW 9.2.3.5 Automatic welding using the GMAW, FCAW, and SAW processes, requires that
each application be studied individually. Operating factors ranging from 50% to values ap-
proaching 100% may be obtained depending on the degree of automation.
Lesson 7
Flux Cored Arc
Electrodes Carbon 9.2.3.6 The chart in Figure 2 shows average operating factor values for the various welding
Low Alloy Steels processes that may be used for cost estimating when the actual operating factor is not known.
Lesson 8
Hardsurfacing
Electrodes
WELDING PROCESS
+ * GMAW
SMAW *FCAW *SAW
Lesson 9 30% 50% 45% 40%

Estimating &
Comparing Weld *Semi-Automatic Only
Metal Costs + Metal Cored Wires are Included
APPROXIMATE OPERATING FACTOR
FIGURE 2
Lesson 10
Filler Metals

Lesson 1
Welding
9.2.4 Deposition Efficiency - Deposition efficiency is the relationship of the weight of
the weld metal deposited to the weight of the electrode (or wire) consumed in making a weld.
Lesson 2 It can be accurately determined only by making a timed test weld, and carefully weighing the
Common Electric
weldment and the electrode or wire, before and after welding. The efficiency can then be
Arc Welding
Processes calculated by the formula:
Deposition efficiency = Weight of Weld Metal ÷ Weight of Electrode Used

Lesson 3 (or)
Covered Electrodes
for Welding Deposition Rate (lbs/hr) ÷ Burn-off Rate (lbs/hr)
Mild Steels
9.2.4.1 The deposition efficiency tells us how many pounds of weld metal can be expected
Lesson 4
Covered Electrodes from a given weight of the electrode or welding wire purchased. As an example, 100 pounds
for Welding Low of a flux cored electrode with an efficiency of 85%, will produce approximately 85 pounds of
Alloy Steels
weld metal, while 100 pounds of coated electrode with an efficiency of 65%, will produce
approximately 65 pounds of weld metal, less the weight of the stubs discarded, as described
Lesson 5 below.
for Stainless Steels 9.2.5 Coated Electrodes - The deposition efficiency of coated electrodes by AWS
definition, and in published data, does not consider the loss of the unused electrode stub that
is discarded. This is understandable since the stub length can vary with the operator and the
Lesson 6
Carbon & Low Alloy application. Long continuous welds are usually conducive to short stubs while on short inter-
Steel Filler Metals - mittent welds, stub length tends to be longer. Figure 3 illustrates how the stub loss influences
GMAW,GTAW,SAW
the electrode efficiency when using coated electrodes.
Lesson 7 9.2.5.1 In Figure 3, a 14” long by 5/32” diameter E7018 electrode at 140 amperes is con-
Flux Cored Arc sidered. It is 75% efficient, and a two inch stub loss is assumed. The 75% efficiency applies
Electrodes Carbon
Low Alloy Steels
12" LENGTH OF ELECTRODE CONSUMED

Lesson 8
Hardsurfacing 2"
AMOUNT THAT BECOMES WELD METAL
STUB
Electrodes (LENGTH CONSUMED X EFFICIENCY)
LENGTH
Lesson 9 LOST TO
Estimating & 9" SLAG,SPATTER
Comparing Weld & FUMES
Metal Costs 14"
DEPOSITION EFFICIENCY = 75%

actual efficiency, including stub loss = 9 ÷ 14 = 64.3%
Lesson 10 FIGURE 3
Reliability of Welding © COPYRIGHT 2000 THE ESAB GROUP, INC.
Filler Metals -4-
Lesson 1
Welding
only to the 12” of the electrode consumed in making the weld, and not to the two inch stub.
When the two inch stub loss and the 25% that is lost to slag, spatter and fumes are consid-
Lesson 2 ered, the efficiency minus stub loss is lowered to 64.3%. This means that for each 100 pounds
Common Electric
of electrodes purchased, you can expect an actual deposit of approximately 64.3 pounds of
Arc Welding
Processes weld metal if all electrodes are used to a two inch stub length.
9.2.5.2 The formula for the efficiency including stub loss is important, and must always be
Lesson 3 used when estimating the cost of depositing weld metal by the SMAW method. Figure 4
Covered Electrodes
for Welding shows the formula used to establish the efficiency of coated electrodes including stub loss. It
Mild Steels is based on the electrode length, and is slightly inaccurate, i.e. it does not take into consider-
ation that the electrode weight is not evenly distributed, due to the flux being removed from the
Lesson 4 electrode holder end. (Indicated by the dotted lines in Figure 3.) Use of the formula will result
Covered Electrodes in a 1.5-2.3% error that will vary with electrode size, coating thickness and stub length. The
for Welding Low
Alloy Steels formula however, is acceptable for estimating purposes.
9.2.5.3 For the values given in Figure 3 the formula is:

Lesson 5
for Stainless Steels EFFICIENCY = (ELECTRODE LENGTH — STUB LENGTH) X DEPOSITION EFFICIENCY
MINUS STUB LOSS ELECTRODE LENGTH
EFFICIENCY MINUS STUB LOSS

Lesson 6
FIGURE 4
Carbon & Low Alloy
GMAW,GTAW,SAW Efficiency - Stub Loss = (14-2) x .75
14
Lesson 7 = 12 x .75
Flux Cored Arc
14
Electrodes Carbon
Low Alloy Steels = 9
14
= .6429 or 64.3%
Lesson 8
Hardsurfacing
Electrodes In the above example, the electrode length is known, the stub loss must be estimated, and the
efficiency taken from the tables in Figures 8 and 9. Use an average stub loss of three inches
for coated electrodes if the actual shop practices concerning stub loss are not known.
Lesson 9
Estimating & 9.2.5.4 The following stub loss correction table will assist in your determination of coated
Comparing Weld
Metal Costs electrode efficiencies. Figure 5 lists various efficiencies at a given stub loss.
Lesson 10
Filler Metals

Lesson 1
Welding
ELEC. DEPOSITION 2" 3" 4" 5"
LENGTH EFFICIENCY STUB STUB STUB STUB
60% 50.0% 45.0% 40.0% 35.0%

Lesson 2
Common Electric 65% 54.2% 48.7% 43.3% 37.9%
Arc Welding 12" 70% 58.3% 52.5% 46.6% 40.8%
Processes 75% 62.5% 56.2% 50.0% 43.7%
80% 66.6% 60.0% 53.3% 46.6%
STUB LOSS CORRECTION
60% 51.4% 47.1% 42.8% 38.5%
TABLE FOR COATED
Lesson 3 65% 55.7% 51.1% 46.4% 41.8%
Covered Electrodes ELECTRODES
14" 70% 60.0% 55.0% 50.0% 45.0%
for Welding EFFICIENCY INCLUDING
75% 64.3% 58.9% 53.6% 48.2%
Mild Steels STUB LOSS
80% 68.5% 62.8% 57.1% 51.4%
FIGURE 5 60% 53.3% 50.0% 46.6% 43.3%
Lesson 4 65% 57.7% 54.2% 50.5% 46.9%

Covered Electrodes 18" 70% 62.2% 58.3% 54.4% 50.5%
for Welding Low 75% 66.6% 62.5% 58.3% 54.2%
Alloy Steels 80% 71.1% 66.6% 62.2% 57.7%
9.2.6 Efficiency of Flux Cored Wires - Flux cored wires have a lower flux-to-metal ratio
Lesson 5 than coated electrodes, and thereby, a higher deposition efficiency. Stub loss need not be
for Stainless Steels considered since the wire is continuous. The gas shielded wires of the E70T-1 and E70T-2
types have efficiencies of 83%-88%. The gas shielded basic slag type (E70T-5) is 85%-90%
efficient with CO2 as the shielding gas, and the efficiency can reach 92% when a 75% argon,
Lesson 6 25% CO2 gas mixture is used. Use the efficiency figures in Figure 9 for your calculations if the
Carbon & Low Alloy
Steel Filler Metals - actual values are not known.
GMAW,GTAW,SAW
9.2.6.1 The efficiency of the self-shielded types of flux cored wires has more variation
because of the large variety of available types that have been designed for specific applica-
Lesson 7
Flux Cored Arc tions. The high deposition general purpose type, such as E70T-4, is 81%-86%, depending on
Electrodes Carbon wire size and electrical stick-out. The chart in Figure 9 shows the optimum conditions for each
Low Alloy Steels
wire size and may be used in your calculations.
9.2.7 Efficiency of Solid Wires for GMAW - The efficiency of solid wires in GMAW is
Lesson 8
very high and will vary with the shielding gas or gas mixture used. Using CO2 will produce the
Hardsurfacing
Electrodes most spatter and the average efficiency will be about 93%. Using a 75% argon-25% CO2 gas
mixture will result in somewhat less spatter, and an efficiency of approximately 96% can be
expected. A 98% argon-2% oxygen mixture will produce even less spatter, and the average
Lesson 9
efficiency will be about 98%. Stub loss need not be considered since the wire is continuous.
Estimating &
Comparing Weld Figure 6 shows the average efficiencies you may use in your calculations if the actual effi-
Metal Costs ciency is not known.
Lesson 10
Filler Metals

.045" - 1/16"
Lesson 1
GMAW
Welding
9.2.8 Efficiency of Solid Wires for SAW - In submerged arc welding there is no spatter
loss and an efficiency of 99% may be assumed. The only loss during welding is the short
Lesson 2 piece the operator must clip off the end of the wire to remove the fused flux that forms at the
Common Electric
termination of each weld. This is done to assure a good start on the succeeding weld.
Arc Welding
Processes
Lesson 3 Shielding Efficiency Average

Covered Electrodes Gas Range Efficiency
for Welding
Pure CO2 88 - 95% 93%
Mild Steels
94 - 98% 96%
Lesson 4 98% Ar - 2% O2 97 - 98.5% 98%

Covered Electrodes
for Welding Low DEPOSITION EFFICIENCIES - GAS METAL ARC WELDING
CARBON AND LOW ALLOY STEELS
Alloy Steels
FIGURE 6
Lesson 5 9.2.9 Cost of Electrodes, Wires, Gases and Flux - You must secure the current cost
Welding Filler Metals per pound of the electrode or welding wire, plus the cost of the shielding gas or flux if appli-
cable, from the supplier. The shielding gas flow rate varies slightly with the type of gas used.
The flow rates in Figure 7 are average values whether the shielding gas is an argon mixture or
Lesson 6 pure CO2. Use these in your calculations if the actual flow rate is not available.
Carbon & Low Alloy
Steel Filler Metals - In the submerged arc process (SAW) the ratio of flux to wire consumed in the weld is approxi-
GMAW,GTAW,SAW
mately 1 to 1 by weight. When the losses due to flux handling and flux recovery systems are
considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound
Lesson 7 of wire consumed. If the actual flux-to-wire ratio is unknown, use the 1.4 for cost estimating.
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FCAW/MCAW
Wire Diameter .035" .045" 1/16" 5/64" - 1/8"
Lesson 8
Hardsurfacing CFH 30 35 35 40 45
Electrodes
APPROXIMATE SHIELDING GAS FLOW RATE - CUBIC FEET PER HOUR
FIGURE 7
Lesson 9
Estimating & 9.2.10 Cost of Power - Cost of electrical power is a very small part of the cost of deposit-
Comparing Weld
Metal Costs ing weld metal and in most cases is less than 1% of the total. It will be necessary for you to
know the power cost expressed in dollars per kilowatt- hour ($/kWh) if required for a total cost
estimate.
Lesson 10
Filler Metals

Lesson 1
LESSON IX
The Basics of Arc
Welding
9.3 DEPOSITION DATA CHARTS

Lesson 2
Common Electric 9.3.1 SHIELDED METAL ARC WELDING - Coated Electrodes.
Arc Welding
Processes
E6010 6013
Lesson 3
ELECTRODE DEPOSITION EFFICIENCY ELECTRODE DEPOSITION EFFICIENCY
Covered Electrodes
DIAMETER AMPS RATE lbs/hr % DIAMETER AMPS RATE lbs/hr %
for Welding
Mild Steels 3/32 75 1.5 72.0% 3/32 85 1.6 73.0%
1/8 100 2.1 76.3% 1/8 125 2.1 73.0%
130 2.3 68.8% 5/32 140 2.6 75.6%
Lesson 4 5/32 140 2.8 73.6% 160 3 74.1%
Covered Electrodes 170 2.9 64.1% 180 3.5 71.2%
for Welding Low 3/16 160 3.3 74.9% 3/16 180 3.2 73.9%
Alloy Steels 190 3.5 69.7% 200 3.8 71.1%
7/32 190 4.5 76.9% 220 4.1 72.9%
230 5.1 73.1% 7/32 250 5.3 71.3%
Lesson 5 270 5.7 73.0%
Welding Filler Metals 290 6.1 72.7%
for Stainless Steels E6011
ELECTRODE DEPOSITION EFFICIENCY
DIAMETER AMPS RATE lbs/hr %
E7014
Lesson 6 3/32 75 1.3 61.0% ELECTRODE DEPOSITION EFFICIENCY
Carbon & Low Alloy 1/8 120 2.3 70.7% DIAMETER AMPS RATE lbs/hr %
Steel Filler Metals - 5/32 150 3.7 77.0% 1/8 120 2.4 63.9%
GMAW,GTAW,SAW 3/16 180 4.1 73.4% 150 3.1 61.1%
7/32 210 5 74.2% 5/32 160 3 71.9%
1/4 250 5.6 71.9% 200 3.7 67.0%
Lesson 7
Flux Cored Arc 3/16 230 4.5 70.9%
Electrodes Carbon 270 5.5 73.2%
E6012
Low Alloy Steels 7/32 290 5.8 67.2%
ELECTRODE DEPOSITION EFFICIENCY
330 7.1 70.3%
1/4 350 7.1 68.7%
1/8 130 2.9 81.8% 400 8.7 69.9%
Lesson 8 5/32 165 3.2 78.8%
Hardsurfacing 200 3.4 69.0%
Electrodes 3/16 220 4 77.0%
250 4.2 74.5%
7/32 320 5.6 69.8%
Lesson 9
Estimating & DEPOSITION DATA - SMAW - COATED ELECTRODES
Comparing Weld
FIGURE 8
Metal Costs
NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

Lesson 10
Filler Metals

Lesson 1
Welding
Lesson 2
Common Electric
Arc Welding
Processes
E7016
Lesson 3 ELECTRODE DEPOSITION EFFICIENCY
Covered Electrodes DIAMETER AMPS RATE lbs/hr %
for Welding
1/8 100 1.7 63.9%
Mild Steels LOW ALLOY, IRON POWDER ELECTRODES
130 2.3 65.8%
TYPES E7018, E8018, E9018, E10018, E11018,
5/32 140 3.0 70.5%
160 3.2 69.1% AND E12018
Lesson 4 ELECTRODE DEPOSITION EFFICIENCY
Covered Electrodes 190 3.6 66.0%
3/16 175 3.8 71.0% DIAMETER AMPS RATE lbs/hr %
for Welding Low
Alloy Steels 200 4.2 71.0% 3/32 70 1.37 70.5%
225 4.4 70.0% 90 1.65 66.3%
250 4.8 65.8% 110 1.73 64.4%
1/4 250 5.9 74.5% 1/8 120 2.58 71.6%
Lesson 5
Welding Filler Metals 275 6.4 74.1% 140 2.74 70.9%
for Stainless Steels 300 6.8 73.2% 160 2.99 68.1%
350 7.6 71.5% 5/32 140 3.11 75.0%
170 3.78 73.5%
200 4.31 73.0%
Lesson 6 3/16 200 4.85 76.4%
Carbon & Low Alloy E7024 250 5.36 74.6%
Steel Filler Metals - ELECTRODE DEPOSITION EFFICIENCY
GMAW,GTAW,SAW 300 5.61 70.3%
DIAMETER AMPS RATE lbs/hr % 7/32 250 6.50 75.0%
1/8 140 4.2 71.8% 300 7.20 74.0%
Lesson 7 180 5.1 70.7% 350 7.40 73.0%
Flux Cored Arc 5/32 180 5.3 71.3% 1/4 300 7.72 78.0%
Electrodes Carbon 210 6.3 72.5% 350 8.67 77.0%
Low Alloy Steels 240 7.2 69.4% 400 9.04 74.0%
3/16 245 7.5 69.2%
270 8.3 70.5%
290 9.1 68.0%
Lesson 8
7/32 320 9.4 72.4%
Hardsurfacing
Electrodes 360 11.6 69.1%
1/4 400 12.6 71.7%
Lesson 9
Estimating & DEPOSITION DATA - SMAW - COATED ELECTRODES (Con't.)
Comparing Weld
Metal Costs FIGURE 9
NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

Lesson 10
Filler Metals

0.045
Lesson 1
LESSON IX
The Basics of Arc
Welding
9.3.2 FLUX CORED ARC WELDING/METAL CORED ARC WELDING - Deposition

Lesson 2
data for gas shielded FCAW on all low alloy wire types and MCAW on all alloy types.
Common Electric
Arc Welding
Processes
FLUX CORED ARC WELDING (FCAW)
GAS SHIELDED TYPES E70T-1, E71T-1, E70T-2,
Lesson 3 E70T-5, & ALL LOW ALLOY TYPES
Covered Electrodes ELECTRODE DEPOSITION EFFICIENCY METAL CORED ARC WELDING (MCAW)
for Welding DIAMETER AMPS RATE lbs/hr % E70T-1, E71T-1, AND ALL ALLOY TYPES
Mild Steels
.035 130 3.2 82% ELECTRODE DEPOSITION EFFICIENCY
140 3.6 82% DIAMETER AMPS RATE lbs/hr %
Lesson 4 160 4.2 83% 0.035 150 4.4 93%

Covered Electrodes 180 5.6 83% 200 6.5 92%
for Welding Low 200 6.5 84% 250 9.4 92%
Alloy Steels 220 7.5 85% 250 8 91%
.045 160 4.0 83% 275 11.4 93%
300 11.6 95%
180 4.9 87%
Lesson 5 0.052 275 8 90%
200 6.5 90%
Welding Filler Metals 300 9.6 93%
220 6.8 84% 325 10.1 93%
240 7.3 84% 1/16 300 8.6 89%
280 10.5 89% 350 11.9 94%
.052 170 3.9 84% 400 14.6 93%
Lesson 6 190 5.3 87% 450 16.2 96%
Carbon & Low Alloy 210 5.5 86% 5/64 350 11.6 94%
Steel Filler Metals - 400 13.2 95%
240 6.7 85%
GMAW,GTAW,SAW 450 15.8 97%
270 8.1 85%
500 20.4 97%
300 10.3 87% 3/32 400 11.5 95%
Lesson 7 1/16 180 4.2 87% 450 14.5 97%
Flux Cored Arc 200 4.7 85% 500 16.5 97%
Electrodes Carbon 220 5.6 87% 550 21 98%
Low Alloy Steels 250 7.7 86%
275 8.5 86% NOTE: DATA REFLECTS USE OF 75% ARGON
300 9.3 86% 25% CO2 GAS SHIELDING. DEPOSITION RATES

AND EFFICIENCIES WILL INCREASE WITH THE USE
Lesson 8 350 11.7 86%
OF HIGHER ARGON MIXTURES.
Hardsurfacing 5/64 250 6.4 85%
Electrodes 350 10.5 85%
450 14.8 85%
3/32 400 12.7 85%
Lesson 9 450 15.0 86%
Estimating & 500 18.5 86%
Comparing Weld
Metal Costs
DEPOSITION DATA - FCAW/MCAW
FIGURE 10
Lesson 10
Filler Metals

Lesson 1
Welding
GAS METAL ARC WELDING
9.3.3 FLUX CORED ARC WELDING, SOLID WIRES
GAS METAL ARC WELDING, AND SUB- DEPOSITION RATE lbs/hr

Lesson 2 ELECTRODE 98%A/2%O275%A/25%CO2
Straight CO2
Common Electric MERGED ARC WELDING - Deposition data DIAMETER AMPS *98% *96% *93%
for self-shielded FCAW, and solid wires using .030 75 2.0 1.9 1.8
Arc Welding
100 2.6 2.6 2.5
Processes GMAW and SubArc. 150 4.1 4.0 3.9
200 6.8 6.7 6.5
.035 80 2.2 2.1 2.0
Lesson 3 100 2.7 2.7 2.6
Covered Electrodes 150 4.2 4.1 4.0
for Welding 200 6.2 6.0 5.9
Mild Steels 250 9.0 8.8 8.6
.045 100 2.1 2.0 1.9
FLUX CORED ARC WELDING (FCAW) 125 2.8 2.8 2.7
SELF-SHIELDED 150 3.6 3.5 3.4
Lesson 4 200 5.6 5.5 5.3
Covered Electrodes 250 7.8 7.6 7.4
for Welding Low ELECTRODE DEPOSITION EFFICIENCY
300 10.2 10.0 9.7
Alloy Steels DIAMETER AMPS RATE lbs/hr %
350 13.2 12.9 12.5
E70T-3 3/32 450 14 88% 250 6.5 6.4 6.2
1/16
E70T-4 3/32 400 15 85% 275 7.7 7.6 7.3
0.12 450 20 81% 300 9.0 8.8 8.5
Lesson 5
350 11.9 86% 350 11.3 11.0 10.7
Welding Filler Metals E70T-6 5/64
400 14.0 13.7 13.3
for Stainless Steels 3/32 480 14.7 81%
450 17.4 17.1 16.5
E70T-6 3/32 325 11.4 80%
* USE THIS FIGURE AS THE DEPOSITION EFFICIENCY IN THE
7/64 450 18 86% COST CALCULATIONS ON SHEET ONE.
E71T-7 .068 200 4.2 76%
Lesson 6 SUBMERGED ARC WIRES
Carbon & Low Alloy 5/64 300 8 84% (1" STICKOUT)
Steel Filler Metals - E71T-8 5/64 220 4.4 77%
ELECTRODE MELT-OFF EFFICIENCY
GMAW,GTAW,SAW 3/32 300 6.7 77%
E61T8-K6 5/64 235 4.3 76%
5/64 300 7.0
E70T-10 .045 150 2.6 88% 400 10.2
Lesson 7 1/16 220 3.3 78% 500 15.0
Flux Cored Arc
5/64 250 4 94% 3/32 400 9.4
Electrodes Carbon
Low Alloy Steels E71T-11 .045 150 2.4 82% 500 13.0 Assume
200 3.6 83% 600 17.2
1/16
1/8 400 8.5 99%
5/64 240 4.5 87%
500 11.5
3/32 250 5 91% 600 15.0
Lesson 8 300 14 83% Efficiency
E70T4-K2 3/32 700 19.0
Hardsurfacing
Electrodes E71T-GS .030 100 1.6 75% 5/32 500 11.3
.035 120 2.1 84% 600 14.6
700 18.4
.045 150 2.4 82%
800 22.0
1/16 200 3.6 83%
Lesson 9 900 26.1
5/64 250 3.9 81% 3/16 600 13.9
Estimating &
Comparing Weld 700 17.5
Metal Costs 800 21.0
900 25.0
DEPOSITION DATA 1000 29.2
1100 34.0
FIGURE 11
Lesson 10 NOTE: Values for 1" Stickout
Filler Metals

Lesson 1
Welding
9.4 COST CALCULATIONS - EXAMPLE 1
9.4.1 Calculating the Cost Per Pound of Deposited Weld Metal
Lesson 2
Common Electric
Arc Welding 9.4.1.1 Example 1 - Calculate the cost of welding 1,280 ft. of a single bevel butt joint as
Processes shown in Figure 14 using the following data.
a. Electrode - 3/16” diameter, 14” long, E7018, operated at 25 volts, 250 amps.
Lesson 3
b. Stub Loss - 2 inches
Covered Electrodes
for Welding c. Labor and Overhead - $30.00/hr
Mild Steels
d. Electrode Cost - $.57/lb
e. Power Cost - $.045/kWh
Lesson 4
Covered Electrodes 9.4.1.2 The formulas for the calculations are shown on the Weld Metal Cost Worksheet in
for Welding Low
Alloy Steels Figure 12. The following explains each step in the calculations.
Line 1- Labor and Overhead - $30.00/hr (given)

Lesson 5 Deposition Rate - From shielded metal arc welding deposition data chart in
for Stainless Steels Figure 9 = 5.36 lbs/hr.
Operating Factor - Since it is not stated above, use an average value of 30% (.30)
shown in Figure 2.
Lesson 6 The cost of labor and overhead per pound of deposited weld metal can now be
Carbon & Low Alloy
calculated as $18.66/lb.
GMAW,GTAW,SAW
Line 2 - Electrode Cost Per Pound - $.57 (given)
Deposition Efficiency - From the shielded metal arc welding deposition table in
Lesson 7
Flux Cored Arc Figure 9 = 74.6%. Since this is a coated electrode, the efficiency must be adjusted
Electrodes Carbon
for stub loss by the formula following Figure 3. We know that the electrode length is
Low Alloy Steels
14" and the stub loss is 2" (given). The formula becomes:
Efficiency - Stub Loss = (14-2) x .746 ÷ 14 = .639 or 63.9%
Lesson 8 63.9% is the adjusted efficiency to be used in Line 2.
Hardsurfacing The cost of the electrode per pound of deposited weld metal can now be calculated
Electrodes
as $.89/lb.
Lesson 9 Line 3 - Not applicable for coated electrodes.

Estimating &
Comparing Weld
Metal Costs Line 4 - Not applicable for coated electrodes.
Lesson 10
Filler Metals

Lesson 1
Welding
EXAMPLE 1
Lesson 2 WELD METAL COST WORKSHEET
Common Electric COST PER POUND OF DEPOSITED WELD METAL
Arc Welding
Processes
1.
30.00 30.00
LABOR & LABOR & OVERHEAD COST/HR = = = 18.66
Lesson 3 OVERHEAD DEPOSITION OPERATING 5.36 x .30 1.608
Covered Electrodes RATE (LBS/HR) x FACTOR
for Welding
Mild Steels
2. .57
ELECTRODE ELECTRODE COST/LB = = .89
DEPOSITION EFFICIENCY .639
Lesson 4
Covered Electrodes 3. GAS FLOW RATE
GAS N A
for Welding Low (CU FT/HR) x GAS COST/CU FT = = =
Alloy Steels DEPOSITION RATE (LBS/HR)
4. X 1.4 N A
FLUX FLUX COST/LB x 1.4 = = =
Lesson 5 DEPOSITION EFFICIENCY
for Stainless Steels 5. COST/kWh x VOLTS x AMPS =
.045 x 25 x 250
= 281.25 = .052
POWER 1000 x DEPOSITION RATE 1000 x 5.36 5,360
Lesson 6
6. TOTAL COST PER LB. OF SUM OF 1 THROUGH 5 ABOVE $ 19.60
Carbon & Low Alloy DEPOSITED WELD METAL
GMAW,GTAW,SAW
COST PER FOOT OF DEPOSITED WELD METAL

Lesson 7
Flux Cored Arc
7.
Electrodes Carbon COST PER POUND POUNDS PER
= 19.60x .814 = $15.95
Low Alloy Steels OF DEPOSITED X FOOT OF
WELD METAL WELD JOINT
Lesson 8 COST OF WELD METAL - TOTAL JOB

Hardsurfacing
Electrodes 8.
TOTAL FEET X COST PER = 1,280x 15.95 = $20,422
OF WELD FOOT
Lesson 9
Estimating &
Comparing Weld
Lesson 10
Filler Metals

Lesson 1
Welding
Line 5 - Cost of Power - $ .045/kWh (given).
Volts & Amperes - 25V and 250A (given).
Lesson 2 Constant - The 1,000 already entered, is a constant necessary to convert to
Common Electric
watt-hours.
Arc Welding
Processes Deposition Rate - 5.36 lbs/hr as used in Line 1.
The cost of electrical power to deposit one pound of weld metal can now be
calculated as $.052.
Lesson 3
Covered Electrodes
for Welding Line 6 - Total Lines 1, 2, and 5 to find the total cost of depositing one pound weld
Mild Steels
metal. The total of $19.60.
Lesson 4 9.4.2 Calculating The Cost Per Foot of Deposited Weld Metal
Covered Electrodes
for Welding Low
Alloy Steels Calculating the weight of weld metal requires that we consider the following items.
a. Area of the cross-section of the weld.

Lesson 5
b. Length of the weld.
c. Volume of the weld in cubic inches.
d. Weight of the weld metal per cubic inch.

Lesson 6
Carbon & Low Alloy 9.4.2.1 In the fillet weld show in Figure 13, we know that the area of the cross-section (the
GMAW,GTAW,SAW triangle) is equal to one-half the base times the height, the volume of the weld is equal to the
area times the length, and the weight of the weld then, is the volume times the weight of the
material (steel) per cubic inch.
Lesson 7
Flux Cored Arc
Electrodes Carbon 9.4.2.2 We can then write the formula:
Low Alloy Steels
Weight of Weld Metal = ½ x Base x Height x Length x Weight of Material
Lesson 8 Substituting the values from Figure 13, we have:

Hardsurfacing Wt/Ft = .5 x .5 x .5 x 12 x .283 = .4245 lbs
Electrodes
9.4.2.3 Weights may vary depending on the density of the particular material you are at-
tempting to calculate. The chart in Figure 14 will eliminate the need for these calculations for
Lesson 9 steel fillet and butt joints, since it lists the weight per foot directly.
Estimating &
Comparing Weld
Metal Costs 9.4.2.4 Estimating the weight per foot of a weld using the chart, requires that you make a
drawing of the weld joint to exact scale, and dimension the leg lengths, root gap, thickness,
angles and other pertinent measurements as shown in Figure 15. Divide the cross-section of
Lesson 10 the weld into right triangles and rectangles as shown. Sketch in the reinforcement, i.e., the
Filler Metals

Lesson 1
Welding
Lesson 2
Common Electric
Arc Welding
Processes (A) 1/2"
HEIGHT
Volume of Weld = 1/2 B x A x 12

Lesson 3 1/2" Weight of Steel = .283 lb per cu. in.
Weight of Weld = 1/2 (1/2) x 1/2 x 12 x .283
Covered Electrodes (B) BASE = .424 lbs.
for Welding
Mild Steels
CALCULATING THE WEIGHT PER FOOT OF A FILLET WELD
FIGURE 13
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
domed portion above or below the surface of the plate, where required. The reinforcement
Lesson 5 should extend slightly beyond the edges of the joint. Measure the length and height of the
for Stainless Steels reinforcement and note them on your drawing. The reinforcement is only an approximation
because the contour cannot be exactly controlled in welding. Refer to the weight tables in
Figure 14 for the weights per foot of each of the component parts of the weld, as sketched.
Lesson 6 The sum of the weights of all the components is the total weight of the weld, per foot as shown
Carbon & Low Alloy
in Figure 15A.
GMAW,GTAW,SAW
Line 7 - The total cost per pound as determined in Line 6 is entered, and multi-
plied by the weight per foot as determined in Figure 14.
Lesson 7
Flux Cored Arc 9.4.3 Calculating the Cost of Weld Metal - Total Job
Electrodes Carbon
Low Alloy Steels
Line 8 - The cost of the weld for the total job is determined by multiplying the total
feet of weld (given) by the cost per foot as determined in Line 7.
Lesson 8
Hardsurfacing
Electrodes 9.5 COST CALCULATIONS - EXAMPLE 2
Calculate the total cost of depositing 1,280 ft of weld metal using the CO2 shielded, flux cored
Lesson 9 welding process in the double V-groove joint shown in Figure 14 using the following data.
Estimating &
Comparing Weld 1. Electrode - 3/32”, E70T-1 @ 31 volts, 450 amps.
Metal Costs
2. Labor and Overhead - $30.00/hr.
3. Deposition Rate - 15 lbs/hr. From Table in Figure 10.
Lesson 10 4. Operating Factor - 45% (.45). Average from Figure 2.

Filler Metals

V-GROOVE
Lesson 1
Welding
WEIGHT PER FOOT OF WELD METAL FOR FILLET WELDS AND
ELEMENTS OF COMMON BUTT JOINTS (lbs/ft)
STEEL
Lesson 2
Common Electric
Arc Welding
Processes S S S
G G
C C
Lesson 3 T B B B
Covered Electrodes
B
T A T T A T
for Welding
Mild Steels
C C
EQUAL LEG
SINGLE SINGLE
FILLETS
BEVEL V-GROOVE
(USE 45°COLUMN)
Lesson 4
Covered Electrodes
for Welding Low S
S S S S
Alloy Steels G G
C C C H
B B B
T T B B
A
Lesson 5 T A
T T
Welding Filler Metals B B B T
for Stainless Steels C
C
DOUBLE DOUBLE SINGLE V
REINFORCEMENT
BEVEL NO GAP
Lesson 6
lbs./ft. of Rectangle A lbs./ft. of Triangle B lbs./ft. Reinforcement C
Carbon & Low Alloy
T G S H
Inches 1/16" 1/8" 3/16" 1/4" 3/8" 1/2" 5° 10° 15° 22 1/2° 30° 45° 1/16" 1/8" 3/16" 1/4"
GMAW,GTAW,SAW
1/8 .027 .053 .080 .106 .159 .212 .002 .005 .007 .011 .015 .027
3/16 .040 .080 .119 .159 .239 .318 .005 .011 .016 .025 .035 .060 .027
Lesson 7 1/4 .053 .106 .159 .212 .318 .425 .009 .019 .028 .044 .061 .106 .035
Flux Cored Arc
5/16 .066 .133 .199 .265 .390 .531 .015 .029 .044 .069 .096 .166 .044 .884
Electrodes Carbon
3/8 .080 .159 .239 .318 .478 .637 .021 .042 .064 .099 .138 .239 .053 .106
Low Alloy Steels 7/16 .091 .186 .279 .371 .557 .743 .028 .057 .087 .129 .188 .325 .062 .124
.106 .212 .318 .425 .637 .849 .037 .075 .114 .176 .245 .425 .071 .141 .212
9/16 .119 .239 .358 .478 .716 .955 .047 .095 .144 .223 .311 .451 .080 .159 .239
5/8 .133 .265 .398 .531 .796 1.061 .058 .117 .178 .275 .383 .664 .088 .177 .265 .354
Lesson 8 11/16 .146 .292 .438 .584 .876 1.167 .070 .142 .215 .332 .464 .804 .097 .195 .292 .389
3/4 .159 .318 .478 .637 .995 1.274 .084 .169 .256 .396 .552 .956 .106 .212 .318 .424
Hardsurfacing
Electrodes 13/16 .172 .345 .517 .690 1.035 1.380 .098 .198 .301 .464 .648 1.121 .115 .230 .345 .460
7/8 .186 .371 .557 .743 1.114 1.486 .114 .230 .349 .538 .751 1.300 .124 .248 .371 .495
15/16 .199 .398 .597 .796 1.194 1.592 .131 .263 .400 .618 .863 1.493 .133 .266 .398 .530
1 .212 .425 .637 .849 1.274 1.698 .149 .300 .456 .703 .981 1.698 .141 .283 .424 .566
Lesson 9 .239 .478 .716 .955 1.433 1.910 .188 .379 .577 .890 1.241 2.149 .159 .318 .477 .637
Estimating & 1 1/4 .265 .531 .796 1.061 1.592 2.123 .232 .468 .712 1.099 1.532 2.653 .177 .354 .531 .707
Comparing Weld 1 3/8 .292 .584 .876 1.167 1.751 2.335 .281 .567 .861 1.330 1.853 3.210 .195 .389 .584 .777
1 1/2 .318 .637 .955 1.274 1.910 2.547 .334 .674 1.023 1.582 2.206 3.821 .212 .424 .637 .849
Metal Costs
1 5/8 .345 .690 1.035 1.380 2.069 2.759 .393 .792 1.201 1.857 2.589 4.484 .230 .460 .690 .920
1 3/4 .371 .743 1.114 1.486 2.229 2.972 .455 .918 1.393 2.154 3.002 5.200 .248 .495 .743 .990
.390 .796 1.194 1.592 2.388 3.184 .523 1.053 1.599 2.473 3.447 5.970 .266 .531 .796 1.061
2 .425 .649 1.274 1.698 2.547 3.396 .594 1.197 1.820 2.813 3.921 6.792 .283 .566 .849 1.132
Lesson 10
Reliability of Welding 2 1/4 .478 .955 1.433 1.910 2.865 3.821 .752 1.516 2.303 3.561 4.963 8.596 .318 .637 .955 1.273
Filler Metals .530 1.061 1.592 2.123 3.184 4.245 .928 1.871 2.844 4.396 6.127 10.613 .354 .707 1.061 1.415
2 3/4 .584 1.167 1.751 2.335 3.502 4.669 1.123 2.264 3.441 5.319 7.414 12.841 .389 .778 1.167 1.556
3 .636 1.274 1.910 2.547 3.821 5.094 1.337 2.695 4.095 6.330 8.823 15.282 .424 .849 1.273 1.698
FIGURE 14
Lesson 1
Welding 22.5° 22.5°
45°
Lesson 2 1/ C
7/8"
16"
Common Electric C
Arc Welding
Processes B 1/2"
5/8" B 1/2"
A 1"
B
Lesson 3
Covered Electrodes 1/8"
for Welding A B C
1/16"
lbs./ft.
Mild Steels 1/2"
A= .265 lbs./ft.
B= .425
C= .124 B = .176 x 4 = .704
TOTAL WEIGHT/FT. .814 lbs C = .071 x 2 = .142
Lesson 4 TOTAL WEIGHT/FT. .846 lbs
Covered Electrodes
for Welding Low ESTIMATING WELD METAL WEIGHT
Alloy Steels FIGURE 15
Lesson 5 5. Electrode Cost - $.80/lb (from supplier).

Welding Filler Metals 6. Deposition Efficiency - 86% (.86) From Table in Figure 10.
7. Gas Flow Rate - 45 cubic feet per hour. From Figure 7.
8. Gas Cost - $.03/cubic foot (from supplier).
Lesson 6 9. Cost of Power - $.045/kWh.

Carbon & Low Alloy 10. Wt/Ft of Weld - From Figure 15B = .846 lbs/ft.
GMAW,GTAW,SAW These values are shown inserted into the formulas on the Weld Metal Cost Worksheet in
Figure 16.
Lesson 7
Flux Cored Arc 9.6 COMPARING WELD METAL COSTS
Electrodes Carbon
Low Alloy Steels
It is interesting to note that the amount of weld metal deposited in Example 1 and Example 2 is
almost the same, while the total cost of depositing the weld metal is three times higher in
Example 1 as shown below. This is because the flux cored process has a higher deposition
Lesson 8
Hardsurfacing rate, efficiency and operating factor and also allows a tighter joint due to the deep penetrating
Electrodes characteristics of the process.
Example 1 - 1,280 ft x .814 lbs/ft = 1,041.9 lbs at $13,939

Lesson 9
Estimating & Example 2 - 1,280 ft x .846 lbs/ft = 1,082.9 lbs at $ 4,352
Comparing Weld
Metal Costs 9.6.0.1 When comparing welding processes, all efforts should be made to assure that you
use the proper welding current for the electrode or wire in the position in which the weld must
be made. As an example, consider depositing a given size fillet weld in the vertical-up posi-
Lesson 10
Filler Metals

Lesson 1
Welding
EXAMPLE 2
Lesson 2 WELD METAL COST WORKSHEET
Common Electric COST PER POUND OF DEPOSITED WELD METAL
Arc Welding
Processes
1.
30.00 30.00
LABOR & LABOR & OVERHEAD COST/HR = = = 4.44
Lesson 3 OVERHEAD DEPOSITION OPERATING 6.75
15 x .45
Covered Electrodes RATE (LBS/HR) x FACTOR
for Welding
Mild Steels
2. .80
ELECTRODE ELECTRODE COST/LB = = .93
DEPOSITION EFFICIENCY .86
Lesson 4
Covered Electrodes 3. GAS FLOW RATE
GAS 45 x .03 1.35
for Welding Low (CU FT/HR) x GAS COST/CU FT = = = .09
Alloy Steels DEPOSITION RATE (LBS/HR) 1 5 1 5
4. x 1.4 NA
FLUX FLUX COST/LB x 1.4 = = =
Lesson 5 DEPOSITION EFFICIENCY
for Stainless Steels 5. COST/kWh x VOLTS x AMPS .045 x 31 x 450 627.75 .042
= = =
POWER 1000 x DEPOSITION RATE 1000 x 15 15,000
Lesson 6 TOTAL COST PER LB. OF

6. SUM OF 1 THROUGH 5 ABOVE $ 5.51
Carbon & Low Alloy DEPOSITED WELD METAL
GMAW,GTAW,SAW
COST PER FOOT OF DEPOSITED WELD METAL

Lesson 7
Flux Cored Arc
7.
Electrodes Carbon COST PER POUND POUNDS PER
= 5.51 x .846 = $4.66
Low Alloy Steels OF DEPOSITED X FOOT OF
WELD METAL WELD JOINT
Lesson 8 COST OF WELD METAL - TOTAL JOB

Hardsurfacing
Electrodes 8.
TOTAL FEET COST PER = 1,280x 4.66 = $5,965
X
OF WELD FOOT
Lesson 9
Estimating &
Comparing Weld
Lesson 10
Filler Metals

Lesson 1
Welding
tion by the GMAW process and FCAW process semi-automatically. In both processes the
welding current and voltage must be lowered to weld out-of-position, and in GMAW, the short
Lesson 2 circuiting arc transfer must be used. Example 3 compares the weld metal cost per pound
Common Electric
deposited by these processes, using the proper current and voltage for depositing a ¼” fillet
Arc Welding
Processes weld on ¼” plate, vertically up.
Note: The cost of electrical power is comparable in all processes and therefore, can be eliminated as a factor.
Lesson 3
Covered Electrodes 9.6.1 Example 3
for Welding
Mild Steels
FCAW GMAW
Electrode Type - .045” dia. E71T-1 .045” dia. ER70S-3

Lesson 4
Covered Electrodes Labor & Overhead - $30.00/hr $30.00/hr
for Welding Low
Alloy Steels Welding Current - 180 amperes 125 amperes
Deposition Rate - 4.9 lbs/hr (Fig. 9) 2.8 lbs/hr (Fig. 10)
Operating Factor - 45% (Fig. 2) 50% (Fig. 2)

Lesson 5
Welding Filler Metals Electrode Cost - $1.44/lb $.66/lb
Deposition Efficiency - 85% (Fig. 9) 96% (Fig. 6)
Gas Flow Rate - 35 cfh (Fig. 7) 35 cfh (Fig. 7)

Lesson 6
Gas Cost Per Cu. Ft. - $.03 CO2 $.11 75% Ar/25% CO2
Carbon & Low Alloy
GMAW,GTAW,SAW
This data is tabulated in the chart in Figure 17.
Lesson 7 9.6.1.1 As you can see, the cost of depositing the weld metal is about 33% less using the
Flux Cored Arc
Electrodes Carbon Flux Cored Arc Welding process. Since there is no slag to help hold the vertical weld puddle
Low Alloy Steels in the GMAW process, the welding current with solid wire must be lowered considerably. This,
of course, lowers the deposition rate, and since labor and overhead is the largest factor in-
volved, it substantially raises deposition costs. In the flat or horizontal position, where the
Lesson 8 welding current on the solid wire would be much higher, the cost difference would be consider-
Hardsurfacing
Electrodes ably less pronounced.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
The following information/variables must be determined prior to completing calculations:

(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation
Lesson 2 Flux Cored Arc Welding Gas Metal Arc Welding
Common Electric E71T-1 .045 Dia. at 180 Amps (3)
ER70S-3 .045 Dia. at 125 Amps (4)
Actual Labor & O/H Rate for your Customer
Arc Welding $ 30.00 Actual Labor & O/H Rate for your Customer $ 30.00
Deposition Rate in Pounds per Hour
Processes Operating Factor
4.9 Deposition Rate in Pounds per Hour 2.8
45% Operating Factor 50%
Electrode Cost per Pound
$ 1.44 Electrode Cost per Pound $ 0.66
Deposition Efficiency
85% Deposition Efficiency 96%
Gas Type
Lesson 3 Gas Flow Rate
CO2 Gas Type 75% Ar/25% CO2
Covered Electrodes 35 Gas Flow Rate 30
Gas Cost per Cubic Foot
$ 0.03 Gas Cost per Cubic Foot $ 0.11
for Welding Equipment Cost
$ -
Mild Steels Prepared For: NAME INFO Customer Name: NAME INFO Date: Result
(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation (Cost
Reduction )
Formulas for Calculating Flux Cored Arc Welding Gas Metal Arc Welding
Lesson 4 Cost
Cost per Pound Deposited Weld Metal E71T-1 .045 Dia. at 180 Amps ER70S-3 .045 Dia. at 125 Amps Increase
Covered Electrodes
for Welding Low Labor& = Labor & Overhead Cost /Hr = $30.00 = $30.00 = $13.605 $30.00 = $30.00 = $21.429 ($7.823 )
Alloy Steels Overhead Deposition
X
Operating 4.9 X 0.45 = 2.205 2.8 X 0.5 = 1.4
Rate (lbs / hr) Factor
Electrode Electrode Cost/lb = 1.44 = 1.694 0.66 = 0.688 $1.007

Lesson 5 Deposition Efficiency 0.85 0.96
Welding Filler Metals Gas Type = CO2 Gas Type = 75% Ar/25% CO2
for Stainless Steels Gas
Gas Flow Rate (Cuft/hr)
X Gas Cost/Cu ft. = 35 X 0.03 = 1.05 = 0.214 3 0 X 0.11 = 3.3 = 1.179 ($0.964 )
Deposition Rate (lbs&/hr) 4.9 2.8
Total Variable Cost/lb Total Variable Cost/lb

Lesson 6 Sum of the Above
Deposited Weld Metal = $15.514 Deposited Weld Metal = $23.295 ( $7.781)
Carbon & Low Alloy T otal
GMAW,GTAW,SAW
Lesson 7 9.7 OTHER USEFUL FORMULAS

Flux Cored Arc
Electrodes Carbon
The information discussed below will assist you in making other useful calculations:
Low Alloy Steels
TOTAL POUNDS OF ELECTRODES REQUIRED (REF. EXAMPLE 1)

Lesson 8
Hardsurfacing Wt/Ft of Weld x No. of Ft of Weld
Electrodes Total Pounds =
Lesson 9 .814 x 1,280

Estimating & Substituting the values from Example 1: = 1,631 lbs
Comparing Weld .630
Metal Costs
WELDING TIME REQUIRED (REF. EXAMPLE 1)
Lesson 10
Wt/Ft of Weld x Ft of Weld
Reliability of Welding Welding Time =
Filler Metals Deposition Rate x Operating Factor
.814 x 1,280 1,042

Substituting the values in Example 1: = = 648 Hrs.
5.36 x .30 1.608

Current
Lesson 1 Chapter
The Basics of Arc LESSON IX Table of
Welding Contents
The following information/variables must be determined prior to completing calculations:
(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation
Lesson 2 Flux Cored Arc Welding Gas Metal Arc Welding
Common Electric E71T-1 .045 Dia. at 180 Amps (3)
ER70S-3 .045 Dia. at 125 Amps (4)
Actual Labor & O/H Rate for your Customer
Arc Welding $ 30.00 Actual Labor & O/H Rate for your Customer $ 30.00
Deposition Rate in Pounds per Hour
Processes Operating Factor
4.9 Deposition Rate in Pounds per Hour 2.8
45% Operating Factor 50%
Electrode Cost per Pound
$ 1.44 Electrode Cost per Pound $ 0.66
Deposition Efficiency Go To Test
85% Deposition Efficiency 96%
Gas Type
Lesson 3 Gas Flow Rate
CO2 Gas Type 75% Ar/25% CO2
Covered Electrodes 35 Gas Flow Rate 30
Gas Cost per Cubic Foot
$ 0.03 Gas Cost per Cubic Foot $ 0.11 Print
for Welding Equipment Cost
$ -
Mild Steels Prepared For: NAME INFO Customer Name: NAME INFO Date: Result
(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation (Cost
Reduction )
Formulas for Calculating Flux Cored Arc Welding Gas Metal Arc Welding
Lesson 4 Cost
Cost per Pound Deposited Weld Metal E71T-1 .045 Dia. at 180 Amps ER70S-3 .045 Dia. at 125 Amps Increase Glossary
Covered Electrodes
for Welding Low Labor& = Labor & Overhead Cost /Hr = $30.00 = $30.00 = $13.605 $30.00 = $30.00 = $21.429 ($7.823 )
Alloy Steels Overhead Deposition
X
Operating 4.9 X 0.45 = 2.205 2.8 X 0.5 = 1.4
Rate (lbs / hr) Factor
Electrode Electrode Cost/lb = 1.44 = 1.694 0.66 = 0.688 $1.007

Lesson 5 Deposition Efficiency 0.85 0.96
Welding Filler Metals Gas Type = CO2 Gas Type = 75% Ar/25% CO2
for Stainless Steels Gas
Gas Flow Rate (Cuft/hr)
X Gas Cost/Cu ft. = 35 X 0.03 = 1.05 = 0.214 3 0 X 0.11 = 3.3 = 1.179 ($0.964 )
Deposition Rate (lbs&/hr) 4.9 2.8
Turn Pages
Total Variable Cost/lb Total Variable Cost/lb
Lesson 6 Sum of the Above
Deposited Weld Metal = $15.514 Deposited Weld Metal = $23.295 ( $7.781)
Carbon & Low Alloy T otal
GMAW,GTAW,SAW
Lesson 7 9.7 OTHER USEFUL FORMULAS Search

Flux Cored Arc Chapter
Electrodes Carbon (Faster
The information discussed below will assist you in making other useful calculations: Download)
Low Alloy Steels
TOTAL POUNDS OF ELECTRODES REQUIRED (REF. EXAMPLE 1) Search

Document
Lesson 8 (Slower
Hardsurfacing Wt/Ft of Weld x No. of Ft of Weld Download)
Electrodes Total Pounds =
Lesson 9 .814 x 1,280

Estimating & Substituting the values from Example 1: = 1,631 lbs
Comparing Weld .630
Metal Costs
WELDING TIME REQUIRED (REF EXAMPLE 1)
WELDING TIME REQUIRED (REF. EXAMPLE 1)
Lesson 10
Wt/Ft of Weld x Ft of Weld
Reliability of Welding Welding Time =
Filler Metals Deposition Rate x Operating Factor
.814 x 1,280 1,042

Substituting the values in Example 1: = = 648 Hrs.
5.36 x .30 1.608

Lesson 1
Welding
9.8 AMORTIZATION OF EQUIPMENT COSTS
Calculations show that you can save $7.00 per pound of deposited weld metal by switching
Lesson 2
Common Electric from E7018 electrodes and the SMAW process to an ER70S0-3 solid wire using the GMAW
Arc Welding process. However, the cost of the necessary equipment (power source, wire feeder and gun)
Processes
is $2,800. How long will it take to amortize or regain the cost of the equipment knowing that
the deposition rate of the ER70S-3 is 7.4 lbs/hr and the operating factor of the GMAW process
Lesson 3 is 50%? The formula is:
Covered Electrodes
for Welding
Mild Steels Equipment Cost
$ Savings/Lb
÷ (Deposition Rate x Operating Factor) = Man Hrs
Lesson 4
Covered Electrodes 2,800
for Welding Low Substituting the values in the formula:
7.00 ÷ (7.4 x .50) = Man Hrs
Alloy Steels
400 ÷ 3.7 = Man Hrs

Lesson 5
for Stainless Steels If we divide 108 into eight hour days (108 ÷ 8 = 13.5) the deposited weld metal savings of one
man working an eight hour day for 13-1/2 days will pay for the cost of the equipment.
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
BASIC
Covered Electrodes
Mild Steels
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6 LESSON X
Carbon & Low Alloy
Steel Filler Metals - RELIABILITY OF
GMAW,GTAW,SAW
WELDING FILLER METALS
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON X
Lesson 2
RELIABILITY OF WELDING FILLER METALS
Common Electric
Arc Welding
10.1 INTRODUCTION ...................................................................................... 1

Lesson 3
Covered Electrodes
for Welding 10.2 CODES, SPECIFICATIONS, AND STANDARDS .............................. 1
Mild Steels
10.3 THE AMERICAN WELDING SOCIETY ................................................ 2
10.3.1 AWS Filler Metal Specifications ............................................................... 2
Lesson 4
10.3.2 AWS Structural Code - Steel .................................................................... 3
Covered Electrodes
for Welding Low
Alloy Steels 10.4 THE AMERICAN SOCIETY FOR TESTING AND MATERIALS ...... 4
10.5 AMERICAN SOCIETY OF MECHANICAL ENGINEERS .................. 4

Lesson 5
Welding Filler Metals 10.6 SHIP CLASSIFICATION SOCIETIES ................................................... 5
for Stainless Steels 10.6.1 The American Bureau of Shipping ........................................................... 5
10.6.2 Lloyd’s Register of Shipping ..................................................................... 7
10.6.3 Det Norske Veritas .................................................................................... 7
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 10.7 MILITARY SPECIFICATIONS ................................................................. 8
GMAW,GTAW,SAW
10.8 STATE HIGHWAY ELECTRODE CERTIFICATION ........................... 9
Lesson 7 10.9 TESTING PROCEDURES ...................................................................... 9

Flux Cored Arc 10.9.1 Chemical Composition Analysis Test ...................................................... 10
Electrodes Carbon
Low Alloy Steels 10.9.2 Soundness Test, All-Weld-Metal Tension Test and Impact Test ............ 10
10.9.3 Coating Moisture Test ................................................................................ 13
10.9.4 Guided Bend Tests .................................................................................... 13
Lesson 8 10.9.5 Ferrite Test .................................................................................................. 15
Hardsurfacing
Electrodes 10.9.6 Fillet Weld Test ........................................................................................... 16
10.10 CERTIFICATION OF ELECTRODES ................................................... 17
Lesson 9 10.10.1 Typical Properties Certification ................................................................ 17

Estimating & 10.10.2 Actual Certifications ................................................................................... 17
Comparing Weld
Metal Costs 10.11 QUALITY ASSURANCE ......................................................................... 19
Appendix A - TEST QUESTIONS .................................................................................. 26

Lesson 10
Filler Metals

Lesson 1
The Basics of Arc LESSON X
Welding
RELIABILITY OF WELDING FILLER METALS
Lesson 2
Common Electric
Arc Welding
Processes
10.1 INTRODUCTION
Lesson 3 Producing a weld by the arc welding process has often been compared to steelmaking on a
Covered Electrodes very small scale. The weld puddle is molten for a very short time and during that time, a
for Welding
Mild Steels number of reactions must take place between the base plate, the filler metal, and the
electrode coating or shielding gas ingredients. These reactions must result in predictable
mechanical properties and chemical composition of the weld metal produced by each of
Lesson 4
Covered Electrodes the great number of filler materials available. Reliable welding filler metals are the result of
for Welding Low the proper formulation, adherence to certain codes and specifications, and the result of a
Alloy Steels
good quality assurance program.
Lesson 5 10.2 CODES, SPECIFICATIONS AND STANDARDS

The wide use of welding as a fabricating method requires that certain controls be exercised
to assure the safety and protection of persons and property exposed to structures and
Lesson 6 equipment utilizing welded joints. As a result, various codes, specifications and standards
Carbon & Low Alloy have been established by technical societies and professional organizations to assure safe,
sound welds. Among other things, these groups specify or recommend the base metal
GMAW,GTAW,SAW
requirements, joint design, filler metal, welding procedures, operator qualifications, required
weld tests, testing methods, and inspection of welds.
Lesson 7
Flux Cored Arc
Electrodes Carbon 10.2.0.1 The professional technical societies or organizations have no way of enforcing
Low Alloy Steels the codes, specifications or standards that they prepare. However, in many instances,
governing bodies of municipalities, counties, states or federal agencies may adopt all or
part of these documents as law. Private industry may require that work performed under
Lesson 8
contract will conform to one or more of these codes or specifications, and therefore, they
Hardsurfacing
Electrodes become part of a legal document. Lastly, purchase orders issued for welding materials
may state that the terms are to meet a particular code or specification, and as such, these
purchase orders have legal implications.
Lesson 9
Estimating & 10.2.0.2 The following is a description of the major societies and organizations whose
Comparing Weld
Metal Costs specifications and codes are widely used in the welding filler metals industry.
Lesson 10
Filler Metals

Lesson 1
Welding
10.3 THE AMERICAN WELDING SOCIETY (AWS)
Lesson 2 The AWS publishes a number of specifications, standards and codes that have been
Common Electric adopted by many governing bodies and industries. The AWS may be considered to be the
Arc Welding
basic source of welding and welding engineering information in the USA. Many other
Processes
codes and specifications will include or refer to various AWS Filler Metal Specifications.
Electrode and welding filler metal manufacturers assign the appropriate AWS Classification
Lesson 3 to their products wherever possible, as a means of standardization, according to the AWS
Covered Electrodes
for Welding Filler Metal Specifications. The specifications prescribe the classification requirements
Mild Steels including such items such as chemical composition of the weld metal, radiographic (X-ray)
soundness tests, weld metal tension tests, impact tests, bend tests, and fillet weld tests
Lesson 4 where applicable. The following is a complete list of the AWS Filler Metal Specifications for
Covered Electrodes ferrous and non-ferrous materials.
for Welding Low
Alloy Steels
10.3.1 AWS Filler Metal Specifications
Lesson 5
Welding Filler Metals Specification No. Description
A5.1-91 Carbon Steel Covered Arc Welding Electrodes
A5.2-92 Iron & Steel Oxy Fuel Gas Welding Rods
Lesson 6
A5.3-91 Aluminum & Aluminum Alloy Covered Electrodes
Carbon & Low Alloy
Steel Filler Metals - A5.4-92 Corrosion Resisting Chromium & Chromium-Nickel Steel
GMAW,GTAW,SAW Covered Electrodes
A5.5-96 Low Alloy Steel Covered Arc Welding Electrodes
Lesson 7 A5.6-84 Copper & Copper-Alloy Covered Electrodes
Flux Cored Arc
A5.7-84 Copper & Copper-Alloy Bare Welding Rods & Electrodes
Electrodes Carbon
Low Alloy Steels A5.8-92 Brazing Filler Metals
A5.9-93 Corrosion-Resisting Chromium & Chromium-Nickel Steel
Bare & Composite Metal Cored &
Lesson 8 Stranded Electrodes & Welding Rods
Hardsurfacing
Electrodes A5.10-92 Aluminum & Aluminum Alloy Bare Welding Rods & Electrodes
A5.11-90 Nickel & Nickel Alloy Covered Welding Electrodes
A5.12-92 Tungsten Arc Welding Electrodes
Lesson 9 A5.13-80 Solid Surfacing Welding Rods & Electrodes
Estimating &
Comparing Weld A5.14-89 Nickel & Nickel-Alloy Bare Welding Rods & Electrodes
Metal Costs A5.15-90 Welding Rods & Covered Electrodes for Welding Cast Iron
A5.16-90 Titanium & Titanium Bare Welding Rods & Electrodes
Lesson 10
Filler Metals

Lesson 1
Welding
Specification No. Description
Lesson 2 A5.17-89 Carbon Steel Electrodes & Fluxes for Submerged Arc
Common Electric Welding
Arc Welding
Processes A5.18-93 Carbon Steel Filler Metals for Shielded Arc Welding
A5.19-93 Magnesium Alloy Welding Rods & Bare Electrodes
A5.20-95 Carbon Steel Electrodes for Flux Cored Arc Welding
Lesson 3
A5.21-80 Composite Surfacing Welding Rods & Electrodes
Covered Electrodes
for Welding A5.22-95 Flux Cored Corrosion Resistant Chromium &
Mild Steels Chromium-Nickel Steel Electrodes
A5.23-90 Low Alloy Steel Electrodes & Fluxes for Submerged Arc
Lesson 4 Welding
Covered Electrodes A5.24-90 Zirconium & Zirconium Alloy Bare Welding Rods &
for Welding Low
Alloy Steels Electrodes
A5.25-91 Consumables for Electroslag Welding of Carbon & High
Strength Low Alloy Steels
Lesson 5 A5.26-91 Consumables for Electrogas Welding of Carbon & High
for Stainless Steels Strength Low Alloy Steels
A5.27-85 Copper and Copper Alloy Rods for Oxyfuel Gas Welding
A5.28-96 Low Alloy Steel Filler Metals for Gas Shielded Arc
Lesson 6 Welding
Carbon & Low Alloy A5.29-98 Low Alloy Steel Electrodes for Flux Cored Arc Welding
GMAW,GTAW,SAW A5.30-79 Consumable Inserts
A5.31-92 Fluxes for Brazing and Braze Welding
Lesson 7
Flux Cored Arc 10.3.1.1 These filler metal specifications also describe the classification requirements
Electrodes Carbon concerning standardization such as electrode size and length, packaging, spooling, mark-
Low Alloy Steels
ing, labeling, and others.
10.3.2 AWS Structural Welding Code - Steel - The AWS Structural Welding Code -
Lesson 8
Steel (AWS D1.1-96) covers the welding requirements applicable to welded steel structures
Hardsurfacing
Electrodes including buildings, bridges, and structures consisting of tubular shaped members. Factors
such as the design of welded connections, workmanship, welding procedure, welding
operator qualification, and inspection requirements are covered in this code. Previous to
Lesson 9
the 1994 issue of this code, it also specified the tensile strength, yield strength, elongation,
Estimating &
Comparing Weld and impact requirements for the low alloy flux cored electrodes, since no AWS Filler Metal
Metal Costs Specification existed for these electrodes. It is required that the user (contractor or fabrica-
tor) conduct tests to show that the low alloy weld metal would meet the mechanical proper-
ties mentioned above per the code.
Lesson 10
Filler Metals

Lesson 1
Welding
10.3.2.1 With the issuance of AWS A5.29-80, Specification for Low Alloy Steel Electrodes
for Flux Cored Arc Welding, the user now need only furnish the electrode manufacturer’s
Lesson 2 certification that his product will meet the classification requirements of the latest edition of
Common Electric
Arc Welding AWS A5.29.
Processes
10.3.2.2 The AWS Structural Welding Code (AWS D1.1-96) does not prescribe such
design details as the location of parts or stress calculations to determine the size of
Lesson 3
load-carrying members in a structure. These details will be covered in a general Building
Covered Electrodes
for Welding Code that might state, “This structure is to conform to the American Institute of Steel
Mild Steels Construction (AISC) Specification for the Design, Fabrication and Erection of Structural
Steel For Buildings, and the AWS Structural Welding Code, AWS D1.1.” In this case, the
Lesson 4 AWS Structural Welding Code becomes a part of a general building code that may be
Covered Electrodes adopted by a governing body.
for Welding Low
Alloy Steels
10.3.2.3 The AWS publishes other specifications, standards and recommended practices
covering the welding of automotive parts, construction equipment, machinery, ships, and
Lesson 5 water storage reservoirs. These, however, are less concerned with filler metal specification
and selection than they are with welding techniques, procedures, and operator qualifica-
tion.
10.4 AMERICAN SOCIETY FOR TESTING AND

Lesson 6
Carbon & Low Alloy MATERIALS (ASTM)
GMAW,GTAW,SAW
The main objectives of the American Society For Testing & Materials are (1) to further the
knowledge of many types of materials, and (2) establish standardized specifications of and
Lesson 7
Flux Cored Arc standardized test methods for these materials.
Electrodes Carbon
Low Alloy Steels 10.4.0.1 The chemical and mechanical tests that apply to welding filler metals, as de-
scribed by the AWS and other professional organizations, are often based on the ASTM
standard testing methods.
Lesson 8
Hardsurfacing
Electrodes 10.5 AMERICAN SOCIETY OF MECHANICAL
ENGINEERS (ASME)
Lesson 9
Estimating & The ASME is instrumental in establishing many codes and specifications. The
Comparing Weld
ASME Boiler & Pressure Vessel Code is of primary importance for welding materials and
Metal Costs
applications. This code is extensive, and is published in several different sections. Those
parts that refer to welding filler metals and welding requirements are:
Lesson 10
Filler Metals

Lesson 1
LESSON X
The Basics of Arc
Welding
Section I. Power Boilers
Section II. Material Specifications
Lesson 2 Section III. Nuclear Vessels
Common Electric
Arc Welding Section IV. Low Pressure Boilers
Processes Section VIII. Unfired Pressure Boilers
10.5.0.1 Section II of the code, in which welding filler metals are specified, states that the
Lesson 3
Covered Electrodes ASME has adopted the AWS Filler Metal Specifications verbatim (word for word). How-
for Welding ever, they do have their own specification designation. For example, AMSE SFA 5.5-96
Mild Steels
Specification for Low Alloy Steel Covered Arc Welding Electrodes is the same as AWS
A5.5-96.
Lesson 4
Covered Electrodes 10.5.0.2 Under Section III of the code, the ASME issues a Quality System Certificate to
for Welding Low
Alloy Steels manufacturers of materials (including welding electrodes and wire) to be used under the
code. This certificate is issued only after an ASME plant audit and the manufacturer’s
entire quality assurance program is approved. Its issuance allows the manufacturer’s
Lesson 5
products to be used in boiler and pressure vessel work, as well as on nuclear applications
for Stainless Steels as specified in the code. Details of the Quality System Certificate will be covered under the
Quality Assurance Section of this lesson.
Lesson 6
Carbon & Low Alloy 10.6 SHIP CLASSIFICATION SOCIETIES
GMAW,GTAW,SAW 10.6.1 The American Bureau of Shipping (ABS) - The ABS is a non-profit, interna-
tional ship classification society. It certifies the structural integrity and mechanical fitness of
Lesson 7 merchant ships, offshore drilling rigs, and other marine structures.
Flux Cored Arc
Electrodes Carbon 10.6.1.1 Annually, the Bureau publishes a listing entitled “Approved Welding Electrodes,
Low Alloy Steels
Wire-Flux and Wire-Gas Combinations.” The approvals of the filler metals are based upon
tests conducted to standards established by the Bureau or by other recognized agencies.
Lesson 8 As requested by the manufacturer, filler metals may be approved to an AWS Filler Metal
Hardsurfacing Specification, and so listed, or approved to an ABS Grade as shown in Figure 1. In either
Electrodes
case, the approval testing must be made in the manufacturer’s facility in the presence of an
ABS representative. The extent of testing will vary, depending on the type of weld for which
Lesson 9 the product is being qualified (fillet or butt), whether the filler material is being initially tested
Estimating & as a new product, being tested annually, or whether the product is being upgraded at the
Comparing Weld
manufacturer’s request.
Metal Costs
10.6.1.2 At the time of annual testing, the manufacturing facilities and quality control
Lesson 10 procedures are subject to inspection also.

Filler Metals

68
Lesson 1
Welding
ABS FILLER METAL MECHANICAL PROPERTY REQUIREMENTS
ORDINARY STRENGTH HIGHER-STRENGTH

ABS FILLER METAL ABS FILLER METAL
Lesson 2
58,300 71,000
Common Electric TENSILE
TO TO
Arc Welding STRENGTH
95,100 psi 95,000 psi
Processes YIELD 44,100 psi
54,000 psi MIN.
STRENGTH MIN.
ELONGATION
22% MIN. 20% MIN.
2"
Lesson 3
Covered Electrodes ABS 3 1Y 2Y 3Y
1 2
GRADE
for Welding
IMPACT
Mild Steels °F
68 32 14 -4 50 32 32 14 -4 14 -4 -22 -40
FT/LBS.
MANUAL 35 35 45 35 40 – 20 40 – 20 50 40 – 20
Lesson 4 SEMI-AUTO
FT/LBS.
Covered Electrodes 25 25 33 25 30 20 – 30 20 – 38 30 20 –
AUTOMATIC
for Welding Low
Alloy Steels Note: Where more than one test temperature is indicated for a specific grade, satisfactory testing according to any
indicated temperature isacceptable.
GRADE NOTATIONS
1,2,3 (see above) T Two pass automatic

Lesson 5 Y Higher strength & impacts S Semi-automatic only
Welding Filler Metals H Low hydrogen electrode A Automatic only
for Stainless Steels M Multi-pass automatic SA Semi-auto or automatic
ABS FILLER METAL GRADING SYSTEM

FIGURE 1
Lesson 6
Carbon & Low Alloy
Steel Filler Metals - 10.6.1.3 Following are the various grade designations as assigned by the ABS.
GMAW,GTAW,SAW
MANUAL ELECTRODES FILLER METAL GRADES (SMAW)
Lesson 7
Ordinary Strength Higher Strength
Flux Cored Arc
Electrodes Carbon 1 1Y
Low Alloy Steels 2 2Y
3 3Y
2H (Low Hydrogen)
Lesson 8
Hardsurfacing 3H (Low Hydrogen)
Electrodes
WIRE AND WIRE-GAS COMBINATION FILLER METAL GRADES (GMAW FCAW)
Lesson 9 Ordinary Strength Higher Strength

Estimating &
Comparing Weld 1SA, 1A, 1T 1YSA, 1YA, 1YT
Metal Costs 2SA, 1A, 1T 2YSA, 2YA, 2YT
3SA, 1A, 1T 3YSA, 3YA, 3YT
Lesson 10
Filler Metals

Lesson 1
Welding
WIRE-FLUX COMBINATION FILLER METAL GRADES (SAW)

Lesson 2
Common Electric Ordinary Strength Higher Strength
Arc Welding
1TM, 1T, 1M 1YTM, 1YT, 1YM
Processes
Lesson 3
Covered Electrodes
for Welding 10.6.1.4 By using the table and grade notations in Figure 1, you can see that the grade
Mild Steels ABS 2YSA signifies: (2Y) a tensile strength in the 71,000-95,000 psi range, a minimum
yield strength of 54,000 psi, and a minimum elongation of 20% in 2 inches, meets the
Lesson 4 impact requirements of 20 ft.-lbs. at -4°F when welded semi-automatically, and 20 ft.-lbs. at
Covered Electrodes 14°F when welded automatically: (SA) the wire-gas combination has been approved for
for Welding Low
Alloy Steels semi-automatic and automatic welding.
10.6.1.5 In the annual ABS Listing, the approved electrode or wire diameter, welding
Lesson 5 position, shielding gas (if applicable) and type of welding current (AC or DC) are also listed.
Each electrode or filler metal must be re-approved annually.
10.6.2 Lloyd’s Register of Shipping (LRS) - Lloyd’s Register of Shipping is a British

ship classification society similar to the ABS. They also publish an annual approved filler
Lesson 6
Carbon & Low Alloy metal listing with test procedures very similar to the ABS.
GMAW,GTAW,SAW 10.6.3 Det Norske Veritas (DNV) - Det Norske Veritas is a Norwegian ship classifica-
tion society that operates very similarly to the American Bureau of Shipping and Lloyd’s
Lesson 7 Register.
Flux Cored Arc
Electrodes Carbon 10.6.3.1 ESAB has a number of filler metals on the approved list of each of the three ship
Low Alloy Steels
classification societies. Since the listings change annually, they do not appear in this
instructional material. Information on the listings of any specific product may be secured by
Lesson 8 contacting the Technical Services Department.

Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
10.7 MILITARY SPECIFICATIONS
Lesson 2 Military specifications are issued by the Department of Defense and it is mandatory that all
Common Electric work performed for that department be covered by the applicable military specification.
Arc Welding
Military specifications are identified by a letter-number designation and the title. An ex-
Processes
ample is: MIL-E-22200/1E - Electrodes, Welding , Mineral Covered, Iron Powder, Low
Hydrogen, Medium and High Tensile Strength, As-Welded or Stress Relieved Applications.
Lesson 3
Covered Electrodes 10.7.0.1 In the example, MIL designates that it is a Military specification. The first letter E
for Welding
Mild Steels stands for Electrode which is the significant word in the title. The number 22200/1 is the
serial number of the specification; the letter E at the end designates the revision letter and
will change as further revisions are made. The underlined portion is the title of the specifi-
Lesson 4
Covered Electrodes cation.
for Welding Low
Alloy Steels 10.7.0.2 A Military specification may cover only one or a number of electrodes or wires.
When the specification includes more than one item, a “type” designation is necessary. As
an example, an E8018-C3 low alloy electrode would be designated as MIL-E-22200/1E,
Lesson 5
Welding Filler Metals MIL 8018-C3.
10.7.0.3 The following is a partial list, along with a brief description, of the more common
military electrode specifications currently in use.
Lesson 6
Carbon & Low Alloy Specification No. Description
GMAW,GTAW,SAW QQ-E-450a Covered Mild Steel Electrodes
MIL-E-13080 Covered Austenitic Steel Electrodes for Armor
Application
Lesson 7
Flux Cored Arc MIL-E-16053L Bare Aluminum Alloy Wires
Electrodes Carbon MIL-E-16589 Covered Chrome-Molybdenum and Corrosion Resisting Steel
Low Alloy Steels
MIL-E-19933 Bare Chrome-Nickel Stainless Steel Wire
MIL-E-21562 Bare Nickel-Alloy Wires
Lesson 8 MIL-E-22200/1F Covered, Iron Powder, Low Hydrogen, Medium and High
Hardsurfacing Tensile Steel Electrodes
Electrodes
MIL-E-22200/2C Covered Electrode, Austenitic Stainless Steel for
Corrosion and High Temperature Service
Lesson 9 MIL-E-22200/3F Covered Electrode, Nickel-Base and Cobalt-Base Alloy

Estimating & MIL-E-22200/4C Covered Electrode, Copper-Nickel Alloy
Comparing Weld
MIL-E-22200/5B Covered, Iron Powder, Low Hydrogen, Low Alloy Steel for
Metal Costs
Hardening & Tempering
MIL-E-22200/6C Covered Electrode, Low Hydrogen, Medium and High Tensile
Lesson 10 Steel
Filler Metals

Lesson 1
Welding
MIL-E-22200/7B Covered Electrode, Molybdenum Alloy Electrodes
MIL-E-22200/8B Covered Electrode, Low Hydrogen, and Low Hydrogen Iron
Lesson 2 Powder Alloy Steels and Corrosion Resisting Steels
Common Electric
Arc Welding MIL-E-22200/10B Covered, Iron Powder, Low Hydrogen, Medium and High
Processes Tensile Steel Electrodes
MIL-E-23765/B (SH) Bare Solid Mild Steel Wires
MIL-E-24403/A (SH) Flux Cored Electrodes
Lesson 3
Covered Electrodes MIL-E-19933E (SH) Bare Solid Chromium and Chromium-Nickel Steels
for Welding
Mild Steels
10.7.0.4 Some military specifications require varying degrees of testing by the manufac-
turer before a filler metal is submitted for use. These tests and testing procedures are
Lesson 4 spelled out in the specification, and when successfully completed, the electrode or wire is
Covered Electrodes
for Welding Low placed upon a Qualified Products List (QPL). Other specifications require the manufacturer
Alloy Steels to submit an affidavit indicating the success of the testing of each specific shipment.
Lesson 5
Welding Filler Metals 10.8 STATE HIGHWAY ELECTRODE CERTIFICATION
Electrodes and filler metals are approved for bridge and highway construction according to
the Federal Highway Administration Requirements. Electrodes are tested, and certification
Lesson 6
Carbon & Low Alloy is renewed annually to those states that maintain an approved list meeting Federal require-
Steel Filler Metals - ments. These listings vary annually, and the manufacturer should be consulted for verifica-
GMAW,GTAW,SAW
tion.
Lesson 7
Flux Cored Arc 10.9 TESTING PROCEDURES
Electrodes Carbon
Low Alloy Steels Test of welding filler metals per the specifications of the various societies, professional
organizations and governing bodies is time-consuming and expensive. However, accurate
testing is an important factor in producing quality welding filler metals. Test plates must be
Lesson 8
welded according to the procedure stated in the specification, which in many instances
Hardsurfacing
Electrodes requires controlled preheat and interpass temperatures. The specimens must be carefully
machined from the proper portion of the test plate and held to very close dimensional
tolerances so that test results will be accurate. The test equipment must be kept in accu-
Lesson 9
rate calibration.
Estimating &
Comparing Weld
Metal Costs 10.9.0.1 The following are brief, partial descriptions of the more common types of tests
required by various specifications and codes. They are shown here to familiarize you with
the methods by which tests are conducted and are not to be construed as complete test
Lesson 10
procedures.
Filler Metals

Lesson 1
Welding
10.9.1 Chemical Composition Analysis Test - A weld pad for determining the chemi-
cal composition of a filler metal must be prepared as shown in Figure 2.
Lesson 2
Common Electric 10.9.1.1 The base metal size and material is specified, and the weld metal is built up in
Arc Welding
layers to the required height or number of passes to assure that the top surface has no
Processes
dilution with the base metal. The welds are deposited in the flat position. After welding, the
top surface is machined or ground smooth to remove all foreign matter. A sample is taken
Lesson 3
from this surface for chemical analysis by a suitable method agreed upon between the
Covered Electrodes
for Welding supplier and the purchaser.
Mild Steels
CHEMICAL COMPOSITION SAMPLE
TAKEN FROM THIS SURFACE
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy SPECIFIED BY NUMBER OF
Steel Filler Metals - LAYERS IN SOME SPECIFICATIONS
GMAW,GTAW,SAW
TYPICAL WELDPAD FOR
CHEMICAL COMPOSITION ANALYSIS
Lesson 7 Figure 2
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels 10.9.2 Soundness (X-Ray) Test, All-Weld-Metal Tension Test and Impact Test - A
test plate is prepared according to the specification with a sufficient number of passes to fill
the groove, a sample of which is shown in Figure 3.
Lesson 8
Hardsurfacing
Electrodes 10.9.2.1 Some specifications require at least one stop and one start in the area of the
weld that is to be radiographed (X-rayed). The specification may also call for the test plate
to be preheated to a certain temperature before the first pass, and also specify an
Lesson 9 interpass temperature. This means that the test plate must be allowed to cool to a certain
Estimating &
Comparing Weld temperature range before the next pass is applied.
Metal Costs
10.9.2.2 After the plate is completely welded, the test plate is prepared for radiographic
examination by machining off the backing strip from the root (bottom) of the weld, and also
Lesson 10
Filler Metals

Lesson 1
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
ALL WELD METAL TENSION SPECIMEN
V-NOTCH IMPACT TEST SPECIMEN
Lesson 7
Flux Cored Arc
DETAILS OF TEST ASSEMBLY FOR SOUNDNESS, TENSILE AND IMPACT TESTS
Electrodes Carbon
Low Alloy Steels Figure 3
Lesson 8 the reinforcement or excess weld metal from the top (face) of the weld. The plate is then
Hardsurfacing
radiographed to check for porosity or inclusions in the weld metal. The specification will
Electrodes
show several degrees and grades of acceptable porosity or inclusions.
10.9.2.3 Porosity and inclusion diagrams, as shown in Figure 4, are usually labeled as
Lesson 9
Estimating & fine, medium, assorted, and large. A representation of fine and large porosity is shown in
Comparing Weld Figure 4. The allowable amount of porosity may vary for different filler metal specifications.
Metal Costs
Lesson 10
Filler Metals

Lesson 1
Welding
Lesson 2
Common Electric
Arc Welding
Processes LARGE POROSITY OR INCLUSIONS
3/64" to 1/16" DIAMETER OR LENGTH
MAXIMUM NUMBER IN ANY 6" OF WELD = 8
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes FINE POROSITY OR INCLUSIONS
1/64" to 1/32" DIAMETER OR LENGTH
for Welding Low MAXIMUM NUMBER IN ANY 6" OF WELD = 30
Alloy Steels
SOUNDNESS TEST POROSITY AND INCLUSION STANDARDS
Figure 4
Lesson 5
for Stainless Steels 10.9.2.4 After the test plate has been radiographed, the all-weld-metal tension specimen,
and the charpy V-notch impact specimen are machined from the center of the plate as
shown in Figure 3. Only the critical dimensions are shown in the sketches, and as you can
Lesson 6
see, they must be held to rather close tolerances to obtain accurate test results.
Carbon & Low Alloy
GMAW,GTAW,SAW 10.9.2.5 The .500± .010" diameter of the tension specimen is all weld metal since it is
machined from the center of the weld. The area of the impact specimens in which the
Lesson 7 notch is machined is all weld metal also.

Flux Cored Arc
Electrodes Carbon 10.9.2.6 The tensile specimen is placed in a tensile testing machine and pulled until it
Low Alloy Steels
fractures. (Refer to Lesson I, "Yield Strength".) The yield strength and ultimate tensile
strength are recorded on the tensile tester. After fracture, the two halves of the broken
specimen are fitted back together in a jig, and the distance between the two center punch
Lesson 8
Hardsurfacing marks is accurately measured. If this distance is now 2.500", it tells us that the specimen
Electrodes has stretched .500" or 25% of its original length before breaking. This figure is recorded as
the elongation in a 2" length of the weld metal specimen.
Lesson 9 10.9.2.7 The five impact specimens are broken in a Charpy Impact Tester, as described in
Estimating &
Comparing Weld Lesson I, "Charpy Impacts", and the energy absorbed in breaking each of them is re-
Metal Costs corded. In calculating the average impact value, the specimens with the highest and low-
est values are discarded. The average value of the three remaining specimens is recorded
as the impact value.
Lesson 10
Filler Metals

Lesson 1
Welding
10.9.3 Coating Moisture Test - The coating moisture test is conducted by removing a
small amount of the coating from the middle portions of three electrodes, all from the same
Lesson 2 can or package. A small measured amount (4 grams) of this coating sample is tested in
Common Electric
Arc Welding sophisticated laboratory apparatus. The method of moisture testing satisfies AWS A5.5-96
Processes and AWS D1.1 Specifications and is sensitive only to water. It is the most accurate and
reliable method of moisture determination currently in use.
Lesson 3 10.9.4 Guided Bend Tests -

Covered Electrodes
for Welding
Mild Steels 10.9.4.1 Transverse Face Bend, Root Bend and Side Bend Tests. The specifications for
some filler metals require that guided bend tests be made to evaluate the ductility and
soundness of a welded joint. The test plate is welded in the flat position and is made long
Lesson 4
Covered Electrodes enough to produce the necessary number of specimens. See Figure 5.
for Welding Low
Alloy Steels 10.9.4.1.1 The specimens are cut from the test plate, and the backing strip and weld
reinforcement machined flush with the face and root surfaces. If the test plate is greater
Lesson 5 than 3/8" thick, it must be machined to 3/8" thickness, removing the metal from the root
Welding Filler Metals surface for face bends, and from the face surface for root bends. In face bends, the face
of the weld is on the outside or convex surface of the specimen, and in root bends, the root
of the weld is on the outside or convex surface of the bend. The specimen is bent in a
guided bend test jig, the design of which is described in the specification, over a justified
Lesson 6
Carbon & Low Alloy radius (usually a 3/4" radius) through an angle of 180°. When removed from the jig, the
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FACE OR ROOT BEND TEST SIDE BEND TEST PLATE
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
FACE BEND ROOT BEND SIDE BEND
TRANSVERSE GUIDED BEND TESTS

Lesson 10 FIGURE 5
Filler Metals

Lesson 1
Welding
specimen will spring back to about the angle shown in Figure 5. In face and root bends,
defects in the surface of the weld are exposed as cracks, tears, or porosity.
Lesson 2
Common Electric 10.9.4.1.2 Side bend tests are similar to face and root bend tests, except they are bent
Arc Welding
so the side of the weld is on the outside or convex surface of the specimen. Side bends
Processes
expose defects in the interior and fusion zone of the weld.
Lesson 3
Covered Electrodes 10.9.4.2 Transverse Tension and Longitudinal Guided Bend Test. The transverse tension
for Welding
Mild Steels test and longitudinal guided bend test may appear separately in some specifications; how-
ever, it is shown here (Figure 6) as they appear in AWS A5.20-95 (applicable only to the
single-pass electrodes of the E70T-2, E70T-3, E70T-10, and E70T-GS classifications.)
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
DETAILS OF TRANSVERSE TENSION AND GUIDED BEND TESTS
Electrodes FIGURE 6
10.9.4.2.1 An all-weld-metal tensile test, as shown in Figure 3, would not be meaningful

Lesson 9
Estimating & for single-pass electrodes because in single-pass welds, the weld metal is always substan-
Comparing Weld tially diluted with the base metal. The bend test is prescribed for these electrodes because
Metal Costs
they contain relatively high amounts of manganese and silicon that can reduce ductility
somewhat, and can cause cracking in the weld area when present in excessive amounts.
Lesson 10
Filler Metals

Lesson 1
LESSON X
The Basics of Arc
Welding
10.9.4.2.2 The test plate must be a material having a minimum tensile strength equal to
that of the electrode being tested. The test plate is welded with one weld bead on each
Lesson 2 side of the plate. This is considered a single-pass weld since each weld will be diluted with
Common Electric
Arc Welding the base material. The tensile specimen is cut from the plate, machined to the shape
Processes shown in Figure 6, and pulled until fractured. A specimen that breaks in the base plate
shall be considered satisfactory.
Lesson 3
10.9.4.2.3 The weld beads on the bend specimens are ground or machined smooth and
Covered Electrodes
for Welding flush with the surface. The specimen is then uniformly bent over a 3/4" radius through an
Mild Steels angle of 180° in a suitable jig. The specimen, after bending, may show no crack exceeding
1/8" in length in any direction in the weld metal or the base metal.
Lesson 4
Covered Electrodes 10.9.5 Ferrite Test - In austenitic stainless steels, ferrite (as discussed in Lesson V) can
for Welding Low be beneficial in reducing cracking in some stainless steel weld metals, while in other envi-
Alloy Steels
ronments, it can reduce corrosion resistance. It can cause brittleness in high temperature
service, and can reduce toughness in cryogenic service. For these reasons, the amount of
Lesson 5 ferrite in austenitic stainless steel weld metal must be established as accurately as pos-
sible. Ferrite content can be calculated by using the Schaeffler diagram or the WRC dia-
gram as shown in Lesson V, when the chemical analysis of the weld metal is known. It can
also be determined by the use of various magnetic sensing instruments.
Lesson 6
Carbon & Low Alloy 10.9.5.1 To determine the ferrite level by instrument, a weld pad, as shown in Figure 7,
Steel Filler Metals - must be made.
GMAW,GTAW,SAW
10.9.5.2 The copper bars are used as a mold or form to build up the weld metal to the
Lesson 7 proper height as shown. The welding procedure used in preparing test pad is carefully
Flux Cored Arc spelled out in the specification as to welding direction, stops and starts, cleaning and
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating & WELD
DEPOSIT
Comparing Weld 1/2" TO 5/8"
Metal Costs MINIMUM
HEIGHT
WELD PAD PREPARATION FOR FERRITE TEST

Lesson 10 Figure 7
Filler Metals

Lesson 1
LESSON X
The Basics of Arc
Welding
interpass temperature. The top surface of the completed pad is carefully filed by hand in
the direction of the weld. Six readings are taken along the top of the weld pad with a prop-
Lesson 2 erly calibrated magnetic instrument. The six readings are averaged to a single value. This
Common Electric
average becomes the ferrite number.
Arc Welding
Processes
10.9.6 Fillet Weld Test - Some specifications require the fillet weld test be prepared as
shown in Figure 8.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Welding Filler Metals CONVEXITY
for Stainless Steels LEG
Lesson 6 LEG
Carbon & Low Alloy
Steel Filler Metals - FILLET WELD TEST SPECIMEN
GMAW,GTAW,SAW Figure 8
Lesson 7 10.9.6.1 The weld specimen is made using the specified electrode size and plate thick-
Flux Cored Arc
Electrodes Carbon ness. After welding, the plate is cut on the lines indicated, and one side of the 1" wide
Low Alloy Steels section is polished and etched so that the weld bead is clearly visible. The largest possible
right triangle with equal leg lengths is carefully scribed within the fillet weld on this surface,
so that the fillet size, leg lengths, and convexity of the weld can be measured and com-
Lesson 8
Hardsurfacing pared to the allowable deviations in the specification.
Electrodes
10.9.6.2 The welds in the two longer sections are broken by applying a force in the direc-
tion shown in the diagram. The broken surfaces are visually examined for evidence of
Lesson 9 inclusions, gas pockets, or incomplete root fusion.
Estimating &
Comparing Weld
10.9.6.3 Fillet weld tests are especially required for all-position electrodes or wires, and
Metal Costs
the specification will require that the test plates be welded in the vertical-up and overhead
positions.
Lesson 10
Filler Metals

Lesson 1
Welding
10.10 CERTIFICATION OF ELECTRODES
Lesson 2 The certification of electrodes and welding wires has become more critical today, and the
Common Electric number of test certifications requested has increased more than ten-fold in the last several
Arc Welding
years. Conducting certification tests is a costly process, and all efforts must be made to
Processes
provide accurate information to the manufacturer, so that the end-user gets the material
tested to the necessary degree; no more, no less.
Lesson 3
Covered Electrodes 10.10.0.1 Welding filler metals may be certified by one of two methods: typical properties
for Welding
Mild Steels certification or actual properties certification.
10.10.1 Typical Properties Certification - Certifications showing typical chemistry and

Lesson 4 mechanical properties are provided with customer orders when so requested. These
Covered Electrodes
for Welding Low typical properties are based on the results of many tests on similar materials and on a very
Alloy Steels comprehensive, carefully controlled Quality Assurance System. An ESAB Typical Proper-
ties Certificate assures that the
products are tested in compliance
Lesson 5
Welding Filler Metals with AWS and ASME Filler Metal
Specifications. A copy of a Typical
Properties Certificate for Atom Arc
electrodes is shown in Figure 9.
Lesson 6
Carbon & Low Alloy Typical certifications are supplied by
Steel Filler Metals - the manufacturer, on a no-charge
GMAW,GTAW,SAW
basis, by request.
Lesson 7 10.10.2 Actual Certifications -

Flux Cored Arc Actual certification that each lot of a
Electrodes Carbon
Low Alloy Steels particular product shipment will
meet a desired specification is
normally supplied by the manufac-
Lesson 8 turer for a fee. In this case, pack-
Hardsurfacing
Electrodes ages of each lot number of the
product to be shipped will be
opened and tested according to the
Lesson 9 customer’s request.
Estimating &
Comparing Weld
Metal Costs
TYPICAL PROPERTIES CERTIFICATE
FIGURE 9
Lesson 10
Filler Metals

Lesson 1
Welding
10.10.2.1 In order to have the proper tests performed correctly and as inexpensively as
possible, the information that accompanies the order must contain all pertinent information
Lesson 2 such as:
Common Electric
Arc Welding
a. To what specification must the material conform and to what revision of that
Processes
specification?
Lesson 3 b. Must all the tests as required by the specification be performed?

Covered Electrodes
for Welding c. Are there any actual tests required in addition to those covered by the specifica-
Mild Steels tion?
d. Do special marking and packing requirements apply?

Lesson 4
Covered Electrodes e. Is the material for a government contract?
for Welding Low
Alloy Steels f. Where is inspection to be performed and by whom?
g. What number of copies and distribution method is required for the certificates?
Lesson 5
Welding Filler Metals 10.10.2.2 The American Welding Society publishes a document (AWS A5.01-93) entitled
for Stainless Steels “Filler Metal Procurement Guidelines”. This document (together with an AWS Filler Metal
Specification) is intended to assist the buyer in designating those testing requirements that
are applicable to his order. It consists of the following:
Lesson 6
Carbon & Low Alloy
a. The AWS Filler Metal Classification.
GMAW,GTAW,SAW b. Definition of lot classification (AWS A5.01-93 Section 2).
c. The intensity of testing schedule (i.e., number of tests to be conducted) (AWS

Lesson 7
Flux Cored Arc A5.01-93 Section 3).
Electrodes Carbon
Low Alloy Steels 10.10.2.3 A portion of Table 1, “Intensity of Testing” that applies to actual testing reads as
follows:
Lesson 8 Intensity of Testing

Hardsurfacing
Electrodes Schedule Requirements
H Chemical analysis only for each lot shipped.
Lesson 9 I Tests called for in Table 2 “Required Tests” for each lot shipped.
Estimating &
Comparing Weld
J All tests that the classification called for in the pertinent AWS filler metal
Metal Costs
specifications for each lot shipped.
K All tests specified by the purchaser, for each lot shipped.

Lesson 10
Filler Metals

Lesson 1
Welding
10.10.2.4 Table 2, referred to in Schedule I above, lists the “Required Tests” necessary
for actual certification, and in all cases, does not include all tests included in the applicable
Lesson 2 AWS Filler Metal Specification. When the intensity of testing is not specified on an order,
Common Electric
the product will be tested to ESAB standard testing intensity which equals or exceeds those
Arc Welding
Processes tests required under Schedule I above.
10.10.2.5 As an example, stainless steel covered electrodes will only be tested for (1)
Lesson 3 chemical analysis and (2) calculated ferrite content as required by the AWS Filler Metal
Covered Electrodes
for Welding Procurement Guidelines A5.01-93. Any additional testing must be specified.
Mild Steels
10.11 QUALITY ASSURANCE

Lesson 4
Covered Electrodes ESAB has based its Quality Assurance Program around NCA 3800 of the ASME Boiler and
for Welding Low
Pressure Vessel Code, Section III. This means that the program assures accurate docu-
Alloy Steels
mentation, close control of the raw materials including the steel and flux ingredients,
in-process controls and checks, and complete traceability of each lot of product produced.
Lesson 5 It also includes close control of the inspection and measuring equipment which assures
for Stainless Steels accurate testing and certification of test results.
10.11.0.1 Both the Hanover, Pennsylvania and Ashtabula, Ohio Quality System Programs
Lesson 6 have been accepted by the ASME as material manufacturers. This means that customers
Carbon & Low Alloy using our products for nuclear and other applications to ASME requirements need not audit
GMAW,GTAW,SAW our Quality Program. Copies of the ASME Quality System Certificates for both plants are
shown in figures 10 and 11. These certificates are issued only after an in-plant audit by an
ASME representative, and are valid for a three year period.
Lesson 7
Flux Cored Arc
Electrodes Carbon 10.11.0.2 In addition, facilities in Hanover, PA; Ashtabula, OH; Niagara Falls, NY; and
Low Alloy Steels Monterrey, Mexico have been certified to ISO 9002. This quality standard was first estab-
lished in 1987 by the International Organization for Standardization in Geneva, Switzerland.

Certification to this standard covers all areas of product manufacturing, including general
Lesson 8
management, production, research, purchasing, engineering, human resources, and quality
Hardsurfacing
Electrodes assurance. Receipt of this certificate eliminates the costly time consuming audits normally
required by our customers. Copies of these certificates are shown in figures 12 through 15.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals

Lesson 1
LESSON X
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
QUALITY SYSTEM CERTIFICATE, ESAB HANOVER
FIGURE 10
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding QUALITY SYSTEM CERTIFICATE, ESAB ASHTABULA

Lesson 1
LESSON X
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding ISO 9000 CERTIFICATION - ESAB HANOVER
Filler Metals
FIGURE 12

Lesson 1
LESSON X
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
ISO 9000 CERTIFICATION - ESAB ASHTABULA

Lesson 10

Lesson 1
LESSON X
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs ISO 9000 CERTIFICATION - ESAB Niagara Falls
FIGURE 14
Lesson 10
Filler Metals

Lesson 1
LESSON X
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
GMAW,GTAW,SAW
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding ISO 9000 CERTIFICATION - ESAB Monterrey
Filler Metals
FIGURE 15

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Lesson 1

The Basics of Arc

©COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 4 1.1 Source and Manufacturing............................................................. 1

© COPYRIGHT 1998 THE ESAB GROUP, INC

1.6.5 Reduction of Area ............................................................................. 11

Section Nr. Section Title Page

© COPYRIGHT 1998 THE ESAB GROUP, INC

1.8.5 Transformers .................................................................................... 22

Lesson 4 1.9.2 Constant Voltage Characteristics ...................................................... 26

Appendix A Glossary of Terms ............................................................................. 29

© COPYRIGHT 1998 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

Lesson 6 1.2 CLASSIFICATIONS OF STEEL

Low Carbon Up to 0.15% carbon

Lesson 8 Mild Carbon Steels .15% to 0.29% carbon

© COPYRIGHT 1999 THE ESAB GROUP, INC

Lesson 9 required when welding high alloy steels.

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP

Lesson 3 combination of liquids and solids within a

may undergo an alteration in the crystalline

Lesson 9 is called a grain boundary.

Lesson 10 phases in a weld.

© COPYRIGHT 1999 THE ESAB GROUP, INC

DENDRITE INITIAL COMPLETE

© COPYRIGHT 1999 THE ESAB GROUP, INC

amount of expansion is directly proportional to the amount of heat applied. In a weldment,

1.5.5 Annealing - A metal that is annealed is heated to a temperature 50° to 100°

© COPYRIGHT 1999 THE ESAB GROUP, INC

method of cooling. Normalized steel is heated to a temperature approximately 100° above

Lesson 4 1.6 PROPERTIES OF METALS

© COPYRIGHT 1999 THE ESAB GROUP, INC

Ultimate Strength an increased load must be

© COPYRIGHT 1999 THE ESAB GROUP, INC

FRACTURES CRACKS DEFORMS

© COPYRIGHT 1999 THE ESAB GROUP, INC

Low Alloy Steels

Lesson 8 1/8 in. Diameter

Types of Indenters - Hardness Tests

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

1.7.3 Manganese - Manganese in contents up to 1% is usually present in all low alloy

Lesson 3 1.7.4 Chromium - Chromium, in combination with carbon, is a powerful hardening

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

1.8.1.1 The three basis principles of static electricity are as follows:

3. Charges can be transferred from one place to another.

© COPYRIGHT 1999 THE ESAB GROUP, INC

© COPYRIGHT 1999 THE ESAB GROUP, INC

1.8.2.1 The equation is easy to use as seen in the following problems:

2) What voltage is required to pass 15 amps through a resistor of 5 ohms?

80 ÷ 250 = .32 ohms

© COPYRIGHT 1999 THE ESAB GROUP, INC

in Figure 9 will help to illustrate this principle.

Lesson 7 Likewise, if the conductor is moved downwards

the workings of an AC generator.

© COPYRIGHT 1999 THE ESAB GROUP, INC

BASIC AC POWER GENERATION

Comparing Weld applications, 60 cycles per second (60

© COPYRIGHT 1999 THE ESAB GROUP, INC

1.8.4.11 This illustrates that three-phase power is