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Core Wire
Electrode core wire: C 0.10 max; Mn 0.38-0.62; Si
0.03 max; S 0.03 max; P 0.03 max
Important feature: low level of C, Si, S & P
Coating
Arc characteristics – Stability, Striking & Re-
striking, Force, Capability to work in positions, and
in AC & DC sets
Slag characteristics – Good shielding, Capability
to bring impurities out of molten weld metal, Good
detachability, Flowability as well as quick freezing
nature
Functions of the Flux coating
Arc stabilisers
Slag formers
Deoxidisers
Gas forming materials
Binders
Alloying elements
Deposition efficiency improvers
Extruding/slipping agents
Coating types
Rutile
Basic
Cellulosic
Acid
Acid-rutile
Oxidising
Merits/Demerits of coating types
Rutile: Merits
Easy striking/restriking
Good slag control
Good slag detachability
Good positional welding capabilities
Usable in low OCV sets
More welder friendly
Demerits
Limitation in mechanical properties
Alloy transfer difficult
High hydrogen level
Coating Factor
Basic: Merits
Good mechanical properties
Low hydrogen level
Alloy transfer effective
Higher deposition efficiency
Demerits
Greater welder skill required
AC welding difficult, especially in low OCV
High temperature preheating before welding
necessary
Slag detachability not as good as rutile type
Merits/Demerits of coating types
Cellulosic: Merits
High arc force good penetration
Thin coating good manouverability in roots
Less slag volume
Good positional welding
Alloy transfer possible
Demerits
DC based
High hydrogen level
Operator skill is important
Production Of Electrodes
The powdered coating materials are dry mixed and then liquid
silicate is added to form a paste.
The flux paste is extruded onto the core wire in an hydraulic
extruder. The two ends are brushed and linished for gripping
by the electrode holder and easy striking of arc.
The electrodes are then dried at between 110 – 130 C in
continuous or batch type ovens before packing.
Low hydrogen basic coated, stainless steel and other special
electrodes are further baked at 350 – 450 C to remove
moisture to very low levels.
Cellulose coated electrodes are dried at 80 – 90 C so that the
cellulose is not damaged and there is some residual moisture
to augment the arc force.
Handling And Storage Of Electrodes
2. Striking the electrode tip hard with base plate can cause peeling
of flux of electrode tip.
Group contains
- Mild steels to IS : 2062
- Boiler quality steel to IS: 2002
- Micro-alloyed steels to IS : 8500
- Weathering steels to IS : 11587
For mild steel non-critical applications in static loading upto 40
mm combined thickness – E6013 medium coated electrodes
For mild / boiler quality steel semi-critical applications in
dynamic loading upto 40 mm combined thickness – E6013
heavy coated electrodes
For mild / boiler quality steel for all applications above 40 mm
combined thickness – E 7018 electrodes + pre-heat as required
for higher thicknesses
Selection of electrodes for Micro-alloyed
steels
Range of medium and high tensile steel developed to give
improved strength and toughness without impairing
weldability. Covered by IS:8500 - 1991
Small amounts of carbide forming elements eg. Nb, V, Ti etc
added Total amount 0.20% max as such called Micro-
alloyed steels
Controlled rolling at low finish roll temperatures results in
very fine grain size ASTM 12 – 14.
Properties : UTS 450 – 600 MPa
YS 400 – 500 MPa
Elongation 20 – 22 %
Weld all sections with E7018 / E8018 G electrodes
depending on minimum yield requirements
Selection of electrodes for
Weathering steels
These are medium tensile steels with Cu, Cr & small amount of
Phosphorous added to improve atmospheric corrosion
resistance. However P gives hot shortness and lower impacts
and latest grades have reduced P levels
Example - Corten A, B & C and Sailcor –HR & CR steels used
for rolling stock in railways and other transportation sectors.
Corten B & C with lower P levels have better weldability
For the lower strength Corten A & B type use E7018 – W1
electrodes
For higher strength Corten C use E8018 – W2 electrodes.
Note the electrode weld metal does not contain P
MMAW – Best practice
Voltage
Try to use highest voltage setting available,
specially for basic coated low hydrogen
electrodes.
MMAW – Best practice contd.
Operator control
Quality of welding
highly dependent on the
skill of operator
A high level of manual
dexterity is required to
co-ordinate the
electrode to match the
burn off rate and to
maintain a constant
ARC length.
MMAW – Best practice contd.
Stick-out
Features of SAW process
High Productivity
- High amperage is possible
- Easy de-slagging
High Quality
- Deep penetration
- Excellent mechanical properties
Environment friendly
- Very little fume
- Easy operation
Equipment And Accesories
1. WIRE FEEDER
2. WELDING POWER SOURCE
3. FLUX HOLDER AND FEEDER
4. MEANS FOR TRAVERSING THE WELD
JOINT
5. REDRYING ARRANGEMENT FOR
FLUX
6. FLUX RECOVERY UNIT .
7. OTHER ACCESORIES
Consumables
Wire : solid / fluxcored
Soilid wires for mild and low alloy steel applications are
normally copper coated.
Flux cored wires are often referred as composite
electrodes and comes under “EC” designation in wire –flux
classification.
Flux :
A. Fused flux :
Ingredients ( ground minerals ) are mixed and melted in a
pot / furnace at high temperature [ 1600 – 1800 deg.C ].
melt is rapidly solidified and fragmented by quenching in
water. These flux fragments are dried , crushed , sieved ,
sized and packed.
Consumables contd.
B. Agglomerated flux ;
finely powdered ingredients are mixed and mix is steadily
moistened with liquid alkaline silicates.The mixer blades
are designed to assist agglomeration.
The green agglomerates are baked in rotary oven gradually
with final exposure at 600 to 800 deg.C.While baking the
water evaporates leaving the binder as bridges between
particles. The flux is then sieved , graded and packed.
C. Sintered flux :
Produced by grinding the dry charge together, pressing
into small balls and heating to just below melting point
[ 1000 – 1100 deg. C ] in furnace. These semi fused masses
are crushed, sieved, sized and packed.
SAW Wire - Flux Classification
F 7A6 – EM 12K
F – Indicates SAW flux
7 – UTS minimum 70,000 psi
A – As welded condition
( P – post weld heat-treated condition )
6 – Impact minimum 20 ft-lbf at – 60 F
E – Solid wire electrode
M – Medium manganese level wire
12K – specific composition wire
Basicity Index ( B.I )
B.I = BASIC OXIDES / ACIDIC OXIDES =
[CaO+MgO+Na2O+CaF2+1/2(MnO+FeO)]
---------------------------------------------------------------------
[SiO2+1/2 (Al2O3+TiO2+ZrO2)]
kg/m
0,4
0,3
0,2
0,1
0
40 60 80 100 120 140 160
D. Molten flux start – arc starts inside molten flux – used
for multi wire technique
A: 25 mm
B: 57 mm
C: 83 mm
Deposition rate
Recommended current range and deposition rate (kg/h)
for different wire diameters
Deposition rate
As a function of wire diameter and amperage
Kg/
h
16 f
Wire
14 d e g
diameter
a = 1,6 mm 12
b = 2,0 mm 10 a c
c = 2,4 mm b
8
d = 3,2 mm
e = 4,0 mm 6
f = 5,0 mm 4
g = 6,0 mm
2