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Calculating Filler Metal Consumption The number of pounds of welding electrodes or welding wire

necessary to complete a given weld joint may be calculated by the formula:

P = WL /E

Where: P = Pounds of electrode or wire required

W = Weight per foot of weld metal

L = Length of weld (feet)

E = Deposition efficiency

Weight Per Foot of Weld Metal Calculating the weight of weld metal requires that we consider the
following items.

1. Area of the cross-section of the weld.

2. Length of the weld.

3. Volume of the weld in cubic inches.

4. Weight of the weld metal per cubic inch.

3 It must be remembered that when deposition tests are performed in the laboratory, the
deposition efficiency is calculated by the formula: Weight of metal deposited Deposition
Efficiency = Weight of electrode consumed This does not take stub loss into consideration. The
chart below shows how the laboratory established efficiency is effected by the length of the stub.
Stub Loss Correction Table for Coated Electrodes
6 Weld Metal Cost Worksheet Instructions To help you quantify your specific cost of weld metal
deposited, ESAB has developed the weld metal cost worksheet. Directions will assist you in
calculating your specific cost to deposit weld metal while comparing it to alternative methods or
product. 1. Indicate the complete descriptions of the proposed and present products at (1) and
(2). 2. Secure the following information for the formulas (3), and write the data in the proper
blanks in the proposed method and present method columns (4). A. Labor and Overhead Actual
labor and overhead rate of your customer. If this figure is unknown, select a reasonable rate for
your area. This figure will be the same in the proposed and present method columns.
B. Deposition Rate in Pounds Per Hour The deposition rate is the actual weight of weld metal
which can be deposited in one hour at a given welding current at 100% operating factor. In other
words, it is the amount of weld metal which could be deposited in one hour if the welder could
weld for a full hour without stopping. C. Operating Factor Operating factor is the percentage of
a welder’s working day that is actually spent welding. It is the arc time divided by the total hours
worked multiplied by 100 and expressed as a percentage. A 30% (.30) operating factor means
that only 30% of the welder’s day is actually spent welding. If the customer’s operating factor is
not known, assume a 30% operating factor for SMAW, and a 45% operating factor for semi-
automatic GMAW and FCAW. For automatic GMAW and FCAW, an operating factor of 60% to
80% may be assumed. D. Electrode Cost Per Pound Select the quantity price bracket in which
the customer now purchases his filler metal. If unknown, select the price bracket you think
applicable and use for both the present and proposed calculations.
Covered electrodes

Electrode selections

Electrode Selection The following points should be considered when selecting the
proper coated electrode.

1. Match the mechanical properties of the base metal.

2. Match the chemical composition of the base metal as closely as possible.

3. Match electrode to available power supply — AC or DCEN (electrode negative) or DCEP (electrode
positive).

4. Match the electrode to the position of the weld.

5. Observe joint design — Use deep penetrating electrodes for tight fit-up and unbeveled joints. Use
light penetration electrodes for poor fit-up and thin material.

6. Observe service conditions and select electrode accordingly — High temperature, low temperature,
corrosive atmosphere, impact loading. These conditions are best met by using low hydrogen electrodes.
7. Consider welding costs — Highest deposition rate is in the flat position. Use high iron power
electrodes to further increase deposition. By far, the largest factor is labor and overhead.

AWS FILLER METAL SPECIFICATION A5.1 MILD STEEL COVERED ELECTRODES


EXAMPLE: E 60 1 0 (1) (2) (3) ---- (4)
1.E — Stands for electrode.
2.Two digits indicate tensile strength x 1000 PSI.
3.Third digit refers to welding position.
EXX1X All position (flat, horizontal, vertical, overhead).
EXX2X Horizontal and flat only.
EXX3X Flat position only.
EXX4X Flat, overhead, horizontal, vertical down.
4.Last digit indicates usability of the electrode, i.e. type of current and the type of covering. In
some cases, both the third and fourth digits are significant.
Classification Current Arc Penetration Covering & Slag Iron Powder
EXX10 DCEP Digging Deep Cellulose - sodium 0- 10%
EXXX1 AC or DCEP Digging Deep Cellulose - potassium 0
EXXX2 AC or DCEN Medium Medium Titania – sodium 0-10%
EXXX3 AC or DCEN or DCEP Soft Light Titania - potassium 0- 10%
EXXX4 AC or DCEN or DCEP Soft Light Titania - iron powder 25-40%
EXXX5 DCEP Medium Medium Low hyd. – sodium 0
EXXX6 AC or DCEP Medium Medium Low hyd. - potassium 0
EXXX8 AC or DCEP Medium Medium Low hyd. - iron powder 25-40%
EXX20 AC or DCEN Medium Medium Iron oxide - sodium 0
EXX22 AC or DCEN or DCEP Medium Medium Iron oxide - sodium 0
EXX24 AC or DCEN or DCEP Soft Light Titania - iron powder 50%
EXX27 AC or DCEN or DCEP Medium Medium Iron oxide- iron powder 50%
EXX28 AC or DCEP Medium Medium Low hyd. - iron powder 50%
EXX48 AC or DCEP Medium Medium Low hyd. - iron powder 25-40%

DCEP — Direct Current Electrode Positive DCEN — Direct Current Electrode Negative
Note: Iron powder percentage based on weight of the covering.
Mild Steel Covered Electrodes Sureweld 10P-Plus AWS Class E6010 DCEP (Electrode Positive) Electrode
Imprint Marking: 6010 Code and Specification Data: AWS A5.1, Class E6010 Description: The gray
coated Sureweld 10P-Plus is a modified version of the standard 10P electrode. It has also been
developed for the pipe welding industry but has a more consistent burn-off and a more forgiving arc
burn. This provides a better bead profile and sidewall fusion with lower spatter. Sureweld 10P-Plus will
maintain the proper keyhole in an open root and will produce X-ray quality joints in the flat, horizontal,
overhead, vertical-up, and vertical-down procedures. Sureweld 10P is recommended for welding API
grades A25, A, B, and X42 pipe and general structural, ship, barge, and storage tank fabrication. It may
also be used for welding root passes in higher grade pipe in some circumstances. Procedure: Hold a
short arc, but do not allow the coating to touch the molten pool. A slight oscillating motion is
recommended in the horizontal and flat positions. Use a short whipping motion on vertical and
overhead welds, allowing only enough time out of the crater for the metal to set up. Clean thoroughly
between passes. Vertical down and flat position welds should be made at approximately the same
amperages.

ATOM ARC® Iron Powder Low Hydrogen Electrodes The introduction of iron powder into low
hydrogen electrodes greatly increased productivity, making the use of Atom Arc for most
welding operations more than competitive with common mild steel electrodes in overall
cost. The real advantage of course is that by improving the efficiency of welding operations,
fabricators have a means of equalizing increasing overhead and labor costs. Moisture Resistant
Coating
Atom Arc electrodes are manufactured with a flux coating that effectively resists moisture pick-
up for many hours after the container is opened. This improved coating provides an extra degree
of reliability, especially for electrodes exposed to high temperature, high humidity working
conditions. Typical % Moisture in Atom Arc Coatings
It should be noted that even though Atom Arc electrodes resist moisture pick-up longer than ever
before, no moisture resistant electrode will eliminate the need for storage and rebake ovens or the
necessity to follow code requirements for allowable exposure times. The graph above shows the
rate of moisture pick-up of Atom Arc electrodes.

Electrode Storage Unopened containers can be stored safely for an indefinite length of time
under normal dry storage conditions. They should be protected from humid air after the container
is opened by being kept at 225°F to 300°F, (107°C to 149°C) or if the need arises, they can be
reconditioned by baking for one hour at 700°F (371°C).

UNIONMELT® Submerged Arc Fluxes Spoolarc® Solid Wires and ALLOY SHIELD® Composite Wires The
major function of a submerged arc welding flux is to: n Shield the molten puddle from the atmosphere. n
Clean and deoxidize the weld puddle. n Control the chemistry and mechanical properties of the weld
metal. There are two major methods by which fluxes are manufactured: BONDED FLUXES are
manufactured by dry mixing the flux ingredients and then bonding them together using a liquid silicate
binder. The flux pellets are then baked at a relatively low temperature to drive off the water in the
binder. The major advantages of bonded fluxes are: n The flux can contain metallic deoxidizers which
provide good performance over rust and mill scale. n The relatively coarse mesh size feeds easily due to
its uniform size. n Bonded fluxes typically have a lower consumption rate. The use of bonded fluxes are
not without limitation. They include: n Any removal of undersized particles during recycling can change
the overall chemical analysis of a bonded flux and consequently, change the performance characteristics
of the flux. n Segregation within the flux can occur, making some particles richer or leaner in specific
ingredients. This is particularly critical if metals segregate, leading to hard spot formation within the
weld metal. n Bonded fluxes can pick up moisture if stored improperly. They must be baked at a
temperature between 500°-800°F (260°-427°C) to remove any suspected moisture

Carbon Steel Submerged Arc Wires Spoolarc 80 AWS Class EL12 Description: n Low manganese and
silicon wire - minimal rust and mill scale tolerance. n Excellent ductility and crack resistance -
recommended for restrained welds and good machinability. n Suitable for butt or fillet welds on lower
strength carbon steels. n Applications include high speed lap welds, build-up or repair welding prior to
machining and buttering or cladding operations. n Usable with Unionmelt 80, 350, 350M and 231 fluxes.
n Wire diameters: 1/16" (1.6 mm), 5/64" (2.0 mm), 3/32" (2.4 mm), 1/8" (3.2 mm), 5/32" (4.0 mm) &
3/16" (4.8 mm). Spoolarc 29S AWS Class EM13K Description: n Moderate amount of manganese and
silicon (higher than Spoolarc 80) for rust and mill scale tolerance. n Ideally suited for high speed single
pass welding on light gauge steels. n Higher silicon level reduces porosity and pock marking. Good
wetting action and even weld bead profile. n Some caution should be taken when used with an active
flux. n Applications include structural supports, spiral pipe, hot water tanks, and pressure vessel
construction. n Usable with Unionmelt 231, 651VF, 429, 439, 429M, and 656 fluxes. n Wire
diameters: 1/16" (1.6 mm), 5/64" (2.0 mm), 3/32" (2.4 mm), 1/8" (3.2 mm), 5/32" (4.0 mm) & 3/16"
(4.8 mm). Recommended Welding Parameters page 33

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