WELDING CONSUMABLES

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A sustained arc generates the heat for

melting the work piece and filler material.
Consumable electrodes
Non-consumable electrodes

Arc Welding
IT 208

Chapter 14

FACTORS AFFECTING THE

GAS WELDING

Distance between inner cone & metal ~ 3

to

6 mm ideally.

Flux Core Arc Welding (FCAW) developed in the early

1950s as an adaptation to SMAW to overcome limitation
imposed by the use of a stick electrodes. Uses a spool of
filler wire fed through the hand-piece. A core of flux is
inside the wire
Two versions
Self-shielded flux-cored arc welding includes not only
fluxes but also ingredients that generate shielding gases
for protecting the arc.
Gas-shielded flux-cored arc welding developed
primarily for welding steels, obtains a shielding from
externally supplied gases, similar to GMAW

Consumable electrodes
IT 208

Chapter 14

Submerged Arc Welding (SAW) uses a continuous,

consumable bare wire electrode, and arc shielding is
provided by a cover of granular flux. Low-carbon, low alloy,
and stainless steels can be readily welded by SAW.
Electrogas Welding (EGW) uses a continuous
consumable electrode (either flux-cored wire or bare wire
with externally supplied shielding gases) and molding shoes
to contain the molten metal.
Shielded Metal Arc Welding (SMAW) (stick) arc is
struck between the rod (shielded metal covered by flux)
and the work pieces to be joined, the impurities rise to the
top of the weld in the form of slag (18-19a, handout pg.
40)

Consumable electrodes
IT 208

Chapter 14

A sustained arc, shielded by molten slag, is maintained in consumableelectrode welding by the

(a) shielded metal-arc, (b) submerged arc, and (c) electrogas methods.
IT 208

Chapter 14

Lets take a little closer look at the SMAW

Electrode
process
1

Travel direction

Shielding Gas

Travel direction
Slag

56

Shielding Gas
Weld 4
Puddle 3

Arc

Arc

Slag
Solidified Weld Metal

Electrode

Weld Puddle

Solidified Weld Metal

SMAW Process
8

Application Activity
Lets review the SMW process

1 = __________

2 = __________

3 = __________

4 = __________

5 = __________

6 = __________

Average Thickness of Plate or

Section

1.52.0

mm
2.05.0 mm
5.08.0mm
8.0 mm

PLATE THICK

Maximum Recommended
Electrode Diameter

2.5

mm
3.2 mm
4.0 mm
5.0 mm

VS

ELECTRODE
SIZES

Is

a consumable - it gets
melted during the
welding process
Is composed of two parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld

Flux Coating
Produces a shielding gas
Can provide additional filler
Forms a slag

1- The Electrode
11

ELECTRODE SIZE

Electrode
Length
(mm)
4.0MM
350MM
3.2MM
350MM
2.5MM
350MM

RUN LENGTH
Minimum

175 MM
125MM
100 MM

Maximum

300MM
225MM
225MM

ELECTRODE SIZE TO RUN LENGTH

Electrode

(mm)
2.5mm
3.2 mm
4.0 mm
5.0 mm

Size

Current

Range

(Amp)
6095amps
110130amps
140165amps
170260 amps

ELECTRODE SIZE WITH CURRENT

RANGE

Filler

rod should have a tensile strength

greater than the metal to be joined.
Rod must also be compatible with the welded
metal
Welding positions required
Welding current (ac or dc)
Joint design (groove, butt, fillet, etc.)
Thickness and shape of the base metal
Service conditions and specifications
Production efficiency and job conditions

Selection of Welding Rods

IT 208

Chapter 14

14

FLUX COATING OF ELECTRODES:

It is the composition of the coating that differentiates one
type of
electrode from another and, to a degree, what type of
application
it can be used for. MMA electrodes, with a solid wire core,
are
generally categorised by the type of flux coating they
employ.
There are three main groups of electrode coating: rutile,
basic and cellulosic, plus a less-widely-used acid type. The
name of each group is a description of the main constituent
of the coating. Although not strictly a coating type, ironpowder electrodes are often considered as a separate
group.
Electrodes for cutting, grooving and gouging, plus those for
hardsurfacing,
including tubular MMA electrodes, are not classified by
coating type.

WELDING ELECTRODE CLASSIFICATIONS

MILD STEEL COATED ELECTRODES
E7018-X
E Indicates that this is an electrode
70 Indicates how strong this electrode is when welded.
Measured in thousands of pounds per square inch.
1 Indicates in what welding positions it can be used.
8 Indicates the coating, penetration, and current type used.
(See Classification Table below)
X Indicates that there are more requirements.
(See Additional Requirements below)
WELDING POSITIONS
1 Flat, Horizontal, Vertical (up), Overhead
2 Flat, Horizontal
4 Flat, Horizontal, Overhead, Vertical (down)
Flat Position - usually groove welds, fillet welds only if welded like a V
Horizontal - Fillet welds, welds on walls (travel is from side to side).
Vertical - welds on walls (travel is either up or down).
Overhead - weld that needs to be done upside down.

CLASSIFICATION TABLE
Class Electrode Coating

Penetration Current Type

Exxx0 Cellulose, Sodium

Deep

DCEP

Exxx1 Cellulose, Potassium

Deep

AC, DCEP

Exxx2 Rutile, Sodium

Medium

AC, DCEN

Exxx3 Rutile, Potassium

Light

Exxx4 Rutile, Iron Powder

Medium AC, DCEP, DCEN

Exxx5 Low Hydrogen,Sodium

Medium

DCEP

Exxx6 Low Hydrogen, Potassium

Medium

AC, DCEP

Exxx7 Iron Powder, Iron Oxide

Medium

Exxx8 Low Hydrogen, Iron Powder Medium

Exxx9 Iron Oxide, Rutile,Potassium Medium

AC, DCEP, DCEN

AC, DCEN
AC, DCEP
AC, DCEP, DCEN

Rutile Electrodes
Rutile electrodes have a coating that contains about 50% rutile sand
(a pure form of titanium dioxide), plus additions of ferro-manganese,
mineral carbonates and silicates, held together with approximately
15% sodium silicate, also known as waterglass. The rutiles
characteristics include easy striking, stable arc, low spatter, good
bead profile and, generally, easy slag removal from the electrode.
The electrode can operate on both AC and DC currents and
can operate in all positions if the formulation of the coating is
so designed.
One negative aspect of these electrodes is that they produce a high
level of hydrogen, typically greater than 15ml / 100g of deposited
weld metal. This cannot be avoided, because they rely on a certain
amount of moisture being present in the coating to operate properly.
If the electrodes are dried too much, they will fail to function
properly.
Rutile-coated electrodes are manufactured for welding mild and
low-carbon steels. In this context, they are often referred to as
general-purpose or GP electrodes. Some low-alloy grades also
use rutile coatings. Rutile-type coatings, which are modifications
of those used for ferritic steels, are also used on many austenitic
stainless steel electrodes.

Basic Electrodes
Basic, or low-hydrogen, electrodes contain calcium carbonate and
calcium fluoride in place of the rutile sand and mineral silicates. This
makes them less easy to strike and more difficult to re-strike, due
to the very deep cup formed at the tip during operation. They also
have a poorer, more convex bead profile than rutile electrodes. The
slag is more difficult to remove than the rutile types, but they do
give better weld metal properties than rutile types, with a higher
metallurgical quality.
Basic electrodes are capable of being used on AC or DC currents
and can be used in multi-pass welds on materials of all thicknesses.
Basic electrodes do not rely on moisture to function properly, and
for the more critical applications should be used completely dry. It
is important to note that basic electrodes are only lowhydrogen
electrodes if they have been correctly dried before use. This
conventionally involves re-drying in ovens on site in accordance
with manufacturers recommendations. Drying can reduce weld
metal hydrogen to less than 5ml / 100g, as can vacuumpacking the
electrodes. These can be used straight from the packs without any
form of drying required. BOC Smootharc 16 and 18 electrodes are
supplied in hermetically sealed containers, which ensures that they
meet the H4 grade.

Cellulosic Electrodes
Cellulosic electrodes contain a high proportion of organic material,
replacing all or some of the rutile sand. This produces a fierce, deep
penetrating arc and a faster burn-off rate. Cellulosic electrodes are
more prone to spatter than rutile types. Only carbon and some
low-alloy steels are made with a cellulosic coating and most run
only on DC+ polarity, but some are made that will also operate
on AC and DC-. They are truly all-positional electrodes in all sizes
and even larger diameters up to 6 mm will operate verticaldown.
Cellulosic electrodes are used for root passes and pipeline welding.
It should be noted that celullosic electrodes generate high amounts
of hydrogen. This presents a risk of hydrogen-induced cracking if
correct welding procedures are not followed.

Acid Electrodes
Acid electrodes for mild steels have been largely replaced by
rutile
types, but some are still produced by a few manufacturers.
These
electrodes contain high amounts of iron oxide, are relatively
easy
to use and give a voluminous glassy slag that detaches easily.
They
are lower-strength products, so they are confined to use on
nonstructural
components.
Acid-rutile electrodes for stainless steel are now replacing
conventional rutile types. They are higher in silicon, which gives
improved operating and wetting characteristics, and they are
much
more welder-friendly. They strike and re-strike readily and will
operate on AC and DC current. They produce low spatter levels
and an easily removed slag. However, they are prone to start
porosity and need re-drying before use to avoid this.

Iron-powder Electrodes
Iron-powder electrodes are often considered an independent group
of consumables. As their name suggests, these electrodes contain
high levels of iron powder held within the coating as the coating
melts, the iron powder creates more weld metal. This effectively
improves the productivity from the electrode, allowing either larger
or longer welds to be created from a single rod. The amount of iron
powder added depends on the consumable being produced, but it is
not uncommon for 75% of the core weight to be added.
The addition of the iron powder to the coating has the effect of
increasing the overall diameter of the electrode and reducing the
amount of fluxing agent present in the coating. With less fluxing
agent available, the slag coating tends to be thinner, so many of the
MMA electrodes positional welding characteristics are lost. This
means that many of the electrodes can only be used in the flat or
horizontal-vertical (H-V) positions.
Coatings for iron-powder electrodes may be based on either the
rutile or basic systems.

Care and Conditioning of Consumables:

Practical Considerations:
Storage and Re-drying

MMA electrodes should be stored in dry, well-ventilated and

preferably heated stores. For critical applications it is also
recommended that they be held in temperature and humidity
controlled conditions, maintaining humidity below 60%RH (Relative
Humidity) and a temperature above the dew point to avoid
moisture condensing onto the electrodes. Electrodes held in dry
conditions will remain in prime condition for several years, but if the
coating absorbs moisture, this will lead to a gradual deterioration.
Evidence of deterioration includes the presence of white powdery
areas on the surface of the coating, cracks in the coating or missing
pieces of coating.
Electrodes with rutile or cellulosic coating require some moisture in
the coating to operate properly and should not be re-dried. If rutile
electrodes get wet, re-drying at about 80C is all that is needed.
Cellulosic electrodes must not be dried. In some hot environments
they may need wetting to function efficiently.

Basic coated electrodes need to be dry to give low-hydrogen

weld
metal. Before use, these electrodes should be re-dried
according
to manufacturers recommendations, put in holding ovens
and
then transferred to the workstations in heated quivers until
needed. Vacuum-packed basic electrodes can be used
straight from
the packet.
Electrodes for non-ferrous alloys and stainless steel always
need to
be completely dry before use and should be treated in
accordance
with manufacturers requirements.

Recommendations for covered electrodes

The storage of covered electrodes can be a fairly difficult subject as
air always contains moisture and electrode coatings are prone to
moisture pick-up. Too much moisture in the coating can produce
porosity in the weld or else the hydrogen coming from the
moisture causes cracks. An easy way to avoid all these problems is to
use the new VacPac. As long as the vacuum is present, the electrodes
are dry.
There are no restrictions relating to storage climate.
After the final drying at the factory, the electrodes are normally
packed in shrink-film paper boxes. These boxes are not 100% airtight,
which explains how moisture in the surrounding atmosphere can enter
them and be absorbed by the coating. The speed of the moisture
pick-up depends on several factors and, without testing the moisture
content, it is difficult to judge whether or not the electrodes
in a package have too much moisture in their coating.If the packages
are kept in the storage conditions described below, they can be kept
for a maximum of one year for normal use.

Care must also be taken during transportation and handling to

prevent moisture being reabsorbed. If there is any doubt about
whether an electrode is dry enough, it should be redried at the
temperature and time indicated on thelabel on the
package.However, packing electrodes in VacPac means that there
are no restrictions when it comes to storage, other than that the
package must be kept at a temperature that does not exceed
50C.
Redrying
Low-hydrogen basic electrodes should be redried before use
whenever there are application requirements relating to weld
metal hydrogen content and/or radiographic soundness (not
needed for VacPac).Acid rutile stainless electrodes and
all types of basic electrode may produce pores in the weld if they
have not been stored in sufficiently dry conditions. Redrying the
electrodes will restore their usability.Mild steel rutile and acid
electrodes normally need no redrying.Cellulose electrodes must
not be redried.Electrodes which are seriously damaged by
moisture can normally not be redried with first-class results.
These electrodes should be scrapped

Holding oven

The holding oven is used for

intermediate storage to avoid
moisture pick-up in the coating of
low-hydrogen electrodes and acid
Rutile stainless electrodes. The
electrodes which should be stored
in the holding oven are:
1.Electrodes that have been
redried
2.Electrodes that have been
removed from their hermetically sealed
container
3.Electrodes

Storage

Covered electrodes of any type will pick up

moisture only very slowly if they are stored under
the following
climatic conditions:
At temperatures
5-15C max. relative humidity -60%
15-25C max. relative humidity-50%
above 25C max. relative humidity-40%
During the winter, it is possible to maintain low
relative humidity by keeping the temperature in
the store-room at least 10C above the outdoor
temperature.

Precautions on site
Keep the electrodes in electrically heated quivers at a minimum
temperature of 70C. After work, return the remaining
electrodes to the holding oven.
Redrying conditions
Redrying temperatures and holding times are specified on the
package label.The redrying temperature is the temperature in
the bulk of the electrodes.
The redrying time is measured from the point at which the
redrying
temperature has been reached.
Do not stack more than four layers of electrodes in the
redrying oven.
It is recommended not to re dry covered electrodes more than
three times.

Gas Tungsten ARC welding - GTAW (Tungsten inert

gas, a.k.a. TIG) Tungsten electrode not consumed, but
surrounded by an inert gas and produces an arc.
Filler material is usually applied.
Gas tungsten arc welding does not produce as deep a
penetration as stick or other types of welding.
GTAW is a slow method of welding, which results in an
expensive product.
It can be used to weld aluminum, magnesium, titanium,
and stainless steels.
Plasma-Arc welding (PAW) when an arc is created in
a plasma (ionized) gas and a filler material may or may not
be applied to the weld joint

Non-consumable Electrodes
IT 208

Chapter 14

30

Thank You