SPECIFICATION FOR ALUMINUM AND ALUMINUM ALLOY ELECTRODES FOR SHIELDED METAL ARC WELDING SFA-5.3 @ (identical with AWS Specification AS3-91) 1. Scope ‘This specification prescribes requirements for the classification of aluminum and aluminum alloy elec trodes for shielded metal are welding. SECTION A — GENERAL REQUIREMENTS 2. Classification 2.1 The electrodes covered by this specification are classified according to the chemical composition of the core wire as specified in Table 1, and mechanical properties of a groove weld 2.2 An electrode classified under one classification shall not be classified under any other class this specification, 3. Acceptance Acceptancelof the electrode shall be in accordance with the provisions of ANSI/AWS AS.O1, Filler Metal Procurement Guidelines? 4. Certification By affixing the AWS specification and classification designations to the packaging, or the classification to | See AS, Acceptance (ia the Appendix), for Further information conceening sceptance. testing "of the’ material shipped, and ANSIAWS ASI, Filler Metal Procurement Guidelines + AWS Stantards can be obained fom the American Welding Society, 550 NOW. Leleune Road, P.O, Box 351080, Miami, Fonda 33135 33 the product, the manufacturer certifies that the product meets the requirements of this specification? 5. Units of Measure and Rounding-Off Procedure Sa US, Customary Units are the standard units of measure in this specification. The SI Units are given as equivalent values to the U.S. Customary Units. The standard sizes and dimensions in the two systems are not identical, and for this reason conversion from a standard size or dimension in one system will not always coincide with a standard size or dimension in the other. Suitable conversions, encompassing standard sizes of both, can be made, however. if appropriate tolerances are applied in each case. 5.2 For the purpose of determining conformance with this specification, an observed or calculated value shall be rounded to the nearest 1000 psi (7 MPa) for tensile and yield strength, and (0 the “nearest unit" in the last right-hand place of figures used in expressing the limiting value for other quantities in accordance with the rounding-off method given in ASTM E29, Practice for Using Significant Digits in Test Data to Determine Conformance with Specifcations.* "See Ad, Centfcaion (in the Appenli), fr further informstion concemning cerifcaton and the testing called for to mect is requirement “ASTM Stndaeds can be obtained from the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Penasyva nia 191081998 SECTION 1 SFAS3 fi pssoxa ou op Aan ei aunsuo 0} pavei99 tus subujoes0uh Jo unowe ou MOM o asn0> yam wou, rE 24 29 "bapm 3109 ay, “e {ay us pareepuy 5: uaa oye fo 4 ri 2 sua nods 94 40s pesfeue 99 '$10N Topuewsy—ssto~«OO~*«wODS*CS*C«OSC«wSC«CO 0c ress ‘evorew 1008 sppurewmy = sO SOO OOD SOT orosoD LO 90 coocey e003 amu ove sto sv waco, —re— soo ozaso0 e cotter ota Ww rey wea 7a uw wo ow "9 Py 1s ‘wOReUBSOG —_UOTEDYESEID aun jn To wwe a0 ni s «s(AN3OU3d LHOTAM) BYIM 3YO9 YOS SINSWAAINDIY NOLLISOdWOD TWOINZHD TaTavL 34PART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS srass TABLE 2 REQUIRED TESTS Tieaade Bie aus Chemical Tension ee ctassatn nam rey Tee test my BA ri 5 x10, eo x 4 Be, ee x m Mw 64 x eos x wae ‘Chemical analysis of the core wire or the stock from which Its made, b. Two transverse specimens (Figure 2), . Tw transverse specimens — one face and one root (Figure 3. 6. Electrodes zn (4.0 mm) ard smaller shal be classified or the Bass ofthe results obtned with the "Zn (4.0 min) sie afte Same clasifcalon fe: Electrodes %y in. (4.8 mm) and larger shall be clasiied on the bass of the results obtained with the gin. (64 mm) size ofthe same classification. SECTION B — TESTS, PROCEDURES, AND REQUIREMENTS: 6, Summary of Tests The tests required for each classification are specified in Table 2. The purpose of these tests is to determine the chemical composition of the core wire and the mechanical properties of the weld. The base metal for the weld test assemblies, the welding and testing procedures to be employed, and the results required, are given in Sections 8 through 11. 7. Retest If the results of any tests fail to mect the requirement, that test shall be repeated twice. The results of both tests shall meet the requirement. Specimens or samples for retest may be taken from the original test assembly for sample, or from a new test assembly or sample. For chemical analysis, retest need be only for those specific elements that failed to meet the test requirement 8, Weld Test Assembly 8.1 One weld test assembly is required. It is the groove weld in Fig. 1 for mechanical properties of the welded joint 8.2 Preparation of the weld test assembly shall. be as prescribed in 8.3, Fig. 1, and Table 2 (Footnotes d 55 ‘and e) using base metal of the appropriate type specified in Table 3. Testing of the assembly shall be as specified in Sections 10, Tension Test, and 11, Bend Test. 8.3 The test assembly shall be preheated to a tempera- ture between 350°F and 400°F (175°C and 205°C), and shielded metal are (SMA) welded from one side, in the lat position. The test assembly should be precam- bered or restrained so that warping due to welding will not cause the finished test assembly to be out-of-plane by more than 5 degrees. Ifthe completed test assembly is mote than 5 degrees out-of-plane it shall be straight- ened at room temperature. 9. Chemical Analysis 9.1 A sample of the core wire, or the stock from ‘which it is made, shall be prepared for chemical analysis. 9.2 The sample shall be analyzed by accepted analyti- cal methods. The referee method shall be ASTM E34, Standard Methods for Chemical Analysis of Aluminum and Aluminum Alloys. 9.3 The results of the analysis shall meet the require- ments of Table 1 for the classification of electrode under testSFAS3 1998 SECTION II 5 3 q i 34 & i a = 112 3 — 2 5 4 3 - SEGAL | WARPNG SMX a Tae w ey stem en TEER rao eta s AL ONENSONS NINCHES st eouauenrs eee foe Openeg = 118 in we 18 1s 2 Backing material shall be the same alloy as the base mers we a 2 Ba sown. 3 ee tacnwr uaa oa ornare orb eee woM Foe ef RO he 8 FIG. 1 GROOVE WELD TEST ASSEMBLY FOR MECHANICAL PROPERTIES 56PART C — SPECIFICATIONS FOR WELDING RODS, waco Rn mn sass a saa sees rover se sence rma esses TEESE wal wt THIS SECTION MACHINED, = wens ay ag Notes: 1. Weid reinforcement shal be removed fish with the base matal, Undarcut shall not be removed. All mactining shal! be done Uangverse to the weid 2. Al specimens shal be pally identifed on both ends, FIG. 2 TENSION TEST SPECIMEN 10, Tension Test 10.1 Two transverse tension test specimens shall be machined from the groove weld described in Section 8, Weld Test Assembly, and shown in Fig. 1. The dimensions of the specimens shall be as specified in Fig. 2 10.2 The specimens shall be tested in the manner described in the tension test section of ANSI/AWS BAO, Standard Methods for Mechanical Testing of Welds. st 10.3 The results of the tension test shall meet the requirements specified in Table 4, 11, Bend Test 111 One transverse face and one transverse root bend specimen, as required in Table 2, shall be machined from the groove weld test assembly described in Section 8 and shown in Fig. 1. The dimensions of the specimens shall be as shown in Fig. 3SFAS3 TABLE 4 TENSION TEST REQUIREMENTS. Tensile Strenath, Min, aws. Clasifcation Bal MPa en100 72000 227 3003 24000 965 4083 14000 965 Fracture may occur lv ether th Base wital or the weld metal 11.2 The specimens shall be tested in the manner described in the guided bend test section of ANSI/AWS B40 by bending them uniformly through 180? over a 1-1/4 in, (2 mm) radius in any suitable jig. Two standard bend test jigs are shown in Fig. 4. Positioning of the face bend specimen shall be such that the face of the weld is in tension, Positioning of the root bend specimen shall be such that the root of the weld in is tension. For both types of transverse bend specimen, the weld shall be at the center of the bend, 11.3 Each specimen, after bending, shall conform to the 1-1/4 in. (32 mm) radius, with an appropriate allowance for springback, and the weld metal shall show no crack or other open defect exceeding 1/8 in, (G2 mm) measured in any direction on the convex surface, when examined with the unaided eye. Cracks that occur on the corners of a specimen during testing 1998 SECTION It which show no evidence of inclusions or other fusion- type discontinuities, shall not be a basis for rejection. SECTION C — MANUFACTURE, IDENTIFICATION, AND PACKAGING 12, Method of Manufacture ‘The electrodes classified according to this specifica~ tion may be manufactured by any method that will produce electrodes that meet the requirements of this specification, 13, Standard Sizes and Lengths 13.1 Standard sizes (diameter of the core wire) and lengths of electrodes are shown in Table 5. 13.2 The diameter of the core wire shall not vary more than +0.002 in. (005 mm) from the diameter specified. The length shall not vary more than 3/8 in, (£95 mm) from that specified. 14, Core Wire and Covering 14.1 The core wire and covering shall be free of defects that would interfere with uniform deposition of the electrode. 14,2 The core wire and the covering shall be concen- tic to the extent that the maximum core-plus-one- covering dimension shall not exceed the minimum THESE EDGES SHALL BE SAW CUT AND FILED OR MACHINED. ‘SI EQUIVALENTS =r vB 32 we 8s R38 1024 Notes: RAD, 118 IN. MAX 1.Weld reinforcement shall be removed flush with the base metal. Urdercut shall not be removed, All machining shall bs done transverse to the wo. 2. Comers of the bend specimens shall be rounded 3. Al specimens shal be planiyidentted on both ends. FIG. 3 BEND TEST SPECIMEN 58PART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFAS3 ‘AS REQUIRED, HARDENED ROLLERS 1-1/2 IN. IN DIAMETER MAY BE SUBSTITUTED FOR JIG SHOULDERS ‘TAPPED HOLE TO SUIT TESTING MACHINE J ssreourco—j 3718 . ©: 8 oe 4 MEMBER me 8 (A) STANDARD GUIDED BEND TEST JIG [AN denensions in inches. Si EQUIVALENTS ” rm rw 18. 322 3 wa 64242 Ww 27338 88 3 9 378 88 Notes +418 Py 402113 1. Plunger and intoror ie sutaces shal have a machined surface. via 32 e413 2. AN dimersons are in inches. vine 8 east 3. Specie dimensions are given for a 3/8 in, (9.5 mm) thick specimen, rae 18 4. The sie of the specmen tured toward the die shal be the weld "ace forthe face ° 229 bend specimens and the weld root forthe rot-bend specinen. FIG. 4 BEND TEST JIGS 9SFAS3 1998 SECTION 1 ROLLER ANY DIAMETER 2.072. wei SUEQUVALENTS: cm cI 38 95 14 2 2are on (®) WRAP-AROUND BEND TEST JIG Notes: 1. Al mensions are in inchs. 2.Dimensions not shown are the option of the designer. I is essential fr the ig to have adequate rig #0 that the pars wil not spring curing te bercing operation 8. One end of the specimen shal be frmy clamped tothe jg $0 that the specimen does not side during benaing. 4.The weld end heatatfected zone of the transverse bend specimen shall be completely within the bent porion of the specimen afer tasting '5. he side of the specimen turned toward the roller shall be the weld "ace for the face-bend epecimens and the weld root for the root-bend specimens. 6. The specimens shal be removed from the jg whan the outer roll has been rotated 180° from the starting point, FIG. 4 BEND TEST JIGS (CONT’D) TABLE 5 STANDARD SIZES Diameter of ‘Standard Core Wire, Lengths AWS Classification in mm a am %, (0.098) 24 % (325) 32 %, (0.56) 40 380 100, £3003, and E6083 %, (0.186) 48 (0250) 6a %y (0312) 80 8 450PART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES. AND FILLER METALS core-plus-one covering dimension by more than the following: (1) Seven percent of the mean dimension in size 3/32 in. 2.4 mm) (2) Five percent of the mean dimension in sizes 1/8 in, (3.2 mm) and 5/32 in. (40 mm) (3) Four percent of the mean dimension in sizes 3/16 in. (4.8 mm) and larger Concentricity may be measured by any suitable ‘means. 143 The coverings shall be such that they are not readily damaged by ordinary handling, and they shall not blister when heated o 40°F (200°C)) They shal be consumed uniformly during welding and shall not blister or melt back from the core wire. The flux residue they produce shall be readily removable. 15, Exposed Core 15.1 The grip end of each electrode shall be bare (free of covering) for a distance of not less than 1/2 in. (13 mm), nor more than 1-1/4 in, GO mm), for electrodes 5/32 in. (4.0 mm) and smaller, and not less than 3/4 in. (19 mm) nor more than 1-1/2 in. GS mm) for electrodes 3/16 in. (4.8 mm) and larger, 10 provide for electrical contact with the electrode holder. 15.2 The arc end of each electrode shall be sufficiently bare and the covering sufficiently tapered to permit ‘easy striking of the arc. The length of the bare portion (measured from the end of the core wire to the location ‘where the full cross section of the covering is obtained) shall not exceed 1/8 in. (3 mm) or the diameter of the core wire, whichever is less. Electrodes with chipped. coverings near the arc end, baring the core wire no ‘more than the lesser of 1/4 in. (6 mm) of twice the diameter of the core wire, meet the requirements of this specification, provided no chip uncovers more than 50 percent of the circumference of the core, 16, Electrode Identification Alll electrodes shall be identified as follows: 16.1 At least one imprint ofthe electrode classification shall be applied to the electrode covering within 2- 1/2 in, (65 mm) of the grip end of the electrode, 16.2 The numbers and letters of the imprint shall be of bold block type of a size large enough to be legible, 16.3 The ink used for imprinting shall provide suffi cient contrast with the electrode covering so that, in 6 SFAS3 normal use, the numbers and letters are legible both before and after welding. 16.4 The prefix letter “E” in the electrode classifica may be omitted from the imprint. 16.5 In ew of imprinting, electrodes may be identified by the following: (1) Attaching to the bare grip end of each electrode a pressure sensitive tape bearing the classification number. (2) Embossing the classification number on the bare stip end ofeach electrode. In tis cae, a slight fattening of the grip end wil be permitted in the area of the embossing 17, Packaging, 17.1 Electrodes shall be suitably packaged to protect, them from damage during shipment and storage under normal conditions. 172 Standard package weights shall be 1 Ib (0.45 kg), 5 Ib (2.3 kg) and 10 Ib (4.5 kg) net weight. Other package weights meet the requirements of this specification when agreed by the purchaser and supplier. 18, Marking of Packages 18.1 The following product information (as a mini- ‘mum) shall be legibly marked on the outside of each unit package: (1) AWS specification and classification designation (year of issue may be excluded) (2) Supplier's name and trade designation {G) Size and net weight (4) Lot, control, or heat number 18.2 The following precautionary information (as @ minimum) shall be prominently displayed in legible print on all packages of electrodes, including individual unit packages enclosed with a larger package. WARNING: PROTECT yourself and others. READ and understand this information. FUMES AND GASES can be dangerous to your health, ARC RAYS can injure eyes and burn ski ELECTRIC SHOCK can kill.SFAS3 1988 SECTION IL © Before use, read and understand the manufacturer's instructions, manufacturer's Material Safety Data ‘Sheets (MSDSs), and your employer's safety prac- tices. © Keep your head out of the fumes. ‘© Use enough ventilation, exhaust at the are, or both to keep fumes and gases away from your breathing zone and the general area. © Wear corrective eye, ear and body protection. © See American National Standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society, 550 N.W. LeJeune Road, P.O. Box 351040, Miami, Florida 33135; OSHA Safety ‘and Health Standards, 29 CFR 1910, available from the U.S. Government Printing Office, Wash- ington, DC 20402 DO NOT REMOVE THIS INFORMATION aPART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFAS3 Appendix Guide to Specification for Aluminum and Aluminum Alloy Electrodes for Shielded Metal Arc Welding (This Appendix is not « par of ANSVAWS AS.3-91, Specification for Aluminum and Aluminum Alloy Electrodes for Shielded Metal Are Welding, but is inchuded for information purposes only.) is to correlate the electrode classifications with their intended applications so the specification can be used effectively. Reference to appro- priate base metal specifications is made whenever that can be done and when it would be helpful. Such references are intended only as examples rather than ‘complete listings of the materials for which each filler metal is suitable, A2, Classification System “The system for identifying the electrode classifications in this specification follows the standard pattern used in other AWS filler metal specifications. The letler E at the beginning of each classification designation stands for electrode, The numerical portion of the designation in this specification conforms to the Aluminum Associa- tion registration for the composition of the core wire used in the electrode A3, Acceptance Acceptance of all welding materials classified under this specification is in accordance with ANSI/AWS AS.OL, Filler Metal Procurement Guidelines, as the specification states. Any testing a purchaser requires of the supplier, for material shipped in accordance with this Specification, shall be clearly stated in the purchase ‘order, according to the provisions of ANSI/AWS A5.01 In the absence of any such statement in the purchase ‘order, the supplier may ship the material with whatever testing normally is performed on material of that classi- fication, as specified in Schedule F, Table 1, of ANSIAWS A5.01. Testing in accordance with any ‘other Schedule in that Table must be specifically re- {quired by the purchase order. In such cases, acceptance of the material shipped shall be in accordance those requirements. Ad, Certification ‘The act of placing the AWS specification and classi- fication designations on the packaging enclosing the product, or the classification on the product. itself, constitutes the supplier's (manufacturer's) certification that the product meets all of the requirements of the specification. ‘The only testing requirement implicit inthis certifica- tion is that the manufacturer has actually conducted the tests required by the specification on material that is representative of that being shipped and that material met the requirements of the specification. Representative material, in this case, is any production ran of that ‘classification using the same formulation. “Certification” is not to be construed to mean that tests of any kind were necessarily conducted on samples of the specific material shipped. Tests on such material may or may not have been conducted. The basis for the certification required by the specification is the classification test of “tepresentative material” cited above, and the "Manu- facturer's Quality Assurance Program” in ANSI/AWS AS.OLSFAS3 AS. Ventilation During Welding AS.L Five major factors gover the quantity of fumes in the atmosphere to which welders and welding ‘operators are exposed during welding: (Z) Dimensions of the space in which welding is done (with special regard to the height of the ceiling) (2) Number of welders and welding operators work- ing in that space (3) Rate of evolution of fumes, gases, or dust, ac- cording 10 the materials and processes used (4) The proximity of the welders or welding operators. to the fumes as the fumes issue from the welding zone, and to the gases and dusts in the space in which they are working (5) The ventilation provided to the space in which the welding is done AS.2 American National Standard Z49.1, Safety in Welding and Cutting (published by the American Weld- ing Society), discusses the ventilation that is required during welding and should be referred to for details. Attention is drawn particularly to the Section of that document on Health Protection and Ventilation. A6. Welding Consideration A6.1 Welding aluminum by the shielded metal are process is a well established practice. However, develop- ment of the gas shielded arc welding processes and the many advantages of these processes offer has caused 1 shift away from the use of covered electrodes. This shift is expected to continue and the use of SMAW for aluminum will dwindle. When shielded metal are ‘welding, a flux covered electrode is held in the standard electrode holder and welding is done with direct current, electrode positive (DCEP). Important factors to be considered when welding aluminum with covered elec- trodes are moisture content of the electrode covering, and cleanliness of the electrode and base metal. Preheat is usually required to obtain good fusion and to improve soundness of the weld. Residual flux removal between passes is required to provide improved arc stability and weld fusion. Complete removal of the residual flux after welding is necessary to avoid corrosive attack in serviee, A62 The presence of moisture in the electrode covering is @ major cause of weld porosity. Dir. grease, or other contamination ofthe electrode can also Contribute 10 porosity. The absorption of moisture by the covering can be quite rapid, and the covering can deteriorate after only a few hours exposure to humid atmosphere. For this reason, the electrodes should be 1998 SECTION 11 stored in a dry, clean location. Electrodes taken from previously opened packages or those exposed to mois- ture should be “conditioned” by holding them at 350°F to 400°F (175°C to 205°C) for an hour before welding. ‘After conditioning, they should be stored in a heated cabinet at 150°F to 200°F (66°C to 94°C) until used, AG3 The minimum base metal thickness recom- mended for shielded metal are welding of aluminum is 1/8 in. (3.2 mm), For thicknesses less than 1/4 in. (64 mm), no cdge preparation other than a relatively smooth, square cut is required, Material over 1/4 in. (6.4 mm) should be beveled to a single-V-groove with 60 to 90 degree included angle. On very thick ‘material, U-grooves may be used. Depending upon base metal gauge, root-face thicknesses range between 1/16 in, (1.6 mm) and 1/4 in, (64 mm). A root opening of 1/32 in. to 1/16 in, (0.8 to L6 mm) is desirable for all groove welds. AGA Because of the high heat conductivity of alumi- rum, preheating to 250°F to 400°F (120°C to 205°C) is nearly always necessary on thick material to maintain the weld pool and proper fusion. Preheating will also help to avoid porosity due to too rapid cooling of the weld pool at the start of the weld. On complicated welds, preheating is useful in avoiding distortion. Pre- heating may be done by a torch using oxygen and acetylene of other suitable fucl gas, or by electrical resistance heating. Mechanical properties of 6XXX se- ries aluminum alloy weldments can be reduced signifi- cantly if the higher preheating temperatures [350°F (177°C) or higher] are applied. ‘AGS Single-pass SMA welds should be made when- ver possible. However, where thicker plates require multiple passes, thorough cleaning between passes is essential for optimum results. After the completion of any welding, the weld and work should be thoroughly cleaned of residual fux. The major portion of the residual flux can be removed by mechanical means, such a5 a rotary wire brush, slag hammer, or peening hammer, and the rest by steaming oF a hot-water rinse ‘The test for complete removal of residual Aux is to swab a solution of five percent silver nitrate on the weld areas. Foaming will occur if residual fux is present ‘A646 Interruption of the arc when shielded metal are welding aluminum can cause the formation of @ fused flux coating over the end of the electrode. Re- establishing a satisfactory arc is impossible unless this formation is removed,PART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS A7, Description and Intended Use of Electrodes ATA Electrodes of the E1100 classification produce weld metal of high ductility, good electrical conductiv- ity, and a minimum tensile strength of 12 000 psi (82.7 MPa). E1100 electrodes are used 10 weld 1100, 1350(EC), and other commercially pure aluminum alloys. A7.2 Electrodes of the E3003 classification produce weld metal of high ductility and a minimum tensile strength of 14 000 psi (96.5 MPa). E3003 electrodes, are used to weld aluminum alloys 1100 and 3003. A7.3 The E4043 classification contains approximately five percent silicon, which provides superior fluidity at welding temperatures, and for this reason is preferred for gencral purpose welding. The E4043 classification produces weld metal with fair ductility and a minimum tensile strength of 14 000 psi (97 MP2). E4043 elec- trodes can be used to weld the 6XXX series aluminum alloys, the SXXX series aluminum alloys (up to 25 percent Mg content), and aluminum-silicon casting alloys, as well as aluminum base metals 1100, 1350(EC), ‘and 3003, A7A For many aluminum applications, corrosion resistance of the weld is of prime importance. In such ‘cases, it is advantageous fo choose an electrode with a composition as close as practical to that of the base metal. For this use, covered electrodes for base metals SFA-S3 fother than 1100 and 3003 usually are not stocked and must be specially ordered. For application where corrosion resistance is important, it may be advantageous to use one of the gas shielded arc welding processes for which a wider range of filler metal compositions is available. AB. Special Tests It is recognized that supplementary tests may be necessary £0 determine the suitability of the electrodes for certain applications. In such cases, tests to determine specific properties such as corrosion resistance, electrical conductivity. mechanical properties at elevated or cryo- genic temperatures, and suitability for welding different combinations of aluminum base alloys may be required. ‘A9, Chemical Analysis The accepted and most widely used method for chemical analysis is found in ASTM E227, Optical Emission Spectrometric Analysis of Aluminum and Alu- ‘minum Alloy by the Point-to-Plane Technique. This ‘method analyzes a bulk sample and all elements simulta- neously. The ASTM E34, Test Method for Chemical Analysis of Aluminum and Aluminum Alioy prescribes individual test methods for which each element is tested. ‘The ASTM E34 test methods are used as a referee method if a dispute arises concerning a specific element analysis