M.Rogers M.

Rogers
WI 3.1 WI 3.1
Welding Consumables
Welding consumables may be:
§ Shielded arc filler wires, lengths or rolls

§ Covered electrodes

§ Shielding gases
Welding Inspection
Consumables § Separately supplied flux

Course notes section reference 14

§ Fusible inserts
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M.Rogers M.Rogers
WI 3.1
Welding Consumables WI 3.1
MMA Welding Consumables
Welding consumables for MMA
Each consumable is critical in respect to:

§ Size § Consist of a core wire typically between 350-450mm in

length and from 2.5-6mm in diameter
§ Classification / Supplier § The wire is covered with an extruded flux coating

§ Condition § The core wire is generally of a low quality rimming steel

§ The weld quality is refined by the addition of refining
§ Handling and storage agents in the flux coating

§ Treatments e.g. baking / drying § The flux coating contains many elements and
compounds that all have a variety of functions during
Handling and storage is critical for consumable welding
control
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M.Rogers M.Rogers
WI 3.1
MMA Welding Consumables WI 3.1
Welding Consumable Standards
Functions of flux constituents: MMA (SMAW) MIG/MAG (GMAW) TIG (GTAW)

§ To aid arc ignition, to improve arc stabilisation § BS 639: Steel electrodes § BS 2901: Filler wires

§ Deoxidise the solidifying weld metal § BS EN 440: Filler wires

§ BS EN 499: Steel electrodes
§ To produce a shielding gas to protect the arc § AWS A5.9: Filler wires
§ AWS A5.1 Non-alloyed steel
column § BS EN 439: Shielding gases
electrodes
§ To refine and clean the solidifying weld-metal § AWS A5.5 Alloyed steel
SAW
§ To add alloying elements electrodes
§ BS 4165: Wire and fluxes
§ To control hydrogen contents in the weld § BS EN 756: Wire electrodes
§ AWS A5.4 Chromium electrodes
§ To form a cone at the end of the electrode, which § BS EN 760: Fluxes
directs the arc § AWS A5.17: Wires and fluxes

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M.Rogers M.Rogers
WI 3.1
MMA Welding Consumables WI 3.1
MMA Welding Consumables

Common flux types Rutile electrodes

§ Used mainly on general purpose work
§ Rutile § Low pressure pipework, support
brackets.
§ Cellulose
Flux constituents include:
§ Basic § Titanium dioxide, slag former
§ Clay - binding agent
§ Acidic § Sodium silicate - main ionizer

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M.Rogers M.Rogers
WI 3.1
Rutile Electrodes WI 3.1
MMA Welding Consumables
Cellulose electrodes
Advantages Disadvantages
§ Used mainly for pipeline welding
§ Easy to use § High in hydrogen
§ Suitable for welding in all position especially
§ Low cost / control § High crack tendency vertical down, stove technique
§ Smooth weld profiles § Low strength § They produce a gas shield high in hydrogen
§ Slag easily detachable § Low toughness values § Deep penetration/fusion characteristics
(Friable slag) Flux constituents include:

§ High deposition possible § Cellulose, natural organic compounds

§ Titanium dioxide - slag former
with the addition of iron
§ Sodium silicate/potassium silicate - main ionizers
powder
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M.Rogers M.Rogers
WI 3.1
Cellulose Electrodes WI 3.1
MMA Welding Consumables
Basic electrodes
Advantages Disadvantages
§ Used mainly for high pressure work and for materials of
§ Deep penetration/fusion § High in hydrogen high tensile strength
§ They are capable of producing welds of a low hydrogen
§ Suitable for welding in all § High crack tendency
content
positions § Rough cap appearance § Prior to use they may be baked to give a low hydrogen
§ Fast travel speeds § High spatter contents potential typically 300oC for 1 hour plus
§ Large volumes of Flux constituents include:
§ Low deposition rates
§ Limestone (calcium carbonate) - gas former
shielding gas
§ Fluorspar - slag former
§ Low control § Sodium silicate/potassium silicate - main ionizers

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M.Rogers M.Rogers
WI 3.1
Basic Electrodes WI 3.1
BS 639 MMA Covered Electrodes
A Typical BS 639 Specification: E 51 33 B 160 2 0 H
Reference given in box letter A) B) C) D) E) F) G)
Advantages Disadvantages A) Tensile Strength: B) Toughness:

§ High toughness values § High cost Symbol Min Yield

Strength
Tensile Strength
N/mm2
1st Digit
28 J
2nd Digit
47J
Testing
Temperature
N/mm2
§ High control 0 0 Not specified
§ Low hydrogen contents 43 330 430-550 1 1 +20
§ High welder skill required 51 380 510-650 2 2 0
§ Low crack tendency C) Covering types:
3 3 -20
§ Convex weld profiles B Basic
4 4 -30
5 5 -40
§ Poor stop/start properties BB Basic High Efficiency
C Cellulosic D) Electrode Efficiency
(porosity) O Oxidising % Recovery to the nearest 10%
R Rutile Above 10%
RR Rutile High Efficiency
S Other types
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M.Rogers M.Rogers
WI 3.1
BS 639 MMA Covered Electrodes WI 3.1
BS 639 MMA Covered Electrodes
A Typical BS 639 Specification: E 51 33 B 160 2 0 H
Reference given in box letter A) B) C) D) E) F) G) E 51 33 B 160 2 0 H
E) Welding Position: F) Electrical Characteristic
Covered Electrode
Symbol Position Symbol DC Polarity AC min OCV
0 Polarity as Not Yield Strength N/mm2
1 All positions. recommended recommended Tensile Strength N/mm2
2 All positions except vertical 1 + or - 50 OCV
down.
2 - 50 OCV Toughness
3 Flat Butts & Fillets and HV
3 + 50 OCV
Fillets. Flux Covering
4 + or - 70 OCV
4 Flat Butts & Fillets
5 - 70 OCV Weld Metal Recovery
5 Vertical down and position 3 6 + 70 OCV
Iron Powder content
6 Any position not classified 7 + or - 90 OCV Welding Position
above 8 - 90 OCV
Electrical characteristic
G) Hydrogen Control 9 + 90 OCV
H indicates low hydrogen potential Hydrogen Control
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M.Rogers M.Rogers
WI 3.1
BS 639 MMA Covered Electrodes WI 3.1
BS EN 499 MMA Covered Electrodes

Electrodes classified as follows:

Compulsory
§ E 35 - Minimum yield strength 355 N/mm2
Tensile strength 440 - 570 N/mm2
§ E 38 - Minimum yield strength 380 N/mm2
Tensile strength 470 - 600 N/mm2
§ E 42 - Minimum yield strength 420 N/mm2
Tensile strength 500 - 640 N/mm2
§ E 46 - Minimum yield strength 460 N/mm2
Tensile strength 530 - 680 N/mm2
Optional
§ E 50 - Minimum yield strength 500 N/mm2
Tensile strength 560 - 720 N/mm2
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M.Rogers M.Rogers
WI 3.1
BS EN 499 MMA Covered Electrodes WI 3.1
BS EN 499 MMA Covered Electrodes
A Typical BS EN 499 Specification: E 46 3 1Ni B 5 4 H5 A Typical BS EN 499 Specification: E 46 3 1Ni B 5 4 H5
Reference given in box letter A) B) C) D) E) F) G) Reference given in box letter A) B) C) D) E) F) G)
C) Alloying: D) Covering type:
A) Tensile Strength: B) Toughness at a minimum impact Deposited weld metal chemical composition Symbol
Symbol Min Tensile Min energy 47 Joules:
Symbol Mn Mo Ni A Acidic
Yield Strength E % Z No Requirement
None 2.0 - - C Cellulosic
Strength N/mm2 A +20
N/mm2 Mo 1.4 0.3-0.6 - R Rutile
O 0
35 355 440-570 22 Mn Mo >1.4-2.0 0.3-0.6 RR Rutile thick
2 -20 covering
38 380 470-600 20 1Ni 1.4 - 0.6-1.2
3 -30 RC Rutile/Cellulosic
42 420 500-640 20 2Ni 1.4 - 1.8-2.6
4 -40 RA Rutile/Acidic
46 460 530-680 20 3Ni 1.4 - >2.6-3.8
5 -50 RB Rutile/Basic
50 500 560-720 18 Mn 1Ni >1.4 - 0.6-1.2
6 -60 B Basic
1Ni Mo 1.4 0.3-0.6 0.6-1.2

Z Any other agreed

composition
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M.Rogers M.Rogers
WI 3.1

BS EN 499 MMA Covered Electrodes

WI 3.1
BS EN 499 MMA Covered Electrodes
E) Electrical characteristic + Recovery % E 46 3 1Ni B 5 4 H5
A) B) C) D) E) F) G)
E 46 3 1Ni B 5 4 H5
Symbol Recovery % Current type
1 < 105 AC + DC F) Welding Position: Covered Electrode
2 < 105 DC Symbol Position Yield Strength N/mm2
3 > 105 < 125 AC + DC 1 All positions Tensile Strength N/mm2
4 > 105 < 125 DC 2 All positions except
5 > 125 <160 AC + DC vertical down Toughness
6 > 125 <160 DC 3 Flat Butt & Fillet + HV
7 > 160 AC + DC
Fillets Chemical composition
4 Flat Butt & Fillet
8 > 160 DC Flux Covering
5 Vertical down +
G) Hydrogen Content of deposited metal positions of symbol 3 Weld Metal Recovery
Symbol ml/100gm and Current Type
H5 5
H 10 10
Welding Position
H 15 15 Hydrogen Content
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M.Rogers M.Rogers
WI 3.1
AWS A5
A5.5 Alloyed Electrodes WI 3.1
AWS A5.1 & A5.5 Alloyed Electrodes

E 80 1 8 M G Example AWS electrode flux types

Covered Electrode
§Cellulose flux-ends in 0,1
Tensile Strength (p.s.i) E6010, E6011, E7010, E8011

Welding Position
§Rutile flux-ends in 2,3,4
E5012, E6012, E6013, E6014
Flux Covering
§Basic flux-ends in 5,6,7,8
Moisture Control E6016, E7017, E8018, E9018

Alloy Content
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M.Rogers M.Rogers
WI 3.1
MMA Electrode Inspection Points WI 3.1
TIG Welding Consumables
Welding consumables for TIG
§ Consist of a wire and gas, though tungsten electrodes being
1: Electrode size Diameter & length classed as non-consumable may be considered consumables
(dia 1.6-10mm)
§ The wire needs to be of a very high quality as normally no extra
Cracks, chips & concentricity cleaning elements are added
2: Electrode condition
§ The wire is copper coated to resist corrosion
§ The wire normally comes in 1m lengths with the applicable code
stamped onto the wire for traceability
3: Electrode specification Correct specification/code
§ The shielding gases used are mainly Argon and Helium, usually
E 51 33 B
of the highest quality (99.9% pure).
§ Ceramic shields, the size and shape depends on application
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WI 3.1
MIG/MAG Welding Consumables WI 3.1
Fusible Inserts
Welding consumables for MIG/MAG
Pre-placed filler material
§ Consist of a wire and gas, the same quality as for TIG
wires
§ The wires are copper coated, main purpose corrosion
resistance and electrical pick-up Before Welding After Welding
§ Wires are available in sizes from 0.6-1.6 mm in diameter
Other terms used include:
§ Most wires are supplied on a 15kg spool, with finer wires
supplied on a 1kg spool § E B inserts (Electric Boat Company)
§ Gases can be pure CO2, CO2+Argon mixes and
§ Consumable socket rings (CSR)
Argon+2%O2 mixes (stainless steels).

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M.Rogers M.Rogers
WI 3.1 WI 3.1
Questions

Any Questions Welding Consumables

QU 1. Why are basic electrodes used mainly on high strength
materials and what controls are required when using basic
electrodes
QU 2. What standard is the following electrode classification
taken from and briefly discuss each separate part of the
coding E 80 18 M
QU 3. Why are cellulose electrodes commonly used for the
welding of pressure pipe lines
QU 4. Give a brief description of fusible insert and state two
alterative names given for the insert
QU 5. What standard is the following electrode classification
taken from and briefly discuss each separate part of the
coding E 42 3 1Ni B 4 2 H10
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