MEE 714

Advanced Welding Technology

Dr. Arjyajyoti Goswami

[email protected]
+91-9953167384
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Covered in MEC402
SMAW process (in detail)
Straight polarity vs Reverse Polarity
Electrode coating and its functions
Welding DC vs AC supply

To be covered in MEE714
Coding of electrodes
Types of electrode coatings (in more detail)
Thin vs Thick coatings
Constituents of flux (factors to consider for its design)
Basicity Index
Why study about it
Through a system of coding the guidelines and requirements of
welding can easily be communicated from one engineer to another.

Through a system of coding it becomes easier to specify the electrode

suited for a particular condition of welding. It helps in standardization.

AWS codes are prevalent in most parts of world. But in India we use
our own system of electrode codes. In order to pick the best suited
electrode for a particular application we must be aware what the
codes mean. Also we should be able to ask for a particular code which
we think is suitable for our work.
 tl : dr
Codes helps in standardization across engineers and engineering
practices, through effective communication.
Based on IS 814:1991 codes revised on 2004
This coding system is for heavy coated electrodes for C and C-Mg
steels. This system is the most elaborate system of electrode
classification.
An Electrode code has the following elements:
I. A prefix letter
II. A letter or letters to denote the type of covering
III. A code number of four digits
IV. In some cases a suffix consisting of one or more letters to indicate
special characteristics
I. Prefix Letter
E : To indicate a covered electrode manufactured through extrusion.
All electrodes are manufactured through extrusion, hence almost all
codes starts with the prefix letter E.

II. Letter of Letters to denote the type of covering (flux)

A : Acidic RR: Rutile heavy electrode
B : Basic S : Any other type not
C: Cellulosic mentioned above
R : Rutile
(Titania)
III. A Code number of FOUR digits
First Two digits : Mechanical properties of weld metal deposit
Last Two digits : Performance characteristics of the covering

1st digit: it indicates UTS in combination with yield strength

It is either 4 or 5.
4 : it indicated UTS of weld metal deposit in between 410-510N/mm2
and yield strength of 330N/mm2
5: it indicated UTS of weld metal deposit in between 510-610N/mm2
and yield strength of 360N/mm2
2nd digit: it indicates a combination of elongation and impact
properties of the electrode material for the two ranges of tensile
properties specified by the first number.
For tensile range of 410-510N/mm2
Designation digit % elongation on Gauge length of Minm. Impact strength
5.65 (minm. Cross ection of in Joules at ֯ C
tensile specimen)^0.5 (mm)
0 No requirements of elongation and impact value
1 20 47/127
2 22 47/0
3 24 47/-20
4 24 27/-3
For tensile range of 510-610N/mm2
Designation digit % elongation on Gauge Minm. Impact strength in
length of 5.65 (minm. Joules at ֯ C
Cross ection of tensile
specimen)^0.5

0 No requirements of elongation and impact value

1 18 47/27
2 18 47/0
3 20 47/-20
4 20 27/-30
5 20 27/-40
6 20 27/-46
3rd digit: it indicates the welding position in which the elctrode may be
used.
Third Digit Welding position
1 All - Flat, Horizontal, Vertical, Overhead
2 All except Vertical downwards
3 Flat butt, Fillet (Hori. And Flat)
4 Flat butt, Flat fillet
5 Vertical downwards, flat butt, fillet, horizontal flat
6 Any random unspecified
4th digit: it indicates the current and voltage conditions in which the
electrode is to be used
Fourth Digit Welding current and Voltage conditions
0 D+
1 D+/-, A50
2 D- A50
3 D+ A50
4 D+/- A70
5 D- A70
6 D+ A70
7 D+/- A90
8 D- A90
9 D+ A90
D+ : DCEP; D- : DCEN; D+/- : either DCEP or DCEN, A: Welding current
IV. Suffix Letter
H1 : Hydrogen controlled electrode with a diffusible hydrogen up to
15ml/100gm of weld metal deposit
H2: Hydrogen controlled electrode with a diffusible hydrogen up to
10ml/100gm of weld metal deposit
H3: Hydrogen controlled electrode with a diffusible hydrogen up to
5ml/100gm of weld metal deposit
X : Radiography quality weld
Example. ER 4317 H1 X
E: Extruded electrode
R : Rutile (TiO2) covering
4 : UTS of weld metal deposit in between 410-510N/mm2 and yield
strength of 330N/mm2
3 : Minm. Elongation on a gauge length of 5.65(s0)^0.5 should be 24%
with a minimum impact value of 47J at -20֯C
1: All position welding can be done
7: To be used with straight polarity (DCEP) and Welding current of 90A
H1 : It is a Hydrogen controlled electrode using it will result in
diffusible hydrogen up to 15ml/100gm of weld metal deposit
X : Radiography quality weld can be made
American Welding Society
coding system
• The prefix "E" designates an arc welding electrode.
• The first two digits of a 4-digit number and the first three digits of 5-
digit number indicate minimum tensile strength.
For example, E6010 is a 60,000 psi tensile strength electrode while
E10018 designates a 100,000 psi tensile strength electrode.
• The next to last digit indicates position. The "1" designates an all
position electrode, "2" is for flat and horizontal positions only; while
"4" indicates an electrode that can be used for flat, horizontal,
vertical down and overhead.
• Last digit indicate the type of coating and the correct polarity or
current to use.
Chart for the last digit
https://www.weldingtipsandtricks.com/6011-or-7018.html
Example. E 6013
E: Arc Welding electrode
60 : Electrode has a tensile strength of 60,000psi
1 : The electrode can be used for all position weld
3 : The electrode has a coating rich in titania (TiO2) and potassium.
Can be used with DCEP as well as AC.
Functions of flux:
• Provide arc stability
• Protection to metal droplet during
deposition
• Deoxidize the weld metal
• Dissolve any solute gas present
• Protect the weld metal
• Act as a means to transfer alloying
elements to the weld metal
Types of electrode fluxes
Cellulose
This type of covering is aimed mainly at providing gas shielding in the
arc region. Produces less slag, large amount of gases, HIC maybe a
problem.
Using such type of coating generally results in Fine Grained Metal
deposited.
For DC power source the flux composition uses NaSi as binder while for
AC power source KSi is used as a binder.
Rutile
Produces large amount of slag as its main function is to provide the slag
shielding of the deposited weld metal. Produces a quiet arc, low spatter
and the resultant weld generally has a good appearance.
Acidic
Has large amounts of deoxidizers and denitriders in the form of Fe alloys.
The resulting slag dissolves the basic oxides (mainly MnO) and
consequently large amount of Mn is transferred to the slag.
This lowers the viscosity of the slag, improves the appearance of the
weld bead and allows all position welds.
Basic
Using this coating results in lowest hydrogen inclusion, therefore such
electrodes are also called a low hydrogen electrodes.
Commonly used in welding of structural steels. Slags produced are
highly basic in nature.
The welds are highly ductile and resistant to cracking due to lowest
hydrogen cracking.
Oxide
Fe Oxides + Sillica + Natural Silicates
These are called oxide coatings because with this coating the molten slag
absorbs large amount of oxygen, iron oxide or iron nitride.
Produces medium penetration, low spatter, and good appearance
Fe powder coatings
Fe powder is added to increase the deposition efficiency of electrode by
almost 210%.
Higher welding speeds are feasible by virtue of higher current carrying
capacity.
Improves productivity.
Constituent of flux
Gas Former
Flux must contain such element which upon burning will release large
amount of gas at the welding zone, so as to protect/shield the molten
metal from the atmosphere. Most commonly Calcium carbonate is used.
Arc Stabilizers
Elements to promote arcing and its stability. Rutile, Potassium Sillicate,
Potassium Titanate
Slag Formers (Oxides)
Are essential to shield the welding bead from the atmosphere and to
enable it to cool slowly otherwise the bead will become brittle and likely
to crack. Alumina, Rutile.
Binders (Sillicates)
Used to hold the constituents of the flux together as a single mass, so
that the flux will have both cohesion and adhesion w.r.t electrode. KSi,
NaSi
Lubricants
Used to reduce the extrusion pressure and the friction between the
dough and the extrusion cylinder. MICA, Glycerine
Alloying additives
Certain additives which can not be present in the electrode can be made
part of the flux. During welding the flux melts and these additives
combine with the molten metal thus improving its properties.
Basicity Index (Tuliani Equation)

Acidic Flux <1

1< Neutral <1.5
1.5< Semi Basic < 2.5
Basic > 2.5