ARC WELDING ELECTRODE

NAFFAA. AL-ANEZI MECHANICAL INSPECTOR OCTOBER 30,2005

2/16/2013

ARC WELDING ELECTRODES

CONTENTS OF PRESENTATION
HISTORY OF ARC WELDING COATED ELECTRODE WHAT IS AN ELECTRODE ? SIZE OF ELECRODE TYPES OF ELECTRODES COATING OF ELECTRODES TYPES OF ELECTRODE COATING STORAGE AND DRYING OF ELECTRODES TESTING OF ELECTRODES

2/16/2013

ARC WELDING ELECTRODES

HISTORY OF ARC WELDING COATED ELECTRODE

During first stage of work with metal arc welding a bare electrode was in use which was producing brittleness in the welded area and the weld was considerably weak. overheating effect on weld metal was noticed as there was no arc stability. To overcome these difficulties researchers developed a number of electrodes in 1907 that were covered with organic or mineral materials which is known as coating or flux.
2/16/2013

ARC WELDING ELECTRODES

WHAT IS AN ELECTRODE ?
The electrode may be defined as it is metal of which the sole purpose to carry the current and sustain the electric arc between its tip and base metal as well as in some cases it melts and supplies filler metal addition in the proposed joint. Electrode canELECTRODE into be divided two groups depending upon their functions which are given below.
COSUMABLE NON CONSUMABLE

2/16/2013

ARC WELDING ELECTRODES

CONSUMABLE AND NONCONSUMABLE

The

consumable electrodes refers to conduct current from electrode holder to metal and supply filler metal to the joint, like in SMAW. electrodes are only used to work as conductor carrying the current from electrode holder to base metal, like in GMAW
ARC WELDING ELECTRODES
5

non-consumable

2/16/2013

SIZE OF ELECTRODE
THE SIZE OF ELECTRODE REFERS TO THE DIAMETER OF ITS CORE WIRE. THE SIZE IS AVAILABLE IN METRIC AS WELL AS IN ENGLISH SYSTEM. LIKE 1/8, 3/32 AND 2 MM , 4 MM ETC. FLUX OR COVERING d D

STRIKING END

CORE

BARE END FOR GRIPPING

D = COVERING DIA , d= CORE DIA

2/16/2013

ARC WELDING ELECTRODES

TYPES OF ELECTRODE
Arc welding electrodes are classified in groups by American Welding Society (AWS a5.1-91) based upon their type of coating, mechanical properties and performance characteristics as well as weld metal chemistry. for our discussion we can categorize the electrode as under .
2/16/2013

ARC WELDING ELECTRODES

ELECTRODES TYPES
ELECTRODE

BASED UPON MATERIALS

BASED UPON COATING

2/16/2013

ARC WELDING ELECTRODES

BASED UPON MATERIALS

MILD STEEL ELECTRODES (AWS A5.1) LOW ALLOY STEEL ELECTRODES (AWS A5.5) STAINLESS STEEL ELECTRODES (AWS A5.4) ELECTRODES FOR CAST IRON (AWS A5.15) COPPER AND COPPER ALLOY ELECTRODE (AWSA5.6) NICKEL AND NICKEL ALLOY ELECTRODE (AWS A5.11) ALUMINIUM AND ALUMINIUM ALLOY ELECTRODE (AWS A5.3) ONLY FIRST THREE OF THE ABOVE WILL BE DISCUSSED.

2/16/2013

ARC WELDING ELECTRODES

MILD STEEL ELECTRODES

AMERICAN WELDING SOCIETY SPECIFICATION AWS 5.1 DESCRIBES THE REQUIREMENTS FOR MILD STEEL ELECTRODES. AN IDENTIFICATION SYSTEM HAS ADOPTED IN ORDER TO KNOW THE PROPERTIES AND CHEMISTRY OF THE ELECTRODE. THE IDENTIFICATION HAS EXPLAINED AS UNDER.

EXXXX E DESIGNATES FOR ELECTRODE

2/16/2013

ARC WELDING ELECTRODES

10

 EXXXX

FIRST TWO NUMBERS REFER TO TENSILE STRENGTH OF THE DEPOSITED WELD METAL. FOR EXAMPLE : E6010 60 MEANS 60, 000 PSI TENSILE
STRENGTH OF THE DEPOSITED WELD METAL.

2/16/2013

ARC WELDING ELECTRODES

11

EXX X X THIRD NUMBER IS DENOTING THE POSITION IN WHICH THE ELECTRODE CAN BE USED. EXAMPLE: 1 FOR ALL POSTION (F, V,OH,H) 2 FOR FLAT AND H-FILLET POSITION. 3 HAS NO DESIGNATION 4 FOR F, OH, H AND V-DOWN BUT MOSTLY SUITABLE FOR V-DOWN ONLY.

2/16/2013

ARC WELDING ELECTRODES

12

 EXXXX

LAST NUMBER REFERS TO CHEMICAL COMPOSITION PRESENT IN THE ELECTRODE COATING. FOR EXAMPLE : 0 CELLULOSE- SODIUM 1 CELLULOSE- POTASSIUM 2 RUTILE SODIUM 3 RUTILE POTASSIUM 4 RUTILE IRON POWDER 5,6,8 LOW HYDROGEN
2/16/2013

ARC WELDING ELECTRODES

13

EXXXX The last two numbers together indicate the type of welding current the electrode can be used with. For example EXX10 DC+ EXX11 AC OR DC+ EXX20 AC , DC +,EXX12 AC OR DC- EXX24 AC , DC +,EXX13 AC , DC+,- EXX27 AC, DC +,EXX14 AC , DC+,- EXX28 AC, DC + EXX15 DC+ EXX16 AC , DC+ EXX18 AC , DC+

2/16/2013

ARC WELDING ELECTRODES

14

LOW ALLOY STEEL ELECTRODE

THESE ELECTRODES ARE DESIGNED FOR THE WELDING OF LOW-ALLOY STEELS COMMONLY USED IN STRUCTURES, PIPING, PRESSURE VESSEL. THEY GIVE WELD DEPOSITS OF STEEL CONTAINING A SMALL AMOUNT OF ALLOYING ELEMENTS SUCH AS Mo, Cr, Ni, AND V. THESE ELECTRODES ARE SPECIFIED IN AWS A5.5 SPECIFICATION AND IDENTIFICATION IS SAME AS FOR MILD STEEL ELECTRODES.THE ELECTRODES HAS A SUFFIX TO REFER AS LOW ALLOY STEEL CONTENT. LIKE A1 0.5 Mo, B3 ARC WELDING Mo,2.25%Mn , G 1.0% ELECTRODES 0.2% 2/16/2013 15 Mo, 0.3%Mn, 0.1% V

STAINLESS STEEL ELECTRODES

STAINLESS STEEL ELECTRODES ARE USED FOR THE WELDING OF CORROSION RESISTING AND HEAT- RESISTING STEELS. THEY ARE EXPLIANED IN AWS A5.4 SPECIFICATION FOR CORROSION RESISTING Cr AND Cr-Ni STEEL COVERED ELECTRODES. SOME SS ELECTRODES HAVE GIVEN WITH THEIR MECHANICAL PROPERTIES IN THE FOLLOWING TABLE.

2/16/2013

ARC WELDING ELECTRODES

16

Mechanical Properties As Per AWS A5.4

AWS Classificatio n Tensile Strength Ksi Elongation in 2 Min % Heat Treatment

E209 E308L E309L E316 E316H E316L E317 E318

2/16/2013

100 75 80 75 75 70 80 80

15 35 30 30 30 30 30 30

None None None None None None None None

17

ARC WELDING ELECTRODES

BASED UPON COATING

CELLULOS

TYPE RUTILE TYPE ACID TYPE OXIDIZING TYPE BASIC TYPE

2/16/2013

ARC WELDING ELECTRODES

18

CELLULOS TYPE
THE CELLULOSE IS A ORGANIC MATERIAL WHICH CONTAIN 30 % IN THE ELECTRODE COATING BY WEIGHT. IT DECOMPOSES IN THE ARC AND PRODUCE A GAS SHIELD WHICH PROTECTS ARC FROM AUTMOSPHERIC OXYGEN AND NITROGEN. EXX10 IS THE EXAMPLE OF THIS TYPE ELECTRODE COATING. GENERALLY THIS COATED ELECTRODE IS SUITABLE FOR ALL POSITION WITH DC +.

2/16/2013

ARC WELDING ELECTRODES

19

RUTILE TYPE
RUTILE IS NATURALLY- OCCURING SAND USALLY CONTAIN AROUND 95% OF TITANIUM DIOXIDE. THIS TYPE OF ELECTRODE IS GOOD FOR USE WITH AC AND DC + OR DC - . GENERALLY USE FOR VERTICAL AND OVERHEAD POSITIONS AS THE SLAG IS VERY VISCOUS AND QUICKLY FREEZED. EXX12 AND EXX13 ARE THE EXAMPLES OF THIS TYPE OF COATING .

2/16/2013

ARC WELDING ELECTRODES

20

ACID TYPE
THIS TYPE OF COATING CONTAIN IRON-OXIDE AS A MAJOR CONSTITUENT. DURING WELDING IT PRODUCE A IRON-MANGANESE OXIDE SELICA FLUID SLAG WHOSE METALLARGICAL EFFECT IS ACIDIC. THIS SLAG SOLIDIFIES LIKE HONEYCOMBSTRUCTURE AND EASLY DETACHED. ELECTRODE HAVING THIS COATING IS GOOD FOR FILLET WELD ONLY. EXX22 IS THE EXAMPLE OF THIS TYPE OF ELECTRODE.

2/16/2013

ARC WELDING ELECTRODES

21

OXIDIZING TYPE
IT CONTAIN MAINLY IRON-OXIDE AND SILICATES WITH OR WITH OUT MANGANESE OXIDES. IT PRODUCE A HEAVY SLAG WHICH HAS OXIDISING PROPERTIES. THIS TYPE ELECTRODE IS LIMITED IN USE BECAUSE THE RESULTANT WELD METAL IS SOFT AND LOW MECHANICAL PROPERTIES. EXX27 ELECTRODES ARE HAVING THIS TYPE OF COATING, GENERALLY USING FOR FLAT POSITION ONLY.
2/16/2013

ARC WELDING ELECTRODES

22

BASIC TYPE
THIS TYPE OF COATING CONTAINS CALCIUM CARBONATES (CaCO3), CALCIUM FLOURIDE (CaF2) , METAL POWDER AND COMPARATIVELY MORE POWERFUL DEOXIDISERS. THIS RESULTS IN A CHEMICALLY BASIC SLAG, WHICH IS FAIRLY FLUID.THE SOLIDIFIED SLAG, WHICH IS HEAVY AND FRIABLE HAS BROWN TO DARK- BROWN COLOR AND GLASSY APPEARANCE. MOISTURES IS REMOVED FROM THE COATING TO RENDER IT LOW HYDROGEN ELECTRODES. THE ELECTRODES HAVING THIS TYPE OF COATING IS PREFERRED TO USE FOR MINIMISE THE RISK OF HYDROGEN-INDUCED CRACKING OR COLD CRACKING IN THE BASE METAL. EXX15,16,18 OR THE EXAMPLES OF THIS TYPE OF COATING.
2/16/2013

ARC WELDING ELECTRODES

23

STORAGE AND DRYING OF ELECTRODE

Arc welding electrodes must be properly stored in order to deposit quality welds. when electrodes absorb moistures from the atmosphere, they must be dried in order to restore the ability to deposit quality welds. Electrode with too much moisture may lead to Cracking and Porosity. Operational characteristics may be affected as well. If it is experienced unexplained weld cracking problems, or if the electrode arc performance may have deteriorated, it 2/16/2013 24 ARC WELDING ELECTRODES may be due to the storage methods or

All electrodes must be dried to the right level to perform properly. Even a small amount of moisture in low hydrogen electrodes can lead to major weld problems such as internal porosity, weld cracking or poor operating characteristics.

2/16/2013

ARC WELDING ELECTRODES

25

Low Hydrogen Electrodes Storing and exposure limits SMAW electrodes with low hydrogen coatings, such as E7018 and E8018C3, must be kept very dry since hydrogen induced cracking can easily occur, especially in steels that are 80,000 psi and higher yield strengths. To keep these electrodes dry during storage, here are some suggestions:
ARC WELDING ELECTRODES
26

2/16/2013

 Purchase

these electrodes in hermetically sealed containers, which provide excellent protection against moisture pickup. Do not open the hermetically sealed containers until the electrode is needed for use. When the cans are opened, electrodes that will not be immediately used should be placed in a OVEN at 250 degrees F to 300 degrees F
2/16/2013

ARC WELDING ELECTRODES

27

 Electrodes

should be supplied to welders in quantities that can be consumed within time limits that are dependent on the electrode type and strength level. For example, standard E7018 electrodes can be safely be exposed to the atmosphere for 4 hours whereas standard E11018 electrodes are restricted to only hour.

2/16/2013

ARC WELDING ELECTRODES

28

Re-drying Of Low Hydrogen Electrodes

When the electrodes have been exposed to the atmosphere for period of a four hours , the electrode can be re-dried. The following re-drying procedure should be used: To re-dry, electrodes should be removed from the can, and placed in suitable oven. The electrodes should be spread out in the oven so that all electrodes will reach the drying temperature. The can of electrodes should not be put in the oven; the cardboard liners can char, and the temperature of WELDING electrodes will not be the ELECTRODES 2/16/2013 29 ARC

TEMPERATURE REGULATOR

BAKING OVEN
2/16/2013

ARC WELDING ELECTRODES

30

POTABLE OVEN
2/16/2013

ARC WELDING ELECTRODES

31

When the electrodes are initially placed in the oven, the temperature should not be greater than half the re-drying temperature. The electrodes should be held at that temperature for hour before heating the electrode to the final temperature. For mild steel low hydrogen electrodes governed by AWS A5.1 (such as E7018), the final re-drying temperature is typically 500-800 degrees F(260-430 degrees C). For low alloy electrodes governed by AWS A5.5, the final re-drying temperature should be 700-800 degrees F (700 430 2/16/2013 32 ARC manufacturers degrees C). The WELDING ELECTRODES

 One

2/16/2013

hour at the listed final temperature is satisfactory if it is supplied in the dried condition. Do not dry electrodes at higher temperatures. Also, several hours at a lower temperature is not equivalent to using the specified requirements. Moisture becomes chemically bonded (absorbed) to the electrode coating and those chemical bonds must be broken at the proper temperature for the proper length of time.
ARC WELDING ELECTRODES
33

How Many Times Low Hydrogen Electrodes Can Be Re-dried?

Electrodes

may be re-dried only once. Electrodes that have become wet or moist shall not be used and shall be discarded.

2/16/2013

ARC WELDING ELECTRODES

34

Standard Tests For Electrodes

Type Of Test
TENSILE & IMPACT TRANSVERSE BEND TRANSVERSE TENSILE DEPOSITION EFFECIENCY DIFFUSIBLE HYDROGEN CHEMICAL COMPOSITIO N
2/16/2013

ISO BS639 2560

X X X

DIN 1913 X
X

AWS A5.1
X X

X
X X

X
ARC WELDING ELECTRODES
35

THE END
THANKS

2/16/2013

ARC WELDING ELECTRODES

36