UNIT 5.

15

WELD USING MMAW

PROCESS.

RESOURCES NOTES.

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DESCRIPTION AND INTENDED USE OF ELECTRODES:

EXX10 AND EXX11 ELECTRODES:

These electrodes have thin coatings, which contain at least 15% cellulose and up to 30% of Titania as
rutile or titanium white.
They operate with a forceful, deep penetrating, spray type arc with fairly high spatter levels.
A voluminous gas shield is formed as a result of the decomposition of the cellulose material in the
arc region, which protects the weld metal from atmospheric contamination.
The slag is very fluid and may not appear to completely cover the deposit; it is thin friable and easily
removed when cooled.
Horizontal fillet welds are usually flat in profile and have a rather coarse, unevenly spaced ripple.

EXX10 electrodes are designed to operate using D.C electrode positive, however D.C electrode
negative is sometimes used to reduce problems such as internal undercut and hollow bead in pipe
welding and is also suitable for thin wall pipe applications.

EXX11 electrodes are designed to operate satisfactorily using both A.C and D.C electrode positive.
They are suitable for all types of welding on low carbon steel and because of the arc characteristics
and small slag volume are particularly easy to use in all welding positions.
They are specially recommended for applications, which involve changes in welding position during
the running of the electrode, eg pipe welding in situ.
Sizes larger than 5mm are not recommended for welding out of position.

The maximum current to be used with these electrodes is sometimes limited owing to burn-out of the
coating and high spatter, however welding currents near the maximum are commonly used by skilled
operators in field pipeline welding, where the consequent high stubs losses are accepted in view of
the high productivity which can be achieved.

For optimum performance, the coating of these electrodes must contain 3 % to 7% moisture.
Excessive drying will adversely affect their operating characteristics. Suppliers should be consulted
for suitable drying conditions before any re-drying operations are attempted.

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EXX12 ELECTRODES:

Electrodes of EXX12 classifications have thin coatings containing a high proportion of Titania,
usually as mineral rutile.
They operate with a quiet, medium penetrating arc with low spatter levels. The slag is fairly viscous,
with a full covering and easily removed when cool, except from the first run of a deep vee butt weld.

Horizontal-fillet welds tend to be convex in profile, with a smooth even ripple. These electrodes are
designed to operate satisfactorily from A.C or D.C electrode positive or negative polarity, the arc is
usually stable with a low open-circuit voltage.

These electrodes are noted for general ease of handling in all welding positions and ability to bridge
gaps in work having poor fit-up.

Sizes larger than 5mm are not used for vertical up or overhead welding positions. These electrodes
are recommended for general shop and structural fabrications including sheet steel.

EXX13 ELECTRODES:

Electrodes of EXX13 classifications have thin coatings containing a high proportion of Titania,
usually as mineral rutile, with the addition of basic materials to increase the fluidity of the slag.

They operate with a quiet, medium penetrating arc with low spatter levels. The slag is fluid, full
covering and easily removed when cool, even from the first run of a deep vee butt weld.

Horizontal-fillet welds have flat profile with a fine ripple and very neat appearance. These electrodes
are designed to operate satisfactorily from A.C or D.C power sources, and the arc is usually stable
with low open circuit voltages.

These electrodes have similar arc characteristics to EXX12 electrodes, but are more suitable for
welding in the vertical up and overhead welding positions.

They are recommended for general shop and structural fabrication. Small sizes may be used for
welding sheet steel.

Sizes larger than 5mm are not recommended for welding out of position and are generally restricted
to the flat position.

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EXX14 ELECTRODES:

Electrodes of EXX14 classifications have medium to thick coating containing a high proportion of
Titania, usually as mineral rutile, and sufficient iron powder to give metal recovery rates of 105% to
130% of the mass of the core wire melted.

They operate with a smooth, medium penetrating arc with low spatter levels. The slag is fairly
viscous, full covering and easily removed when cool and often self-releasing.

Horizontal-fillet welds tend to be convex in profile with a fine ripple finish. These electrodes are
designed to operate satisfactorily from A.C or D.C power sources and the arc is usually stable with
low open circuit voltages.

These electrodes are suitable for both single-run and multi-run welds in all welding positions and can
sometimes be used to bridge gaps in work having poor fit-up. The use of a medium thick coating,
which does not give excess slag, improves the operating characteristics and allows touch welding to
be used.
They are recommended for general shop and structural fabrication. Some of these electrodes are
suitable for use in the vertical down positions. Sizes larger than 5mm are generally limited to the flat
position.

EXX19 ELECTRODES:

Electrodes of EXX19 classification have coatings based on the mineral ilmenite and consequently an
arc action and slag characteristics intermediate between the EXX12/13 Titania types and the EXX20
iron/manganese oxide type.

The electrodes are characterised by a rather fluid slag system, provide deeper penetration than the
EXX13 group and excellent radiography quality weld metal, meeting the level 1 standard.

They are designed for use on A.C or D.C power sources and are suitable for multi-run welding up to
25mm in plate thickness. Stable arc and good operational characteristics provide smooth even beads
in all positions including vertical up.
The resultant weld metal has excellent ductility and crack resistance with good impact properties.

EXX20 ELECTRODES:

Electrodes of EXX20 classification have medium thick coatings containing a high proportion of
oxides or silicates of iron and manganese.
They operate with a spray type arc with medium to deep penetrating according to the current used.
The slag is fluid, voluminous, completely covers the deposit, and when cool is honeycombed on the
underside, friable, and easily removed, even from the first run of a deep vee butt weld.

Horizontal-fillet welds tend to have a flat or concave finish with a smooth even ripple.
These electrodes are designed to operate satisfactorily in the horizontal-fillet position from o A.C
from D.C electrode negative power sources, and in the flat position from A.C or from D.C electrode
positive or electrode negative power sources.

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These electrodes are principally used for horizontal-fillet and flat butt welds in heavy carbon steel
plate where good penetration is required. Some varieties can be used for deep penetration welding by
taking advantage of the vigorous arc action available at high current values.

EXX24 ELECTRODES:

Electrodes of EXX24 classifications have thick coatings containing a high proportion of Titania,
usually as mineral rutile, and sufficient iron powder to give metal recovery rates in excess of 130% of
the mass of the core wire melted.

They operate with a low to medium penetrating, smooth spray type arc with very low spatter. The
slag is fairly fluid, full covering, dense and when cool, is self-releasing or easily removed.

The deposition rate is very fast owing to the high iron powder content and the thickness of the
coating giving ability to carry a high current in relation to the core wire diameter. Horizontal-fillet
welds have a flat to slightly convex finish with a fine ripple, good blending with the plate at the edge.

They are designed to operate satisfactorily from A.C or from D.C power sources.
Recommended for the high speed welding of low carbon steel in the flat and horizontal-fillet
positions. Touch welding technique is normally used.

EXX27 ELECTRODES:

Electrodes of EXX27 classifications have thick coatings containing a high proportion of oxides or
silicates of iron and manganese, and sufficient iron powder to give recovery rates in excess of 130 %
of the mass of the core wire melted.

They operate with a vigorous, spray-type arc with medium to deep penetrating according to the
current used. The slag is fluid, voluminous, completely covers the deposit, and when cool is well
honeycombed on the underside, friable and easily removed, even from the first run of a deep vee butt
weld.

Horizontal-fillet welds are generally flat to slightly concave in profile with a smooth even ripple and
good blending with the plate at the edges. The electrodes are designed to operate satisfactorily in the
horizontal-fillet position from A.C or from D.C electrode negative power sources, and in the flat
position from A.C or from D.C power sources. The deposition rate is very fast owing to the high iron
powder content and the thickness of the coating giving ability to carry a high current in relation to the
core wire diameter.

These electrodes are recommended for use in the flat and horizontal-fillet positions and are
particularly applicable to high speed welding of low carbon steel where good penetration and ease of
deslagging are required. Touch welding techniques are normally used.

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