Welding Consumables CH-16

Ch-16: Welding Consumables
Contents:
1. Introduction
2. Consumables for MMA welding
3. Consumables for TIG/GTW
4. Consumables for MIG/MAG
5. Consumables for SAW welding
6. Ceramic Backings
7. Inspection and documentation types
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About me
 Name: Sandeep Anand
 Education: Mechanical Engineer
 Experience: 14+ years
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Q. What is welding consumable?
 All items that are used during the welding can be called as
welding consumable. For Example;
 Electrodes
 Filler Metals
 Fluxes
 Shielding Gases etc.
 For every welding process, the list of consumable may change
Inspection of Welding consumables
 Following parameters/points must be checked;
 Size
 Type or specification
 Condition
 Storage
 Checking of suitable storage conditions is a critical part of the

welding inspector’s duty.
Consumables for SMAW/MMA welding
Electrode:
 Typically 350-450 mm length and 2.5-6mm diameter
 Core Wire + Flux coating
ROLE OF FLUX IN MMA/SMAW
 Helps in arc ignition
 Stabilizes the arc
 Produce shielding gas which protect the molten weld pool
and arc from atmospheric contamination
 Forms slag which protects the molten weld pool
 Refine and clean the solidifying weld metal
 Control hydrogen content of the weld metal
 Form a cone at the tip which directs the arc
SMAW Electrodes are grouped by the main constituent in
their flux coating, these are;
Group Constituent AWS A 5.1 Uses

Rutile Titania E 6013 General
purpose
Basic Calcium E 7018 High quality
compounds
Cellulosic Cellulose E 6010 Pipe root
runs
Inspection points for MMA consumables
1. Electrode Size: Diameter and length
2. Condition: Cracks, chips, concentricity & Corrosion
3. Type (specification): Correct specification or
code
4. Storage: Ensure electrodes are dry and warm

Correct baking of basic electrodes
Note: (Baking temp: typically 300-350ºC) for 2 hours then held in a holding oven
(150ºC max) and then supplied to the welders in a portable oven.
MMA/SMAW Electrode Treatment
MMA/SMAW Electrode Treatment
Electrode classification system
 AWS 5.1/5.5
 EN ISO 2560
Consumables for TIG welding
1. Filler Wire: Copper coating to resist corrosion
2. Shielding Gas: Mainly Argon and Helium
3. Tungsten Electrode: Nonconsumable in the welding but consumed due to the
erosion in the arc and by grinding and incorrect welding technique.
4. Fusible Insert: Used during TIG welding of pipes. Also known as EB insert after
the Electric Boat Co of USA. The insert is normally made of material matching the
pipe base metal composition and is fused into the root during welding. CSR
Shielding gas for TIG welding
Argon:
 Low cost and greater availability.
 Heavier than air - lower flow rates than Helium.
 Low thermal conductivity - wide top bead profile.
 Easier arc starting, better arc stability with AC, cleaning effect.
 For the same arc current produce less heat than helium -
reduced penetration, wider HAZ.
 To obtain the same arc power, argon requires a higher current
- increased undercut.
Helium:
 Costly and lower availability than Argon.
 Lighter than air - requires 2-3 times higher flow rate than argon
 Poor arc stability with AC, less forgiving for manual welding.
 For the same arc current produce more heat than argon - increased
penetration, welding of metals with high melting point or thermal
conductivity.
 To obtain the same arc power, helium requires a lower current - no
undercut.
Hydrogen:
 Not an inert gas - not used as a primary shielding gas.
 Faster travel speed and increased penetration.
 Better wetting action - improved bead profile.
 Produce a cleaner weld bead surface.
 Added to argon (up to 5%) - only for austenitic stainless
steels and nickel alloys.
 Flammable and explosive.
Nitrogen:
 Not an inert gas.
 High availability – cheap.
 Added to argon (up to 5%) - only for back purge for duplex
stainless, austenitic stainless steels and copper alloys.
 Not used for mild steels (age embrittlement).
 Strictly prohibited in case of Ni and Ni alloys (porosity).
Consumables for MIG/MAG welding
1. Filler Wire: 0.6-1.6mm diameter, Copper coated
2. Shielding Gas: Pure argon, Pure CO2, Argon + 5-

20% CO2, Argon + 1-2% O2 or
CO2
Filler wire designation as per AWS A-5.18:
Filler wire designation as per BS EN 14341:
Shielding Gas for MIG/MAG Welding:
Consumables for SAW
 Filler Wire:
 Also acts as an electrode for arc generation.
 Grading similar to MIG and TIG electrode wires.
 Flux:
 Fused and Agglomerated. Flux Grading based on their
manufacture and composition.
Filler Wire:
 Carbon steel and low alloy steel are copper coated
 Stainless steel wires are not coated
 Filler wire must be clean and free from any foreign
material like oil, grease and dust etc.
Copper Coating Functions:
 Provide good electric contact between wire and
contact tip.
 Provide smooth feed of the wire through the
guide tube, feed rolls and contact tip (decrease
contact tube wear).
 To provide protection against corrosion.
Fused Flux Manufacturing
Agglomerated Flux Manufacturing
Fused Flux Agglomerated Flux
Fused flux V/S Agglomerated flux
Fused flux Agglomerated flux
• Flaky appearance • Granulated appearance
• Lower weld quality • High weld quality
• Low moisture intake • Addition of alloys
• Low dust tendency • Lower consumption
• Good re-cycling • Easy slag removal
• Very smooth weld profile • Smooth weld profile
SAW Wire/Flux designation as per AWS A-5.17
SAW Wire/Flux designation as per BS EN 14171
Fused Flux Advantages:
 Good chemical homogeneity
 Easy removal of fines without affecting flux composition
 Normally not hygroscopic
 Easy storage and handling
 Readily recycled without significant change in particle size or composition
Fused Fluxes Disadvantages:

 Difficult to add deoxidizers and ferro-alloys (due to segregation or extremely
high loss)
 High temperatures needed to melt ingredients limit the range of flux
compositions
Agglomerated Flux Advantages:
 Easy addition of deoxidizers and alloying elements
 Usable with thicker layer of flux when welding
 Colour identification
Agglomerated Fluxes Disadvantages:

 Agglomerated fluxes contain chemically bonded water
 Similar treatment as basic electrodes
 Possible gas evolution from the molten slag leading to porosity
 Possible change in flux composition due to segregation or removal of fine
mesh particles
Mixed fluxes
• Two or more fused or bonded fluxes are mixed in any ratio
necessary to yield the desired results
Mixed fluxes advantages:
• Several commercial fluxes may be mixed for highly critical or
proprietary welding operations.
Mixed fluxes disadvantages:
• Segregation of the combined fluxes during shipment, storage
and handling.
• Segregation occurring in the feeding and recovery systems
during welding.
• Inconsistency in the combined flux from mix to mix.
Ceramic Backing
 Used to support the weld
pool on root runs.
 Usually fitted on an aluminium
self adhesive tape.
 Allow increased welding current
without danger of burn-through
Increased productivity
 Consistent quality.
 Different profiles to suit different
applications YouTube: www.youtube.com/weldingandndt
Inspection and Documentation (BS EN 10204)
Non-specific inspection Specific inspection

• Inspection done by the • Inspection done before delivery in
accordance to the product
manufacturer as per their own specification.
procedures.
• The inspected items are a part of
• The inspected product may NOT the products to be supplied or
necessarily be supplied to the belongs from the part of which the
products are supplied.
client
Non-Specific Inspection Documents
Type 2.1 Type 2.2

• Name: Declaration of • Name: Test report
compliance with the order • Content: statement of
• Content: statement of compliance with the order
compliance with the order (Test (include test results)
result not included) • Who validate it – the
• Who validate it – the manufacturer.
manufacturer.
Specific Inspection Documents
Type 3.1 Type 3.2
• Name: Inspection certificate 3.1. • Name: Inspection certificate 3.2
• Content: statement of • Content: statement of compliance
compliance with the order with the order (include specific test
(include specific test results) results!)
• Who validate it – the • Who validate it – the manufacturer
inspection (independent of
manufacturer inspection
manufacturing department!) &
(independent of manufacturing purchaser’s/official designated
department!) authorised inspector.
Thank You

Welding Consumables CH-16

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Ch-16: Welding Consumables

 Education: Mechanical Engineer

 Experience: 14+ years

 Hobby: I like to share knowledge through

1. Exclusive member-only videos

2. Can attend the live sessions

3. Priority reply to your comments

 For every welding process, the list of consumable may change

 Checking of suitable storage conditions is a critical part of the

Group Constituent AWS A 5.1 Uses

4. Storage: Ensure electrodes are dry and warm

2. Shielding Gas: Pure argon, Pure CO2, Argon + 5-

 Stainless steel wires are not coated

 Filler wire must be clean and free from any foreign

material like oil, grease and dust etc.

Fused Fluxes Disadvantages:

Agglomerated Fluxes Disadvantages:

Non-specific inspection Specific inspection

Type 2.1 Type 2.2

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