WIS5 Con 06

M.
Rogers
WI 3.1
TECHNOLOGY
Welding Inspection
Consumables
Course notes section reference 14
Copyright © 2005 TWI Ltd World Centre for Materials Joining Technology
M.Rogers
WI 3.1
Welding Consumables
Welding consumables may be:
TECHNOLOGY
 Shielded arc filler wires, lengths or rolls
 Covered electrodes
 Shielding gases
 Separately supplied flux
 Fusible inserts
M.Rogers
WI 3.1
TECHNOLOGY Welding Consumables
Each consumable is critical in respect to:
 Size
 Classification / Supplier
 Condition
 Handling and storage
 Treatments e.g. baking / drying
Handling and storage is critical for consumable

control
M.Rogers
WI 3.1
MMA Welding Consumables
Welding consumables for MMA
TECHNOLOGY
 Consist of a core wire typically between 350-450mm in

length and from 2.5-6mm in diameter
 The wire is covered with an extruded flux coating
 The core wire is generally of a low quality rimming steel
 The weld quality is refined by the addition of refining
agents in the flux coating
 The flux coating contains many elements and
compounds that all have a variety of functions during
welding
M.Rogers
WI 3.1
Functions of flux constituents:
TECHNOLOGY
 To aid arc ignition, to improve arc stabilisation

 Deoxidise the solidifying weld metal
 To produce a shielding gas to protect the arc
column
 To refine and clean the solidifying weld-metal
 To add alloying elements
 To control hydrogen contents in the weld
 To form a cone at the end of the electrode, which
directs the arc
M.Rogers
WI 3.1
TECHNOLOGY Welding Consumable Standards
MMA (SMAW) MIG/MAG (GMAW) TIG (GTAW)
 BS 639: Steel electrodes  BS 2901: Filler wires

 BS EN 440: Filler wires
 BS EN 499: Steel electrodes
 AWS A5.9: Filler wires
 AWS A5.1 Non-alloyed steel
 BS EN 439: Shielding gases
electrodes
SAW
 AWS A5.5 Alloyed steel
 BS 4165: Wire and fluxes
electrodes
 BS EN 756: Wire electrodes
 AWS A5.4 Chromium
 BS EN 760: Fluxes
electrodes
 AWS A5.17: Wires and fluxes
M.Rogers
WI 3.1
TECHNOLOGY MMA Welding Consumables
Common flux types
 Rutile
 Cellulose
 Basic
 Acidic
M.Rogers
WI 3.1
Rutile electrodes
 Used mainly on general purpose work
 Low pressure pipework, support
brackets.
Flux constituents include:
 Titanium dioxide, slag former
 Clay - binding agent
 Sodium silicate - main ionizer
M.Rogers
WI 3.1
TECHNOLOGY Rutile Electrodes
Advantages Disadvantages
 Easy to use  High in hydrogen
 Low cost / control  High crack tendency
 Smooth weld profiles  Low strength
 Slag easily detachable  Low toughness values
(Friable slag)
 High deposition
possible with the
addition of iron powder
M.Rogers
WI 3.1
Cellulose electrodes
TECHNOLOGY
 Used mainly for pipeline welding

 Suitable for welding in all position especially
vertical down, stove technique
 They produce a gas shield high in hydrogen
 Deep penetration/fusion characteristics
 Cellulose, natural organic compounds
 Titanium dioxide - slag former
 Sodium silicate/potassium silicate - main ionizers
M.Rogers
WI 3.1
TECHNOLOGY Cellulose Electrodes
 Deep penetration/fusion  High in hydrogen
 Suitable for welding in all  High crack tendency
positions  Rough cap appearance
 Fast travel speeds  High spatter contents
 Large volumes of  Low deposition rates
shielding gas
 Low control
M.Rogers
WI 3.1
Basic electrodes
 Used mainly for high pressure work and for materials of
high tensile strength
 They are capable of producing welds of a low hydrogen
content
 Prior to use they may be baked to give a low hydrogen
potential typically 300oC for 1 hour plus
 Limestone (calcium carbonate) - gas former
 Fluorspar - slag former
 Sodium silicate/potassium silicate - main ionizers
M.Rogers
WI 3.1
TECHNOLOGY Basic Electrodes
 High toughness values  High cost
 High control
 Low hydrogen contents
 High welder skill required
 Low crack tendency
 Convex weld profiles
 Poor stop/start properties
(porosity)
M.Rogers
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)
TECHNOLOGY
A) Tensile Strength: B) Toughness:

Symbol Min Yield Tensile Strength 1st Digit 2nd Digit Testing
Strength N/mm2 28 J 47J Temperature
N/mm2 0 0 Not specified
43 330 430-550 1 1 +20
51 380 510-650 2 2 0
3 3 -20
C) Covering types:
4 4 -30
B Basic
5 5 -40
BB Basic High Efficiency
C Cellulosic D) Electrode Efficiency
O Oxidising % Recovery to the nearest 10%
R Rutile Above 10%
RR Rutile High Efficiency
S Other types
M.Rogers
WI 3.1
A Typical BS 639 Specification: E 51 33 B 160 2 0 H
TECHNOLOGY
E) Welding Position: F) Electrical Characteristic

Symbol Position Symbol DC Polarity AC min OCV
0 Polarity as Not
1 All positions. recommended recommended
2 All positions except vertical 1 + or - 50 OCV
down.
2 - 50 OCV
3 Flat Butts & Fillets and HV
3 + 50 OCV
Fillets.
4 + or - 70 OCV
4 Flat Butts & Fillets
5 - 70 OCV
5 Vertical down and position 3
6 + 70 OCV
6 Any position not classified 7 + or - 90 OCV
above 8 - 90 OCV
G) Hydrogen Control 9 + 90 OCV
H indicates low hydrogen potential
M.Rogers
WI 3.1
E 51 33 B 160 2 0 H
TECHNOLOGY
Covered Electrode
Yield Strength N/mm2
Tensile Strength N/mm2
Toughness
Flux Covering
Weld Metal Recovery
Iron Powder content
Welding Position
Electrical characteristic
Hydrogen Control
M.Rogers
WI 3.1
TECHNOLOGY BS 639 MMA Covered Electrodes
Compulsory
Optional
M.Rogers
WI 3.1
TECHNOLOGY BS EN 499 MMA Covered Electrodes
Electrodes classified as follows:

 E 35 - Minimum yield strength 355 N/mm2
Tensile strength 440 - 570 N/mm2
M.Rogers
WI 3.1
BS EN 499 MMA Covered Electrodes
A Typical BS EN 499 Specification: E 46 3 1Ni B 5 4 H5
TECHNOLOGY
A) Tensile Strength: B) Toughness at a minimum impact

Symbol Min Tensile Min energy 47 Joules:
Yield Strength E % Z No Requirement
Strength N/mm2 A +20
N/mm2
O 0
35 355 440-570 22
2 -20
38 380 470-600 20
3 -30
42 420 500-640 20
4 -40
46 460 530-680 20
5 -50
50 500 560-720 18
6 -60
M.Rogers
WI 3.1
A Typical BS EN 499 Specification: E 46 3 1Ni B 5 4 H5
TECHNOLOGY
C) Alloying: D) Covering type:

Deposited weld metal chemical composition Symbol
Symbol Mn Mo Ni A Acidic
None 2.0 - - C Cellulosic
Mo 1.4 0.3-0.6 - R Rutile
Mn Mo >1.4-2.0 0.3-0.6 RR Rutile thick
1Ni 1.4 - 0.6-1.2 covering
2Ni 1.4 - 1.8-2.6 RC Rutile/Cellulosic
3Ni 1.4 - >2.6-3.8 RA Rutile/Acidic
Mn 1Ni >1.4 - 0.6-1.2 RB Rutile/Basic
1Ni Mo 1.4 0.3-0.6 0.6-1.2 B Basic
Z Any other agreed

composition
M.Rogers
WI 3.1

E) Electrical characteristic + Recovery % E 46 3 1Ni B 5 4 H5
TECHNOLOGY
Symbol Recovery % Current type A) B) C) D) E) F) G)

1 < 105 AC + DC F) Welding Position:
2 < 105 DC Symbol Position
3 > 105 < 125 AC + DC 1 All positions
4 > 105 < 125 DC 2 All positions except
5 > 125 <160 AC + DC vertical down
6 > 125 <160 DC 3 Flat Butt & Fillet + HV
Fillets
7 > 160 AC + DC
4 Flat Butt & Fillet
8 > 160 DC
5 Vertical down +
G) Hydrogen Content of deposited metal positions of symbol 3
Symbol ml/100gm
H5 5
H 10 10
H 15 15
M.Rogers
WI 3.1
E 46 3 1Ni B 5 4 H5
TECHNOLOGY
Covered Electrode
Yield Strength N/mm2
Tensile Strength N/mm2
Toughness
Chemical composition
Flux Covering
Weld Metal Recovery
and Current Type
Welding Position
Hydrogen Content
M.Rogers
WI 3.1
AWS A5.5 Alloyed Electrodes
E 80 1 8 M G
TECHNOLOGY
Covered Electrode
Tensile Strength (p.s.i)
Welding Position
Flux Covering
Moisture Control
Alloy Content
M.Rogers
WI 3.1
TECHNOLOGY AWS A5.1 & A5.5 Alloyed Electrodes
Example AWS electrode flux types
Cellulose flux-ends in 0,1

E6010, E6011, E7010, E8011
Rutile flux-ends in 2,3,4
E5012, E6012, E6013, E6014
Basic flux-ends in 5,6,7,8

E6016, E7017, E8018, E9018
M.Rogers
WI 3.1
TECHNOLOGY MMA Electrode Inspection Points
1: Electrode size Diameter & length
2: Electrode condition Cracks, chips & concentricity
3: Electrode specification Correct specification/code

E 51 33 B
M.Rogers
WI 3.1
TIG Welding Consumables
Welding consumables for TIG
TECHNOLOGY
 Consist of a wire and gas, though tungsten electrodes being

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
cleaning elements are added
 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
 The shielding gases used are mainly Argon and Helium, usually
of the highest quality (99.9% pure).
 Ceramic shields, the size and shape depends on application
M.Rogers
WI 3.1
MIG/MAG Welding Consumables
Welding consumables for MIG/MAG
TECHNOLOGY
 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
 Wires are available in sizes from 0.6-1.6 mm in diameter
 Most wires are supplied on a 15kg spool, with finer wires
supplied on a 1kg spool
 Gases can be pure CO2, CO2+Argon mixes and
Argon+2%O2 mixes (stainless steels).
M.Rogers
WI 3.1
TECHNOLOGY Fusible Inserts
Pre-placed filler material
Before Welding After Welding
Other terms used include:
 E B inserts (Electric Boat Company)
 Consumable socket rings (CSR)
M.Rogers
WI 3.1
Any Questions
TECHNOLOGY
Copyright © 2005 TWI Ltd

?
World Centre for Materials Joining Technology
M.Rogers
WI 3.1
Questions
Welding Consumables
TECHNOLOGY
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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M.

 Shielded arc filler wires, lengths or rolls

 Separately supplied flux

 Handling and storage

 Treatments e.g. baking / drying

Handling and storage is critical for consumable

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

 To aid arc ignition, to improve arc stabilisation

 BS 639: Steel electrodes  BS 2901: Filler wires

Common flux types

 Used mainly for pipeline welding

A) Tensile Strength: B) Toughness:

E) Welding Position: F) Electrical Characteristic

Electrodes classified as follows:

A) Tensile Strength: B) Toughness at a minimum impact

C) Alloying: D) Covering type:

Z Any other agreed

BS EN 499 MMA Covered Electrodes

Symbol Recovery % Current type A) B) C) D) E) F) G)

Tensile Strength (p.s.i)

Cellulose flux-ends in 0,1

Basic flux-ends in 5,6,7,8

1: Electrode size Diameter & length

2: Electrode condition Cracks, chips & concentricity

3: Electrode specification Correct specification/code

 Consist of a wire and gas, though tungsten electrodes being

 Consist of a wire and gas, the same quality as for TIG

Pre-placed filler material

Before Welding After Welding

Other terms used include:

 E B inserts (Electric Boat Company)

 Consumable socket rings (CSR)

Copyright © 2005 TWI Ltd

QU 1. Why are basic electrodes used mainly on high strength

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