WELDING CONSUMABLES

SFA
NUMBER
 SFA NUMBER
AS PER ASME SECTION II PART C
SFA 5.1 CARBON STEEL ELECTRODES FOR SMAW
SFA 5.2 CARBON & LOW ALLOY STEEL RODS FOR OFW
SFA 5.3 ALUMINUM & ALUMINUM ALLOY
ELECTRODES FOR SMAW
SFA 5.4 STAINLESS STEEL RODS FOR SMAW
SFA 5.5 LOW ALLOY STEEL ELECTRODES FOR SMAW
SFA 5.6 COPPER & COPPER ALLOY STEEL ELECTRODES
FOR ARC WELDING
SFA 5.7 COPPER & COPPER ALLOY BARE WELDING
RODS AND ELECTRODE
FILLER METAL FOR BRAZING AND BRAZE
SFA 5.8
WELDING
 SFA NUMBER (CONT’D)
SFA 5.9 BARE STAINLESS STEEL WELDING ELECTRODE
& RODS
SFA 5.10 ALUMINUM & AL ALLOY WELDING ELECTRODES
AND RODS
SFA 5.11 NICKEL & NICKEL ALLOY WELDING ELECTRODE
FOR SMAW
SFA 5.12 TUNGSTEN/ TUNGSTEN ALLOY ELECT. (ARC
WELDING/CUTTING)
SFA 5.13 SOLID SURFACING WELDING RODS AND
ELECTRODES
SFA 5.14 NICKEL & NICKEL ALLOY BARE WELDING RODS
AND ELECTRODES
SFA 5.15 WELDING ELECTRODES FOR CAST IRON
SFA 5.16 TITANIUM & TITANIUM ALLOY WELDING RODS
AND ELECTRODES
 SFA NUMBER (CONT’D)
SFA 5.17 CARBON STEEL ELECTRODES AND FLUX FOR SAW
SFA 5.18 CARBON STEEL ELECTRODES FOR GMAW
SFA 5.20 CARBON STEEL ELECTRODES FOR FCAW PROCESS
SFA 5.21 COMPOSITE SURFACING WELDING RODS AND
ELECTRODES
SFA 5.22 STAINLESS STEEL ELECTRODES FOR FCAW AND
GTAW
SFA 5.23 LOW ALLOY STEEL ELECTRODES AND FLUXES
FOR SAW
SFA 5.24 CIRCONIUM & CIRCONIUM ALLOY WELDING
ELECTRODES AND RODS
SFA 5.25 CARBON AND LOW ALLOY STEEL ELECTRODES
& FLUXES FOR ESW
 SFA NUMBER (CONT’D)
SFA 5.26 CARBON AND LOW ALLOY STEEL ELECTRODES
FOR EGW
SFA 5.28 LOW ALLOY STEEL ELECTRODES AND RODS FOR
GMAW
SFA 5.29 LOW ALLOY STEEL ELECTRODES FOR FCAW

SFA 5.30 CONSUMABLE INSERT

SFA 5.31 FLUXES FOR BRAZING AND BRAZE

WELDING
SFA 5.01 FILLER METAL PROCUREMENT
GUIDELINES
 ELECTRODES FOR SMAW
ELECTRODES FOR SMAW (MMA) ARE GROUPED DEPENDING ON
THE MAIN CONSTITUENT IN THEIR FLUX COATING :

GROUP CONSTITUENT SHIELD GAS USE AWS A 5.1

RUTILE TITANIA CO2 GENERAL E 6013
PURPOSE
CELLULOSE CELLULOSE CO2 PIPE ROOT RUNS E 6010
BASIC CALCIUM
COMPOUNDS H2+CO2 HIGH QUALITY E 7015,6 & 8

IRON IRON CO2 F & HV E 6014

POWDER POWDER POSTION
 SMAW CONSUMABLES

Common flux  Rutile

types :  Cellulose
 Basic
 Acidic
CLASS CURRENT PENETRATION COVERING SLAG
E XXX0 DCEP DEEP CELLULOSE – SODIUM
E XXX1 AC / DCEP DEEP CELLULOSE - POTASIUM
E XX20 AC / DC MEDIUM IRON OXIDE - SODIUM
E XXX2 AC / DCEN MEDIUM RUTILE - SODIUM
E XXX3 AC / DC LIGHT RUTILE - POTASIUM
E XXX4 AC / DC LIGHT RUTILE – IRON POWDER
E XX24 AC / DC LIGHT RUTILE – IRON POWDER
E XXX5 DCEP MEDIUM LOW HYDROGEN - SODIUM
E XXX6 AC / DCEP MEDIUM LOW HYDROGEN - POTASIUM
E XXX8 AC / DC MEDIUM LOW HYDROGEN – IRON
POWDER
E XX28 AC / DC MEDIUM LOW HYDROGEN - POTASIUM
E XX27 AC / DC MEDIUM IRON OXIDE – IRON POWDER
 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, E7016, E8018, E9018
 SMAW CONSUMABLES (CONT’D)

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
 SMAW CONSUMABLES (CONT’D)
RUTILE ELECTRODES
Advantages Disadvantages
 Easy to use  High in
 Low cost / control hydrogen
 Smooth weld profiles  High crack
 Slag easily detachable
tendency
 (Friable slag)
 High deposition possible
 Low strength
with the addition of iron
 Low toughness
powder values
 SMAW CONSUMABLES (CONT’D)
Cellulose electrodes :
 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

Flux constituents include :

 Cellulose, natural organic compounds
 Titanium dioxide - slag former
 Sodium silicate/potassium silicate - main ionizers
 CELLULOSE ELECTRODES

Advantages Disadvantages
 Deep penetration/fusion  High in hydrogen
 Suitable for welding in all  High crack tendency
positions  Rough cap
 Fast travel speeds appearance
 Large volumes of shielding  High spatter contents
gas  Low deposition rates
 Low control
 SMAW CONSUMABLES (CONT’D)
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
Flux constituents include :
 Limestone (calcium carbonate) - gas former
 Fluorspar - slag former
 Sodium silicate/potassium silicate - main ionizers
 BASIC ELECTRODES
Advantages Disadvantages

High cost
 High toughness

High control
values

High welder skill
 Low hydrogen
required
contents
 Convex weld profiles
 Low crack tendency
 Poor stop/start properties
(porosity)
TYPICAL ELECTRODE SPECIFICATION (CONT’D)
SFA No. A 5.1 - SMAW
FOR CARBON STEEL
E : ELECTRODE
X : POSITIONAL
CAPABILITIES
E XXXX-1 IMPACT VALUE
OF 20 FT-LB AT –
50O F

XX :TENSILE STRENGTH XX: ELECTRODE

MULTIPLED BY 1O3 COATING &
PSI CURRENT
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
WELDING POSITION
1 - ALL POSITION ( F, H, V and OH )
2 - F and H Fillet
4 - F, H, OH and V down
ELECTRODE COATING & CURRENT
No. COATING TYPE CURRENT F No. A No.
10 CELLULOSE SODIUM DCEP 3 1
11 CELLULOSE POTASIUM AC or DCEP 3 1
12 TITANIA SODIUM AC or DCEN 2 1
13 TITANIA POTASIUM AC or DC 2 1
14 IRON POWDER TITANIA CURRENT 2 1
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
ELECTRODE COATING
No. COATING TYPE CURRENT F No. A No.
15 LOW HYDROGEN SODIUM DCEP 4 1
16 LOW HYDROGEN POTASIUM AC or DCEP 4 1
18 LOW H. POTASIUM IRON POWDER AC or DCEP 4 1
24 IRON POWDER TITANIA AC or DC 1 1
2
27 IRON OXIDE, IRON POWDER AC or DC 1
28 LOW H. POTASIUM IRON AC or DC 4 1
POWDER
48 LOW H. POTASIUM IRON AC or DC 4 1
POWDER
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
CHROMIUM & CHROMIUM NICKEL STEEL ELECTRODE

SFA No. A 5.4 - SMAW X : USEABILITY

(POSITIONAL & CURRENT
TYPE)
15 - LIME COVERING & DCEP
E : ELECTRODE 16 - ADD OF Mo & REDUCE C

CARBON CONTENTS :
E XXX XX - XX L - LOW CARBON
Cb - ADD
COLUMBIUM
XX : BASIC REDUCE CARBON
COMPOSITION Mo - ADD
(ONE or MORE MOLYBDENUM
XXX : CHEMICAL LETTERS) REDUCE CARBON
COMPOSITION
TYPICAL ELECTRODE SPECIFICATION (CONT’D)

SFA No. A 5.5 - SMAW

LOW ALLOY STEEL
E : ELECTRODE
X : POSITIONAL
CAPABILITIES
CHEMICAL
E XX X X - A1 COMPOSITION
(ONE or MORE
LETTERS)
XX : TENSILE
STRENGTH XX : ELECTRODE
MULTIPLED BY COATING & CURRENT
1O00 PSI
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
CHEMICAL COMPOSITION
LEGEND MATERIAL TYPE ELEMENT A No.
A1 CARBON MOLYBDENUM 0.5% Mo (Nominal) 2
B1 CHROMIUM MOLYBDENUM 0.5 % Cr, 0.5 % Mo (Nom) 3

B2 CHROMIUM MOLYBDENUM 1.25% Cr, 0.5% Mo (Nom) 3

B3 CHROMIUM MOLYBDENUM 2.25% Cr, 0.5% Mo (Nom) 4

C1 NICKEL 2.5% Ni (Nominal) 10

C2 NICKEL 3.25% Ni (Nominal) 10

C3 NICKEL 1% Ni, 0.35% Mo, 0.15 Cr 10

(Nom)
D1 MANGANESE MOLYBDENUM 0.25 – 0.45% Mo 1.25 – 1.75% Mn 11

D2 MANGANESE MOLYBDENUM 0.25 – 0.45% Mo, 1.65 – 2% Mo 11

 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
SFA No. A 5.9 - SMAW, GMAW & SAW
CHROMIUM-NICKEL STEEL (S/S)
(RODS & BARE) ELECTRODES
E : ELECTRODE XXX : CHEMICAL
COMPOSITION
CARBON CONTENTS :
L - LOW CARBON
E R XXX XX Cb - ADD
COLUMBIUM
REDUCE CARBON
Mo - ADD
XX : BASIC COMPOSITION MOLYBDENUM
R : ROD (ONE or MORE LETTERS)
REDUCE CARBON
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)

SFA No. A 5.11 - SMAW

NICKEL – NICKEL ALLOY
XXXX : ALLOYING
E : ELECTRODE ELEMENTS

Cu - COPPER
Cr - CHROMIUM
E Ni XXXX X Fe
Mo
-
-
IRON
MOLYBDENUM

Ni : NICKEL BASE X : ROD TYPE

ALLOY
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
SFA No. A 5.14 - GTAW, GMAW & SAW
NICKEL – NICKEL ALLOY
BARE RODS & ELECTRODES
E : ELECTRODE XXXX : ALLOYING
R : ROD ELEMENTS

Cu - COPPER
Cr - CHROMIUM
E R Ni XXXX X Fe
Mo
-
-
IRON
MOLYBDENUM

Ni : NICKEL BASE
ALLOY X : ROD TYPE
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)

SFA No. A 5.17 FOR SAW (C/S)

E : ELECTRODE XX : NOMINAL
CARBON CONTENTS

E XXXK-N
N: INDICATES
INTENDED FOR
X : MANGANESE EXPOSURE TO
CONTAIN RADIATION
L : LOW MAX. 0.60%
M : MEDIUM MAX. 1.40%
H : HIGH MAX. 2.25% K : SILICON KILLED
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
( TYPE OF FLUXES FOR SAW )
FUSED FLUXES :
These particle again resemble small silvers of black glass, irregular
shape and can not crushed in the hand. Fused fluxes tend to be of a
ACIDIC TYPE , low quality weld metal (mechanical properties of
tensile and toughness. Need to baked at a very high temperatures.
(when cooled then pulverised into small particles.

AGGLOMERATED FLUXES :
These fluxes are dull generally round granules, can also very
brightly coloured. Agglomerated fluxes tend to be of a BASIC
TYPE, high quality weld metal that is of much higher strength and
toughness. Bake at a lower temperatures.
 Submerged Arc Welding Fluxes

AGGLOMERATED
FUSED FLUXES
FLUXES
 Submerged Arc Welding Fluxes
Fused Flux : Agglomerated Flux :
 Flaky appearance  Granulated appearance
 Lower weld quality
 High weld quality
 Addition of alloys
 Low moisture intake
 Lower consumption
 Low dust tendency  Easy slag removal
 Good re-cycling  Smooth weld profile
 Very smooth weld  High moisture intake
profile
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)
SFA No. A 5.17 ( FLUXES FOR SAW )
X: TENSILE STRENGTH MIN. TEMP. FOR
MULTIPLE BY 1O.000 IMPACT VALUES OF
PSI 20 FT-LB
Z - NOT REQUIRED
F X X X – E XXX 0
2
-
-
AT 00 F
MINUS 200 F
F : FLUX 4 - MINUS 400 F
X : PWHT REQ’D AFTER 6 - MINUS 600 F
WELDING
A : AS WELDED (N/A) DESIGNING
P : PWHT IS NEEDED ELECTRODE USE
 TYPICAL ELECTRODE SPECIFICATION (CONT’D)

SFA No. A 5.18 FOR GTAW, GMAW & PAW

E : ELECTRODE S : BAR, SOLID ELECTRODE or
ROD

CLASSIFICATION
E RXXS-X BASED ON
MANUFACTURER
CHEMICAL
COMPOSITION

XX : TENSILE STRENGTH
R : ROD MULTIPLED BY 1000 PSI
TYPICAL ELECTRODE SPECIFICATION (CONT’D)

SFA No. A 5.20 - FCAW ( C/S )

E : ELECTRODE
T : TUBULAR WITH
FLUX IN TUBE

E XXT-X CHEMICAL COMPOSITION,

SHIELDING GAS &
APPLICATION

X : POSITIONAL
X : TENSILE STRENGTH WELD
MULTIPLED BY 10.000 PSI
 TYPICAL ELECTRODE SPECIFICATION (CONT’D )
SFA No. A 5.22 FOR FCAW & GTAW ( S/S )
E : ELECTRODE
T : TUBULAR WITH
FLUX IN TUBE
E XXXT-X SHIELDING GAS
1 - CO2
2 - ARGON + CO2
3 - NONE
XXX : CHEMICAL G - CONSULT MANUF’R
COMPOSITION
 TYPICAL ELECTRODE SPECIFICATION (CONT’D )

SFA No. A 5.23 - SAW

( LOW ALLOY STEEL )

XX :CARBON
CONTENT

E XXXK K : SILICON KILLED

E : ELECTRODE E M 12 K
X : CHEMICAL
COMPOSITION
TYPICAL ELECTRODE SPECIFICATION (CONT’D )

SFA No. A 5.23 - SAW

( LOW ALLOY STEEL )
E : ELECTRODE

E XX XX : CHEMICAL
CONTENT

E A1
E CXX XX : SPECIFIC FLUX
E CA1
C : CORE