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If you

have any specific

requirements

not covered

in our range, please feel free to write to our WORKS. We would be too glad to develop the electrodes to your specification.

4th Edition

II
QUALITY

DET NORSKE VERITAS SYSTEM CERTIFICATE

Certificate No. QSC - 5H56

r1 ~ \ ' . t,?-JJ~
\

This istocertify that

(/ theQuality System

~1Y1 '1.iAILAM MET~LOGEN

(P) LTD.

~-

at Pondid1erry. india
Has been found to conform to the Quality System Standa'rd:

ISO 9002,1994
This Certificalt! is valid for the follou"ng prod1ld or seroia ranges:

Manufacture

and Supply of Welding Consumables.

Piau

arid dah.

71,i.1 Cmifratl

is valid

u7UiL-

Rotterdam,

January

31st, 1997

January

31st, 2000

tIu Acm</iUd Unil: '"ORSKE VERIT AS

On'ginal

Cmification

@k'

January

31st, 1997

B'V"

--~----_u
"

E NETIiERLANDS ..

~ ,-" ---, --

1.

Accredited hy lhe RvA

Ron} Managrmn~

Meijer , &prt'smtallut

DI'iV Mt\NAC;U.fE~TSY~n't:M CERITFICA'110N

Lack of fulfilment of conditions f'

1':{.I(:~i.U..:-.l!t!.Ii.
DIT NORSKE VERITAS SV. H~a\lrc(hmra.a[

a~ set out ill the Appendix

Ulay render

tlm Ct'rtificatc

invalid.
OQ,

7, ~OiO DC ROItt'rd<tI1J, -nIt' NC'lherJ.uul"

TEL I~'T

+31

10 ,179 86

FAX

+:51

101797111

.J
~CONTENTS Page No.

1.
2. 3. 4. 5. 6.

MILD STEEL ELECTRODES

LOW ALLOY AND HIGH TENSILE STEEL ELECTRODES

PIPE WELDING ELECTRODES HARDFACING ELECTRODES

5 11 13 17 25 27 29 35 38

STAINLESS AND HEAT RESISTING STEELELECTRODES CAST IRON ELECTRODES CUTTING AND GOUGINGELECTRODES MAINTENANCE ELECTRODES GUIDE FOR IS DESIGNATIONS GUIDE FOR AWS DESIGNATIONS

7.
8. 9. 10. 11. 12. 13. 15. 16.

CHEMICALCOMPOSITIONREIlUIREMENTSFORSTAINLESSSTEELWELDMETAL 39 41 HARDNESS CONVERSIONTABLE 43 CONVERSIONTABLE FOR WELDING ENGINEERS 45 ELECTRODEAPPROVAL CHART 48 ELECTRODECARE AND CONDITIONING

MAILAM

METALLOGEN (P) LTD

IIWIIIIT IUJiII

.J

MILD STEEL
PRODUCT DESCRIPTION
CODING & CLASSIFICA TION

ELECTRODES
TYPICAL WELD
METAL Chemical % PROPERTIES Physical Size mm CURRENT Length mm AND PACKING DATA Pieces per box 875 525 325 200 Current (Amps) Pieces per carton 175 105 65 40

MAILOFINE
A heavy coated, mild steel electrode giving a deposit of pure iron which is made highly resistant to corrosion by molten zinc. The weld deposit is ductile with very low impurities. The arc is smooth and the slag is easily detachable.

IS 814 ES 4122

C Mn Si

- 0.06 - 0.20 - 0.02

YS : 400 N/mm2 UTS: 500 N/mm2 E : 24%{L=4d} CVN at RT 60 J

2.50 3.15 4.00 5.00

350 450 450 450

60 - 90 90 - 130 140 - 180 180 - 220 AC, DC(-)

MAILARC

- 12
for all posi-

A medium rutile coated general purpose electrode

tion welding including vertical down with easy detachable slag. Used for welding in general fabrication, ship building, storage . tanks, busbodies, frame works etc,

IS 814 ER4112 AWS A51 E 6012

C Mn Si

- 0.10

0.40

- 0.15

YS UTS: E eVN

: 400 N/mm2 480 N/mm2 . 27%{L=4d} at RT 60 J

2.50 3.15 4.00 5.00

350 450 450 450

60 90 140 170

- 90 - 120 - 180 - 220

200 125 80 55

1000 625 400 275

AC, DC(-)

MAILARC

- 13PLUS
with medium penetra-

A medium coated, all position electrode

tion, low spatter and easy detachable slag. Used for welding tanks, ralls, coaches, boilers, ships, pipes and various fabrication jobs. Operates in all positions including vertical down.

IS 814 ER 4212 AWS A5.1 E 6013

e Mn Si

- 0.10 - 0.40 - 0.15

YS : 400 N/mm2 UTS: 490 N/mm2 E : 26%{L=4d} eVN at oDe 60 J

2.50 3.15 4.00 5.00 6.30

350 350 450 450 450

60 90 140' 180 230

90 140 190 240 310

200 125 80 55 35

1000 625 400 275 175

AC, DC(-)

MAILARC

- 13R

A medium heavy coated, rutile type, all position electrode giving good penetration, low spatter and easy peeling slag Weld deposit is of radiographic quality. Application includes pressure pipes, tubes, boilers etc., Best suited for sheet metal welding.

IS 814 ER 4222X AWS A5.1 E 6013

C Mn Si

- 0.08 - 0.45 - 0.17

YS : 390 N/mm2 UTS: 480 N/mm2 E : 28%{L=4d} eVN at OOC 70J

2.00 2.50 3.15 4.00 5.00 6.30

300 350 450 450 450 450

I.

40 - 60 60 - 90 100 - 140 140 - 190 180 - 250 250 - 330 AC,DC(-)

250 150 100 70 40 25

1250 750 500 350 200 125

\8
11111111I11III

.J

MILD STEEL
PRODUCT DESCRIPTION CODING & CLASSIFICA TION

ELECTRODES
TYPICAL WELD METAL PROPERTIES Chemical
~!

CURRENT Size mm Length mm

AND

PACKING

DATA Pieces per box 600 400 250 175 100

Physical

Current (Amps)

Pieces per carton 120 80 50 35 20

MAILARC 13RR A heavy coated, rutile type electrode giving radiographic welds
with negligible spatter, very smooth arc and a self peeling slag. Can be used as a touch electrode and gives an excellent bead appearance. Ideal for automobile frames, storage tanks, rail coaches, boilers etc.,

IS AWS E 6013

814 A5.1

ERR 4222X

C Mn Si

- 0.08 - 0.48 - 0.18

YS UTS: E CVN

: 390 N/mm2

480 N/mm2 : 29%{L=4d} at OOC90 J

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 - 90 100 - 140 140 - 190 180 - 250 250 - 330 AC, DC(-)

MAILARC

- 14
IS 814 ERR 5222XJ AWS A5.1 E 7014

An all position iron powder mild steel electrode giving radiographic welds. The deposition efficiency is 110% approximately. An ideal mild steel electrode for obtaining higher welding output with very high current.

C Mn Si

- 0.08 - 0.60 - 0.18

YS UTS. E CVN

: 450 N/mm2 540 N/mm2 : 26%{L=4d} at OOC80 J

3.15 400 5.00

450 450 450

100 - 140 150 - 200 200 - 250 AC, DC(-)

105 65 40

525 325 200

MAILARC

- 24
IS 814 ERR 5242XK AWS A5.1 E 7024'

A super heavy coated, iron powder electrode havillg a metal recovery of 140% approximately. Suitable for fast downhand and horizontal fillet welding giving excellent weld bead finish. Gives radiographic quality welds.

C Mn Si

- 0.08 - 0.80 - 0.18

YS : 470 N/mm2 UTS: 540 N/mm2 E : 26%{L=4d) CVN at OOC80 J

3.15 4.00 5.00

450 450 450

150 - 170 200 250 250 - 290

50 35 25

250 175 125

AC, DC(-)

.MAILARC

- 18
IS 814 EB 5426H2JX AWS A5.1 E 7018

A heavy coated, low hydrogen, iron powder type electrode with an extremely smooth arc, medium penetration and least spatter. Ideally suited for producing tough and ductile welds of radi\>graphic quality in boilers, pressure vessels and heavy structures subjected to dynamic loading. Deposition efficiency is 115% approximately. 3

C Mn Si

- 0.06 - 125 - 0.42

YS : 470 N/mm2 UTS: 550 N/mm2 E : 28%{L=4d} CVN at -30C 70J

2.00 2.50 3.15 4.00 5.00 6.30

300 350 450 450 450 450

40 - 70 60 - 100 100 - 140 150 - 200 200 - 240 270 - 360 '\C(70V), DC(+)

150 100 75 50 30 20

750 500 375 250 150 .100

--_U'-'_._"--'

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IIIUIIIIIIlI&I

LOW ALLOY & HIGH TENSILE

PRODUCT DESCRIPTION

.JSTEEL ELECTRODES
TYPICAL WELD METAL PROPERTIES Chemical % Physical Size mm CURRENT Length mm AND PACKING DATA Pieces per box 600 400 300 200 125 Current (Amps) Pieces per carton 120 80 60 40 25

CODING & CLASSIFICATION

MAILARC -16
A medium heavy coated, low hydrogen all position electrode giving X-ray quality welds for welding of mild steel, medium high tensile steel and low alloy steel. The deposit acts as a buffer before hardfacing and has excellent impact properties. Slag is quite easy to remove. Ideal for joining mild steel to cast steel and for depositing non-machinable welds on cast iron.

IS 814 EB 5426H)< AWS A5.1 E 7016

C Mn Si

- 0.08 - 1.20 - 0.45

YS : 490 N/mm2 UTS: 550 N/mm2 : 26%{L=4d} E

CVN at -30DC 1OOJ

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 - 90 100 - 140 140 - 190 190 - 240 250 - 340 AC(70V), DC(+)]

MAILARC

- 165
IS 814 EB 5426H)< AWS A5.1 E 7016

A medium heavy coated, low hydrogen, all position electrode giving X-ray quality welds. Ideal for welding cast steel, steels with very high carbon and sulphur contents, low alloy steel and steels of unknown composition. Weld metal has high impact properties and high resistanceJo cracking.

C Mn Si

- 0.08 - 1.00 - 0.50

YS : 450 N/mm2 UTS: 520 N/mm2 : 26%{L=4d} E CVN at -30DC80 J

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 100 140 180 240

90 140 180 230 320

120 80 60 40 25

600 400 300 200 125

AC(70V), DC(+) 2.50 3.15 4.00 5.00 6.30 350 450 450 450 450 60 - 90 90 - 140 140 - 180 180 - 250 270 - 320 AC(90V),DC(+) 100 75 50 30 15 500 375 250 150 75

MAILARC -18(5PECIAL)
An iron powder, low hydrogen type electrode. giving radiographic welds with excellent impact properties at sub-zero temperatures. Ideal for welding rigid restrained structures, pressure vessels, carbon steels etc.,

IS 814 EB 5529H2JX AWS A5.1 E 7018 - 1

C Mn Si

- 0.08 - 1.40 - 0.35

YS : 500 N/mm2 UTS: 550 N/mm2 : 28%{L=4d} E CVN at -46DC50 J

MAILARC

- 88G
IS 1395
E 55BG129Fe AWS -: A5.5 E 8018G

A medium heavy coated, low hydrogen, iron powder type electrode giving a weld metal containing 1.5% Mn and 0.6%Ni. Specially developed for welding of high tensile fine grained steels used for tankages, pressure vessels, penstocks etc., The electrode gives smooth arc, medium penetration and low spatter. The welds are of radiographic quality.

C Mn Si Ni

0.08 1.50 0.45 0.60

YS : 500 N/mm2 UTS: 600 N/mm2 E : 28%{L=4d}

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 90 140 180 270

90 140 180 250 320

100 75 50 30 20

500 375 250 150 100

AC(90V),DC(+)

6
>4

II

~.
MIUIIIITAU.m

._~

~~._--

LOW ALLOY & HIGH TENSILE

PRODUCT DESCRIPTION CODING & CLASSIFICATION

.J

STEEL
Chemical Iii

ELECTRODES
CURRENT
Size mm Length mm

TYPICAL WELD METAL PROPERTIES Physical

AND PACKING DATA

Current (Amps) Pieces per carton 100 75 50 30 15 Pieces per box 500 ~75 250 150 75

MAILARC

- 98G
IS 1395 E 63BG129Fe AWS A5.5 E 9018G C Mn Si Ni 007 1.40 0.45 0.65 YS : 600 N/mm2 UTS. 650 N/mm2 24%{L=4d} E CVN at -30C 50J
.

A low hydrogen, iron powder electrode giving radiographic welds with a smooth arc and least spatter. Ideal for welding heavy duty structures, high tensile steels involving dynamic loading penstocks, earthmoving equipments etc.,

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 90 140 180 260

90 140 180 250 320

AC(90V),DC(+)

MAILARC

- 108M
IS 1395 E 68BM229Fe AWS A5.5 E 10018M C - 0.07 Mn - 1.20 Si - 0.45 Ni - 1.80 Cr - 023 Mo - 0.30 YS : 630 N/mm2 UTS . 740 N/mm2 20%{L=4d} E CVN at -51C 40 J 2.50 3.15 4.00 5.00 6.30 350 450 450 450 450
60

An all position, low hydrogen electrode ideally suited for welding high 'tensile steels, earthmoving equipments, USS-T1 steels etc., The weld metal is of radiographic quality. Tendency for hydrogen induced cracking is reduced by the low hydrogen level in the deposit.
.

90 140 180 260

90 140 180 250 320

100 75 50 30 15

500 375 250 150 75

AC(90V),DC(+) 60 90 140 180 260 90 140 180 250 320 100 75 50 30 15 500 375 250 150 75

MAILARC

- 118M
IS 1395 E 76BM329Fe AWS A5.5 E 11018M C - 0.06 Mn - 1.40 Si - 0.40 Ni - 2.10 Cr - 0.30 Mo - 0.30 YS : 730 N/mm2 UTS: 810 N/mm2 : 22%{L=4d} E CVN at -51C 40 J 2.50 3.15 4.00 5.00 6.30 350 450 450 450 450

A heavy coated, all position, low hydrogen electrode, for welding high tensile steels like USS-T1'steel ,earthmoving equipments, quenched and tempered steels. The weld metal is of radiographic quality and yields high impact value at subzero temperatures upto -51C MAILARC

AC(90V),DC(+) 120 80 50 40 20 600 400 250 200 100

- Mo
1395 IS E 49BA126Fe AWS A5.5 E 7018 - A1

A heavy coated, all position, low hydrogen, iron powder type electrode. Deposit has 0.5% Mo and hence ideal for welding 0.5% Mo 1% Cr steels. The weld metal has good creep resisting properties. Also ideal for welding boiler plates, tubes, pipelines at elevated temperature upto 540C. Deposit is of radiographic quality .

C Mn Si Mo

- 0.06 - 0.65 - 0.30

YS

: 460 N/mm2

UTS . 560 N/mm2

: 26%{L=4d} E CVN at RT 140J

- 0.50

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 100 140 190

- 90 - 130 - 190 - 250

250 - 300
AC(70V), DC(+)

MIIWIIITIllOOII

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. ~--"._~._-'_.._----

.J

LOW ALLOY & HIGH TENSILE

PRODUCT DESCRIPTION
CODING & CLASSIFICATION

STEEL
. METAL
Chemical %

ELECTRODES
CURRENT Size mm Length mm AND PACKING DATA Pieces per box 500 375 250 150 100 Physical Current (Amps) Pieces per carton 100 75 50 30 20

TYPICAL WELD
PROPERTIES

MAILARC -1CR
A heavy coated, all position, low hydrogen, iron powder elec.

trode, with excellent creep and heat resisting properties at

elevated temperature upto 550 C. Deposit is of radiographic quality. Ideal for welding boiler and refinery chrome moly plates and pipe lines.

IS 1395 E 55BB226Fe AWS A5.5 E8018-B2

C Mn Si Cr Mo

0.06 0.65 0.35 1.20 0.50

YS : 520 N/mm2 UTS: 600 N/mm2 : 22%{L=4d} E CVN at RT 100J

2.50 3.15 4.00 5.00 6.30

350 450 450 450 450

60 100 140 190 250

90 130 180 250 310

AC(70V).DC(+) 2.50 3.15 4.00 5.00 6.30 350 450 450 450 450 60 100 140 190 250 90 130 180 240 310 100 75 50 30 20 500 375 250 150 100

MAILARC

- 2CR
IS 1395 E 63BB326Fe AWS A5.5 E 9018 - B3 C Mn Si Cr Mo

A heavy coated, all position, low hydrogen, iron powder type electrode. Deposit is of radiographic quality and has approximately 1% Mo and 2.25% Cr and has very good creep and oxidation resistance upto 575C. Ideal for welding boiler, refinery pipelines and plat~s of chemical plants having similar Cr-Mo compositions.

- 0.07 - 0.65
- 0.35

- 2.25
- 1.00

YS : 560 N/mm2 UTS: 650 N/mm2 : 22%{L=4d} E CVN at RT 50 J

AC(70V),DC( +) C Mn Si Ni Cr 3.15 4.00 5.00 450 450 450 90 - 140 140 - 1'80 180 - 250 AC(90V),DC( +) 75 50 30 375 250 150

MAILARC

- aaw
IS 1395 E 55BG129Fe AWS A5.5 E8018-W2
and weathering steels like CORTEN

A medium heavy coated, low hydrogen electrode giving a deposit of radiographic quality. The weld metal offers excellent resistance to atmospheric corrosion. Ideal for welding high
tensile steels

CORTEN

- B etc.

- A,

MAILARC

- aaWR
IS 1395 E 55RG125 AWS A5.5 E 8013 - W2

- 0.08 - 1.00 - 0.40 - 0.60 - 0.55 Cu - 0.50 C

YS : 510 N/mm2 UTS: 600 N/mm2 : 22%{L=4d} E CVN at -18C 50 J

A heavy coated all position rutile type, low alloy, high tensile electrode giving a deposit of radiographic quality. Has an excellent atmospheric corrosion resistance. Ideal for welding high tensile steels and weathering steels like CORTEN - A,

CORTEN- B etc.,

- 0.08 YS : 510 N/mm2 - 1.00 UTS: 600 N/rrim2 Si - 0.40 E : 22%{L=4d} Ni - 0.60 CVN at -18C40 J Cr - 0.55 Cu - 0.50
Mn

2.00

300

40 -

70

175

875

2.50 3.15 4.00 5.00

350 450 450 450

60 100 140 190

90 130 180 240

120 80 50 35

600 400 250 175

AC(70V),DC(-)
9

10

-8
IIIIIIIITIIUIII

PIPE WELDING
PRODUCT DESCRIPTION CODING & CLASSIFICA TION

ELECTRODES
TYPICAL WELD
METAL Chemical
II r'

.!

PROPERTIES Physical Size mm

CURRENT Length mm

AND

PACKING

DATA Pieces per box 1000 625 400 275

Current (Amps)

MAILARC

- 10
IS 814 E C4310X AWS A51 E 6010 C Mn Si

Pieces per carton 200 125 80 55

A cellulosic type electrode for all position welding including vertical down with a powerful penetrating arc and easily detachable slag. Ideally suited for achieving excellent penetration in root (;Jassesin cross country pipeline with conventional or stove pipe technique. The weld deposit is of radiographic quality.

0.10

OAO - 0.22

YS : 400 N/mm2 UTS. 480 N/mm2 E . 25%{L=4d} CVN at -29C 60J

2.50 315 4.00 500

350 350 350 350

40 70

70
120

120 - 160 140 - 210 OC(+)

MAILARC

- 10G
AWS A5.5 E 7010G C Mn Si Ni

A c"lIulosic type electrode ideally suited for all position welding including vertical down. Gives a smooth penetrating arc. The weld deposit is of radiographic .quality and has excellent mechanical properties. Ideal for welding pipeline of high strength pipe steel, storage tanks, drill platforms etc., using down hill travel.

0.10

0.50
018

YS 470 N/mm' UTS 530 N/mm' E . 26%{L=4d}

- 051

2.50 315 400 500

350 350 350 350

70 130 120 - 180 140 - 220

40 70

200 125 80 55

1000 625 400 275

OC( +)

MAILARC

- 10G1
AWS E 8010G A5.5 C Mn Si Ni Mo 0.12 0.60 0.15 0.25 0.40 YS : 510 N/mm2 UTS : 590 N/mm2 E : 24%{L=4d } 2.50 3.15 4.00 5.00. 350 350 350 350 40 70 120 140 - 70 - 130 - 180 - 220 OC(+) 200 125 80 55 1000 625 400 275

A cellulosic, all position, medium coated electrode giving a very smooth arc. Specially designed for high strength pipeline welding, using both stove pipe and conventional techniques. The slag is quick freezing and easily removable. Weld metal is of radiographic quality.

MAILARC

- 10Mo
AWS A55 E 7010-A1 C Mn Si Mo - 0.11 - OA5 - 0.36 YS : 430 N/mm2 UTS : 510 N/mm2 : 27%{L=4d} E 2.50 3.t5 4.00 5.00 350 350 350 350

A medium coated, cellulosic type electrode, ideally suited for welding in all position including vertical down. Gives a deep penetrating arc with a thin friable slag. Weld metal is ductile and gives creep resistant 0.5 % Mo deposit which is of radiographic quality. Ideal for pipeline applications using stove pipe or conventional techniques. II

- 90 75 - 140 120 180

60

OA8

140

- 230

200 125 80 55

1000 625 400 275

OC(+)

12

(I

,J

MIUIIII1I1.lIm

HARDFACING
PRODUCT DESCRIPTION / APPLICATIONS

ELECTRODES
CURRENT WELD METAL PROPERTIES Size mm Length mm AND PACKING DATA Pieces per box 500 350 200

Current (Amps)

Pieces per carton 100 70 40

MAILHARD

- RI -J - RII

A rutile type electrode giving a machinable deposit of hardness

250 BHN approximately.

Ideal for rail crossings, gear shafts, hammers, axles etc.,

AS WELDED Hardness on 3 layers 250 BHN (approx.)

3.15 4.00 5.00

450 450 450

/
,,/

100 - 120 140 - 180 180 - 220 AC,DC( - ) 100 - 120

140

MAILHARD

A rutile type electrode giving a deposit of hardness 350 BHN approximately and has good resistance to impact. It has good sliding properties.

Typical applications include drive sprockets, wheels, shafts, pullies,

axles, rail crossings, etc. ,

AS WELDED Hardness on 3 layers 350 BHN (approx.)

3.15 400 5.00

450 450 450

180

180 - 220
AC, DC(

100 70 40

500 350 200

-)

MAILHARD

- Rill

A rutile type electrode giving a non machinable deposit of hardness 600 BHN approximately. An initial buffer layer of Mailex - 18/8/6 is recommended while using on austenitic manganese steels.

Ideal for hardfacing applications on canes, and bamboo . cutting knives, shear blades, crusher hammers, sprockets etc., Application includes bamboo, chipper knives, sprockets, conveyor buckets, crusher jaws. cane cutting knives. oil expeller worms etc.,
Applications includes cement die rings, oil expellerworrns, concrete mixer blades, screw conveyors, muller tyres bucket lips etc.,

AS WELDED Hardness on 3 layers 600 BHN (approx.)

3.15 4.00 5.00

450 450 450

100 - 120 140 - 180 180 - 220 AC, DC( - )

100 70 40

500 350 200

MAILHARD

- BIIILH

A heavy coated, basic type, hydrogen controlled iron powder electrode with a smooth are, medium penetration and least spatter. Gives a hard and non-machinable deposit which can withstand very high abrasion and impact and can only be ground.

AS WELDED Hardness on 3 layers 550 BHN (approx.)

3.15 4.00 5.00

450 450 450

100 - 140 140 - 180 190 - 240 AC(70V),DC(+)

75 50 30

375 250 150

MAILHARD

- BV

A medium heavy coated basic type electrode with a smooth arc and least spatter and works easily even at low currents: Gives an air hardening alloyed cast iron deposit which is extremely hard and resists very high abrasion and moderate impact. Ideal for hardfacing. application requiring resistance to scratching or mild grin9ing abrasions. 13

AS WELDED Hardness on 3 layers 600BHN (approx.)

3.15 4.00 5.00

450 450 450

90 - 110 120 - 150 140 - 190 AC ,DC(+)

80 60 40

400 300 200

14

MAIJII METIUIIGEII

HARbFACING
PRODUCT DESCRIPTION APPLICATIONS

ELECTRODES
CURRENT WELD METAL
PROPERTIES Size mm Length mm Current (Amps) Pieces per carton Pieces per box

AND PACKING DATA

MAILMANGAN -12
A heavy coated, basic type electrode with mild steel core wire giving a deposit of 12% Mn. Gives a smooth are, least spatter and also gives a weld deposit of hardness 200 BHN in as welded condition which work hardens to over 500 BHN under impact.

Typical application includes rock crushers,

steel rails, cement grinding

rings, ball mills, manganese steel parts of earth moving equ.ipments, surfacing of hammers, dredger bucketteeth etc.,

AS WELDED Hardness - 200 BHN (approx) increases to 500 BHN under impact in service.

3.15 4.00 5.00

450 450. 450

100 - 120 140 180 180 - 220

75 50 30

375 250 150

AC(70V),DC( +)

MAILMANGAN - 14/4
A heavy coated, low hydrogen type austenitic manganese steel electrode depositing 14% Mn and 4% Ni. The deposit is of workhardening type. Hardness increases from 200 BHN in as welded condition to 500 BHN under impact. For hardfacing applications on mild steel and low alloy steel a buffer layer of Mailex 18/8/6 is recommended.

Ideal for manganese steel rails, cement grinding rings, rock crusher. jaws, crusher mantles, hammers, muller tyres etc.,

AS WELDED Hardness on 3 layers 200 BHN (approx) increases to 500 BHN under impact in service.

3.15 4.00 5.00

450 450 450

100 130 140 - 180 180 - 220 AC(70V),DC{ +)

75 50 30

375 250 150

MAILHARD - 35CR
A basic coated electrode giving a deposit of 3.5% C and 35% Cr for hardfacing applic:ations. The deposit is highly resistant to abrasion. It also resists oxidation even upto 10000C and has a hardness of 600 BHN.

Application includes ceramic handling equipments, sand blasting equipment, conveyor screws, tube mill, rolling mill guides, plough shares, coke chutes etc.,

AS WELDED Hardness on 2 layer 600 BHN (approx)

315 4.00 5.00

350 350 350

100 - 130 130 - 170 170 - 210 AC,DC( + )

} } 2 Kgs. }

} } 10 Kgs. }

15

16

IIAllAUnillOGfli

.!

STAINLESS AND HEAT

PRODUCT DESCRIPTION
CODING & CLASSIFICA TION

RESISTING STEEL ELECTRODES

TYPICAL WELD
METAL Chemical % PROPERTIES Physical Size mm CURRENT Length mm AND PACKING DATA Pieces per box Current (Amps) Pieces per carton

MAILEX

-A
IS 5206 E 19.9.R 26 AWS A5.4 E 308 - 16

A rutile coated stainless steel electrode yielding a deposit of 19% Cr and 10% Ni and having an excellent resistance to corrosion upto 8000 C. Ideal for welding stainless steel jobs of similar composition like AISI 301, 302, 304, 308 etc.,

C Mn Si Cr Ni

- 0.05 - 1.50 - 0.45 - 19.00 - 10.00

UTS: 590 N/mm2 E : 40%{L=4d} FN = 5

2.00 2.50 3.15 4.00 5.00

300 350 350 350 350

30 50 70 100 140

- 50 - 70 - 100 - 140 - 180

150 100 60 45 30

750 500 300 225 150

AC,DC( +)

MAILEX-

ANb
IS 5206 E 19.9.NbR 26 AWS A5.4 E347-16

A rutile coated stainless steel electrode yielding a deposit of 19% Cr 10%Ni and about 0.5% Nb with maximum resistance to cracking, corrosion and high temperatures upto 8000C. Presence of Niobium prevents intergranular corrosion. Ideal for welding of AISI 304, 304L, 321,347 steels and also for welding stabilised stainless steel of process equipment in food and chemical industries.

C Mn Si Cr Ni Nb

0.05 1.50 0.60 19.20 10.00 0.60

UTS: 620 N/mm2 : 36%{L=4d} E FN = 7

2.00 2.50 3.15 4.00 5.00

300 350 350 350 350

30 - 50 50 - 70 70. - 100 100 - 140 140 - 180

150 100 60 45 30

750 500 300 225 150

AC,DC( +)

MAILEX

- AL
IS 5206 E 19.9LR 26 AWS A5.4 E 308L - 16

An extra low carbon, rutile coated stainless steel electrode giving a deposit of 19% Cr and 10% Ni. Has excellent resistance to intergranular corrosion and also to cracking, oxidation and scaling at elevated temperatures. Ideal for welding of stainless steel of similar composition like 304L, 308L etc., with low carbon level.

C Mn Si Ni Cr

0.03 1.50 0.45 10.00

UTS: 590 N/mm2 :40%{L=4d} E FN = 5

- 19.50

2.00 2.50 3.15 4.00 5.00

300 350 350 350 350

30 50 70 100 140

- 50 - 70 - 100 - 140 - 180

150 100 60 45 30

750 500 300 225 150

AC,DC( +)
17 18

MAllAMMETIllOGlll

_.~

"._,-_._-

~.,.

~-~-~-<~O.'-'-~--

"'.

,.I

STAINLESS
PRODUCT DESCRIPTION

AND HEAT
CODING & . CLASSIFICATION

RESISTING
. Chemical
(oo

STEE~ :f:LECTRODES
CURRENT
,",

TYPICAL WELD METAL PROPERTIES

Physical
(

AND PACKING DATA

,',

Size mm

Length mm

Current (Amps)
;;.

Pieces per
carton

Pieces per
box

MAILEX - Mo
A rutile coated stainless steel electrode giving a deposit of 19% Cr, 13%Ni and 2.5% Mo. Electrode offers excellent creep strength and maximum resistance to cracking, corrosion and scaling at elevated temperature even as high as 850C. IS 5206 E 19.12.2.R26 AWS A 5.4 E 316 -16

. .I
'

C Mn Si Ni Cr Mo

. -

0.05 1.50 0.50 1250, 19.00 2.4 0

UTS . 59.0N/mm2 E : 4Q%{L=4d} FN = 6

.::..

2.00 2.50 3.15 4,00 5.00

..,

300 350 350 350 350

30 - 50 50' - 70 70' - 100" 100 - 140 140 180

150 100 60 45 30

750 ~OO 300' 225 150

AC,DC( +)
",

MAILEX - MoNb
A rutile type stainless steel electrode giving niobium stabilised 18% Cr 13% Ni and 2.5% Mo weld metal. The weld metal possesses good resistance to corrosion and pitting and improved creep strength. The weld metal has excellent resistance to intergranular corrosion. Most suitable for welding AISI 316, 317 and 318 types when maximum resistance to corrosion is required.

0.05

IS 5206 E 19.12.2NbR 26 AWS A 5.4 E 318 - 16

Mn Si Ni Cr Mo Nb C Mn Si Ni Cr Mo

- 1.50" - 050. - 12.70 - 18.80 .. 2.50 .. 0.60 0.03 - 1.50 .. 0.50 - 13.00 - 19.00 .. 2.50

UTS . 630 N/mm2 1.",~.90 , 2.5Q E .: 37%{J-=4d} 3.15., FN = 6 14.00 5.00

,.

300 35Q .350 350 350

30,., 5Q,

50 70

70 - 100
100 - 140 140 - 180 AC,DC( +) 30 .. 50 50 .. 70 70 -100;~ 100 -140 140- 180 AC,DC( +)

150 100 60 45 30

750 500 300 225 150

"

MAILEX - MoL
An extra low carbon rutile coated stainless steel electrode giving 18%Cr,13%Ni and 2.5% Mo. Has excellent resistance to intergranular corrosion and also to cracking and oxidation at elevated temperatures. Ideal for welding stainless steel of similar composition like 316L, 317L etc., with low carbon level. IS 5206 E 19.12.2.LR26 AWS A 5.4 16 E 316L -

UTS : 600 N/mni :40%{L=4d} E FN = 5

2.00 2.50 3.15) 4.00. r 5.00 )'

300 350 350 350 350'

'"

150 100 60 45 30 .('.'

750 500 300 225 150 t,

',;;

MAILEX - 25/12
A rutile type stainless steel electrode giving 25%Cr,12%Ni deposit. Weld metal offers excellent resistance to corrosion at high temperatures upto 11OooC. Ideal for welding AISI 309 grade steels, cladding of 18/8 clad steels and steels of dissimilar composition. 19

IS 5206 E 23.12.R 26 AWS A 5.4 E 309 - 16

C Mn Si Cr Ni

0.08 1.60 0.50

23.50

UTS.: 570 N/mm2 E : 40%{1. =4dJ

- 13.00
,

2.00 2.50 3.15,. 4.00 5.00

300 350 350 3S0 350

30 .. 50 50 .. 70 70 .100" 100- 140c 140 - 180 AC,DC( +)

150 100 60 45 30

-750 ' 90G 300" 225 150

20

-..,

I)

MIlAM IIIIUM

STAINLESS
PRODUCT DESCRIPTION

AND HEAT
CODING & CLASSIFICATION

RESISTING STEEL ~ELECTRODES

TYPICAL WELD
METAL PROPERTIES Physical Size mm Chemical %

CURRENT
Length mm

AND PACKING DATA

Current (Amps) Pieces per carton
...

MAILEX

- 25/12L
IS 5206 E 23.12:LR26 AWS A 5.4
E 309L - 16

t
C
Mn Si

Pieces per box

750 500

An extra low carbon, rutile type stainless steel electrode giving 25%Cr and 12%Ni deposit. Weld metal has excellent resistance to corrosion and scaling at high temperatures. Ideally suited for welding of 18/8 stainless steels,to carbon steel and for welding clad side of 18/8 clad stainless steels.

...

0.03

2.00 UTS: 590 N/mm2

...

Ni Cr

1.60 ... 0.50 ... 13.00

: 38%{L=4d}

2.50

300 350

- 23.50

3.15 4.00 5.00

350 350 350

30 50 70 100 140

- 50 - 70 - 100 - 140 - 180 AC,DC( +)

150 100

60 45 30

300 225 150

MAILEX

- 25/12Mo
IS 5206 E 23.12.2R 26 AWS A 5.4 E 309Mo - 16

C
Mn Si

A rutile type stainless steel electrode yielding a deposit of 25% Cr, 12% Ni and 2.5% Mo, Has excellent resistance to oxidation upto 1100 C. Ideal for welding 309 Mo steels and as buffer layer in welding dissimilar steels.

0.06 1.60 ... 0.50

...

...

UTS:

620 N/mm2

200 2.50

Ni Cr Mo

: 35%{L=4d}

300 350

- 13.00 - 23.50 - 2.50

3.15 4.00 5.00

350 350 350

30 50 70 100 140

- 50 - 70 - 100 - 140 - 180 AC,DC( +)

150 100

750 500

60 45 30

300 225 150

MAILEX

- 25/20
IS 5206 E 25.20.2R 26X AWS A 5.4 E 310 ~16

A rutile type stainless steel electrode giving 25%Cr 20% Ni deposit. Weld metal offers excellent resistance to oxidation at elevated temperatures upto 12000C. Ideal for welding steels of composition like AISI 310. Also best suited for welding Cr-Mo steels, clad steels, fumace retorts etc.,

C Mn Si Ni Cr

... ...

0.10 0.50

.. 2.00

UTS: 590 N/mm2 E : 35%{L=4d}

- 20.50
- 25.50

.2.00 2.50 3.15 4.00 500

300 350 350 350 350

30 50 70 100 140

MAILEX

- 18/8/6
IS 5206
C
Mn Si E 18.8.MnR26 0.09 5.50 ... 0.50
... ...

- 50 - 70 - 100 - 140 - 180 AC,DC( +)

150 100 60 45 30

750 500 300 225 150

A low hydrogen type electrode with mild steel core wire but giving a deposit of 18%Cr 8%Ni 6%Mn. Weld metal is highly resistant to corrosion and heat at elevated temperatures. Ideal for welding difficult steels such as harden able steels, armour plates, for joining austenitic manganese steel to mild steel and for laying buffer layer before hardfacing.

UTS:

600 N/mm2

2.50

350

: 38%{L=4d}

Cr Ni

.. 9.00

- 19.00

3.15 4.00 5.00

350 350 350

100 - 120

85

425

150 - 170 200 - 220 240 - 280 AC,DC(-)

50 35 25

250 175 125

21

22

IIIIJIIIIHIU.Ir.III

,J

STAINLESS
PRODUCT DESCRIPTION

AND HEAT
CODING & CLASSIFICATION

RESISTING
TYPICAL WELD METAL PROPERTIES Chemical
(j~)

STEEL
Size mm

ELECTRODES
AND PACKING DATA Pieces per box Length mm Current (Amps) Pieces per carton

CURRENT

Physical

f
MAILEX

- 18/8/655
5206 IS E 18.8 MnR20

A heavy coated electrode with stainless steel core wire giving a deposit of 18%Cr, 8%Ni and 6% Mn. The deposit has excellent resistance to heat and corrosion. Best suited for joining austenitic manganese steel to mild steel, welding of difficult steels such as high alloy steels, armour plates etc., and for laying buffer layer before hardfacing.

C Mn Si Ni Cr

0.09

600 0.50 900 19.00

UTS' E

600 N/mm2 . 38%{L=4d)

2.50 3.15 4.00 5.00

350 350 350 350

50 - 70 80 - 110 130 110 150 - 200

100 60 45 30

500 300 225 150

AC,DC( +)

MAILEX

- 13CR

A basic coated electrode giving a deposit of 13% Cr of radiographic quality. Ideal for joining materials having similar alloy composition and for surfacing applications in turbine parts, valve seats etc., Best suited for joining straight chromium steels.

AWS E410 -15

A 5.4

C Mn Si Cr Ni

- 0.08 - 0.75 - 0.55 - 13 00 - 0.60

UTS: 550 N/mm2 : 20%{L=4d} E

2.50 3.15 4.00 5.00

350 350 350 350

- 70 70 , 130 130 - 160 160 - 220

50

85 50 35 25

425 250 175 125

DC(+)

\~

23

24

~
IIIIi

IIIUIIIIT Il1fIa

PRODUCT DESCRIPTION

CAST IRON
CODING & CLASSIFICATION

ELECTRODES
TYPICAL WELD METAL PROPERTIES Chemical % Physical Size mm

.J

CURRENT
Length' mm

AND PACKING DATA

Current (Amps) Pieces per carton 120 80 60 40 Pieces per box 600 400 300 200

MAILOCAST
A basic coated electrode for producing non-machinable welds on cast iron and for joining cast iron to mild steel.

AWS ESt

A5.15

2.50 3.15 4.00 500

350 450 450 450

60 100 140 190

- 90 - 130 - 180 - 240

AC(90V),DC(+)

MAILOMONEL
A medium coated electrode with monel core wire giving a machinable deposit of Ni-Cu alloy for welding of cast iron. No preheating is needed. Ideal for repair work on cast iron castings. filling up of cracks etc.,

AWS A5.15 E NiCu-B

C Ni Fe Cu

- 0.75 - 63.00 - 4.00 - Bal

HARDNESS 160 - 190 BHN

2.50 3.15 400 5.00

350 350 450 450

40 80 110 140

- 60 - 100 - 140 - 170

) II } Kg.

) 112 Kgs. }

AC, DC(+)

MAILONICKEL
A medium coated electrode with nickel core wire giving a soft and machinable deposit of nickel for welding of cast iron. No preheating is required. Ideal for repair jobs on cast iron casting, surfacing or wornout castings, filling up of cracks etc., AWS E Ni-C! A5.15 C Fe Ni - 0.75 - 4.00 - Bal HARDNESS 160 - 190 BHN

2.50 3.15 4.00 5.00

350 350 350 350

40 - 60
70 - 90 100 - 120 140 - 170 AC,DC(+)

} } I Kg. }

I
} 12 Kgs. }

MAILOCAST - FN
A medium heavy coated electrode with ferro nickel wire giving a soft and machinable deposit of iron-nickel alloy for welding of cast iron. Ideal for producing crack free weld joints on cast iron and for joining cast iron to mild steel. No preheating is necessary.

AWS A5.15 E NiFe-CI

L I

Ni - 55.00 Fe - Bal

- 0.80

HARDNESS 170 - 190 BHN

2.50

350

3.15 4.00 5.00

350 350 350

70 - 110 110 - 130 140 - 180 AC,DC(+)

50 -

70

f I Kg.
I

} 12 Kgs. }

25

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(I

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IIWIIIIIIllfSII

MAINTENANCE
PRODUCT DESCRIPTION

ELECTRODES
CURRENT APPLICATIONS Size mm Length mm

AND PACKING
Current (Amps)

DATA

MAILMAIN
A maintenance

Minimum Packing

- 135
electrode giving a smooth uniform bead which

is of radiographic quality. For welding of thin sheets, lower current is to be used to avoid distortion.

Best suited for fabrication of storage tanks, automobile chassis, rail coaches. Very ideal for rebuilding wornout rollers and sugar mill trunions etc.,

3.15 4.00 5.00

350 350 350

90 - 140 120 - 170 180 - 220 AC,DC( + )

Available in 3 Kg. Packing

MAILMAIN
A maintenance

- 185
electrode giving an extremely ductile and crack appearance and The weld bead has good quality.

resistant deposit. is of radiographic

For joining and building up of low and medium carbon steels. Ideal for joining dissimilar joints and oil soaked parts. Used as cushioning alloy under hardfacing deposits. Also finds applications in pressure vessels, pipes, steel

3.15 4.00 500

350 350 350

90 - 140 120 - 170 180 - 240 AC,DC(+)

Available in 3 Kg. Packing

casting, heavy machinery parts etc., For joining and surfacing of high carbon, low and high alloy steels, spring steels, manganese steels, case hardening steels, high speed steels, cast steels, and difficult to weld steels and unidentified steels. Can be used as buffer layer before hardfacing and
also for welding parts subjected to wear,

MAILEX

- 29/9

A maintenance electrode giving a deposit of 29%Cr, 9%Ni. The weld metal is crack resistant, ductile, shock proof and tough. Gives smooth arc and least spatter.

2.50 3.15 4.00 5.00

350 350 350 350

- 75 75 - 120 90 ...;150 130 - 180

50

Available in 3 Kg. Packing

AC,DC(+)

corrosion and impact.

MAILMAIN

- 4370

A maintenance electrode depositing austenitic stainless steel. The weld metal is resistant to corrosion by atmosphere. sea water, weak acids and has excellent heat resistance.

For welding of austenitic manganese steel, materi~ls of difficult weldability, manganese steel to mild steel, armour steels. Ideal for providing cushioning layer before hardfacing. Repairing cracks in austenitic manganese steel castings, surfacing manganese steel rails etc.,

2.50 315 4.00 500

350 350 350 350

- 70 70 - 100 100 - 140 140 - 180

50

Available in 3 Kg. Packing

AC,DC(+)

29

30

IIIUII1I!111l11GEM

MAINTENANCE
PRODUCT DESCRIPTION

ELECTRODES
CURRENT APPLICATIONS Size mm Length mm AND PACKING DATA Current (Amps) Minimum Packing

MAILMAIN - CINM
A maintenance electrode giving a non-machinable deposit for welding of cast iron to steel. Close colour match between deposit and base material is possible. Has good bonding properties even on difficult-to-weld cast iron.

For joining of cast ironto steel.Welding and surfacing of cast iron. Can be successfully used on rusty,corroded and oil soaked parts.

2.50 3.15 4.00 5.00

350 350 350 350

40 60 90 150

- 80 -120 - 140 -180

Available in 3 Kg. Packing

AC,DC(+) For building up of parts Hardness subjected to friction wear 320 BHN and shocks. Forging dies, striking tools,carbon steel rails, rims, die plates etc.,

MAILMAIN - 320
A maintenance electrode with good welding properties in all positions. Thick deposits can be made without buffer layers. Weld metal is resistant to shock and impact stresses.

3.15 4.00 5.00

450 450 450

100 130 170

- 130 -170 -210

Available in 3 Kg. Packing

AC, DC(+)

MAILMAIN - 550
A maintenance electrode giving a non-machinable deposit of 600 BHN approximately. with smooth appearance Has excellent resistance to abrasion and superior weld beads.

For building up of parts subjected to wear by abra- Hardness sion and shocks, worm 600 BHN screws, beaters, crusher jaws, buckets, fan blades, dredger teeth, repair of cutting tools etc.,
For hardfacing of parts subjected to heavy abrasion,and

3.15 4.00 5.00

450 450 450

100 -120 140 - 180 180 - 220 AC, DC(+)

Available in 3 Kg. Packing

MAILCARB
A maintenance electrode with high metal recovery and exceptional abrasion resistance at high temperatures.

Hardness metal to metal wear with 600 BHN moderate impact. Suitable for cement press screws, dredging buckets, edge runner bottom, knife, palm nut screws, boring bits, blast furnace bells and hoppers.

315 4.00 500

350 350 350

100 - 130 130 - 170 170 - 210 AC, DC(+)

Available in 3 Kg. Packing

31

32

-<~'~

~-

.!

MII.IMIIITIIUJra

MAINTENANCE
PRODUCT DESCRIPTION

ELECTRODES
CURRENT APPLICA TIONS Size mm
For wear resistant surfacing

AND

PACKING

DATA

Length mm

Current (Amps)

Minimum Packing

MAILMAIN - 600
A maintenance electrode giving a hard wear resistant deposit.

of mild and low alloy steels. Building machines, conHardness veyor screws, scrapper 600 BHN blades, muller tyres, trampers etc.,

3.15 4.00' 5.00

350 350 350

90 -110 110 -140 150 -180 AC. OC(+)

Available in 3 Kg. Packing

MAILMAIN - BRONZE
A maintenance electrode for welding of copper and bronze. The weld deposit is free from porosity and crack. The weld bead is smooth and uniform.

For welding and surfacing of copper. brass and bronze, joining copper and bronze to cast iron overlays and steel. Filling cavities in copper alloy castings.

3.15 4.00 5.00

350 350 350

80 - 110 110 140 130 - 180

Available in 3 Kg. Packing

AC, OC(+) For cutting and piercing of carbon steel cast iron, copper, aluminium, brass and other metals and alloys. Ideal for cutting of unwanted materials without the use of oxyacetylene or compressed air.
For chamfering and gouging of low alloy

MAILMAIN CUT
A maintenance electrode for cutting and piercing of all metals

3.15 4.00 5.00

450 450 450

150 - 240 190 - 280 240 - 360 AC, OC(-)

-i

Available in 3 Kg. Packing

MAILMAIN-GRU
A maintenance electrode used for chamfering and for producing smooth grooves.

steels, stainless steel, cast iron, carbon steels etc.,and to remove defects in
weld metal without the use of oxyacety-

3.15 4.00 5.00

350 350 350

'T50 - 200 230 - 280 270 - 350 AC, OC(+)

Available in 3 Kg. Packing

lene.

MAILMAIN-CINI
A maintenance electrode for cold welding of cast iron and for joining cast iron to mild steel.

For welding joints as well as surfacing

and repairs of machine frames, housings,

bearing blocks, cylinder blocks, sugar mill rollers, cast iron dies etc.,

2.50 3.15 4.00

350 350 350

40 - 70 60 - 100 80 - 120 AC, OC(+)

Available in 3 Kg. Packing

33

34

(I

.!

IIAIlJIIIITIWIIiII

GUIDE FOR IS DESIGNATIONS OF MANUAL ARC WELDING ELECTRODES

(AS PER IS 814: 1991)

For tensile

range 510

- 610 N/mm2

MAIN CODING
First prefix letter 'E' indicates a covered electrode manufactured Second prefix letter indicates the type of covering. by extrusion process.

a 1 2 3 4 5 6

No elongation and impact requirements 18 18 20 20 20 20

47 J/ + 27C

47J/
47J/ 27J/
27 J/

aoc

20C 30C
40C

27J/

A B C R RR S
The flIst

Acid Basic
Cellulosic Rutile Rutile, heavy coated Any other type not mentioned digit indicates ultimate tensile above in combination with the yield stress.

- 46C

The third digit indicates welding position 1. 2. 3. 4. 5. 6. All positions All positions except vertical down Flat butt weld, flat fillet weld and horizontal/vertical fillet weld . Flat butt weld and flat fillet weld. Vertical down,. flat butt, flat fillet and horizontal/vertical fillet weld. Any other posItion or combination of positions not classified above.

strength

The fourth digit indicates the current condition in which electrode to be used

Designation Digit 4 5
The second digit indicates

Ultimate Tensile Strength N/mm2

Yield Strength (Min) N/mm2 330 360

Welding current and voltage conditions: Digit (1) 0 1 2 3 4 5 6 7 8 9 1) 2) + + or+ + or+ Symbol 0 reserved for electrodes exclusively used on D.C. Positive polarity +. Negative polarity 36 D.C. Recommended Electrode polarity (2) + + orA.C., OCV V-min (3) Not recommended 50 50 50 70 70 70 90 90 90

410 510

- 510 - 610
elongation in combination Elongation

the percentage Percentage

with the impact values.

Designation Digit

Impact Strength in Joules (Min) at

Minon 5.65.;so

For tensile range 410 510 N/mm2 No elongation and impact requirements 0 20 47 J / + 27"C 1 22' 47 J / OOC 2 24 47 J / - 2O"C 3 24 27 J / - 3O"C 4

35

,,!

111.111111I10OIII

GUIDE FOR AWS DESIGNATIONS

OF

MANUAL ARC WELDING ELECTRODES ADDITIONAL CODING Performance characteristics

IThe letter and figure H1, H2 and H3 for hydrogen controlled electrode.
H1 = H2 = H3 =
Upto Upto Upto 15 ml of diffusible 10 ml of diffusible 5 ml of diffusible Hydrogen Hydrogen Hydrogen per 100 gms of deposited per 100 gms of deposited per 100 gms of deposited metal. metal. metal.

The prefix "E" designates arc welding electrode The first two digits of four digit numbers and the first three digits of five digit number indicate minimum tensile strength. E-60xx E-70xx E-110xx E-xx 1x E-xx2x 60,000 psi. Minimum tensile strength 70,000 psi. Minimum tensile strength

- 110,000 psi. Minimum tensile strength The next to last digit indicates position. - All positions - Flat position and horizontal fillets - 16 and EXX-18) must be kept

I The letter indicating

J K L

The last two digits indicate the types of electrode covering, current and polarity. All low

increased metal recovery as effective electrode efficiency.

hydrogen type covering (those ending in EXX -15, EXX in an oven at 250'C minimum before use.

110 - 129 percent 130 - 149 percent

The su1'tix(Example: EXXX - A1) indicates the approximate alloy composition in the weld deposits.

150 percent and above the radiographic quality.

IThe i",:'er indicating

A1 B1 B2 B3 B4 B5 B6 B7 B8 B9 G

- 0.50% Mo - 0.50% Cr 0.5% Mo - 1.25% Cr 0.5% Mo - 2.25% Cr 1.0% Mo - 2.00% Cr 0.5% Mo - 0.50% Cr 1.0% Mo - 5.00% Cr 0.5% Mo 0.4% Ni - 7.00% Cr 0.5% Mo 0.4% Ni - 9.00% Cr 1.0% Mo 0.4% Ni

C1 C2 C3 C4 C5 01,02 03

-2.5%

Ni.

-3.5% Ni - 1.0% Ni 0.3% Mo 0.15% Cr -1.5% Ni -6.5%Ni - 0.25 - 0.45% Mo, 1.75% Mn - 0.40 - 0.65% Mo, 1.75% Mn

The letter 'X' shall be included in the classification as a suffix for those electrodes which deposit radiographic quality welds.

- 9.00% Cr 1.0% Mo 1.0% Ni - 1.00% Mn(min), 0.8%Si (min), 0.5% Ni (min) 0.3% Cr(Min), 0.2% Mo(Min), 0.1% V(Min), 0.2% Cu(Min). (Atleast one of the elements listed to meet the minimum values.) Additional chemical requirements may be as agreed between supplier and purchaser)

37

38

(I

UMllMMmllDGll

Ch emlca

I Composition
Weight

Requirements
Percent
Mo Cb(nb) Plus Ta
a,b

for Stainless

Steel Weld Metal

\, Cu

AWS Classification"

UNsd Number

Cr

NI

Mn

Si

E209-XX' E219-XX E240.XX E307 .XX E308-XX E308H-XX E308L-XX E308Mo-XX 308MoL-XX E309-XX E309L-XX E309Cb-XX E309Mo-XX E309MoL-XX E310-XX E310H-XX E310Cb-XX E310Mo-XX E312-XX E316-XX E316H-XX E316L-XX E317 .XX E317L-XX E318-XX E320-XX

W3221 0

006

205-240

95-12.0

15.30

CD '"

19.0-21.5 006 W32310 170-190 0.06 W32410 W30710 0.04-014 18.0-215 18.0-210' 0.08 W30810 18.0-210 W30810 004-008 180-210 004 W30813 180-21.0 008 W30820 180-210 0.04 W30823 22 0-250 0.15 W3091 0 22.0-25.0 0.04 W30913 22.0-250 0.12 W30917 22.0-250 012 W30920 22.0-25.0 0.04 W30923 W31010 0 08-0 20 250-280 W31015 0 35-045 25.0-280 250-280 0.12 W31017 25.0-280 012 W31020 28.0-32.0 0.15 W31310 17.0-200 0.06 W31610 W31610 004-0'08 170-200 17.0-20.0 0.04 W31613 160-21.0 0.08 W31710 18.0-210 0.04 W31713 170-200 0.08 W31910 W88021 0.07 19.0-210

0.75 55- 70 075 4.0-60 05- 15 9.0-107 075 9.0-110 0.75 9.0-110 0.75 90-110 20 - 30 90-120 20- 30 9.0-120 075 12.0-140 0.75 120-140 0.75 12.0-14.0 12.0-14.0 20- 30 20 12.0-14.0 -30 0.75 20.0-22.5 0.75 200-225 0.75 200-220 200-22.0 20 - 30 0.75 80-10.5 11.0-14.0 20-30 11.0-14.0 20- 30 110-14.0 20-30 120-14.0 30 - 4.0 12.0-14.0 30 - 4.0 11.0-14.0 20-30 320-360 20- 3 0

40 - 70 0.90 80 .100 100 1.00 105.12.5 0.90 3.30.475 090 05 - 25 0.5 - 2.5 0.90 090 05.25 090 05.25 05 - 2 5 090 05 - 2 5 090 05- 2 5 090 05 - 2.5 0.90 100 0.70 0.5 - 2.5 090 0.5 - 2.5 0.90 0.75 1.0 - 25 0.75 1.0 - 25 0.75 25 1.0 (1.70 - 1.00 0.75 1.0.2.5 0.5 - 2.5 0.90 05- 2.5 090 0.5 - 2.5 0.90 0.90 0.5 - 25 090 05-25 0.90 05-25 05 - 2 5 090 6xC, min to 1.00 max axc, min to '.00 max 05.25 060

004 0.04 004 004 004 004 004 004 004 004 004 004 004 0.04 0.03 0.03 0.03 003 0.04 004 0.04 0.04 0.04 0.04 0.04 004

003

0.10.030

075 0.75 0.75 0.75 075 075 075 075 0.75 075 075 0.75 0.75 0.75 075 075 0.75 0.75 0.75 0.75 075 075 0.75 0.75 0.75 30 - 40

010-030 003 010-030 0.03 003 0.03 003 0-03 003 003 003 003 003 0.03 003 0.03 003 0.03 003 0.03 003 0.03 003 0.03 0.03 003 003

Chemical
f. AWS Classification" E320LR-XX
E330-XX

Composition

Requirements
Weight

for Stainless
a,b

Steel Weld Metal

Percent
Cb(Nb) Plus T a

UNSd Number W88022 W88331 W88335 W34710

Cr

Ni

Mo

Mn

Si

. Cu

0.03 0.18-0.25 0.35-0.45 0.08 0.13 0.03 003 0.12 0.06 0.10 0.10 010 0.05 0.10 0.10 0.04 0,06

19.0-210 14.0-170 14.0-17.0 18.0-21.0

32.0-360 33 0-37.0 330-370 9.0-11.0

2.0.3.0 0.75 0.75 0.75 0.35-0,65 3.2 - 4.2 42 - 5.2 0.75 0.40-0.70 0.75 0,45.0.65 0,85.1,20 0.75 1,0 -2.0 0.45-0.65 2.5 - 3.5 2.9 - 3.9

8xC. min to 0.40 max 8xC, min to 1.00 max 0.75 - 1,20

1.5 - 2.5 1.0.2.5 0.5-2.5

0.30 0.90 0.90 0.90 0.90 0.90 0,75 0.90 0.90 0.90 0,90 0,90 0.75 0,60 0.90 0.90 1,00

0.02 0.04 0.04 0.04 0.04 0.02 0.03 O.O~ 0,04 0.04 0.04 0.04 0,04 0,03 0.04 0.0., -0,04

0.015 0.03 0.03 0,03 0,03 0,02 0.02 0,03 0.03 0.03 0,03 0.03 0,03 0.03 0.03 0,03 0,03

3.0-4.0 0.75 0.75 0.75 0.75 0,6-1.5 1.2-20 0.75 0.75 0.75 0.75 3.25-4,0 0,75 0,75 0.75 0.08.0.20 0.10.0.25 1,50-2.5

1.0 - 2.5

E330H-XX E347 -xx

E349-XX' '.
E383-XX E385-XX E410-XX E410NiMo-XX E430-XX E502.XX E505.XX E630.XX E16.8-2.XX E7Cr-XX E2209-XX E2553.XX

W34910
W88028 W88904 W41010 W41016 W43010 W5021 0 W50410 W37410 W3681 0 W50310 W39209 W39553

~ 0

8.0-10.0 18,0-210 265- 29,0 30.0-33.0 24.0-260 195-215 0.7 11.0-13.5 11.0-12.5 4,0-5.0 0.6 15.0.180 04 4.0 -6,0 0,4 80.10,5 4,5.5.0 160-16,75 7.5.9.5 14.5'16.5 0.4 6.0 - 8.0 21,5-23.5 85-10.5 24.0-27.0 6.5-85

0.15 -0.30

0,5 2.5 0.5 - 2.5 1,0 2,5 1,0 1.0 1,0 1.0 1.0 0,25.0,75 0,5 . 2.5 1.0 0.5.2.0 0.5 -1.5

0.75

Notes a) Analysis shall be made for elements for which specific values are shown in the table. If, however, the presence of other elements is indicated in the course of routine analysis. further analysis shall be made to determine that the total of these other elements. except iron, is not present in excess of 0.50 percent. Single values are maximum percentages. Classification suffix -XX may be 15 - 16 - 17 . 25 or -26. SAE/ASTM Unified Number System for Metals and Alloys. Vanadium shall be 0,10 to 0,30 per cent. Titanium shall be 0,15 percent maximum, Tungsten shall be from 1.25 percent to 1.75 percent.

b) c) d) e) f) g)

(I
UJ

HARDNESS
VICKERS HARDNESS BRINELL

CONVERSION
ROCKWELL HARDNESS

TABLE
VICKERS HARDNESS

(Approx.)
BRINELL HARDNESS

II1II.111 M11U.tra

ROCKWELL HARDNESS ~~"0

HARDNESS

a,
Ci III CD OIl"", .)1:;:
~0 IIIJ "0

0,
"0 c 0 E :it. C 0 U)"D .... , IV
U J tn.!! ~0 'C ED J

C 0 E ~Ct.!!
::Jt.C

c::

0 .0"0 or to 0

C:."" 0 E It cu ~~E .>CIl.. ""

'i C.tJ ! IP ","0 ~:e :J C'O

I-U

f
ii III 'i GI U).GI III Q.

ii III
ID

c:

C)'t"" ::Jt.;:

'iii 0
a .....,..

;n
....

C."" 0 E It cu ~~E .>0 CIl. "'"

ru c:.tJ ! 4) (11'0 ~:e

I-U

ii III

in.Q,I UI
Co GI 0

-; Q)

Q. 'Uj 0
""''1'''"

~cu

u;
225 220 215 210 206 201 197 193 190 186 183 180 177 174 171 168 165 162 160 158 154 150 145 140

67 66 65 64 ~63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44

..'

918 884 852 822 793 765 740 717 694 672 650 630 611 592 573 556 539 523 508 493 479 465 452 440

820 796 774 753 732 711 693 675 657 639 621 604 588 571 554 538 523 508 494 479 465 452 440 427

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

98.9 98.1 97.5 969 96.2 955 94.9 94.1 93.4 926 91.8 912 90.3 897 890 883 875 87.0 860 85.5 845 832 820 80.5

240 235 231 227 223 219 215 211 207 203 199 196 192 189 186 183 179 177 173 171 167 162 157 153

231 226 222 218 214 210 206 202 199 195 191 187 184 180 177 174 171 169 165 163 159 153 148 144

107 106 103 102 100 99 97 95 93 91 90 89 88 87 85 84 83 82 81 80 78 76 74 72 . ~--

...

...
..

...

500 488 476 464 453 442 430 419

283 273 264 256 246 237 231 221 215 208

...

:.

43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21

...

... .., ... ... ... ...

...

-.. 100.2 99.5

428 417 406 396 386 376 367 357 348 339 330 321 312 304 296 288 281 274 267 261 255 250 245

415 408 405 398 394 387 385 377 375 367 365 357 356 347 346 337 337 327 329 318 319 309 310 301 302 294 293 286 286 279 278 272 271 265 264 259 258 253 252 247 246 241 241 235 236 230

201 194 188 181 176 170 165 160 155 149 147 142 139 136 132 129 126 123 120 118 115 112 110

...

'."

.., ...

79.0 77.5 76.0 74.0 72.0 70.0 68.0 66.0 64.0 610 58.0 55.0 51.0 47.0 44.0 39.0 35.0 30.0 24.0 20.0 11.0 0

149 143 139 135 129 125 120 116 112 108 104 99 95 91 88 84 80 76 72 69 65 62

140 134 130 126 120 116 111 107 104 100 95 91 86 83 80 76 72 67 64 61 57 54

136 131 127 122 117 113 108 104 100 96 92 87 83 79 76 72 68 64 60 57 53 50

70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28

.J
CONVERSION
81 Units

I111J11II1I11J18

USEFUL
Quantity

TABLE

FOR WELDING
To

ENGINEERS
Multiply by

To convert from

Mass

Kilogram (kg) 1 tonne = 103kg

kg tonne(t)

Ib ton (long) ton (short) Ibf kgf, kp kgf/mm2. kp/mm2 ksi pa Ibf/in2 kgf/cm2 atm

2.205 0.984 1.102 224.8 102.0 0.102 0.145 1.0x1OS 14.5 1.02 0.987 0.7376 0.1020 7.2331 5.7864 2.362 3.60 2.205 2.119 0.(>6 25.4 mm

ELECTRODE SIZE EQUIVALENTS

Force

newton (N)
1N = 1kgm/sec2

kN

Stress

pascal (Pa) 1 pa = 1N/m2 N/mm(MPa) bar

DIAMETER SWG

LENGTH in mm in

1.6 2.0 2.5 3.15 4 5 6 7 8

16 14 12 10 8 I'; 4 2

1/16 5/64 3/32 1/8 5/32 3/16 1/4 9/32 5/16

Pressure

pascal (Pa) 1 bar = 105 Pa = 10-1N/mm-2 joule (J) 1J = 1 Nm 1J = 0.1 daJ

250 300 350 400 450 600 700

10 12 14 16 18 24 28

Energy

ft Ibf kgfm ft Ibf ftlb* inch/min m/hr Ib/hr ft3/hr m3/hr kJ/in

kgfm, kpm kgfm/cm2 Speed mm/sec mm/sec

Dep Rate Flow Rate

kg/hr litre/min

kg/hr litre/min

Heat Input

JIm

kJ/mm

True for standard Charpy V-notch impact specimen 43

44

, ~-

~-

MAILAMIITAlIlii

I)
SI.

ELECTRODE
TYPE AWS
CLASSIFICATION

.J

#BIS LRS

ABS

APPROVAL
SI. MMD ROSQ ElL

IRS

BV

DNV

BAX

CIB MND

CHART
* * *

MAILARC-13

PLU~ E 6013

2
3 4 5 6 7

MAILARC - 13R MAILARC - 13RR MAILARC 10 MAILARC -10G

E6013
E 6013
E 6010 E 7010G E 7016 E 7016 E 7018

. . .

. .

. . .

. . .

. . .

. .

PDIL UHDE IDEA BHEL BHEL BHEL BHPV TRY HYD RPT VIZAG NLC TNEB HSL WART FICH

* 3 *

* *
*

MAILARC - 168
MAILARC 16 MAILARC -18

. . . .
.

. . . . .
.

. . . . .

. .

5
6
7
8

* * *
*

. *

* *

* *

* * *
* *

8 9
10 11 12 13 14

MAILARC - 18 8PL E7018-1 MAILARC - 24 MAILARC - 88G MAILARC 88W MAILARC - 98G MAILARC Mo MAILARC - 118M MAILHARD R III MAILOCUT MAILEX - A MAILEX - ANb E 7024 E 8018G E 8018W E 9018G E7018-A1 E 11018M

9 10
11
12 13

*
*

*
*

*
*

.
*

:I:

*
*

*
*

*
*

14 15

15
16 17 18 19

E308-16 E 347 16 E 308L - 16

16 17

*
:I: *

*
*
:(:

. . .
.

20 MAILEX-AL 21 MAILEX. Mol,

22 23 24 # MAILEX 25/12 MAILEX - 13CR MAILEX - 18/8/6

18 19

E 316L. 16 E 309- 16
E410-16 -

20 21 22

* *

* * *

23
24
45

*
*

*
*

*
46

For abbreviation see overleaf

; I
I

I1W11II1I1U1111

8
BIS ABS IRS BV

.!
. BUREAU OF INDIAN STANDARDS ELECTRODE CARE AND

LRS

LLOYD'S REGISTER OF SHIPPING BUREAU OF SHIPPING CONDITIONING REGISTER OF SHIPPING

. moisture if exposed or durin'g I e ectrodes to Pick up atmospheric storage This may lead to faulty welds and poor performan ce 0 ~n~ e ectrodes. This IS more so with low hydrogen electrOdes where the hydrogen level is expected to be at the lowest . Th e I' ow hydrogen electrodes if allowed to catch U moisture may d evelop underbead P heavy restraint Joints In all su h crac k'Ing In the heat affected zone of c cases, the. redrYlng of electrdes is a must and the recom~en ded temperature for different range of electrodes is given below:

- AMERICAN - INDIAN

- BUREAU VERITAS - DET NORSKE VERITAS - BAXCOUNSEL - CHIEF INSPECTOR OF BOILERS - M.N. DASTUR & COMPANY LIMITED - MERCANTILE MARJNE DEPARTMENT - RESEARCH DESIGN AND STANDARDS ORGANISATION - ENGINEERS INDIA LIMITED - PROJECTS & DEVELOPMENT INDIA LTO. . INTERNATIONAL DEVELOPMENT AND ENGG. ASSOCIATED LTD., - UHDE INDIA LIMITED. . BHARAT HEAVY ELECTRICALS LIMITED, TRICHY. - BHARAT HEAVY ELECTRICALS LIMITED, HYDERABAD.

DNV BAX CIB MND MMD RDSO ElL POlL IDEA UHDE BHEL, TRY. BHEL, HYD. BHEL, RPT BHPV, VIZAG. NLC TNEB HSL WART FICH

There is a tendency for the

TYPE

AWSClassification)

TEMPERATURE DC 90 - 100 70 - 80 150 - 180

TIME

6012,6013,7014 6010, 7010G, 7010-:\1, 8010G 7024, ENiCu-B, ENi-C:, ENiFe-CI 7016, Hardfacing, Low alloy Electrodes and Stainless Steel Electrodes 7018,7018-1, and other Hydrogen controlled electrodes

- BHARAT HEAVY ELECTRICALS LIMITED, RANIPET. - BHARAT HEAVY PLATE & VESSELS LIMITED, VISAKHAPATTINAM. - NEYVELI LIGNITE CORPORATION - TAMILNADU ELECTRICITY BOARD

1 Hr.' 1 Hr. 1 Hr.

HINDUSTAN SHIPYARD LIMITED

- WARTSILA NSD CORPORATION - FICHTNER CONSULTING ENGINEERS (INDIA) PVT. LTD.,

200

- 250

2 Hrs.

300

2 Hrs.

47

48