ELECTRODES & FLUX

- Can welding be done by bare electrodes ?

- Why do we require coating at all ?
- Reasons are instability of arc, lack of
shielding, poor mechanical properties
- What are the different type of coating
TYPE OF COATING
Cellulose material - It is made by hard or soft wood,
pulp & similar substance. Washing, drying &
grading into different mesh sizes.

- High arc force, large volume of gas mostly

hydrogen
RUTILE
- It is a crystalline form of titanium dioxide.
Available in beach sand. Concentration - 87% App.
- Arc Stabilizer.
- Good Slag remover.
BALL CLAY It is a compound of silica &
alumina commonly known as alumino silicate.
- Slag remover
- Gives plasticity in the wet paste.

IRON POWDER Sometimes added to flux

coating to add strength to weld
- Gives good mechanical strength, arc stabilizer.
PURPOSE OF FLUX COATING

- Gas shielding of arc.

- Stabilizer of the arc (potassium silicate).
- Provides slag blanket.
- Alloying elements will improve mechanical
properties (Iron oxide, Ferro manganese).
- Gives good penetration.
- Welding in all positions becomes easy.
- Compensate oxidation loss.
ELECTRODE CLASSIFICATION

BASED ON COVERING
- Rutile Electrode Quite & smooth arc, Excellent
slag removal, fine ripples, medium penetration, thick
slag.
- Cellulose electrode forceful & noisy arc, coarse
slag, deep penetration, more gas shield, thin slag
cover.
- Basic Electrode Adequate penetration, slag
removal is good, contains more iron powder, good
mechanical properties.
BASED ON APPLICATIONS
- Stainless steel electrode
- Low alloy electrodes
- Copper & copper alloy electrode
- Aluminum & alloy electrodes
- Hard facing electrodes.

WHAT IT INDICATES
E6010
E Electrode
60 min tensile strength 60000 psi (410 mpa)
1- Welding position
0 Coating current & condition.
 AWS ELECTRODE CLASSIFICATION SYSTEM
FOR CARBON & LOW - ALLOY STEEL
ELECTRODES (SMAW)

AWS Specification A5.1

E 60 1 0 Type of Coating
& Current
Electrode

Strength in PSI Position

 E 80 1 8 - B1
Electrode

80 PSI Min.

All Position

For AC or DCEP
Chemical Composition of
Weld Metal Deposit
 POSITION

DIGIT POSITION
1 Flat, Horizontal, Vertical, Overhead
2 Flat & Horizontal Only
3 Flat, Horizontal, Vertical down,
Overhead
 TYPE OF COATING & CURRENT

DIGIT TYPE OF COATING CURRENT

0 Cellulose Sodium DCEP
1 Cellulose Potassium AC or DCEP or DCEN

2 Titania Sodium AC or DCEN

3 Titania Potassium AC or DCEP
4 Iron Powder Titania AC or DCEP or DCEN

5 Low Hydrogen Sodium DCEP

6 Low Hydrogen Potassium AC or DCEP
7 Iron Powder Iron Oxide AC or DCEP or DCEN

8 Iron Powder Low Hydrogen AC or DCEP

 CHEMICAL COMPOSITION OF WELD DEPOSIT

Suffix %Mn %Ni %Cr %Mo %V

A1 1/2
B1 1/2 1/2
B2 1-1/4 1/2
B3 2-1/4 1
C1 2-1/2
C2 3-1/4
C3 1 0.15 0.35
D1&D2 1.25-2.00 0.25-0.45

G 0.50 0.3Min 0.20Min 0.10Min

 AWS ELECTRODE CLASSIFICATION SYSTEM
FOR CARBON STEEL ELECTRODES (GMAW)

Chemical
Composition
ER 70 S- X & Shielding
Electrode
or rod

Strength in PSI Solid Electrode Wire

SPECIFICATIONS FOR GMAW ELECTRODES

BASE MATERIAL TYPE AWS

SPECIFICATION
Carbon Steel A5.18
Low Alloy Steel A5.28
Al Alloy A5.10
Cu Alloy A5.7
Magnesium A5.19
Nickel Alloys A5.14
Stainless Steel A5.9
Titanium A5.16
 AWS CLASSIFICATIONS FOR GTAW
ELECTRODES

AWS COMPOSITION COLOR

CLASS. CODE
EWP Pure Tungsten Green
EWCe-2 97.3% Tungsten, 2% Cerium Oxide Orange
EWLa-1 98.3% Tungsten,1% lanthanum Oxide Black
EWTh-1 98.3% Tungsten,1% lanthanum Oxide Yellow
EWTh-2 97.3% Tungsten,2% lanthanum Oxide Red
EWZr-1 99.1% Tungsten,0.25%Zirconium Oxide Brown
EWG 94.5% Tungsten,remainder not specified Gray
 ALLOY STEELS

Steel is considered to be alloy - steel when the

maximum of the range given for the content of alloying
elements exceeds one or more of the following limits

Manganese 1.65%
Silicon 0.60%
Cu 0.60% or

in which the limits of any of the following elements is

specified or required
Al, Boron, Cr 3.99%
Cobalt, Columbium, Mo, Ni, Ti, Tungsten, Vanadium or
any other element added to obtain the desired alloying
element.
 ALLOY STEELS

AWS Filler Metal Specifications

Suffix Letter designate the chemical composition

of the deposited weld metal
Suffix Letter indicate the following chemistry

Suffix Letter Chemistry

A C - Mo Steel
B Cr - Mo Steel
C or NI Ni Steel
D Mn - Mo Steel
NM Ni - Mo Steel
G, K, M and W Other Low Alloy Steel
 ALLOY STEELS

To Weld Alloy Steel successfully four factors

must be considered

1. Always use a low - hydrogen welding procedure,

process & filler metal

2. Select a filler metal that matches the strength

level of the alloy steel

3. Select a filler metal that comes close to

matching the composition of alloy steel

4. Use proper welding procedure

 CARBON STEELS & LOW - ALLOY STEELS

Wrought Iron No Carbon ( < 0.08%)

Low Carbon Steels 0.15 % Carbon (Max)
0.25 - 1.5 % Manganese
Mild Steel 0.15 - 0.29 % Carbon
Medium Carbon Steel 0.25 - 0.50 % Carbon
0.60 - 1.65 % Manganese

High Carbon Steels 0.50 - 1.03 % Carbon

0.30 - 1.00% Manganese

Low Alloy Steels 0.29 % Carbon (Max.)

Total Metal Alloys <= 2.0 %

Cast Iron 2.1 % Carbon

 CARBON STEELS & LOW - ALLOY STEELS

STEEL ELECTRODES AISI

Low Carbon Steels E60XX & E70XX
1008
1025

Medium Carbon Steel E70XX 1030

1050

High Carbon Steels Pre - Heating &PWHT 1055

(200 - 310o C) 1095

Low Alloy Steels E80XX, E90XX

 LOW - ALLOY STEELS

Low Nickel Steel AISI 2315, 2515, 2517

Carbon 0.12 - 0.30%
Mn 0.40 - 0.60%
Si 0.20 - 0.45%
Ni 3.25 - 5.25 %

Electrode With the C-1, C - 2 Suffix

if C < 0.15% No preheat, except for heavy

section

if C > 0.15% Preheat up to 260o C

Stress Relieving Advisable

 LOW - ALLOY STEELS

Low Ni - Cr Steel AISI 3120, 3135, 3140, 3310, 3316

Carbon 0.14 - 0.34%
Mn 0.40 - 0.90%
Si 0.20 - 0.35%
Ni 1.10 - 3.75 %
Cr 0.55 - 0.75%

Electrode E80XX & E90XX

if C < 0.15% No preheat, except for heavy

section

if C > 0.20% Preheat up to 316o C

Stress Relieving Advisable

 LOW - ALLOY STEELS

Low Manganese Steel AISI 1320, 1330, 1335, 1340, 1345

Carbon 0.18 - 0.48%

Mn 1.60 - 1.90%
Si 0.20 - 0.35%

Electrode E80XX & E90XX With A-1, D-1 or

D-2 Suffix

Low Range of C & Mn No preheat

if C >= 0.25% Preheat desirable(121o C- 149o C)
High Range Mn Mandatory
Thicker Section (240o C- 290o C)

Stress Relieving Advisable

 LOW - ALLOY STEELS

Low Alloy Cr Steel AISI 5015 to 5160

Carbon 0.12 - 1.10%

Mn 0.30 - 1.00%
Si 0.20 - 0.30%
Cr 0.20 - 1.60%

Electrode E80XX & E90XX With B Suffix

Low Range of C & Cr No preheat

High Range C & Cr 399o C
Thicker Section (240o C- 290o C)

Stress Relieving Advisable

 LOW - ALLOY STEELS

Low Alloy Cr Steel AISI 5015 to 5160

C.E. = C% + Mn% + Ni% + Cr% + Mo% + Cu%

6 20 10 40

if C.E. < 0.40% Material is readily weldable

C.E. > 0.40% Special Controls Required

Preheating
Low Hydrogen Processes

Procedure Should be Qualified

 STAINLESS STEELS

Also called Corrosion - Resistant Steels

They do not rust
Strongly resist attack by great many liquids, gases
& chemicals
Good low - temperature toughness & ductility
Good Strength & Resistance to High Temp.
Iron as main element
Chromium - 11 to 30 %
 STAINLESS STEELS

AISI Identification System

Three Digit Number e.g. AISI 304
First Digit indicates Group
Last Two indicates specific alloy

Series Metallurgical Principle Magnetic

Design. Group Elements

2XX Austenitic Cr-Ni-Mn Non Magnetic

3XX Austenitic Cr-Ni -do-
4XX Martensitic Cr Magnetic
4XX Ferritic Cr -do-
5XX Martensitic Cr-Mo -do-
LOW HYDROGEN ELECTRODES
These electrodes are having covering that is
low in hydrogen bearing compound.

- Hydrogen has limited solubility in steel.

- Solubility is high in liquid state
- Beyond solubility limit, it retained in weld
called traps.
- Localization of hydrogen takes place which

creates under bead crack, Hydrogen

induced crack.
SELECTION OF ELECTRODES

- Composition & strength of BM

- Penetration requirement
- Position of welding.
- Fit up condition
- Skill of welding personnel
- Cost of welding operation.
- Service requirement of weld joint.
PREHEATING & POST HEATING

It is to elevate base metal temp before or after

welding operation.
Purpose - to reduce cooling rate
- To avoid cold cracks
- To avoid hydrogen entrapment
- To remove moisture

Carbon equivalent = C+Mn/6+(Cr+Mo+V)/5 +

(Ni+Cu)/15
0.40 Below Preheating optional
0.40 - 0.60 Preheating 150 to 200 deg c
0.60 & above Preheating & Post heating
200 370 deg C

POST WELD HEAT TREATMENT

- Rate of heating
- Soaking & soaking time
- Rate of cooling
WELDING DEFECTS
In the correct sense, a defect is a rejectable discontinuity
or a flaw of rejectable in nature. Certain flaws acceptable
in one type of product need not be accepted nature in
another product. A defect is definitely a discontinuity but
a discontinuity need not necessary be a defect.
ACCEPTANCE / REJECTION CRITERIA
- Stress to which the parts will be subjected.
- Type of material used.
- The temp & pressure to which the parts will be
stressed & Its thickness
- Consequence of failure & cost &accessibility of
repair.
DEFECT CHARACTERISTICS
- Size of defect
- Sharpness or notch effect
- Orientation of defect
- Location of defect (surface, root, weld metal, HAZ,
Parent metal.
BROAD CLASSIFICATIONS
Planer defect (two dimensional) - cracks, lack of fusion,
lack of penetration, lamination

Voluminar defect (three dimensional) Slag inclusion,

Porosity, cavity, root concavity.
Geometric defects
Misalignment, undercut, concavity , convexity,
excessive reinforcement, improper reinforcement,
overlap, burn through, incomplete penetration, lack of
fusion, surface irregularity

Incomplete penetration Lack of penetration &

excessive penetration.
- Excessive thick root face or insufficient root opening
can be avoided by use proper joint geometry.
- Insufficient heat input.
- Slag flooding ahead of welding Use small
electrodes in root .
- Misalignment - id matching
- Bridging or root opening.
INCOMPLETE FUSION
- Insufficient heat input, wrong size of electrode,
improper joint design follow correct WPS
- Incorrect electrode position maintain correct
position.
- Weld metal running ahead of arc lower the current
& speed
SLAG INCLUSION
- Improper joint design-increase groove angle of joint.
- Oxide inclusions proper gas shielding.
- Poor electrode manipulative techniques.
- Change electrode or flux to improve slag control.
- Failure by welder to remove slag
POROSITY

- Improper arc length, welding current, electrode

manipulation change welding condition &
techniques.
- Excessive moisture in electrode-use correct baking
& holding temp.
- Excessive Hydrogen & nitrogen in weld atmosphere

by use low hydrogen electrodes.

- High solidification rate use preheat
- Dirty metal or filler metal.
 LACK OF FUSION
WELD DEFECTS
EL P MOCNI
 WELD DEFECTS

INCOMPLETE PENETRATION
 WELD DEFECTS

CONTINUOUS INCOMPLETE PENETRATION

 ROOT CONCAVITY
WELD DEFECTS
RHT NRUB
 CRACK ADJACENT TO THE ROOT
WELD DEFECTS
REVS NART
 WELD DEFECTS
YTI S OR OP
 WELD DEFECTS

CRACK
HCT A MSI M
 TUNGUSTEN INCLUSION
WELD DEFECTS
L CNI GAL S
WELD DEFECTS
 EXCESSIVE PENETRATION
WELD DEFECTS
UC RE DNU
 WELD DEFECTS

WELDING EXAMPLES RELATED TO BAD PRACTICES

EFFECT OR VARIATION OF PARAMETERS
CURRENT TOO LOW
Poor penetration
Slag inclusion
Irregular ripples
Uneven bead height
CURRENT TOO HIGH
Excessive penetration
More spatter
Poor ripple appearance
Porosity
Undercut
ARC TOO SHORT
Irregular ripples
Electrode freezing the job
ARC TOO LONG
Wide ripples
More spatters, blow holes
TRAVEL TOO FAST
Narrow width of bead
Porosity
TRAVEL TOO LOW
More width & height of bead
Slag inclusion
DISTORATION & RESIDUAL STRESS
Distortion or residual shape change occur during
welding.
These imperfections adversely affect further assembly.
Designers are often constrained to design structure free
from distortion
Distortion control is often tackled by shop floor
engineers.
This is a after effect of welding that remains permanent
in the component till the equilibrium is disturbed.
PROCESS Localized application of heat causes
plastic deformation. As a result thermal shrinkage occur
near that zone & the metal or weldment changes its
shape during cooling.
METHOD TO PREVENT
Minimizing weld joints.
Minimizing weld sizes.
Minimizing unsupported length
Selection of appropriate edge preparation
Use of intermittent welding.
Using proper jigs & fixtures
Using welding sequence
Minimizing heat input rate