Sfa 5.21

2007 SECTION II, PART C SFA-5.
21
SPECIFICATION FOR BARE ELECTRODES AND RODS

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FOR SURFACING
SFA-5.21
(Identical with AWS Specification AWS A5.21:2001. In case of dispute, the original AWS text applies.)
1. Scope ASTM A 285/A 285M, Specification for Pressure Vessel

1.1 This specification prescribes the requirements for Plates, Carbon Steel, Low and Intermediate Tensile
the classification of bare electrodes and rods for surfacing. Strength
The specification does not provide for classification of ASTM DS-56/SAE HS-1086, Unified Numbering Sys-
electrode-flux combinations for submerged arc welding. tem for Metals and Alloys
1.2 Safety and health issues and concerns are beyond

the scope of this standard and, therefore, are not fully 3. Classification
addressed herein. Some safety and health information can 3.1 The surfacing electrodes and rods covered by this
be found in the Annex sections A5 and A10. Safety and specification are classified according to the following:
health information is available from other sources, includ-
ing, but not limited to, ANSI Z49.1, Safety in Welding, 3.1.1 Solid surfacing electrodes and rods, are classi-
Cutting, and Allied Processes, and applicable federal and fied on the basis of the composition of the material as
state regulations. manufactured (or the stock from which it was made) (see
Tables 1, 2, and 4).
3.1.2 Metal cored and flux cored composite (tubular)
PART A — GENERAL REQUIREMENTS surfacing electrodes and rods, except for tungsten carbide
2. Normative References rods, are classified on the basis of the composition of an
2.1 The following AWS standards1 are referenced in undiluted weld deposit, as shown in Tables 1, 3, and 4.
the mandatory sections of this document: 3.1.3 Tubular tungsten carbide surfacing rods are
AWS A5.01, Filler Metal Procurement Guidelines classified on the basis of the mesh range, quantity, and
ANSI Z49.1, Safety in Welding, Cutting, and Allied Pro- composition of the tungsten carbide granules, as shown in
cesses Tables 5 and 6.
2.2 The following ASTM standards2 are referenced in 3.2 Material classified under one classification shall
the mandatory sections of this document: not be classified under any other classification in this speci-
ASTM E 29, Practice of Using Significant Digits in Test fication.
Data to Determine Conformance with Specifications
ASTM A 36/A 36M, Specification for Structural Steel
ASTM B 214, Test Method for Sieve Analysis for Granu- 4. Acceptance
lar Metal Powder
Acceptance3 of the welding electrodes and rods shall be
in accordance with the provisions of AWS A5.01, Filler
1
AWS standards may be obtained from the Global Engineering Docu- Metal Procurement Guidelines.
ments, An Information Handling Services Group Company, 15 Inverness
Way East, Englewood, CO 80112-5776. Telephone (800) 854-7179, (303)
397-7956; FAX (303) 397-2740; Internet: www.global.ihs.com.
2 3
ASTM standards may be obtained from American Society for Testing See Section A3, Acceptance (in the Annex), for further information
and Materials, 100 Barr Harbor Drive, West Conshohocken, PA concerning acceptance, testing of the material shipped, and AWS A5.01,
19428-2959. Filler Metal Procurement Guidelines.
461
Copyright ASME International
Provided by IHS under license with ASME Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome
No reproduction or networking permitted without license from IHS Not for Resale, 08/20/2007 05:55:22 MDT
SFA-5.21
Provided by IHS under license with ASME

TABLE 1
SOLID AND CORED IRON BASE ELECTRODES AND RODS — CHEMICAL COMPOSITION REQUIREMENTS a
UNS Numbers g Composition, Weight Percent b, c, d, e Other
AWS f Annex A Elements,
No reproduction or networking permitted without license from IHS

Classification Reference Solid Cored C Mn Si Cr Ni Mo V W Fe Total h
ERFe-1 A7.1.1 T74000 W74030 0.04-0.20 0.5-2.0 1.0 0.5-3.5 — 1.5 — — Rem 1.0
ERFe-1A A7.1.1 T74001 W74031 0.05-0.25 1.7-3.5 1.0 0.5-3.5 — — — — Rem 1.0
ERFe-2 A7.1.1 T74002 W74032 0.10-0.30 0.5-2.0 1.0 1.8-3.8 1.0 1.0 0.35 — Rem 1.0
ERFe-3 A7.1.2 T74003 W74033 0.50-0.80 0.5-1.5 1.0 4.0-8.0 — 1.0 — — Rem 1.0
ERFe-5 A7.1.3 T74005 W74035 0.50-0.80 1.5-2.5 0.9 1.5-3.0 — — — — Rem 1.0
ERFe-6 A7.1.4 T75006 W77530 0.6-1.0 0.4-1.0 1.0 3.0-5.0 — 7.0-9.5 0.5-1.5 0.5-1.5 Rem 1.0
ERFe-8 A7.1.5 T75008 W77538 0.30-0.60 1.0-2.0 1.0 4.0-8.0 — 1.0-2.0 0.50 1.0-2.0 Rem 1.0
ERFeMn-C A7.1.6 — W79230 0.5-1.0 12-16 1.3 2.5-5.0 2.5-5.0 — — — Rem 1.0
ERFeMn-F A7.1.6 — W79630 0.7-1.1 16-22 1.3 2.5-5.0 1.0 — — — Rem 1.0
ERFeMn-G A7.1.6 — W79231 0.5-1.0 12-16 1.3 2.5-5.0 1.0 — — — Rem 1.0
ERFeMn-H A7.1.6 — W79232 0.30-0.80 12-16 1.3 4.5-7.5 2.0 — — — Rem 1.0
ERFeMnCr A7.1.7 — W79730 0.25-0.75 12-18 1.3 11-16 2.0 2.0 — — Rem 1.0
ERFeCr-A A7.1.8 — W74531 1.5-3.5 0.5-1.5 2.0 8.0-14.0 — 1.0 — — Rem 1.0
462
ERFeCr-A1A A7.1.9 — W74530 3.5-5.5 4.0-6.0 0.5-2.0 20-25 — 0.50 — — Rem 1.0
ERFeCr-A3A A7.1.10 — W74533 2.5-3.5 1.5-3.5 0.5-2.0 14-20 — — — — Rem 1.0
ERFeCr-A4 A7.1.9 — W74534 3.5-4.5 1.5-3.5 1.5 23-29 — 1.0-3.0 — — Rem 1.0
ERFeCr-A5 A7.1.11 — W74535 1.5-2.5 0.5.-1.5 2.0 24-32 4.0 4.0 — — Rem 1.0
ERFeCr-A9 A7.1.12 — W74539 3.5-5.0 0.5-1.5 2.5 24-30 — — — — Rem 1.0
2007 SECTION II, PART C
ERFeCr-A10 A7.1.13 — W74540 5.0-7.0 0.5-2.5 1.5 20-25 — — — — Rem 1.0
NOTES:
a. Covered composite iron base electrodes that were included in AWS A5.21-80, Specification for Bare Surfacing Electrodes and Rods, have been deleted. They now appear in AWS A5.13:2000,
Specification for Surfacing Electrodes for Shielded Metal Arc Welding.
b. Single values are maximum. Rem p Remainder
c. Electrodes and rods shall be analyzed for the specific elements for which values are shown in this table. If the presence of other elements is indicated in the course of this work, the amount
of those elements shall be determined to ensure that their total does not exceed the limit specified for “Other Elements, Total” in the last column of the table.
Not for Resale, 08/20/2007 05:55:22 MDT

d. Sulfur and phosphorus contents shall not exceed 0.035% each.
e. For solid electrodes and rods, composition is that of the electrode itself or the stock from which it was made. For metal cored or flux cored electrodes, the composition is that of a weld
deposit prepared in accordance with 9.3 or 9.4.
f. For metal cored and flux cored composite (tubular) electrodes and rods, insert “C” in the classification designation just after the “R.”
g. ASTM DS-56/SAE HS-1086 Unified Numbering System for Metals and Alloys.
h. Aluminum and magnesium contents of weld metal deposited by self-shielding electrodes shall not be included in the value of “Other Elements, Total.”
Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome

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TABLE 2
SOLID COBALT AND NICKEL BASE BARE ELECTRODES AND RODS — CHEMICAL COMPOSITION REQUIREMENTS
Composition, Weight Percent a, b, c
Other
AWS Annex A UNS Elements,
Classification Reference Number d C Mn Si Cr Ni Mo Fe W Co B V Total
ERCoCr-A A7.2.1 R30006 0.9-1.4 1.0 2.0 26-32 3.0 1.0 3.0 3.0-6.0 Rem — — 0.50
ERCoCr-B A7.2.2 R30012 1.2-1.7 1.0 2.0 26-32 3.0 1.0 3.0 7.0-9.5 Rem — — 0.50
ERCoCr-C A7.2.3 R30001 2.0-3.0 1.0 2.0 26-33 3.0 1.0 3.0 11.0-14.0 Rem — — 0.50
ERCoCr-E A7.2.4 R30021 0.15-0.45 1.5 1.5 25-30 1.5-4.0 4.5-7.0 3.0 0.50 Rem — — 0.50
ERCoCr-F A7.2.5 R30002 1.5-2.0 1.0 1.5 24-27 21-24 1.0 3.0 11-13 Rem — — 0.50
ERCoCr-G A7.2.6 R30014 3.0-4.0 1.0 2.0 24-30 4.0 1.0 3.0 12-16 Rem — — 0.50
ERNiCr-A A7.3.1 N99644 0.20-0.60 — 1.2-4.0 6.5-14.0 Reme — 1.0-3.5 — — 1.5-3.0 — 0.50
ERNiCr-B A7.3.1 N99645 0.30-0.80 — 3.0-5.0 9.5-16.0 Reme — 2.0-5.0 — — 2.0-4.0 — 0.50
463
ERNiCr-C A7.3.1 N99646 0.50-1.00 — 3.5-5.5 12-18 Reme — 3.0-5.5 — — 2.5-4.5 — 0.50
ERNiCr-D A7.3.4 N99647 0.6-1.1 — 4.0-6.6 8.0-12.0 Reme — 1.0-5.0 1.0-3.0 0.10 0.35-0.60 — 0.50
Sn p 0.5-0.9
ERNiCr-E A7.3.4 N99648 0.1-0.5 — 5.5-8.0 15-20 Reme — 3.5-7.5 0.5-1.5 0.10 0.7-1.4 — Others p 0.50
ERNiCrMo-5A A7.3.2 N10006 0.12 1.0 1.0 14-18 Reme 14-18 4.0-7.0 3.0-5.0 — — 0.40 0.50
ERNiCrFeCo A7.3.3 F46100 2.5-3.0 1.0 0.6-1.5 25-30 10-33 7-10 20-25 2.0-4.0 10-15 — — 0.50
NOTES:
a. Single values are maximum. Rem p Remainder
b. Electrodes and rods shall be analyzed for the specific elements for which values are shown in this table. If the presence of other elements is indicated in the course of this work, the amount

c. Sulfur and Phosphorus content shall not exceed 0.03% each.
d. ASTM/SAE Unified Numbering System for Metals and Alloys.
e. Includes incidental cobalt.

SFA-5.21
SFA-5.21

TABLE 3
METAL CORED AND FLUX CORED COMPOSITE COBALT AND NICKEL-BASE BARE ELECTRODES AND RODS — CHEMICAL
COMPOSITION REQUIREMENTS
Composition, Weight Percent a, b, c
Other
AWS Annex A UNS Elements,
Classification d Reference Number e C Mn Si Cr Ni Mo Fe W Co B V Total
ERCCoCr-A A7.2.1 W73036 0.7-1.4 2.0 2.0 25-32 3.0 1.0 5.0 3.0-6.0 Rem — — 1.0
ERCCoCr-B A7.2.2 W73042 1.2-2.0 2.0 2.0 25-32 3.0 1.0 5.0 7-10 Rem — — 1.0
ERCCoCr-C A7.2.3 W73031 2.0-3.0 2.0 2.0 25-33 3.0 1.0 5.0 11-14 Rem — — 1.0
ERCCoCr-E A7.2.4 W73041 0.15-0.40 2.0 1.5 25-30 1.5-4.0 4.5-7.0 5.0 0.50 Rem — — 1.0
ERCCoCr-G A7.2.6 W73032 3.0-4.0 1.0 2.0 24-30 4.0 1.0 5.0 12-16 Rem — — 1.0
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ERCNiCr-A A7.3.1 W89634 0.20-0.60 — 1.2-4.0 6.5-14.0 Remf — 1.0-3.5 — — 1.5-3.0 — 1.0
464
ERCNiCr-B A7.3.1 W89635 0.30-0.80 — 3.0-5.0 9.5-16.0 Remf — 2.0-5.0 — — 2.0-4.0 — 1.0
ERCNiCr-C A7.3.1 W89636 0.50-1.00 — 3.0-5.5 12-18 Remf — 3.0-5.5 — — 2.5-4.5 — 1.0
ERCNiCrMo-5A A7.3.2 W80036 0.12 1.0 2.0 14-18 Remf 14-18 4.0-7.0 3.0-5.0 — — 0.40 1.0
ERCNiCrFeCo A7.3.3 W83032 2.2-3.0 1.0 2.0 25-30 10-33 7-10 20-25 2.0-4.0 10-15 — — 1.0
NOTES:
a. Single values are maximum. Rem p Remainder
c. Sulphur and Phosphorus contents shall not exceed 0.03% each.
d. The designator “C” indicates that the electrode or rod is a metal cored or flux cored composite (tubular) product.
e. ASTM/SAE Unified Numbering System for Metals and Alloys.

f. Includes incidental cobalt.

TABLE 4
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SOLID AND CORED COPPER BASE ELECTRODES AND RODS — CHEMICAL COMPOSITION REQUIREMENTS
UNS Numbers e Composition, Weight Percent a, b, c
Other
AWS Annex A Elements,
Classification d Reference Solid Cored Fe Cu Al Zn Si Pb Sn P Mn Totalf
ERCuAl-A2g A7.4.1.1 C61800 W60618 0.5-1.5 Rem 8.5-11.0 0.02 0.10 0.02 — — — 0.50
ERCuAl-A3g A7.4.1.2 C62400 W60624 2.0-4.5 Rem 10.0-11.5 0.10 0.10 0.02 — — — 0.50
ERCuAl-C A7.4.1.3 C62580 W60626 3.0-5.0 Rem 12-13 0.02 0.04 0.02 — — — 0.50
ERCuAl-D A7.4.1.3 C62581 W61626 3.0-5.0 Rem 13-14 0.02 0.04 0.02 — — — 0.50
ERCuAl-E A7.4.1.3 C62582 W62626 3.0-5.0 Rem 14-15 0.02 0.04 0.02 — — — 0.50
ERCuSi-Ag A7.4.1.4 C65600 W60657 0.50 Rem 0.01 1.0 2.8-4.0 0.02 1.0 — 1.5 0.50
465
ERCuSn-Ag A7.4.1.5 C51800 W60518 — Rem 0.01 — — 0.02 4.0-6.0 0.10-0.35 — 0.50
ERCuSn-D A7.4.1.5 C52400 W60524 — 88.5 min 0.01 — — 0.05 9.0-11.0 0.10-0.35 — 0.50
NOTES:
a. Single values are maximum, except where otherwise specified. Rem p Remainder
c. For solid electrodes and rods, composition is that of the electrode itself, or the stock from which it was made.
d. For metal cored and flux cored composite (tubular) electrodes and wires, insert “C” in the classification designation just after the “R.”
e. ASTM/SAE Unified Number System for Metals and Alloys.
f. Sulfur content shall not exceed 0.015%.

g. These AWS classifications are intended to correspond to the same classification that appears in AWS A5.7, Specification for Copper and Copper Alloy Bare Welding Rods and Electrodes.
Due to possible ongoing revisions, the composition ranges may not be identical.

SFA-5.21
SFA-5.21 2007 SECTION II, PART C
TABLE 5
MESH SIZE AND QUANTITY OF TUNGSTEN CARBIDE (WC) GRANULES IN THE
CORE OF TUNGSTEN CARBIDE BARE RODS AND ELECTRODES
U.S. Standard SI Equivalents
Mesh Size of Quantity of Tungsten
Tungsten Carbide (WC1 + WC2)
Carbide Granules, Weight U.S. Standard
a,b,c
AWS Classification Granulesd Percente Mesh Size Opening, mm
12
(ER/R)WCX- ⁄30 thru 12-on 30 60 12 1.70
(ER/R)WCX-20⁄30 thru 20-on 30 60 20 0.85
(ER/R)WCX-30⁄40 thru 30-on 40 60 30 0.6
(ER/R)WCX-40 thru 40 60 40 0.43
(ER/R)WCX-40⁄120 thru 40-on 120 60 120 0.13
NOTES:
a. “X” designates the type of tungsten carbide granules; Xp1 for WC1 granules, Xp2 for WC2 granules,
Xp3 for a blend of WC1 and WC2 granules.
b. The C normally present in composite designations can be deleted in these classificaitons, as tungsten
carbide electrodes and rods are composite.
c. See A7.5 in Annex A.
d. The mesh size of the tungsten carbide granules may vary from that specified above, provided that no
more than 5.0% of the granules is retained on the “thru” sieve and that no more than 20.0% passes
the “on” sieve.
e. The tolerance +2.0%, −1.5% of the amount specified.
TABLE 6 equivalent values to the U.S. Customary Units. The stan-

CHEMICAL COMPOSITION OF TUNGSTEN CARBIDE dard sizes and dimensions in the two systems are not identi-
GRANULES cal, and for this reason conversion from a standard size or
Composition, Weight Percenta dimension in one system will not always coincide with a
Element WC1 WC2 WC3 standard size or dimension in the other. Suitable conver-
C 3.6-4.2 6.0-6.2
sions, encompassing standard sizes of both, can be made,
Si 0.3 0.3 however, if appropriate tolerances are applied in each case.
Ni 0.3 0.3 As agreed
Mo 0.6 0.6 between purchaser
6.2 For purposes of determining conformance with this
Co 0.3 0.3 and supplier specification, an observed or calculated value shall be
W 94.0 min 91.5 min rounded to the nearest unit in the last right-hand place
Fe 1.0 1.0 of figures used in expressing the limiting value in the
Th 0.01 0.01 appropriate table for quantities in accordance with the
NOTE:
rounding-off method given in ASTM E 29, Practice of
a. Single values are maximum, unless noted otherwise. Using Significant Digits in Test Data to Determine Confor-
mance with Specifications.
5. Certification4 PART B — TESTS, PROCEDURES, AND

By affixing the AWS specification and classification REQUIREMENTS
designations to the packaging, or the classification to the 7. Summary of Tests
product, the manufacturer certifies that the product meets 7.1 Solid Electrodes or Rods. Chemical analysis of the
the requirements of this specification. filler metal itself (or the stock from which it is made) is
the only test required for classification of a product under
6. Units of Measure and Rounding-Off Procedure this specification.
6.1 U.S. Customary Units are the standard units of 7.2 Metal Cored and Flux Cored Composite (Tubu-
measure in this specification. The SI Units are given as lar) Electrodes and Rods
7.2.1 Chemical analysis of a pad of undiluted weld
4
See Section A4, Certification (in the Annex), for further information metal, as shown in Fig. 1, or a fused sample as agreed
concerning certification and the testing specified to meet this requirement. upon by the supplier and purchaser, is the only test required
466
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2007 SECTION II, PART C SFA-5.21
FIG. 1 PAD FOR CHEMICAL ANALYSIS OF UNDILUTED WELD METAL
SI Equivalents
in. mm
0.045 1.2
Electrode Size Weld Pad Size 0.052 1.3
1
in. in. minimum ⁄16 1.6
5
⁄64 2.0
0.045 L p2 3
⁄32 2.4
0.052 W p 1⁄2 7
1 ⁄64 2.8
⁄16 (0.062) H p 1⁄2
0.120 3.0
5 1
⁄64 (0.078) L p3 ⁄8 3.2
3
⁄32 (0.094) W p 1⁄2 5
⁄32 4.0
7
⁄64 (0.109) H p 5⁄8 3
⁄16 4.8
1
0.120 ⁄4 6.4
5
1
⁄8 (0.125) L p3 ⁄16 8.0
1
5
⁄32 (0.156) W p 1⁄2 ⁄2 13
5
3
⁄16 (0.188) H p 3⁄4 ⁄8 16
3
1
⁄4 (0.250) ⁄4 19
5
⁄16 (0.312) 2 50
3 76
467
for classification. In case of dispute, the weld pad described 9.3 For composite metal cored electrodes or rods other
in 9.4 shall be the referee method. than tungsten carbide rods (see 9.7), samples for chemical
analysis may be obtained by any method producing undi-
7.3 Tungsten Carbide Rods
luted weld metal that is agreed upon by the purchaser and
7.3.1 The amount and mesh size distribution of the
supplier or from a weld pad (Fig. 1) deposited with the
tungsten carbide granules shall be determined (see Table
welding process for which it was designed to operate. In
5). Sieve analysis shall be in accordance with ASTM B
case of a dispute, the weld pad described in 9.4 shall be
214, Test Method for Sieve Analysis for Granular Metal
the referee method.
Powder.
9.3.1 For flux cored composite electrodes and rods,
7.3.2 Chemical analysis of the tungsten carbide gran-
including self-shielded electrodes, the sample for chemical
ules shall be determined (see Table 6).
analysis shall be obtained from an undiluted weld pad (see
Fig. 1) deposited with the welding process for which it
8. Retest was designed.
If the results of any test fail to meet the requirement, 9.4 The dimensions of the completed pad shall be as
that test shall be repeated twice. The results of both retests shown in Fig. 1 for each size of electrode. Testing shall
shall meet the requirement. Material, specimens, or sam- be as specified in 9.5.
ples for retest may be taken from the original test assembly
or sample, or from one or two new test assemblies or 9.4.1 The weld pad test assembly shall be welded
samples. For chemical analysis, retest need be only for in the flat position using welding conditions specified by
those specific elements that failed to meet the test require- the manufacturer.
ment. If the results of one or both retest fail to meet the 9.4.2 The base metal shall conform to one of the
requirement, the material under test shall be considered as following specifications or its equivalent:
not meeting the requirements of this specification for that
9.4.2.1 ASTM A 285/A 285M, Specification for
classification.
Pressure Vessel Plates, Carbon Steel, Low and Intermedi-
In the event that, during preparation or after completion
ate Tensile Strength, Grade A.
of any test, it is clearly determined that prescribed or proper
procedures were not followed in preparing the weld test 9.4.2.2 ASTM A 36/A 36M, Specification for
assembly or test specimen(s) or in conducting the test, the Structural Steel.
test shall be considered invalid, without regard to whether
9.5 The sample for analysis shall come from the asma-
the test was actually completed or whether test results
nufactured solid electrode or rod or from feedstock from
met, or failed to meet, the requirement. That test shall be
which it is drawn or from the undiluted weld metal ingot
repeated, following proper prescribed procedures. In this
or from an undiluted region of the weld pad that is located
case, the requirement for doubling the number of test speci-
entirely within the top layer of weld deposit. The sample
mens does not apply.
may be removed by any convenient method. Postweld heat
treatment may be used to facilitate this removal procedure.
9. Chemical Composition Requirements Chemical analysis may be made by any suitable method
9.1 The need for a weld pad test assembly or an undi- agreed upon by the manufacturer and purchaser. The ref-
luted weld metal ingot shall be determined based on eree method shall be the appropriate ASTM method for
whether the electrode or rod is solid or composite as speci- the element being determined.
fied in these subsequent paragraphs.
9.6 The results of the analysis shall meet the require-
9.2 For solid drawn bare surfacing electrodes or rods, ments in either Table 1, 2, 3, or 4, for the classification of
the requirements are based on the chemical analysis of the bare surfacing electrode or rod under test.
as-manufactured material, or the stock from which it was
made. For cast bare surfacing electrodes or rods, the 9.7 Tungsten Carbide Rods
requirements are based on the chemical analysis of the 9.7.1 Weight-percentage of the tungsten carbide
as-manufactured material only. Solid filler metal, when granules, as specified in Table 5, shall be determined by
analyzed for elements that are present in a coating (copper the following steps:
flashing for example), shall be analyzed without removing (a) Record the weight of the tungsten carbide welding
the coating. When the electrode is analyzed for elements electrode or rod sample to the nearest tenth of a gram.
other than those in the coating, the coating must be removed (b) Remove the tungsten carbide from the tube and clean
if its presence affects the results of the analysis for other it by washing with water and treating with 1-1 hydrochloric
elements. Rod stock may be analyzed prior to coating for acid, as required, to remove any flux, powdered iron, graph-
those elements not added in the coating. ite, etc. Heating of the acid may be required. Hot or cold
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468
1-1 hydrochloric acid will not appreciably attack cast tung- TABLE 7
sten carbide in less than an hour. When handling any acids STANDARD SIZES OF BARE ELECTRODES AND RODS
appropriate safety precautions should be followed. USING SOLID DRAWN OR COMPOSITE (TUBULAR)
(c) Wash and rinse thoroughly with tap water. WIRE a,b
(d) Dry the tungsten carbide particles by holding in an Diameter Tolerance
oven at 250° ± 25°F (120° ± 15°C) for a minimum period in. mm in. mm
of one hour.
0.045 1.2 ±0.002 ±0.05
(e) Weigh the cleaned and dried tungsten carbide gran- 0.052 1.3 ±0.002 ±0.05
ules, and calculate the percentage of tungsten carbide from 1
⁄16 (0.062) 1.6 ±0.002 ±0.05
the initial weight of the tube. See formula below: 5
⁄64 (0.078) 2.0 ±0.003 ±0.08
3
⁄32 (0.094) 2.4 ±0.003 ±0.08
% of tungsten carbide granules p 7
⁄64 (0.109) 2.8 ±0.003 ±0.08
0.120 3.0 ±0.003 ±0.08
weight of clean and dried tungsten carbide granules
ⴛ 100 1
⁄8 (0.125) 3.2 ±0.005 ±0.13
weight of bare electrode or rod sample 5
⁄32 (0.156) 4.0 ±0.005 ±0.13
3
9.7.2 Chemical composition of tungsten carbide ⁄16 (0.188) 4.8 ±0.005 ±0.13
1
granules shall conform to the requirements of Table 6. ⁄4 (0.250) 6.4 ±0.005 ±0.13
5
⁄16 (0.312) 7.9 ±0.005 ±0.13
Chemical analysis may be made by any suitable method
agreed upon by the supplier and purchaser. Tungsten car- NOTES:
bide granules for chemical analysis shall be free of any a. Other diameter electrodes may be supplied as agreed upon between
surface contaminant. the manufacturer and purchaser.
b. Electrode and rod length may be supplied as agreed upon between
the manufacturer and purchaser.
PART C — MANUFACTURE, IDENTIFICATION,
AND PACKAGING
TABLE 8
10. Method of Manufacture STANDARD SIZES FOR CAST
The electrodes and rods classified according to this speci- ELECTRODES AND RODS a,b
fication may be manufactured by any method that will Nominal Diameter Tolerance
produce material which meets the requirements of this in. mm in. mm
specification. For tungsten carbide rods, any carbon steel 3
⁄32 (0.094) 2.4 ±0.02 ±0.5
sheath material that will not significantly alter the matrix 1
⁄8 (0.125) 3.2 ±0.02 ±0.5
of the deposit may be used. 5
⁄32 (0.156) 4.0 ±0.02 ±0.5
3
⁄16 (0.188) 4.8 ±0.02 ±0.5
1
⁄4 (0.250) 6.4 ±0.03 ±0.8
11. Standard Sizes and Lengths 5
⁄16 (0.312) 7.9 ±0.03 ±0.8
Standard sizes of electrodes and rods shall be as shown
NOTES:
in Tables 7, 8, and 9. Standard size refers to the nominal a. Other diameter electrodes or rods may be supplied as agreed upon
diameter of the electrode or rod. Nonstandard diameters between the manufacturer and purchaser.
and lengths of welding electrodes and rods shall be as b. Electrode and rod length may be supplied as agreed upon between
agreed upon between the purchaser and manufacturer. the manufacturer and purchaser.
12. Finish and Uniformity 12.3 The core ingredients in metal cored and flux cored
12.1 All electrodes and rods shall have a smooth finish composite (tubular) electrodes or rods shall be distributed
that is free from slivers, depressions, scratches, scale, with sufficient uniformity throughout the length of the
seams, laps [exclusive of the longitudinal joint in metal electrode so as not to adversely affect the performance of
cored and flux cored composite (tubular) electrodes or the electrode or the properties of the weld metal.
rods], and foreign matter that would adversely affect the
welding characteristics, the operation of the welding equip- 12.4 A suitable protective coating may be applied to
ment, or the properties of the weld metal. any product in this specification. Copper may be used as
a coating for any classification.
12.2 Each continuous length of electrode or rod shall
be from a single heat or lot of material. Welds, when
present, shall have been made so as not to interfere with 13. Standard Package Forms
the uniform, uninterrupted feeding of the electrode or rod 13.1 Standard package forms are straight lengths, coils
on automatic and semiautomatic equipment. with support, coils without support, spools, and drums.
469
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TABLE 9 (a) form a circle not less than 4 in. (100 mm) nor more
STANDARD SIZES FOR TUNGSTEN than 15 in. (380 mm) in diameter, and
CARBIDE (WC) RODS
(b) rise above the surface no more than 1/2 in. (13 mm)
Nominal Diameter a at any location.
in. mm Length
1
14.4 The cast and helix of solid welding wire on all
⁄8 (0.125) 3.2
5
⁄32 (0.156) 4.0
other package forms shall be such that a specimen long
3
⁄16 (0.188) 4.8 See Note b enough to produce a single loop, when cut from the package
1
⁄4 (0.250) 6.4 and laid unrestrained on a flat surface, will:
5
⁄16 (0.312) 7.9 (a) form a circle not less than 15 in. (380 mm) in diame-
3
⁄8 (0.375) 9.5
ter, and
NOTES: (b) rise above the surface no more than 1 in. (25 mm)
a. Diameter tolerance is ± 1⁄16 (0.063) in. (± 1.6 mm) from the nomi- at any location.
nal diameter. Certain bulk packages may contain wire that has been
b. Rod length may be supplied as agreed upon between the manufac-
elastically twisted or otherwise mechanically treated in
turer and purchaser.
order to provide straighter wire feed. The wire from these
packages will not form a circle when cut. Traditional cast
and helix measurements may have no relevance. Wire thus
treated shall conform to the winding requirements of 14.1
Standard package dimensions for each form are given in and 14.2. Any method of wire inspection shall be as agreed
Table 10, and in Figs. 2 and 3. Package forms, other than between purchaser and supplier.
these, shall be as agreed upon between purchaser and sup-
plier.
15. Filler Metal Identification
13.2 The liners in coils with support shall be designed
and constructed to prevent distortion of the coil during 15.1 The product information and the precautionary
normal handling and use, and they shall be clean and information required in Section 17 for marking each pack-
dry enough to maintain the cleanliness of the electrodes age shall also appear on each coil, spool and drum.
and rods.
15.2 Coils without support shall have a tag containing
13.3 Spools and drums shall be designed and con- this information securely attached to the filler metal at the
structed to prevent distortion of the electrodes and rods inside end of the coil.
during normal handling and use and shall be clean and
15.3 Coils with support shall have the information
dry enough to maintain the cleanliness of the electrodes
securely affixed in a prominent location on the support.
and rods.
15.4 Spools shall have the information securely affixed
in a prominent location on the outside of at least one flange
14. Winding Requirements of the spool.
14.1 Welding wire in drums and in spools and coils
shall be wound so that kinks, waves, sharp bends, overlap- 15.5 Drums shall have the information securely affixed
ping, or wedging are not encountered, leaving the welding in a prominent location on the side of the drum.
wire free to unwind without restriction. The outside end
of the welding wire (the end with which welding is to
16. Packaging
begin) shall be identified so it can be located readily and
shall be fastened to avoid unwinding. 16.1 Bare welding electrodes and rods in all product
forms, except welding rods in straight lengths, shall be
14.2 The cast and helix of welding wire in coils, spools, packaged in accordance with Table 10.
and drums, shall be such that the electrode will feed in
an uninterrupted manner in automatic, and semiautomatic 16.2 Packaging of straight lengths of bare welding
equipment. rods shall be as agreed upon between the purchaser and
manufacturer.
14.3 The cast and helix of solid wire in 4 in. (100 mm)
spools shall be such that a specimen long enough to produce 16.3 Welding electrodes and rods shall be suitably
a single loop, when cut from the spool and laid unrestrained packaged to protect against damage during shipment and
on a flat surface, will: storage under normal conditions.
--```,```,`,`````,``,,`,`,`,```-`-`,,`,,`,`,,`---
470
TABLE 10
PACKAGING REQUIREMENTS a
Package Size d Net Weight of Electrode b
Type of Package in. mm lb kg (approx.)
c
Coil without support As specified by purchaser As specified by purchaserc
6-3⁄4 ID 170 ID
Coils with support (see below) 12 ID 300 ID 14 25, 30, 50, and 60 6.4 11, 14, 23, and 27
1 1
Spools 4 OD 100 OD 1- ⁄2 and 2- ⁄2 0.7 and 1.1
8 OD 200 OD 10, 15, and 22 4.5, 6.8, and 10
12 OD 300 OD 25, 30, and 35 11, 14, and 16
14 OD 350 OD 50 and 60 23 and 27
22 OD 560 OD 250 110
24 OD 610 OD 300 140
30 OD 760 OD 600, 750, and 1000 270, 340, and 454
Drums 15-1⁄2 OD 400 OD As specified by purchaserc
20 OD 500 OD As specified by purchaserc
23 OD 600 OD 300 and 600 140 and 300
Coils with Support—Standard Dimensions and Weighta
Coil Dimensions
Electrode Size lb kg (approx.) in. mm in. (max.) mm (max.)
All 14 6.4 6-3⁄4 ± 1⁄8 170 ± 3 3 75
25 and 30 11 and 14 12 ± 1⁄8 305 ± 3 2-1⁄2 or 4-5⁄8 65 or 120
50, 60, and 65 23, 27, and 30 12 ± 1⁄8 305 ± 3 4-5⁄8 120
NOTES:
a. Sizes and net weights other than those specified may be supplied as agreed between supplier and purchaser.
b. Tolerance on net weight shall be ± 10%.
c. As agreed between supplier and purchaser.
d. ID p inside diameter
OD p outside diameter
17. Marking of Packages 17.2 The appropriate precautionary information5 given

in ANSI Z49.1, latest edition (as a minimum) or its equiva-
17.1 The following product information (as a mini-
lent, shall be prominently displayed in legible print on all
mum) shall be legibly marked so as to be visible on the
packages of electrodes and rods, including individual unit
outside of each unit package: packages within a larger package.6
(1) AWS specification and classification (year of issue 5
Typical examples of “warning labels” are shown in figures in ANSI
may be excluded) Z49.1 for some common or specific consumables used with certain pro-
(2) Supplier’s name and trade designation cesses.
6
American National Standard ANSI Z49.1, Safety in Welding, Cutting,
(3) Standard size and net weight and Allied Processes, published by the American Welding Society, 550
(4) Lot, control, or heat number N.W. LeJeune Road, Miami, FL 33126.
471
FIG. 2 STANDARD SPOOLS — DIMENSIONS OF 4, 8, 12, AND 14 IN. [100, 200, 300, AND 350 MM] SPOOLS
Driving
hole
E
A
D
C
Dimensions
4 in. (100 mm) 8 in. (200 mm) 12 in. (300 mm) 14 in. (350 mm)
Spools Spools Spools Spools
in. mm in. mm in. mm in. mm

A Diameter, max 4.0 102 8.0 203 12 305 14 355
B Width 1.75 46 2.16 56 4.0 103 4.0 103

Tolerance ±0.03 +0, −2 ±0.03 +0, −3 ±0.06 +0, −3 ±0.06 +0, −3
C Diameter 0.63 16 2.03 50.5 2.03 50.5 2.03 50.5

Tolerance +0.01, −0 +1, −0 +0.06, −0 +2.5, −0 +0.06, −0 +2.5, −0 +0.06, −0 +2.5, −0
D Distance Between Axes — — 1.75 44.5 1.75 44.5 1.75 44.5

Tolerance ±0.02 ±0.5 ±0.02 ±0.5 ±0.02 ±0.5
E Diameter [Note (1)] — — 0.44 10 0.44 10 0.44 10

Tolerance +0, −0.06 +1, −0 +0, −0.06 +1, −0 +0, −0.06 +1, −0
GENERAL NOTES:
(a) Outside diameter of barrel shall be such as to permit feeding of the filler metals.
(b) Inside diameter of the barrel shall be such that swelling of the barrel or misalignment of the barrel and flanges will not result in the inside
of the diameter of the barrel being less than the inside diameter of the flanges.
NOTE:
(1) Holes are provided on each flange, but they need not be aligned. No driving holes required for 4 in. (100 mm) spools.
472 --```,```,`,`````,``,,`,`,`,```-`-`,,`,,`,`,,`---

FIG. 3 STANDARD SPOOLS — DIMENSIONS OF 22, 24, AND 30 IN. [560, 610, AND 760 MM] SPOOLS
A B
C
F A
Section A–A
A
Dimensions
22 in. (560 mm) Spools 24 in. (610 mm) Spools 30 in. (760 mm) Spools
in. mm in. mm in. mm

A Diameter, max. 22 560 24 610 30 760
B Width, max. 12 305 13.5 345 13.5 345
C Diameter 1.31 35.0 1.31 35.0 1.31 35.0

Tolerance +0.13, −0 ±1.5 +0.13, −0 ±1.5 +0.13, −0 ±1.5
D Distance, Center-to-Center 2.5 63.5 2.5 63.5 2.5 63.5

Tolerance ±0.1 ±1.5 ±0.1 ±1.5 ±0.1 ±1.5
E Diameter [Note (1)] 0.69 16.7 0.69 16.7 0.69 16.7

Tolerance +0, −0.06 ±0.7 +0, −0.06 ±0.7 +0, −0.06 ±0.7
GENERAL NOTES:
(a) Outside diameter of barrel, dimension F, shall be such as to permit proper feeding of the electrode.
(b) Inside diameter of barrel shall be such that swelling of the barrel or misalignment of the barrel and flanges will not result in the inside of the
diameter of the barrel being less than the inside diameter of the flanges.
NOTE:
(1) Two holes are provided on each flange and shall be aligned on both flanges with the center hole.
473 --```,```,`,`````,``,,`,`,`,```-`-`,,`,,`,`,,`---

Annex
Guide to AWS Specification for Bare Electrodes and Rods
for Surfacing
(This Annex is not a part of AWS A5.21:2001, Specification for Bare Electrodes and Rods for Surfacing, but is included for information purposes
only.)
A1. Introduction TABLE A1

ELECTRODE CLASSIFICATION COMPARISON
This guide has been prepared as an aid to prospective A5.21-80 AND A5.21:2001
users of the electrodes and rods covered by the specification A5.21-80 A5.21:2001
in determining the classification of filler metal best suited Classification Classification
for a particular application, with due consideration to the RFe5-A Deleted
particular requirements for that application. RFe5-B Similar to ERFe6
RFeCr-A1 Similar to ERFeCr-A1A
EFe5-A Deleted
A2. Classification System EFe5-B Moved to A5.13:2000
Composition similar to ERFe-6
A2.1 The system for identifying the electrode classifi- EFe5-C Deleted
cations in this specification follows the standard pattern EFeMn-A Moved to A5.13:2000
used in other AWS filler metal specifications. The letters EFeMn-B Moved to A5.13:2000
ER at the beginning of each classification designation stand EFeCr-A1 Moved to A5.13:2000
for electrode and rod, indicating that the filler metal may Composition similar to ERFeCr-A1A
be used either way. The letter R alone means the electrode RWC-5/8 Deleted
may be used only as a welding rod. The designator C, RWC-8/12 Deleted
RWC-12/20 Similar to ER/R WC-12/30
when it appears after ER or R, indicates that the electrode RWC-20/30 ER/RWCX-20/30
or rod is either a metal cored or flux cored composite RWC-30/40 ER/RWCX-30/40
(tubular) electrode or rod. RWC-30 Deleted
RWC-40 ER/RWCX-40
A2.2 The letters immediately after the R, RC, ER, or RWC-40/120 ER/RWCX-40/120
ERC are the chemical symbols for the principal elements in
the classification. Thus, CoCr is a cobalt-chromium alloy,
CuAl is a copper-aluminum alloy, etc. Where more than
one classification is included in a basic group, the individ-
ual classifications in the group are identified by the letters, A2.4 Request for Filler Metal Classification
A, B, C, etc., as in ERCuSn-A. Further subdivision is done
by using a 1, 2, etc., after the last letter, as the “2” in (a) When a surfacing electrode or rod cannot be classi-
ERCuA1-A2. An additional letter or number has been fied as given in this specification, the manufacturer may
added to some designations if the composition require- request that a classification be established for that welding
ments in this specification differ somewhat from those electrode. The manufacturer may do this by following the
of the earlier versions for electrodes of the same basic procedure given here.
classification. (b) A request to establish a new electrode or rod classi-
fication must be in written request, and it needs to provide
A2.3 Refer to Table A1 for a comparison of electrode sufficient detail to permit the Committee on Filler Metals
classifications used in ANSI/AWS A5.21-80 and those and Allied Materials or the subcommittee to determine
used in the current document; some classifications have whether the new classification or the modification of an
been moved to AWS A5.13:2000, and others have been existing classification is more appropriate, and whether
discontinued (see Table A2). either is necessary to satisfy the need. The request needs
474
TABLE A2 (2) Confirm receipt of the request and give the identi-
DISCONTINUED AND TRANSFERRED fication number to the person who made the request.
ELECTRODE AND ROD CLASSIFICATIONS a (3) Send a copy of the request to the Chair of the A5
Last A5.21 Committee on Filler Metals and Allied Materials, and the
AWS Classification Publication Date Chair of the particular Subcommittee involved.
RFe5-A 1980 (4) File the original request.
RFe5-B 1980 (5) Add the request to the log of outstanding requests.
RFeCr-A1 1980
(d) All necessary action on each request will be com-
EFe5-A 1980
EFe5-B 1980 pleted as soon as possible. If more than 12 months lapse,
EFe5-C 1980 the Secretary shall inform the requestor of the status of
EFeMn-Ab 1980 the request, with copies to the Chairs of the Committee
EFeMn-Bb 1980 and of the Subcommittee. Requests still outstanding after
EFeCr-A1 1980
18 months shall be considered not to have been answered
RWC-5/8 1980
RWC-8/12 1980 in a “timely manner” and the Secretary shall report these
RWC-12/20 1980 to the Chair of the A5 Committee on Filler Metals and
RWC-30 1980 Allied Materials, for action.
EWC-12/30c 1980 (e) The Secretary shall include a copy of the log of all
EWC-20/30c 1980
EWC-30/40c 1980
requests pending and those completed during the preceding
EWC-40c 1980 year with the agenda for each Committee on Filler Metals
EWC-40/120c 1980 and Allied Materials meeting. Any other publication of
requests that have been completed will be at the option of
NOTES: the American Welding Society, as deemed appropriate.
a. See A9, Discontinued Classifications (in Annex), for information
on discontinued classifications.
b. These AWS classifications have been transferred to AWS A5.13 A3. Acceptance
without a change in classification designation.
c. These AWS classifications have been transferred to AWS A5.13
Acceptance of all welding materials classified under this
with a change in classification to EWCX-X/X. specification is in accordance with AWS A5.01, Filler
Metal Procurement Guidelines, as the specification states.
Any testing a purchaser requires of the supplier, for mate-
to state the variables and their limits, for such a classifica-
rial shipped in accordance with this specification, shall
tion or modification. The request should contain some indi-
be clearly stated in the purchase order, according to the
cation of the time by which completion of the new
provisions of AWS A5.01, Filler Metal Procurement
classification or modification is needed.
Guidelines. In the absence of any such statement in the
In particular, the request needs to include:
purchase order, the supplier may ship the material with
(1) All classification requirements as given for
whatever testing he normally conducts on material of that
existing classifications, such as, chemical composition
classification, as specified in Schedule F, Table 1, of the
ranges and usability test requirements.
AWS A5.01, Filler Metal Procurement Guidelines. Testing
(2) Any testing conditions for conducting the tests in accordance with any other Schedule in that table must
used to demonstrate that the product meets the classifica- be specifically required by the purchase order. In such
tion requirements. (It would be sufficient, for example, to cases, acceptance of the material shipped will be in accor-
state that welding conditions are the same as for other dance with those requirements.
classifications.)
(3) Information on Descriptions and intended Use,
which parallels that for existing classifications, for that A4. Certification
section of the Annex. The act of placing the AWS specification and classifica-
A request for a new classification without the above tion designations on the packaging enclosing the product,
information will be considered incomplete. The Secretary or the classification on the product itself, constitutes the
will return the request to the requestor for further infor- supplier’s (manufacturer’s) certification that the product
mation. meets all of the requirements of the specification.
(c) The request should be sent to the Secretary of the The only testing requirement implicit in this “certifica-
A5 Committee on Filler Metals and Allied Materials at tion” is that the manufacturer has actually conducted the
AWS Headquarters. Upon receipt of the request, the Secre- tests required by the specification on material that is repre-
tary will: sentative of that being shipped and that the material met
(1) Assign an identifying number to the request. This the requirements of the specification. Representative mate-
number will include the date the request was received. rial, in this case, is any production run of that classification
475
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using the same formulation. “Certification” is not to be A6.2 For additional surfacing considerations refer to
construed to mean that tests of any kind were necessarily the appropriate volume of the AWS Welding Handbook.
conducted on samples of the specific material shipped.
Tests on such material may or may not have been made. The
basis for the “certification” required by the specification A7. Description and Intended Use of Electrodes and
is the classification test of “representative material” cited Rods for Surfacing
above, and the “Manufacturer’s Quality Assurance Sys- A7.1 Iron Base Electrodes and Rods
tem” in AWS A5.01, Filler Metal Procurement Guidelines. A7.1.1 ERFe-1, ERFe-1A, and ERFe-2 Electrodes
A7.1.1.1 Characteristics. Deposits made with
A5. Ventilation During Welding these electrodes and rods are a machinery-grade steel suit-
able for application on carbon and alloy steels. With care,
A5.1 Five major factors govern the quantity of fume they can be applied crack-free. Deposits are machinable
to which welders and welding operators are exposed during with carbide tipped tools. Deposit hardness generally is in
welding. These are as follows: the range of 25–50 HRC with ERFe-2 filler metal providing
(a) Dimensions of the space in which welding is done weld metal with the higher hardness. These deposits con-
(with special regard to the height of the ceiling) tain sufficient alloy to attain full hardness without the need
(b) Number of welders and welding operators working of heat treatment. Abrasion resistance is comparable to
in that space heat treated steels of equal hardness.
(c) Rate of evolution of fumes, gases, or dust, according A7.1.1.2 Applications. These electrodes and rods
to the materials and processes involved are used to restore worn machinery parts to their original
(d) The proximity of the welder or welding operator to dimensions. Deposit surfaces are suitable for metal-to-
the fumes as they issue from the welding zone, and to the metal rolling and sliding contact such as occurs on large
gases and dusts in the space in which he is working low speed gear teeth, shafts, etc. High compressive strength
(e) The ventilation provided to the space in which the makes these materials suitable as a base for more abrasion
welding is done resistant materials.
A5.2 American National Standard ANSI Z49.1, Safety A7.1.2 ERFe-3 Electrodes and Rods
in Welding, Cutting, and Allied Processes (published by A7.1.2.1 Characteristics. Weld metal deposited
the American Welding Society), discusses the ventilation by these electrodes and rods is an air-hardening tool steel
that is required during welding and should be referred to type with high room-temperature hardness (55–60 HRC).
for details. Attention is particularly drawn to the section Deposits can be applied crack-free with careful procedures.
entitled “Ventilation.” The deposits cannot be machined and generally are ground
when finishing is required.
A7.1.2.2 Applications. ERFe-3 electrodes and
A6. Surfacing Considerations
rods are used to overlay surfaces and edges requiring high
A6.1 Role of Hydrogen in Surfacing. Hydrogen can be hardness and crack-free deposits such as the edges of tools
detrimental to surfacing deposits. The effect varies widely and dies. Deposits are suitable for subsequent surfacing
from one alloy type to another. In general, hydrogen’s with high-nickel alloys and many tool steels. Although
detrimental effect on microstructure is most pronounced generally used for metal-to-metal applications, the weld
for martensitic types, with austenitic types being the least metal performs well in earth-abrasion applications where
affected. Other factors influencing hydrogen’s effect high impact is encountered.
include carbon and alloy contents plus inservice welding
A7.1.3 ERFe-5 Electrodes and Rods
variables.
In welding there are many sources for hydrogen contami- A7.1.3.1 Characteristics. These electrodes and
nation with moisture being one of the most important. rods deposit a cold work tool steel weld metal. Hardness
Most electrodes and welding rods are manufactured and as deposited should be in the range of 50–55 HRC. Weld
packaged to control moisture. When received, consider- metal deposited by ERFe-5 electrodes is air hardening and
ation must be given to proper storage to prevent moisture machinable only after annealing. Typical deposit character-
pick-up. During use, improper regard to welding procedure istics include high compressive strength with moderate
and environment variables can result in spalling or “hydro- abrasion resistance.
gen-induced” (underbead) cracking. In austenitic materials, A7.1.3.2 Applications. These electrodes are used
excessive hydrogen can manifest itself as porosity in the for metal-to-metal wear applications such as machine com-
deposit. ponents, shafts, brake drums, and knife edges.
476
A7.1.4 ERFe-6 Electrodes and Rods deposits ideal for rebuilding of worn rock-crushing equip-
A7.1.4.1 Characteristics. Weld metal deposited ment and parts subject to impact loading such as rail-
by ERFe-6 electrodes and rods is a high-speed tool steel road frogs.
with a hardness in the range of 60 HRC or higher. The A7.1.7 ERFeMnCr Electrodes and Rods
deposit maintains a high degree of hardness to 1100°F A7.1.7.1 Characteristics. Weld metal deposited
(593°C). Weld metal deposited by ERFe-6 electrodes is by ERFeMnCr electrodes have similar characteristics to
air hardening and is machinable only after annealing. those of the austenitic manganese deposits. The high-chro-
A7.1.4.2 Applications. Weld deposits may be used mium content improves the stability of austenite when
for metal-to-metal wear applications at temperatures to compared to ERFeMn deposits. These deposits cannot be
1100°F (593°C). Typical applications combine high-tem- flame cut, and care must be taken in application to avoid
perature service with moderate abrasion and severe metal- heat build-up.
to-metal wear. A7.1.7.2 Applications. Like ERFeMn-type elec-
A7.1.5 ERFe-8 Electrodes and Rods trodes and rods, ERFeMnCr electrodes and rods are used
A7.1.5.1 Characteristics. Weld metal deposited for rebuilding, repair, and joining of equipment made from
by ERFe-8 electrodes and rods is similar to an H12 hot austenitic manganese steels. ERFeMnCr electrodes and
work tool steel with an as-deposited hardness of HRC 54– rods offer the added advantage of being usable for joining
60. The microstructure consists of martensite plus alloy austenitic manganese steel both to itself and to carbon
carbides to produce a tough, hard deposit on either carbon steel. ERFeMnCr weld metals often are used as a base for
or low-alloy steel base metal. Proper preheating (consult surfacing with ERFeCr-X types for parts subject to both
the manufacturer) is essential to ensure crack-free deposits. abrasion and impact.
The deposit may be finished by grinding. A7.1.8 ERFeCr-A Electrodes and Rods
A7.1.5.2 Applications. This composition is used A7.1.8.1 Characteristics. Weld metal deposited
for overlaying surfaces subjected to moderate abrasive by these electrodes and rods will contain moderate amounts
wear with high impact. Applications typically include of chromium carbides in a high-carbon austenitic matrix.
machine tools and components subject to sliding metal-to- Two layers are recommended to maintain uniform hardness
metal wear. and deposit composition. Additional layers may be prone
A7.1.6 ERFeMn Series Electrodes and Rods to spalling and should be applied with caution. The deposit
(except ERFeMnCr) provides greater impact resistance but decreased abrasion
A7.1.6.1 Characteristics. Deposits made with resistance as compared to other ERFeCr-XX classifica-
these electrodes and rods nominally contain 14% manga- tions. The deposits should be ground if finishing is required
nese, although they may vary from 12 to 22%. This is an as they are not readily machined or flame cut. Weld metal
amount sufficient to yield austenitic weld deposits. Austen- deposited by ERFeCr-A electrodes may be applied to car-
ite is a nonmagnetic, tough form of steel. To preserve the bon, low-alloy, austenitic manganese steel and austenitic
toughness, excessive heat must be avoided during welding. stainless steel base metals.
Stringer beads and skip welding are recommended. The A7.1.8.2 Applications. A general purpose hard-
additions of other alloys, such as 4% nickel, are made to facing alloy which can be used where limited stress-relief
give more stability to the austenite. Chromium and molyb- cracks (checks) are acceptable but severe abrasion is not
denum can also be added to increase the yield strength. encountered.
Abrasion resistance is only a little better than that of low- A7.1.9 ERFeCr-A1A and ERFeCr-A4 Electrodes
carbon steel unless there has been sufficient impact to cause and Rods
work hardening. As deposited, surfaces generally are no A7.1.9.1 Characteristics. Weld metal deposited
harder than HRC 20, but can work harden to HRC 55. by these electrodes and rods will contain massive chro-
Deposits are difficult to machine; grinding is preferred for mium carbides in an austenitic matrix providing excellent
finishing. wear resistance and fair toughness. Surface checks are
Weld metal deposited by ERFeMn-F electrodes differ normal and give a degree of stress relief. Deposits cannot
from the other austenitic manganese classifications in that be machined and must be ground when finishing is
a one layer deposit will be fully austenitic when deposited required. To achieve the desired composition, a minimum
on carbon steel or low-alloy steel base metal. This is the of two layers is usually recommended. Additional layers
direct result of the higher carbon and manganese contents may be prone to spalling and must be applied with caution.
of the filler metal. These electrodes are suitable for welding on carbon, low-
A7.1.6.2 Applications. These electrodes are used alloy, and austenitic steels and cast irons. The weld metal
for the rebuilding, repair, and joining of austenitic manga- deposited by ERFeCr-A1A electrodes generally provides
nese steels. Ability to absorb high impact makes such greater impact resistance than ERFeCr-A4.
477
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A7.1.9.2 Applications. Typical applications A7.2 Cobalt Base Electrodes and Rods
include bucket lips and teeth, impact hammers, and con- A7.2.1 ERCoCr-A Electrodes and Rods
veyors used for crushing and transporting rock, ore, etc.
A7.2.1.1 Characteristics. Weld metals deposited
Very low coefficients of friction develop as a result of
by ERCoCr-A electrodes and rods are characterized by a
scouring by earth products.
hypoeutectic structure, consisting of a network of about
A7.1.10 ERFeCr-A3A Electrodes and Rods 13% eutectic chromium carbides distributed in a cobalt-
A7.1.10.1 Characteristics. The microstructure of chromium-tungsten solid solution matrix. The result is a
weld metal deposited by ERFeCr-A3A electrodes and rods material with a combination of overall resistance to low
resembles that of white cast iron. The deposit has higher stress abrasive wear, with the necessary toughness to resist
toughness than weld metal deposited by ERFeCr-A1A, some degree of impact. Cobalt alloys also are inherently
ERFeCr-A4, ERFeCr-A9, or ERFeCr-A10 electrodes, but good for resisting metal-to-metal wear, particularly in high
is accompanied by a reduction in abrasion resistance. load situations that are prone to galling. The high-alloy
A7.1.10.2 Applications. This weld metal is a gen- content of the matrix also affords excellent resistance to
eral-purpose hardfacing alloy typically used as a final over- corrosion, oxidation, and elevated temperature retention of
lay on roll crushers, hammer mill hammers, and cone hot hardness up to a maximum of 1200°F (650°C). These
crushers over a buildup of austenitic manganese material. alloys are not subject to allotropic transformation and there-
fore do not lose their properties if the base metal is subse-
A7.1.11 ERFeCr-A5 Electrodes and Rods quently heat treated.
A7.1.11.1 Characteristics. The weld deposit con-
A7.2.1.2 Applications. The alloy is recommended
tains chromium carbide in an austenitic matrix. The non-
for cases where wear is accompanied by elevated tempera-
magnetic weld metal has fair machinability. Build-up
tures and where corrosion is involved, or both. Some typi-
should be restricted to three layers to minimize relief
cal applications are automotive and fluid flow valves, chain
checking.
saw guides, hot punches, shear blades, and extruder screws.
A7.1.11.2 Applications. Component’s surfaced
A7.2.2 ERCoCr-B Electrodes and Rods
with these electrodes and rods are frequently used for appli-
cations involving metal-to-metal friction wear or earth A7.2.2.1 Characteristics. Weld metal deposited
scouring under low-stress abrasive conditions. by ERCoCr-B electrodes and rods is similar in composition
to deposits made using ERCoCr-A electrodes and rods
A7.1.12 ERFeCr-A9 Electrodes and Rods except for a slightly higher percentage (approximately
A7.1.12.1 Characteristics. The deposit contains 16%) of carbides. The alloy also has a slightly higher
hexagonal chromium carbides in an austenitic matrix with hardness and better abrasive and metal-to-metal wear
a hardness of 50–60 HRC. Deposits develop relief checks. resistance. Impact and corrosion resistance are lowered
The weld metal may be applied on carbon or low-alloy slightly. Deposits can be machined with carbide tools.
steel, austenitic manganese steel; oraustenitic stainless steel
A7.2.2.2 Applications. ERCoCr-B electrodes and
base metal.
rods are used interchangeably with ERCoCr-A electrodes
A7.1.12.2 Applications. These electrodes are fre- and rods. Choice will depend on the specific application.
quently used for applications involving abrasive wear com- A7.2.3 ERCoCr-C Electrodes and Rods
bined with moderate impact.
A7.2.3.1 Characteristics. This alloy has a higher
A7.1.13 ERFeCr-A10 Electrodes and Rods percentage (approximately 19%) of carbides than deposits
A7.1.13.1 Characteristics. Weld metal deposited made using either ERCoCr-A or ERCoCr-B class. In fact,
by these electrodes and rods contains massive hexagonal the composition is such that primary hypereutectic carbides
carbides in an austenite-carbide matrix. The deposit has a are found in the microstructure. This characteristic gives
hardness of HRC 58–63 which is maintained to a tempera- the alloy higher wear resistance accompanied by reductions
ture of 1400°F (760°C). The deposit cannot be flame cut. in the impact and corrosion resistance. The higher hardness
Finishing is by grinding only. also means a greater tendency to check during cooling.
The composition provides the ultimate in low stress The checking tendency may be minimized by closely moni-
abrasion resistance, but with reduced impact resistance. toring preheating, interpass temperature, and postheating
Deposit thickness should not exceed two layers. techniques.
A7.1.13.2 Applications. Deposits of this type may While the cobalt-chromium deposits soften somewhat
be used in the most severe abrasive applications that at elevated temperatures, they normally are considered
involve minimal impact. Typical applications include coal immune to tempering.
pulverizing and handling equipment, glass sand handling A7.2.3.2 Applications. Weld metal deposited by
equipment, and certain high-temperature applications. ERCoCr-C electrodes and rods is used to build-up items
478
such as mixers, rotors or wherever harsh abrasion and low CoCr-A 23–47 HRC
impact are encountered. CoCr-B 34–47 HRC
A7.2.4 ERCoCr-E Electrodes and Rods CoCr-C 43–58 HRC
A7.2.4.1 Characteristics. Welds made using CoCr-E 20–35 HRC
ERCoCr-E electrodes and rods have very good strength CoCr-F 32–46 HRC
and ductility in temperatures up to 2100°F (1150°C). CoCr-G 52–60 HRC
Deposits are resistant to thermal shock and oxidizing and
reducing atmospheres. Early applications of these types of A7.3 Nickel Base Electrodes and Rods
alloys were found in jet engine components such as turbine A7.3.1 ERNiCr-A, -B, and -C Electrodes and Rods
blades and vanes. A7.3.1.1 Characteristics. Undiluted weld metals
The deposit is a solid solution strengthened alloy with of these compositions exhibit a structure consisting of
a relatively low weight-percent carbide phase in the micro- borides and chromium carbides in a nickel-rich matrix.
structure. Hence, the alloy is very tough and will work The nickel-base and high-chromium content gives these
harden. Deposits possess excellent self-mated galling deposits good heat and corrosion resistance. Care should
resistance and also are very resistant to cavitation erosion. be taken when cooling these deposits because of a tendency
A7.2.4.2 Applications. Welds made using to stress crack. These alloys possess excellent resistance to
ERCoCr-E electrodes and rods are used where the resist- low-stress abrasion which increases with increasing boron
ance to thermal shock is important. Typical applications, content in the deposit.
similar to those of deposits made using ERCoCr-A elec- Weld metal deposited by these electrodes and rods flows
trodes and rods, include guide rolls, hot extrusion and very easily, has very high abrasion resistance, and normally
forging dies, hot shear blades, tong bits, valve trim, etc. takes on a high polish.
A7.2.5 ERCoCr-F Electrodes and Rods The deposits have high corrosion resistance and nor-
mally require grinding for finishing. Single-layer deposits
A7.2.5.1 Characteristics. ERCoCr-F differs from
typically have a hardness between 35 and 45 HRC.
the other cobalt chrome tungsten alloys due to the addition
Multilayer deposits typically have a hardness between 49
of over 20% nickel. This alloy was developed to impart
and 56 HRC.
additional oxidation and corrosion resistance, especially
where lead additives are made to automotive engine fuels. A7.3.1.2 Applications. Typical applications
Other properties, such as hot hardness, metal-to-metal wear include cultivator sweeps, plow shares, extrusion screws,
resistance and thermal fatigue, are similar to type pump sleeves, pistons, impellers, capstan rings, glass mold
ERCoCr-A type deposits. faces, centrifuge filters, and sucker pump rods.
A7.2.5.2 Applications. ERCoCr-F is used almost A7.3.2 ERNiCrMo-5A Electrodes and Rods
exclusively on automotive (gasoline) exhaust valves, espe- A7.3.2.1 Characteristics. Weld metal of this com-
cially on air-cooled (higher operating temperature) engines. position is a solid solution strengthened alloy with a rela-
Most surfacing is done with automatic equipment by the tively low weight-percent carbide phase. The resultant
original equipment manufacturer, and very little by the deposit is tough and work hardening.
maintenance market. Both oxyfuel gas welding (OFW) and Deposits have the ability to retain hardness to 1400°F
gas tungsten arc welding (GTAW) are used. (760°C). Deposits are machinable with high-speed tool bits
A7.2.6 ERCoCr-G Electrodes and Rods and have excellent resistance to high-temperature wear and
A7.2.6.1 Characteristics. ERCoCr-G is a higher impact.
carbon and tungsten version of ERCoCr-C that imparts A7.3.2.2 Applications. These electrodes are used
excellent abrasion resistance under high loads. The increase to rebuild and repair hot extrusion and forging dies, sizing
in the volume fraction of primary carbides also increases punches, hot shear blades, guide rolls, tong bits, blast fur-
the average hardness and adhesive wear resistance. This nace bells, etc.
type of material is sensitive to cracking in the weld deposits A7.3.3 ERNiCrFeCo Electrodes and Rods
and therefore, pre-heat and interpass temperatures as well
as cooling rate must be closely controlled. A7.3.3.1 Characteristics. Filler metal deposited
by these electrodes is a nickel-chromium-iron-cobalt base
A7.2.6.2 Applications. ERCoCr-G is used exten- alloy containing a fairly large volume fraction of hypereu-
sively on bearing areas of tri-cone type drilling tools. Appli- tectic chromium carbides distributed throughout the micro-
cation is typically by gas tungsten arc (GTA) manual or structure. The alloy offers many of the same high
automated, and oxyfuel gas welding (OFW). performance characteristics of deposits made using
A7.2.7 Typical hardness values for multilayer welds ERCoCr-C or ERNiCr-C electrodes or rods in terms of
made using cobalt base electrodes and rods are as follows: abrasive wear resistance. The reduced content of nickel or
479
cobalt, or both, lowers corrosion properties and galling A7.4.1.4 ERCuSi-A (copper-silicon) filler metal
resistance. The high volume fraction of carbides makes is used primarily for corrosion-resistant surfaces. Copper
this alloy sensitive to cracking during cooling. silicon deposits are generally not suited for bearing service
Hardness values for single layer deposits will be lower applications.
because of dilution from the base metal. A7.4.1.5 ERCuSn-A, ERCuSn-D (copper-tin) fil-
A7.3.3.2 Applications. Welds made using ERNi- ler metal is primarily used to build-up bearing surfaces
CrFeCo electrodes or rods are preferred where high abra- where lower hardness is required. This alloy is used for
sion with low impact is a major factor. Typical applications corrosion-resistant surfaces, and occasionally, for wear-
are feed screws, slurry pumps, and mixer components. resistance applications. The higher tin content of
ERCuSn-D weld deposits has improved wear resistance
A7.3.4 ERNiCr-D and E Electrodes and Rods
but also has increased hot shortness of the alloys.
A7.3.4.1 Characteristics. Undiluted weld metals
A7.4.2 Applications
of these compositions with Si/B greater than 3.3 exhibit a
structure consisting of a nickel solid solution, a binary A7.4.2.1 Hot Hardness. The copper base filler
eutectic of nickel solid solution and nickel silicide; and a metals are not recommended for use at elevated tempera-
ternary eutectic of nickel solid solution, nickel silicide and tures. Mechanical properties will decrease as the tempera-
nickel boride. There are also carbide and boride particles ture increases above 400°F (205°C).
dispersed in the matrix. The microstructures differ from A7.4.2.2 Abrasion. Copper-base weld deposits are
those of ERNiCr-A, B, and C in that the brittle binary not recommended for use where severe abrasion is encoun-
eutectic of nickel solid solution and nickel boride does tered in service.
not form, thus improving the cracking resistance during A7.4.2.3 Metal to Metal Wear. Bearing surface
welding. overlays are often designed with preferential wear require-
A7.3.4.2 Applications. Welds of these composi- ments. To do this with copper-base alloys, select a material
tions are used for hardfacing the trims of fluid control that will result in a weld deposit of 50–75 points Brinell
valves. In the nuclear industry, they are used to replace softer than the mating surface. This will assure a preferen-
cobalt-containing weld overlays in order to reduce the tial wear system.
cobalt content in the process stream. A7.4.2.4 Machinability. All of the copper-base
weld deposits are machinable.
A7.4 Copper Base Electrodes and Rods
A7.4.2.5 Preparation and Welding Characteris-
A7.4.1 Introduction. The copper base solid welding
tics. The base metal should be machined or ground prior
materials classified by this specification are used to deposit
to application of the first pass. The weld deposits should
overlays for bearings and wear-resistant surfaces and to
be wire brushed or ground between passes. The first pass
resist corrosion.
should be applied at the low end of amperage to minimize
A7.4.1.1 ERCuAl-A2 filler metal is used for build- dilution. Excessive base metal dilution can result in reduced
ing up bearing surfaces between the hardness range of machinability and service performance. The manufacturer
130–150 HB. It is also used for wear-resistant surfaces as should be consulted for specific welding parameters.
well as for corrosion-resistant surfaces subject to saltwater A7.4.2.6 Preheat. Preheating may be desirable
and many commonly used acids. depending on the base metal to be overlaid. Generally, no
A7.4.1.2 ERCuAl-A3 filler metal deposits pro- preheat is necessary on low carbon steel. Medium-to-high
duce a deposit of high strength and good ductility with a carbon steel may require 300°F–600°F (150°C–315°C)
nominal hardness of 166 HB. This alloy is ideal for bearing preheat, depending on the carbon content. On subsequent
surfaces requiring high strength and good ductility such layers, an interpass temperature of 500°F (260°C) should
as for a forge press piston. not be exceeded. The manufacturer should be consulted
for complicated overlays.
A7.4.1.3 ERCuAl-C, ERCuAl-D, ERCuAl-E, fil-
ler metals have excellent wear-resisting characteristics and A7.5 Tungsten Carbide Electrodes and Rods
are used where extreme wear and high pressure are encoun- A7.5.1 Characteristics. Tungsten carbide electrodes
tered in service. ERCuAl-D and ERCuAl-E are also used and rods classified in this specification contain 60% by
for fabricating new or rebuilding worn ferrous dies used weight of tungsten carbide granules. The WC1 carbide is
for forming or drawing titanium, low-carbon and stainless a mixture of WC and W2C. The W2C carbide is microcrys-
steel. These alloys are not recommended for corrosion. talline WC. Hardness of the matrix of the deposit can be
Typical hardness levels for ERCuAl-C, ERCuAl-D, and varied from 30–60 HRC depending on welding technique.
ERCuAl-E are 250–290 HB, 310–350 HB, and 340–380 Hardness of individual carbide particles typically is about
HB, respectively. 2400 HV20.
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480
Abrasion resistance of tungsten carbide deposits is out- A8.4 A sample made using the composite type filler
standing. metal which has been fused in a copper mold will be
A7.5.2 Applications. Tungsten carbide deposits are undiluted since there will be essentially no admixture with
applied on surfaces subject to sliding abrasion combined base metal.
with a limited amount of impact. Such applications are A8.5 A sample made using the composite type filler
encountered in earth drilling, digging, and farming. Spe- metal deposited on a steel base plate, Fig. 1, will become
cific tools that may require this type of a surfacing overlay diluted and contaminated by admixture with the base metal.
include oil drill bits and tool joints, earth handling augers, Such a deposit will have to be multilayered to overcome
excavator teeth, farm fertilizer applicator knives, and culti- this dilution. To ensure an undiluted sample, the pad will
vator shares. need to be 1/2 in. (13 mm) minimum height for electrode
diameters 0.045 in. through 1 / 16 in. (1.2 mm through
A8. Suggested Methods for Preparation of Fused
1.6 mm), 5/8 in. (16 mm) minimum height for electrode
Samples for Analysis
diameters 5 / 64 in. through 0.120 in. (2.0 mm through
A8.1 The determination of the chemical composition 3.0 mm), and 3/4 in. (19 mm) minimum height for larger
of the as-manufactured solid bare electrodes and rods pres- electrode sizes.
ents no technical difficulties. The filler metal, in the form
of a solid wire, may be subdivided for analysis by any A8.6 Assurance that an undiluted sample is being
convenient method, and all samples or chips will be repre- obtained from the chosen size of pad at the selected distance
sentative of the lot of filler metal. Difficulties are encoun- above the base can be obtained by analyzing chips removed
tered in obtaining a representative sample of metal cored from successively lower layers of the pad. Layers which
and flux cored composite (tubular) electrodes and rods. are undiluted will all have the same chemical composition.
Some filler metal of the composite type is in the form of Therefore, the determination of identical compositions for
a tubular wire, the core of which is filled with a mixture two successive layers of deposited filler metal will provide
of particles, often unbounded. Samples obtained by merely evidence that the last layer is undiluted.
cutting or subdividing the composite type of filler metal
may not prove representative of the filler metal due to the A9. Discontinued Classifications
possible loss of some of the core material at the ends of
the sample. Therefore, the sheath and core of composite- Some classifications have been discontinued from one
type welding electrodes and welding rods must be com- revision of this specification to another. This results either
bined before a sample representative of the filler metal can from changes in commercial practice or changes in the
be obtained. To accomplish this, the specification requires classification used in the specification. The classifications
the preparation of an essentially homogeneous fused sam- that have been discontinued are listed in Table A2, along
ple of the metal cored electrode or rod and a weld metal with the year they were last included in the specification.
pad of the flux cored composite (tubular) electrode or rod.
These samples can then be subdivided by routine methods. A10. Safety Considerations
A8.2 Preparation of a fused sample by gas tungsten arc
NOTE: Safety and health issues and concerns are beyond the scope of
welding using argon or helium shielding gas will transfer this standard and, therefore, are not fully addressed herein. Some safety
essentially all of the components of the composite-type and health information can be found in Annex section A5 and below.
welding rods through the arc. Some slight loss in carbon Safety and health information is available from other sources, including
will occur, but such loss will never be greater than would but not limited to ANSI Z49.1, Safety in Welding, Cutting, and Allied
be encountered in an actual welding operation, regardless Processes, and applicable federal and state regulations.
of process. Nonmetallic ingredients, if present in the core, A10.1 Burn Protection. Molten metal, sparks, slag, and
will form a slag on the top of the deposit which must be hot work surfaces are produced by welding, cutting, and
removed and discarded. The specification classifies the allied processes. These can cause burns if precautionary
filler metals only on the basis of metallic chemical compo- measures are not used. Workers should wear protective
sition. Gas tungsten arc welded fused samples should not clothing made of fire-resistant material. Pant cuffs, open
be prepared using composite tubular electrodes of the self- pockets, or other places on clothing that can catch and
shielded type as the formation of reactive gases will cause retain molten metal or sparks should not be worn. High-top
instabilities in the arc. shoes or leather leggings and fire-resistant gloves should be
A8.3 The sample of fused filler metal must be large worn. Pant legs should be worn over the outside of high-
enough to provide the amount of undiluted material top shoes. Helmets or hand shields that provide protection
required by the chemist for analysis. No size or shape for the face, neck, and ears, and a head covering to protect
of deposited pads has been specified because these are the head should be used. In addition, appropriate eye pro-
immaterial if the deposit is truly undiluted. tection should be used.
481
When welding overhead or in confined spaces, ear plugs not be touched. The manufacturer’s instructions and recom-
to prevent weld spatter from entering the ear canal should mended safe practices should be read and understood.
be worn in combination with goggles, or the equivalent, Faulty installation, improper grounding, and incorrect oper-
to give added eye protection. Clothing should be kept free ation and maintenance of electrical equipment are all
of grease and oil. Combustible materials should not be sources of danger.
carried in pockets. If any combustible substance has been All electrical equipment and the workpieces should be
spilled on clothing, a change to clean, fire-resistant clothing grounded. The workpiece lead is not a ground lead; it
should be made before working with open arcs or flames. is used only to complete the welding circuit. A separate
Aprons, cape sleeves, leggings, and shoulder covers with connection is required to ground the workpiece.
bibs designed for welding service should be used. Where The correct cable size should be used since sustained
welding or cutting of unusually thick base metal is overloading will cause cable failure and can result in possi-
involved, sheet metal shields should be used for extra ble electrical shock or fire hazard. All electrical connections
protection. Mechanization of highly hazardous processes should be tight, clean, and dry. Poor connections can over-
or jobs should be considered. Other personnel in the work heat and even melt. Further, they can produce dangerous
area should be protected by the use of noncombustible arcs and sparks. Water, grease, or dirt should not be allowed
screens or by the use of appropriate protection as described to accumulate on plugs, sockets, or electrical units. Mois-
in the previous paragraph. Before leaving a work area, hot ture can conduct electricity. To prevent shock, the work
work pieces should be marked to alert other persons of this area, equipment, and clothing should be kept dry at all
hazard. No attempt should be made to repair or disconnect times. Welders should wear dry gloves and rubber-soled
electrical equipment when it is under load. Disconnecting shoes, or stand on a dry board or insulated platform. Cables
electrical equipment while it is under load produces arcing and connections should be kept in good condition.
of the contacts and may cause burns or shock, or both. Improper or worn electrical connections may create condi-
(Note: Burns can be caused by touching hot equipment tions that could cause electrical shock or short circuits.
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such as electrode holders, tips, and nozzles. Therefore, Worn, damaged, or bare cables should not be used. Open-
insulated gloves should be worn when these items are circuit voltage should be avoided. When several welders
handled, unless an adequate cooling period has been are working with arcs of different polarities, or when a
allowed before touching.) number of alternating current machines are being used, the
The following references are for more detailed informa- open-circuit voltages can be additive. The added voltages
tion on personal protection: increase the severity of the shock hazard.
(1) American National Standards Institute. ANSI/ASC In case of electric shock, the power should be turned
Z87.1, Practice for Occupational and Educational Eye and off. If the rescuer must resort to pulling the victim from
Face Protection. New York: American National Standards the live contact, nonconducting materials should be used. If
Institute.7 the victim is not breathing, cardiopulmonary resuscitation
(2) American National Standards Institute. ANSI Z41, (CPR) should be administered as soon as contact with the
American National Standard for Personal Protection— electrical source is broken. A physician should be called
Protective Footwear. New York: American National Stan- and CPR continued until breathing has been restored, or
dards Institute. until a physician has arrived. Electrical burns are treated
(3) American Welding Society. ANSI Z49.1, Safety in as thermal burns; that is, clean, cold (iced) compresses
Welding, Cutting, and Allied Processes. Miami, FL: Ameri- should be applied. Contamination should be avoided; the
can Welding Society.8 area should be covered with a clean, dry dressing; and
(4) OSHA. Code of Federal Regulations, Title 29— the patient should be transported to medical assistance, if
Labor, Chapter XVII, Part 1910. Washington, DC: U.S. necessary.
Government Printing Office.9 Recognized safety standards should be followed, such
as ANSI Z49.1, Safety in Welding, Cutting, and Allied
A10.2 Electrical Hazards. Electric shock can kill. Processes, and NFPA No. 70, National Electrical Code.10
However, it can be avoided. Live electrical parts should
A10.3 Fumes and Gases. Many welding, cutting, and
allied processes produce fumes and gases which may be
7 harmful to health. Fumes are solid particles which originate
ANSI standards may be obtained from the American National Stan-
dards Institute, 11 West 42nd Street, 13th Floor, New York, NY 10036. from welding filler metals and fluxes, the base metal, and
8
AWS standards may be obtained from the Global Engineering Docu- any coatings present on the base metal. Gases are produced
ments, An Information Handling Services Group Company, 15 Inverness during the welding process or may be produced by the
Way East, Englewood, CO 80112-5776. Telephone (800) 854-7179, (303)
397-7956; FAX (303) 397-2740; Internet: www.global.ihs.com.
9 10
OSHA standards may be obtained from the Superintendent of Docu- NFPA documents are available from the National Fire Protection
ments, P.O. Box 371954, Pittsburgh, PA 15250-7954. Association, 1 Batterymarch Park, Quincy, MA 02269.
482
effects of process radiation on the surrounding environ- More detailed information on fumes and gases produced
ment. Management, welders, and other personnel should by the various welding processes and the specific products
be aware of the effects of these fumes and gases. The may be found in the following:
amount and composition of these fumes and gases depend (1) The permissible exposure limits required by OSHA
upon the composition of the filler metal and base metal, are published in Code of Federal Regulations. Title 29—
welding process, current level, arc length, and other factors. Labor, Chapter XVII, Part 1910.
The possible effects of overexposure range from irrita- (2) The recommended threshold limit values for these
tion of eyes, skin, and respiratory system to more severe fumes and gases are published in Threshold Limit Values
complications. Effects may occur immediately or at some for Chemical Substances and Physical Agents in the Work-
later time. Fumes can cause symptoms such as nausea, room Environment, available from the American Confer-
headaches, dizziness, and metal fume fever. The possibility ence of Governmental Industrial Hygienists (ACGIH).11
of more serious health effects exists when especially toxic (3) The results of an AWS-funded study are printed in
materials are involved. In confined spaces, the shielding a report entitled, Fumes and Gases in the Welding Environ-
gases and fumes might displace breathing air and cause ment, available from the American Welding Society.
asphyxiation. One’s head should always be kept out of the (4) The Manufacturer’s Material Safety Data Sheet
fumes. Sufficient ventilation, exhaust at the arc, or both, (MSDS) for the product.
should be used to keep fumes and gases from your breath-
A10.4 Radiation. Welding, cutting and allied opera-
ing zone and the general area.
tions may produce radiant energy (radiation) harmful to
In some cases, natural air movement will provide enough
health. One should become acquainted with the effects of
ventilation. Where ventilation may be questionable, air this radiant energy.
sampling should be used to determine if corrective mea- Radiant energy may be ionizing (such as X-rays) as
sures should be applied. described in AWS C7.1, Recommended Practices for Elec-
Special precautions should be used when surfacing with tron Beam Welding, or nonionizing (such as ultraviolet,
electrodes rods of the ERFeMn-X series of classifications. visible light, or infrared) as described below. Radiation
As a group, the fumes from these electrodes are rather can produce a variety of effects such as skin burns and
voluminous and contain a significant concentration of man- eye damage, depending on the radiant energy’s wavelength
ganese. Cumulative excessive overexposure to manganese and intensity, if excessive exposure occurs.
present in welding fumes may affect the central nervous
A10.4.1 Nonionizing Radiation. The intensity and
system. The effects may include muscular weakness, poor
wavelengths of nonionizing radiant energy produced
coordination, difficulty in speaking, and tremors of the
depend on many factors, such as the process, welding
arms or legs. These effects are considered irreversible.
parameters, electrode and base metal composition, fluxes,
The potential short-term health effects resulting from
and any coating or plating on the base metal. Some pro-
excessive overexposure to copper welding fumes can
cesses such as resistance welding and cold pressure weld-
include metal fume fever, muscle ache and respiratory
ing ordinarily produce negligible quantities of radiant
irritation. The long-term effects are not known.
energy. However, most arc welding and cutting processes
The potential short-term health effects resulting from (except submerged arc when used properly), laser welding
excessive overexposure to cobalt welding fumes can and torch welding, cutting, brazing, or soldering can pro-
include pulmonary irritation, coughing and dermatitis. The duce quantities of nonionizing radiation such that precau-
possible long-term effects include lung fibrosis and respira- tionary measures are necessary.
tory hypersensitivity. Protection from possible harmful effects caused by non-
The potential short-term effects resulting from excessive ionizing radiant energy from welding include the following
overexposure to chromium and nickel in the fume can measures:
cause symptoms such as nausea, headaches, respiratory (a) One should not look at welding arcs except through
irritation and skin rash. Some forms of hexavalent chro- welding filter plates which meet the requirements of ANSI/
mium and nickel are considered as carcinogens by the ASC Z87.1, Practice for Occupational and Educational
National Institute for Occupational Safety and Health Eye and Face Protection. It should be noted that transparent
(NIOSH). Additional information on the possible effects welding curtains are not intended as welding filter plates,
of exposure to chromium and nickel in the welding fume but rather are intended to protect passersby from incidental
can be obtained from AWS Safety and Health Fact Sheet exposure.
No. 4.
The omission of special precautions for other hazardous 11
ACGIH documents are available from the American Conference
compounds found in welding fumes is not intended to of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive,
minimize their potentially harmful effect on one’s health. Cincinnati, OH 45240.
--```,```,`,`````,``,,`,`,`,```-`-`,,`,,`,`,,`---
483
(b) Exposed skin should be protected with adequate (4) Hinrichs, J.F. January 1978. Project Committee on
gloves and clothing as specified in ANSI Z49.1, Safety in Radiation C Summary report. Welding Journal 57:62–65.
Welding, Cutting, and Allied Processes. (5) Marshall, W.J., Sliney, D.H., et al. March 1980.
(c) Reflections from welding arcs should be avoided, Optical radiation levels produced by air-carbon arc cutting
and all personnel should be protected from intense reflec- processes. Welding Journal 59(3): 43–36.
tions. (Note: Paints using pigments of substantially zinc (6) Moss, C. E., and Murray, W. E. September 1979.
oxide or titanium dioxide have a lower reflectance for Optical radiation levels produced in gas welding, torch
ultraviolet radiation.) brazing, and oxygen cutting. Welding Journal 58(9): 37–
(d) Screens, curtains, or adequate distance from aisles, 46.
walkways, etc., should be used to avoid exposing passersby (7) Moss, C. E. March 1979. Optical radiation transmis-
to welding operations. sion levels through transparent welding curtains. Welding
(e) Safety glasses with UV-protective side shields have Journal 58: 69-s to 75-s.
been shown to provide some beneficial protection from (8) National Technical Information Service. Nonioniz-
ultraviolet radiation produced by welding arcs. ing radiation protection special study No. 42-0053-77,
A10.4.2 Nonionizing radiation information sources Evaluation of the Potential Hazards from Actinic Ultravio-
include: let Radiation Generated by Electric Welding and Cutting
Arcs. Springfield, VA: National Technical Information
(1) American National Standards Institute. ANSI/ASC
Service.12
Z136.1, Safe Use of Lasers. New York: American National
Standards Institute. (9) National Technical Information Service. Nonioniz-
ing radiation protection special study No. 42-0312-77,
(2) American National Standards Institute. ANSI/ASC
Evaluation of the Potential Retina Hazards from Optical
Z87.1, Practice for Occupational and Educational Eye and
Radiation Generated by Electrical Welding and Cutting
Face Protection. New York: American National Standards
Arcs. Springfield, VA: National Technical Information
Institute.
Service.
(3) American Welding Society. ANSI Z49.1, Safety in
Welding, Cutting, and Allied Processes. Miami, FL: Ameri- 12
National Technical Information documents are available from the
can Welding Society. National Technical Information Service, Springfield, VA 22161.
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484

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2007 SECTION II, PART C SFA-5.

SPECIFICATION FOR BARE ELECTRODES AND RODS

1. Scope ASTM A 285/A 285M, Specification for Pressure Vessel

1.2 Safety and health issues and concerns are beyond

Provided by IHS under license with ASME

No reproduction or networking permitted without license from IHS

ERFeCr-A10 A7.1.13 — W74540 5.0-7.0 0.5-2.5 1.5 20-25 — — — — Rem 1.0

Not for Resale, 08/20/2007 05:55:22 MDT

Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome

Copyright ASME International

Not for Resale, 08/20/2007 05:55:22 MDT

Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome

Provided by IHS under license with ASME

Not for Resale, 08/20/2007 05:55:22 MDT

Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome

Not for Resale, 08/20/2007 05:55:22 MDT

Licensee=Setal Engenharia Construcoes e Perfuracoes S.A./5941776001, User=Gome

TABLE 6 equivalent values to the U.S. Customary Units. The stan-

5. Certification4 PART B — TESTS, PROCEDURES, AND

Copyright ASME International

FIG. 1 PAD FOR CHEMICAL ANALYSIS OF UNDILUTED WELD METAL

Copyright ASME International

17. Marking of Packages 17.2 The appropriate precautionary information5 given

in. mm in. mm in. mm in. mm

B Width 1.75 46 2.16 56 4.0 103 4.0 103

C Diameter 0.63 16 2.03 50.5 2.03 50.5 2.03 50.5

D Distance Between Axes — — 1.75 44.5 1.75 44.5 1.75 44.5

E Diameter [Note (1)] — — 0.44 10 0.44 10 0.44 10

Copyright ASME International

in. mm in. mm in. mm

B Width, max. 12 305 13.5 345 13.5 345

C Diameter 1.31 35.0 1.31 35.0 1.31 35.0

D Distance, Center-to-Center 2.5 63.5 2.5 63.5 2.5 63.5

E Diameter [Note (1)] 0.69 16.7 0.69 16.7 0.69 16.7

Copyright ASME International

A1. Introduction TABLE A1

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