TWI CSWIP 3.1 Wis 5 Welding Inspection Consumables Identification and Control

TWI CSWIP 3.
1 WIS 5 WELDING INSPECTION

CONSUMABLES IDENTIFICATION AND CONTROL
Copyright 2004, TWI Ltd
World Centre for Materials Joining Technology
Welding consumables
All those things used up in the production of a weld Though generally, we refer to those elements that are used in a specific welding process i.e:
Electrodes, Wires, Fluxes and Gases
Consumable types
welding fluxes (SAW) TIG/PAW rods
cored wire
SAW strips
MIG/MAG solid wire covered electrodes
SAW solid wire

Courtesy of ESAB AB
welding gases (MIG/MAG, FCAW, TIG)

BS EN 499 electrode designation

Positional capabilities Flux coating type Toughness 47 Joules Electrode
E 46 31Ni B
Tensile & yield strength Any light alloying composition Electrical parameters & efficiency Low hydrogen content achievable Strength Toughness Coating Shown on all electrodes
BS 639 electrode designation

Low hydrogen content achievable Positional capabilities Electrode efficiency Electrode E 51 33 B Tensile & yield strength Toughness 28 & 47 Joules Flux coating type Electrical capability Strength Toughness Coating Shown on all electrodes
AWS A5.1 electrode designation

Positional capabilities
Electrode
E 8018
Tensile strength (PSI x 1000) Flux coating & electrical characteristics
AWS A5.4 electrode designation

Weld metal chemical composition Specification number
AWS A5.4 E 308L-16

Electrode Welding current type
MAG filler material

Wire designation acc. BS EN 440: Type of shielding gas Tensile properties
Standard number
EN 440 - G 46 3 M G3Si1
Weld deposit produced by gas shielded metal arc welding Impact properties Type of wire electrode
MAG filler material

Wire designation acc. AWS A-5.18: Chemical composition of the solid wire or of the weld metal in case of composite electrodes Minimum UTS of weld metal (ksi) Standard number
AWS A-5.18 ER 70 S-6 S-6

Designate an electrode/rod (ER) or only an electrode (E) Solid (S) or composite (C) wire
SAW filler material

Wire/flux combination designation acc. BS EN 756: Type of welding flux Tensile properties
Standard number
EN 756 - S 46 3 AB S2
Wire electrode and/or wire/flux combination Impact properties Chemical composition of wire electrode
SAW filler material

Wire/flux combination designation acc. AWS A-5.17: Temperature for impact test Minimum UTS of weld metal (10 ksi) Standard number
AWS A-5.17 F 6 A 2-EM12K 2 EM12K

SAW welding flux
Heat treatment conditions

Chemical composition of wire electrode
Covered electrode packages

Plastic foil sealed cardboard box rutile electrodes general purpose basic electrodes
Courtesy of Lincoln Electric Courtesy of Lincoln Electric
Tin can cellulosic electrodes
Vacuum sealed pack extra low hydrogen electrodes

Type of coverings
Cellulosic covering:
flour and wood pulp are common constituents very high in hydrogen does not require backing or drying (excessive heat will damage electrode covering!)
Rutile covering:
are based on titanium oxide can be dried NOT BAKED!!! needs a reasonable proportion of combined water to keep the covering intact if moisture is driven off, the binding of the flux will suffer
Type of coverings
Basic covering: contain calcium compounds like calcium fluoride and calcium carbonate a.k.a. lime-coated electrodes basic refers to the chemical behaviour of the flux have the lowest level of hydrogen (less than 5 ml/100 g of weld metal needs backing to perform correctly baking at approximately 350C for 2,5 hours (see also manufacturer recommendations!) after baking, maintain at minimum 120C to avoid moisture pick-up cannot be rebaked indefinitely!
Moisture pick-up
Moisture pick-up as a function of: temperature humidity

Covered electrode treatment

Baking oven need temperature control
requires calibration
Heated quivers only for maintaining of electrodes after baking


Cellulosic electrodes Use straight from the box - No baking/drying! If necessary, dry up to 120C- No baking!
Rutile electrodes
Vacuum packed basic electrodes
Use straight from the pack within 4 hours No rebaking!

Basic electrodes Baking in oven 2,5 hours at 350C!
Limited number of rebakes!
After baking, maintain in oven at 150C
If not used within 4 hours, return to oven and rebake!

Use from quivers at 75C
Weld
Other filler material treatment

Welding flux:
might be fused or agglomerated supplied in bags must be kept warm and dry handling and stacking requires care
Courtesy of Lincoln Electric
Fused fluxes are normally not hygroscopic but particles can hold surface moisture so only drying
Agglomerated fluxes contain chemically bonded water. Similar treatment as basic electrodes
If flux is too fine it will pack and not feed properly. It cannot be recycled indefinitely

Welding wires: supplied on wire/plastic spools or coils
random or line winding
plastic spool
wire spool
coil

Welding wires: carbon and low alloy wires are copper coated stainless steel wires are not coated
wires must be kept clean and free from oil and dust flux cored wires does not require baking or drying
Courtesy of ESAB AB

Welding rods: supplied in cardboard/plastic tubes
must be kept clean and free from oil and dust

might require degreasing
Gases
supplied in cylinders
colour coded to minimise wrong use subject to regulations concerned handling, quantities and positioning of storage areas
for large quantities, storage tanks

Quality assurance
filler material must be stored in an area with controlled temperature and humidity
poor handling and incorrect stacking may damage coatings, rendering the electrodes unusable
there should be an issue and return policy for welding consumables (system procedure) control systems for electrode treatment must be checked and calibrated; those operations must be recorded filler material suppliers must be approved before purchasing any material

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TWI CSWIP 3.

1 WIS 5 WELDING INSPECTION

World Centre for Materials Joining Technology

Electrodes, Wires, Fluxes and Gases

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

MIG/MAG solid wire covered electrodes

SAW solid wire

welding gases (MIG/MAG, FCAW, TIG)

World Centre for Materials Joining Technology

BS EN 499 electrode designation

World Centre for Materials Joining Technology

BS 639 electrode designation

World Centre for Materials Joining Technology

AWS A5.1 electrode designation

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

AWS A5.4 electrode designation

AWS A5.4 E 308L-16

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

MAG filler material

World Centre for Materials Joining Technology

MAG filler material

AWS A-5.18 ER 70 S-6 S-6

World Centre for Materials Joining Technology

SAW filler material

World Centre for Materials Joining Technology

SAW filler material

AWS A-5.17 F 6 A 2-EM12K 2 EM12K

Heat treatment conditions

World Centre for Materials Joining Technology

Covered electrode packages

Tin can cellulosic electrodes

Vacuum sealed pack extra low hydrogen electrodes

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Moisture pick-up as a function of: temperature humidity

World Centre for Materials Joining Technology

Covered electrode treatment

Heated quivers only for maintaining of electrodes after baking

World Centre for Materials Joining Technology

Covered electrode treatment

Vacuum packed basic electrodes

Use straight from the pack within 4 hours No rebaking!

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Covered electrode treatment

Limited number of rebakes!

After baking, maintain in oven at 150C

If not used within 4 hours, return to oven and rebake!

Use from quivers at 75C

World Centre for Materials Joining Technology

Other filler material treatment

World Centre for Materials Joining Technology

Other filler material treatment

random or line winding

Courtesy of Lincoln Electric