7/29/2019 8. Consumables
1/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
TWICSWIP 3.1WIS 5
WELDING INSPECTION
CONSUMABLESIDENTIFICATION AND
CONTROL
7/29/2019 8. Consumables
2/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
All those things used up in the production of a weld
Though generally, we refer to those elementsthat are used in a specific welding process i.e:
Electrodes, Wires, Fluxes and Gases
Welding consumables
7/29/2019 8. Consumables
3/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Courtesy of ESAB AB
Consumable types
welding gases (MIG/MAG, FCAW, TIG)
coveredelectrodes
MIG/MAGsolid wire
cored wire
TIG/PAW rods
SAW strips
weldingfluxes(SAW)
SAWsolid wire
7/29/2019 8. Consumables
4/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Positional capabilities
Flux coating type
Toughness 47 Joules
Electrode
Tensile & yield strength
Any light alloying composition
Electrical parameters & efficiency
Low hydrogen content achievable
E 46 31Ni B
Strength
Toughness
Coating Shown on all electrodes
BS EN 499 electrode designation
7/29/2019 8. Consumables
5/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Strength Toughness Coating Shown on all electrodes
BS 639 electrode designation
Positional capabilities
Flux coating type
Toughness 28 & 47 Joules
Electrode
Tensile & yield strength
Electrical capability
Low hydrogen content achievable
E 51 33 B
Electrode efficiency
7/29/2019 8. Consumables
6/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Electrode
Tensile strength(PSI x 1000)
Positional capabilities
Flux coating &electrical characteristics
E8018
AWS A5.1 electrode designation
7/29/2019 8. Consumables
7/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
AWS A5.4 electrode designation
Specification number
Electrode
Weld metal chemical composition
Welding current type
AWS A5.4 E 308L-16
7/29/2019 8. Consumables
8/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
MAG filler materialWire designation acc. BS EN 440:
EN 440 - G 46 3 M G3Si1
Standard number
Weld deposit produced
by gas shielded metalarc welding
Tensile properties
Impact properties
Type of shielding gas
Type of wire electrode
EN 440 G463MG3Si1
7/29/2019 8. Consumables
9/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
MAG filler material
Wire designation acc. AWS A-5.18:
Minimum UTS of weld metal (ksi)
Chemical composition of the solidwire or of the weld metal in caseof composite electrodes
AWS A-5.18 ER 70 S-6
Standard number
Designate an electrode/rod(ER) or only an electrode (E)
Solid (S) or composite (C) wire
AWS A-5.18 ER70S-6
7/29/2019 8. Consumables
10/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
SAW filler materialWire/flux combination designation acc. BS EN 756:
EN 756 - S 46 3 AB S2
Standard number
Wire electrode and/or
wire/flux combination
Tensile properties
Impact properties
Type of welding flux
Chemical composition of
wire electrode
EN 756 S463ABS2
7/29/2019 8. Consumables
11/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
SAW filler materialWire/flux combination designation acc. AWS A-5.17:
Minimum UTS ofweld metal (10 ksi)
Temperature forimpact test
Standard number
SAW welding fluxHeat treatmentconditions
Chemical composition
of wire electrode
AWS A-5.17 F 6 A 2-EM12KAWS A-5.17 F6A2EM12K
7/29/2019 8. Consumables
12/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Covered electrode packages
Plastic foil sealed cardboard box
rutile electrodes
general purpose basic electrodes
Tin can
cellulosic electrodes
Vacuum sealed pack
extra low hydrogen electrodes
Courtesy of Lincoln Electric
Cou
rtesy
ofLincolnE
l
ectric
7/29/2019 8. Consumables
13/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Type of coverings
Cellulosic covering:
Rutile covering:
flour and wood pulp are common constituents
very high in hydrogen
does not require backing or drying (excessiveheat will damage electrode covering!)
are based on titanium oxide
can be dried NOT BAKED!!!
needs a reasonable proportion of combinedwater to keep the covering intact
if moisture is driven off, the binding of the fluxwill suffer
7/29/2019 8. Consumables
14/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Type of coverings
Basic covering:
contain calcium compounds like calcium fluorideand 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 5ml/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!
7/29/2019 8. Consumables
15/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Moisture pick-up
Moisture pick-up as a function of: temperaturehumidity
7/29/2019 8. Consumables
16/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Covered electrode treatment
Baking oven
Heated quivers
only for maintainingof electrodes afterbaking
need temperaturecontrol
requires calibration
7/29/2019 8. Consumables
17/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Covered electrode treatment
Cellulosic electrodes
Rutile electrodes
Use straight from
the box - Nobaking/drying!
If necessary, dry
up to 120C- Nobaking!
Vacuum packedbasic electrodes
Use straight from thepack within 4 hours -No rebaking!
7/29/2019 8. Consumables
18/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Covered electrode treatment
After baking, maintainin oven at 150C
Basic electrodes Baking in oven 2,5hours at 350C!
Use fromquivers at 75C
If not used within4 hours, return tooven and rebake!
Weld
Limited numberof rebakes!
7/29/2019 8. Consumables
19/24Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Other filler material treatment
Welding flux:
might be fused or agglomerated
supplied in bags
Fused fluxes are normally not hygroscopic butparticles can hold surface moisture so only drying
Agglomerated fluxes contain chemically bondedwater. Similar treatment as basic electrodes
If flux is too fine it will pack and not feed properly.
It cannot be recycled indefinitely
must be kept warm and dry
handling and stacking requires careCourtesy of Lincoln Electric
7/29/2019 8. Consumables
20/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Other filler material treatment
Welding wires:
supplied on wire/plastic spools or coils
plastic spool wire spool coil
random or line winding
Courtesy of Lincoln ElectricCourtesy of Lincoln Electric Courtesy of Lincoln Electric
7/29/2019 8. Consumables
21/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Other filler material treatment
Welding wires:
carbon and low alloy wires are copper coated
wires must be kept clean and free from oil and dust
flux cored wires does not require baking or drying
stainless steel wires are not coated
Courtesy of Lincoln Electric Courtesy of ESAB AB
7/29/2019 8. Consumables
22/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Other filler material treatment
Welding rods:
supplied in cardboard/plastic tubes
must be kept clean and free from oil and dust
might require degreasing
Courtesy of Lincoln Electric
7/29/2019 8. Consumables
23/24
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Gases
supplied in cylinders
for large quantities,storage tanks
colour coded to minimise wronguse
subject to regulations concerned
handling, quantities andpositioning of storage areas
7/29/2019 8. Consumables
24/24
C i ht 2004 TWI Ltd World Centre for Materials Joining Technology
Quality assurance
filler material must be stored in an area withcontrolled temperature and humidity
poor handling and incorrect stacking maydamage coatings, rendering the electrodes
unusablethere should be an issue and return policy forwelding consumables (system procedure)
control systems for electrode treatment must be
checked and calibrated; those operations must berecorded
filler material suppliers must be approved beforepurchasing any material