NF 16
Unit 5
Welding Consumables
Unit Outline
 Electrodes and filler wires in conjunction with the parent metal are of
prime importance as far as weld joint strength and quality are
concerned. Proper selection should therefore be subject to intelligent
control. Electrodes and filler wires should be specified by the designer
in conjunction with the welding engineer so as to be compatible with
strength and soundness requirements and the available equipment
and conditions of operation.
 Supervisors and inspectors have the responsibility to see that the
specified electrodes and filler wires are used and stored in a
satisfactory condition during the progress of the work. Electrodes and
filler wires are manufactured to the Standards Association of
Australia's codes and these classifications are shown on manufacturers
packaging and on welding specifications.
Unit Objectives
 On the completion of this topic using the prescribed
texts, reading the supplied text and completing the
assessment exercise, you should be able to:
 identify consumable classification systems;
 select welding consumables by classification;
 determine storage requirements in accordance with
codes and manufacturer's recommendations.
Classification of Welding
Consumables/Gas
Classification of Welding Consumables/Gases
Non-alloy
MMAW
GMAW
AS/NZS
4855
AS/NZS 2717
GTAW
SAW
Flux/Wire
FCAW
Hardfacing
Brazing
Shielding
Gases
High
strength
AS/NZS
4857
AS1858.1
AS/NZS
ISO 17632
Creep
resistant
AS/NZS
4856
AS/NZS 1167.2
DR 87241
AS/NZS
ISO 18276
AS/NZS
ISO 17634
AS 2576
AS/NZS 1167.1
AS 4882
Stainless
Aluminium
AS/NZS
4854
AS/NZS
ISO 14343
N/A
AS/NZS
ISO 17633
AS/NZS
ISO 17633
AS/NZS
ISO 18273
N/A
N/A
Welding Comsumables
 AS/NZS 1553.1: 1995 , Covered Electrodes for
welding , Part 1 : Low carbon steel
electrodes for manual metal-arc welding of
carbon steels and carbon-manganese steels.
Supersede by AS/NZS 4855:2007
(ISO2560:2002) , Welding consumables –
Covered electrodes for manual metal arc
welding of non-alloy and fine grain steels
Welding Consumables
 AS/NZS 1553.2-2004 , Covered Electrodes for
Welding,
Part 2 – Low and Intermediate Alloy Steel
Electrodes for Manual Metal Arc Welding of
Carbon Steels and Low and Intermediate Alloy
Steels.
Supersede by AS/NZS 4857 , Welding consumablescovered electrodes for manual metal arc welding of
high –strength steels - Classification
Welding Consumables
 AS 1858.1- 2003 , Electrodes and Fluxes for submerged
arc welding .
Part 1 : Carbon steels and carbon Manganese Steels.
 AS 2203 – Carbon Steel Electrodes Cored ( for Arc
Welding )
Supersede by : AS/NZS ISO 17632-2004 , Welding
consumables –Tubular core electrodes for gas shield
and non-gas shielded metal arc welding of welding of
non-alloy and fine grain steels Classification
Welding Consumables
 AS 2717.1 , Welding Electrodes – Gas Metal Arc Ferritic
Steel Electrodes.
 AS2717 .2 , Welding- Electrodes Gas Metal Arc
Part 2 – Aluminium and Aluminium Alloys .
Supersede by : AS/NZS ISO 18273 , Welding
consumables – Wire electrodes , wire and rods for
welding of Aluminium and Aluminium Alloys –
Classification.
Welding Comsumables
 AS2576 , Welding Consumables for Building –up and
Wear Resistance – Classification.
 AS1167.1 , Welding and Brazing Filler Metals
Part 1 – Filler Metal for Brazing and Braze Welding.
AS 1553.1 classification
E xx yz - nHmR
Hydrogen level (HmR)
Rm/10 (xx)
H5 = 5 ml / 100g of WM
R = low moisture pick-up
41 = 410 MPa min
48 = 480 MPa min
Useable positions (y)
1=all positions
2=flat + horizontal
4=vertical down
Flux type (yz)
20 = acid (iron oxide)
10, 11 = cellulosic
12, 13 = rutile
24 = rutile iron powder
27 = acid iron powder
16 = basic
18, 28 = basic iron powder
Impact properties (n)
0 = 47J at 0°C
2 = 47J at -20°C
3 = 47J at -30°C
4 = 47J at -40°C
AS/NZS 4855 supersede AS1553.1
 The international Standard recognizes that there are
two somewhat different approaches in the global
market to classifying electrodes , and allows for either
or both to be used , to suit a particular market need .
 Classification designations are based upon two
approaches to indicate the tensile properties and the
impact properties of the all –weld metal obtained with
a given electrode.
 ISO 2560-A , classification system based upon yeild
strength and 47 J minimum impact energy.
 ISO 2560-B , classification system based upon tensile
strength and 27 J minimum impact energy.
ISO 2560-A classfication
H5= hydrogen
contents
4= Welding position
E 46 3 1Ni B 54 H4
5=nominal electrode
efficiency and type of
current
Nominal electrode
Type of current a b
efficiency,
%
4.5
Symbol
for
type
of
electrode covering
Alloy
a b c
Chemical
composition
%) and
< >47 J
symbol
4.5A
Classification
by yield(mass
strength
Symbol
Positions
Symbol
Temperature
for
B=
Symbol
for
type
of
a.c.
+
d.c.
1
ij 105impact energy
Hydrogen content
Symbol minimum average
2
Ni
impact
energyMn
of 47 J max. ml/100 g Mo
3=impact
properties
of electrode
deposited
weld covering
metal
^105
E=covered
ThePD,
type
ofd.c.
a covered
electrode depends
1
PA, PB,
PE, of covering
PF,
PG
oCPC,
> 105substantially
but
« 125 on the
a.c.of+d.c.
type
No
2,0
—
—
H5 symbol
5slag-forming
electrode/manual 34
Z
No requirement
2
PA,
PB,
PC,
PD,
PE,
PF
>
105
but
s=
125
d.c.
components.
The
symbols
indicating
the type shall be
H10
10
metal arc welding 5
a.c.
+15d.c.or groups
Mo
>125butsc
1,4 160
0,3 to
0,6
—
formed
by the following
letters
of letters:
H15
63
d.c.
>
125
but
s;
160
PA,
PB
A
+20A
1Ni=chemical
composition
acid
covering
MnMo >160 1,4 to 2,0 =
0,3 to
0,6
—
a.c.
+ d.c. covering
74
O
0 C
Symbol
Minimum
Tensile
Minimum
= all-weld
cellulosic
of
metal
PA
8
Yield
strength
elongation
=
rutile covering
1Ni
— d.c.
0,6 to 1,2
>160
strength
2
-20R1,4
a 2
46=460
N/mm2N/mm
N/mm2
%
5
PA,
PB,
PG
RR
=
rutile
thick
covering
In order to demonstrate
operability on a.c.,-30tests shall be carried out with no load voltage higher
than 65 V.
3
2Ni
1,4
—
1,8
to
2,6
Minimum Yield Stregth
RC
=
rutile-cellulosic covering
4
-40
b
=
covering
a.c.
=
alternating
current;
d.c.
= RA
direct
3Ni
1,4 current.
— rutile-acid2,6
to 3,8
35
355
440 to 570
22
5
-50RB
=
rutile-basic covering
MnINi
— basic covering.
0,6 to 1,2
6
-60B 1,4 to 2,0 =
Symbol
38
380
470 to 600
20
42
420
500 to 640
20
46
460
530 to 680
20
50
500
560 to 720
18
1NiMo
1,4
0,3 to 0,6
0,6 to 1,2
Z
Any other agreed composition
If not specified, Mo < 0,2; Ni<0,3; Cr<0,2; V<0,05; Nb < 0,05; Cu < 0,3. b
Single values shown in the table mean maximum values. c The results shall
be rounded to the same number of significant figures as in the specified value
using the rules according to ISO 31-0:1992, Annex B, Rule A.
a
ISO 2560-B - Classification
Alloy symbol
Chemical composition
Principal alloy element(s)
Nominal level
Symbol
No symbol, -1, or-P1
Type of covering
Welding positions
mass % a
03
-1M3
Rutile basic
Allb
10
-3M2
11
-3M3
12
Cellulosic
All
Mn
Mo
Type of current
H5= Hydrogen contents
1
0,5
a.c. and d.c. (+)
d.c. (+)
E 55 18 – N2 A U H5
Mn Mo
1,5 0,4
Cellulosic
All strength and a.c.
4.6B Classification
by tensile
27 and
J d.c. (+)
1,5 0,5
Mn Mo
Rutile
All
a.c. and d.c. (-)
impact energy
0,5
-N1
Ni
13Manual
All
Symbol
Minimum
tensile
E=cover electrode/
Rutilehas
a.c. and d.c. (±)
If the electrode
been strength
classified
in the as-welded
metal arc welding
1
-N214
Rutile
+Niiron powder
All added to
a.c. and d.c. (+)
condition, the
symbol
A2 shall be
the U=
supplemental impact
Hydrogen
content
N/mm
Symbol
1,5
-N315
Ni
All
Basic
d.c.
(+)
classification.
If the
electrode
has
been
classified
in
the of 47 J at the basic 27 J
max. ml/100 g of
deposited
weld metal
U=indicating
that
the
requirement
16
All
1,5 1,5
Basic Mn Ni
a.c. and
d.c. (+)
430 electrode
-3N3
post-weld heat-treated
condition,
the temperature
oftest
impact
temperature
has
satisfied
H5
5a
55= Tensile43
strength
49
490
Basic
+
iron
powder
post-weld heat-treatment
shallAllbe 620°C±15°C
-N518
Ni
2,5
H10
requirement
for
47 J10a.c. and d.c. (+)
55 19
550
All
llmenite
15a.c. and
(605°C±15°CH15in
the
cases of chemical
compositions
N5d.c. (±)
-N7
Ni
3,5
impact
energy
at
the
18=type of 57
electrode
of postweld
20
PBA=Condition
Iron oxide 570
a.c. and d.c. (-)heat
and N7, and 600°C±15°C
in thePA,
case
of chemical
-N13
Ni
6,5
temperature
normally
covering ,type24of current
,and theRutile
under
which
+ iron
powder
PA, PBtreatment
composition
N13),
and
the
symbol
P shall
be
added
tod.c.the
a.c.
and
(±) all-weld
Ni Mo
1
0,5
-N2M3
used
forPA,27
J requirement
welding positions
Iron oxide
+ iron
powder heat
the classification.
Postweld
treatment
time a.c.
shall
be(-)
27
PBtest was conducted
and d.c.
Ni
Cu
0,5
0,4
-NC
Basic
+ iron powder
1 h (+1o min) at
temperature.
If PA,
the
has a.c.
been
28
PB,electrode
PC
and d.c. (+)
0,5
0,4
N2=chemical
composition
Cr
Cu
-CC40
classified in both
conditions,
theManufacturer's
symbol AP
shall
be added to
recommendations
Not specified
b
b
b
b
b
b
b
-NCC
48
NOTE
-NCC1
the classification.
ofCr all
Cu –metal All
Basic Ni
-G
a.c. and d.c. (+)
A description of the characteristics
given
annex C.
Ni Cr Cu of each of the types of covering is 0,6
0,6in0,5
= flat,
Ni Cr
Cu PB = horizontal
-NCC2 Positions are defined in ISO 6947. PA
a
0,2 0,6 0,5
0,3 0,2 0,5
vertical fillet, PC = horizontal, PG = vertical down.
Any other agreed composition
b
All position may or may not include vertical down welding. This shall be specified in the manufacturer's trade literature.
Discussion