Welding Consumables

Welding Consumables
TWI Training & Examination
Copyright © TWI Ltd 2008

Services
Course Reference WIS 5

Course notes section reference 16
Welding consumables
Welding consumables are any products that are used up in

the production of a weld
Welding consumables may be:

• Covered electrodes, filler wires and electrode wires.
• Shielding or oxy-fuel gases.

• Separately supplied fluxes.
• Fusible inserts.
Welding Consumable Standards
MMA (SMAW) MIG/MAG (GMAW) TIG (GTAW)

• BS EN 499: Steel electrodes • BS 2901: Filler wires
• AWS A5.1 Non-alloyed steel • BS EN 440: Wire electrodes
electrodes • AWS A5.9: Filler wires
• AWS A5.4 Chromium • BS EN 439: Shielding gases
electrodes SAW
• AWS A5.5 Alloyed steel • BS 4165: Wire and fluxes

electrodes • BS EN 756: Wire electrodes
• BS EN 760: Fluxes
• AWS A5.17: Wires and fluxes
Welding Consumables
TIG/PAW rods
welding
fluxes
(SAW)
cored wire
SAW strips

MIG/MAG
solid wire
SAW covered
solid wire electrodes
Courtesy of ESAB AB
Welding Consumable Gases
welding gases
• GMAW, FCAW, TIG, Oxy- Fuel
• Supplied in cylinders or storage
tanks for large quantities
• Colour coded cylinders to minimise
wrong use
• Subject to regulations concerned
handling, quantities and positioning
of storage areas

• Moisture content is limited to avoid
cold cracking
• Dew point (the temperature at which
the vapour begins to condense)
must be checked
Welding Consumables
Each consumable is critical in respect to:

• Size
• Classification / Supplier
• Condition

• Treatments e.g. baking / drying
• Handling and storage is critical for consumable control
• Handling and storage of gases is critical for safety
Quality Assurance
Welding Consumables:
• 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
Welding Consumables
MMA Covered Electrodes

MMA Welding Consumables
Welding consumables for MMA:

• Consist of a core wire typically between 350-450mm in length
and from 2.5-6mm in diameter
• The wire is covered with an extruded flux coating
• The core wire is generally of a low quality rimming steel
• The weld quality is refined by the addition of alloying and
refining agents in the flux coating

• The flux coating contains many elements and compounds that
all have a variety of functions during welding
Function of the Electrode Covering:

• To facilitate arc ignition and give arc stability
• To generate gas for shielding the arc & molten metal from air
contamination
• To de-oxidise the weld metal and flux impurities into the slag
• To form a protective slag blanket over the solidifying and
cooling weld metal

• To provide alloying elements to give the required weld metal
properties
• To aid positional welding (slag design to have suitable
freezing temperature to support the molten weld metal)
• To control hydrogen contents in the weld (basic type)
The three main electrode covering types used in MMA welding
• Cellulosic - deep penetration/fusion

• Rutile - general purpose
• Basic - low hydrogen

Plastic foil sealed cardboard box

•rutile electrodes
•general purpose basic electrodes
Courtesy of Lincoln Electric

Tin can
•cellulosic electrodes

Vacuum sealed pack
•extra low hydrogen electrodes
Cellulosic electrodes:
• covering contains cellulose (organic material).
• produce a gas shield high in hydrogen raising the arc voltage.
• Deep penetration / fusion characteristics enables welding at
high speed without risk of lack of fusion.
• generates high level of fumes and H2 cold cracking.
• Forms a thin slag layer with coarse weld profile.
• not require baking or drying (excessive heat will damage

electrode covering!).
• Mainly used for stove pipe welding
• hydrogen content is 80-90 ml/100 g of weld metal.
Cellulosic Electrodes
Disadvantages:
• weld beads have high hydrogen
• risk of cracking (need to keep joint hot during welding to allow
H to escape)
• not suitable for higher strength steels - cracking risk too
high (may not be allowed for Grades stronger than X70)

• not suitable for very thick sections (may not be used on
thicknesses > ~ 35mm)
• not suitable when low temperature toughness is required
(impact toughness satisfactory down to ~ -20°C)
Cellulosic Electrodes
Advantages: Disadvantages:
• Deep penetration/fusion • High in hydrogen
• Suitable for welding in all • High crack tendency
positions
• Rough weld appearance

• Fast travel speeds • High spatter contents
• Large volumes of shielding gas • Low deposition rates
• Low control
Rutile electrodes:
• covering contains TiO2 slag former and arc stabiliser.
• easy to strike arc, less spatter, excellent for positional
welding.
• stable, easy-to-use arc can operate in both DC and AC.
• slag easy to detach, smooth profile.
• Reasonably good strength weld metal.
• Used mainly on general purpose work.

• Low pressure pipework, support brackets.
• electrodes can be dried to lower H2 content but cannot be
baked as it will destroy the coating.
• hydrogen content is 25-30 ml/100 g of weld metal.
Rutile electrodes
Disadvantages:
• they cannot be made with a low hydrogen content
• cannot be used on high strength steels or thick joints -
cracking risk too high
• they do not give good toughness at low temperatures

• these limitations mean that they are only suitable for general
engineering - low strength, thin steel
Rutile Electrodes
Advantages: Disadvantages:
• Easy to use • High in hydrogen
• Low cost / control • High crack tendency
• Smooth weld profiles • Low strength

• Slag easily detachable • Low toughness values
• High deposition
possible with the
addition of iron powder
High Recovery Rutile Electrodes

Characteristics:
• coating is ‘bulked out’ with iron powder
• iron powder gives the electrode ‘high recovery’
• extra weld metal from the iron powder can mean that weld
deposit from a single electrode can be as high as 180% of
the core wire weight

• give good productivity
• large weld beads with smooth profile can look very similar to
SAW welds
High Recovery Rutile Electrodes

Disadvantages:
• Same as standard rutile electrodes with respect to hydrogen
control
• large weld beads produced cannot be used for all-positional
welding
• the very high recovery types usually limited to PA & PB

positions
• more moderate recovery may allow PC use
Basic covering:
• Produce convex weld profile and difficult to detach slag.
• Very suitable for for high pressure work, thick section steel
and for high strength steels.
• Prior to use electrodes should be baked, typically 350°C for 2
hour plus to reduce moisture to very low levels and achieve
low hydrogen potential status.
• Contain calcium fluoride and calcium carbonate compounds.

• cannot be rebaked indefinitely!
• low hydrogen potential gives weld metal very good
toughness and YS.
• have the lowest level of hydrogen (less than 5 ml/100 g of
weld metal).
Basic Electrodes
Disadvantages:
• Careful control of baking and/or issuing of electrodes is
essential to maintain low hydrogen status and avoid risk of
cracking
• Typical baking temperature 350°C for 1 to 2hours.
• Holding temperature 120 to 150°C.

• Issue in heated quivers typically 70°C.
• Welders need to take more care / require greater skill.
• Weld profile usually more convex.
• Deslagging requires more effort than for other types.
Basic Electrodes
Advantages Disadvantages
• High toughness values • High cost
• Low hydrogen contents • High control
• Low crack tendency • High welder skill

required
• Convex weld profiles
• Poor stop / start
properties
BS EN 499 MMA Covered Electrodes
Compulsory

Optional
Copyright © 2004 TWI Ltd

E 50 3 2Ni B 7 2 H10
Covered Electrode
Yield Strength N/mm2
Toughness
Chemical composition
Flux Covering

Weld Metal Recovery
and Current Type
Welding Position
Hydrogen Content
Electrodes classified as follows:

• E 35 - Minimum yield strength 350 N/mm2
Tensile strength 440 - 570 N/mm2

BS EN 499 electrode designation
Recovery and type of current Welding position

designation designation
Weld metal Type of Symbol Welding position
Symbol
recovery (%) current
1 All positions
1 105 AC/DC
2 All positions except
2 105 DC vertical down
3 >105 125 AC/DC 3 Flat butt/fillet,
>105 125 horizontal fillet

4 DC
5 >125 160 AC/DC 4 Flat butt/fillet
6 >125 160 DC 5 Flat butt/fillet,

horizontal fillet,
7 >160 AC/DC vertical down
8 >160 DC
AWS A5.1 Alloyed Electrodes
E 60 1 3
Covered Electrode
Tensile Strength (p.s.i)
Welding Position
Flux Covering

AWS A5.5 Alloyed Electrodes
E 70 1 8 M G
Covered Electrode
Tensile Strength (p.s.i)
Welding Position
Flux Covering

Moisture Control
Alloy Content
TYPES OF ELECTRODES
(for C, C-Mn Steels)
BS EN 499 AWS A5.1
• Cellulosic E XX X C EXX10
EXX11
• Rutile E XX X R EXX12
EXX13

• Rutile Heavy Coated E XX X RR EXX24
• Basic E XX X B EXX15
EXX16
EXX18
AWS A5.1 & A5.5 Alloyed Electrodes
Example AWS electrode flux types:

• Cellulosic: flux-ends in 0 - 1
Examples: E6010, E6011, E7010, E8011
• Rutile: flux-ends in 2 - 3 - 4
Examples: E5012, E6012, E6013, E6014

• Basic: flux-ends in 5 - 6 - 7 - 8
Examples: E6016, E7017, E8018, E9018
Moisture pick-up

•temperature
Moisture pick-up as a function of: •humidity
Electrode efficiency
up to 180% for iron powder electrodes
Mass of weld metal deposited

Electrode Eficiency =
Mass of core wire melted

75-90% for usual electrodes
Covered electrode treatment
Baking oven:
• need temperature control
• requires calibration

Heated quivers:
• only for maintaining
moisture out of electrodes
after baking
Cellulosic Use straight from the

box - No baking/drying!
electrodes
If necessary, dry up to
Rutile 120°C- No baking!
electrodes

Vacuum Use straight from the pack
within 4 hours - No
packed basic rebaking!
electrodes
Baking in oven 2 hours

Basic electrodes
at 350°C!
Limited number of After baking, maintain in

rebakes! oven at 150°C

If not used within 4
Use from quivers at
hours, return to oven Weld
75°C
and rebake!
Covered electrode inspection
1: Electrode size (diameter and length)
2: Covering condition: adherence, cracks, chips and concentricity

3: Electrode designation
EN 499-E 51 3 B
Arc ignition enhancing materials (optional!)
See BS EN ISO 544 for further information

Any Questions

Welding Consumables
TIG Consumables

TIG Welding Consumables
Welding consumables for TIG:

• Filler wires, Shielding gases, tungsten electrodes (non-
consumable).
• Filler wires of different materials composition and variable
diameters available in standard lengths, with applicable code
stamped for identification
• Steel Filler wires of very high quality, with copper coating to resist
corrosion.

• shielding gases mainly Argon and Helium, usually of highest
purity (99.9%).
Welding rods:
•supplied in cardboard/plastic tubes

•must be kept clean and free from oil and dust

•might require degreasing
Fusible Inserts
Pre-placed filler material
Before Welding After Welding

Other terms used include:
 EB inserts (Electric Boat Company)
 Consumable socket rings (CSR)

Fusible Inserts
Consumable inserts:
• used for root runs on pipes
• used in conjunction with TIG welding
• available for carbon steel, Cr-Mo steel, austenitic stainless
steel, nickel and copper-nickel alloys
• different shapes to suit application

Radius
Fusible Inserts
Application of consumable inserts

Shielding gases for TIG welding
Argon
• low cost and greater availability
• heavier than air - lower flow rates than Helium
• low thermal conductivity - wide top bead profile
• low ionisation potential - easier arc starting, better arc stability
with AC, cleaning effect
• for the same arc current produce less heat than helium - reduced

penetration, wider HAZ
• to obtain the same arc arc power, argon requires a higher current
- increased undercut
Helium
• costly and lower availability than Argon
• lighter than air - requires a higher flow rate compared with argon
(2-3 times)
• higher ionisation potential - poor arc stability with AC, less
forgiving for manual welding
• for the same arc current produce more heat than argon -

increased penetration, welding of metals with high melting point
or thermal conductivity
• to obtain the same arc arc power, helium requires a lower current
- no undercut
Hydrogen
• not an inert gas - not used as a primary shielding gas
• increase the heat input - faster travel speed and increased
penetration
• better wetting action - improved bead profile
• produce a cleaner weld bead surface
• added to argon (up to 5%) - only for austenitic stainless steels

and nickel alloys
• flammable and explosive
Nitrogen
• not an inert gas
• high availability - cheap
• added to argon (up to 5%) - only for back purge for duplex
stainless, austenitic stainless steels and copper alloys
• not used for mild steels (age embritlement)
• strictly prohibited in case of Ni and Ni alloys (porosity)

Any Questions

Welding Consumables
MIG / MAG Consumables

MIG/MAG Welding Consumables
Welding consumables for MIG/MAG

• Spools of Continuous electrode wires and shielding gases
• variable spool size (1-15Kg) and Wire diameter (0.6-1.6mm)
supplied in random or orderly layers
• Basic Selection of different materials and their alloys as
electrode wires.
• Some Steel Electrode wires copper coating purpose is corrosion

resistance and electrical pick-up
• Gases can be pure CO2, CO2+Argon mixes and Argon+2%O2
mixes (stainless steels).
Welding wires:
•supplied on wire/plastic spools or coils
•random or line winding

Courtesy of Lincoln Electric Courtesy of Lincoln Electric
plastic spool wire spool coil
Welding wires:
•carbon and low alloy wires may be copper coated
• stainless steel wires are not coated

Courtesy of Lincoln Electric Courtesy of ESAB AB
•wires must be kept clean and free from oil and dust
•flux cored wires does not require baking or drying
How to check the quality of welding wires:
Cast Helix size - limited to 25

diameter mm to avoid problems
with arc wandering!

Cast diameter improves the contact force and defines the
contact point; usually 400-1200 mm
Contact point close to contact Contact point remote from

tip end - GOOD! contact tip end - POOR!
MIG/MAG shielding gases
Ar Ar-He He CO2
Argon (Ar):
higher density than air; low thermal conductivity  the arc has a
high energy inner cone; good wetting at the toes; low ionisation
potential
Helium (He):

lower density than air; high thermal conductivity  uniformly
distributed arc energy; parabolic profile; high ionisation potential
Carbon Dioxide (CO2):
cheap; deep penetration profile; cannot support spray transfer; poor
wetting; high spatter
Gases for dip transfer:

• CO2: carbon steels only; deep penetration; fast welding speed;
high spatter levels
• Ar + up to 25% CO2: carbon and low alloy steels; minimum
spatter; good wetting and bead contour
• 90% He + 7,5% Ar + 2,5% CO2:stainless steels; minimises
undercut; small HAZ

• Ar: Al, Mg, Cu, Ni and their alloys on thin sections
• Ar + He mixtures: Al, Mg, Cu, Ni and their alloys on thicker
sections (over 3 mm)
Gases for spray transfer

• Ar + (5-18)% CO2: carbon steels; minimum spatter; good wetting
and bead contour
• Ar + 2% O2: low alloy steels; minimise undercut; provides good
toughness
• Ar + 2% O2 or CO2: stainless steels; improved arc stability;
provides good fusion
• Ar: Al, Mg, Cu, Ni, Ti and their alloys

• Ar + He mixtures: Al, Cu, Ni and their alloys; hotter arc than pure
Ar to offset heat dissipation
• Ar + (25-30)% N2: Cu alloys; greater heat input
Any Questions

Welding Consumables
Flux Core Wire Consumables

Function of the filling

Functions of metallic powder:
• stabilise the arc
sheath:
• provide form stability • add alloy elements

to the wire • produce gaseous
• serves as current shield
transfer during • produce slag
welding • add iron powder
Types of cored wire
Seamless Butt joint Overlapping

cored wire cored wire cored wire
• not sensitive to moisture • sensitive to

pick-up • good resistance to moisture pick-

• can be copper coated  moisture pick-up up
better current transfer • can be copper • cannot be
• thick sheath  good form coated copper coated
stability  2 roll drive • thick sheath • thin sheath
feeding possible • difficult to seal the • easy to
• difficult to manufacture sheath
manufacture
Cored wire manufacturing process
Strip reel
Flux input
Closing Thin sheet

rollers metal

Forming
Draw die rollers
Core elements and their function
Aluminium - deoxidize & denitrify
Calcium - provide shielding & form slag
Carbon - increase hardness & strength
Manganese - deoxidize & increase strength and toughness
Molybdenum - increase hardness & strength
Nickel - improve hardness, strength, toughness & corrosion
resistance

Potassium - stabilize the arc & form slag
Silicon - deoxidize & form slag
Sodium - stabilize arc & form slag
Titanium - deoxidize, denitrify & form slag
Any Questions

Welding Consumables
SAW Consumables

SAW filler material
Welding wires
•supplied on coils, reels or drums
•random or line winding

Courtesy of Lincoln Electric Courtesy of ESAB AB
coil (approx. reel (approx. drum (approx.

25 kg) 300 kg) 450 kg)
SAW filler material
Welding wires can be used to weld:

•carbon steels
•low alloy steels
•creep resisting steels
•stainless steels
•nickel-base alloys

•special alloys for surfacing applications
Welding wires can be:
•solid wires
•metal-cored wires
SAW filler material
Welding wires:
•carbon and low alloy wires are copper coated
•stainless steel wires are not coated

Courtesy of Lincoln Electric Courtesy of Lincoln Electric
•wires must be kept clean and free from oil and dust
SAW filler material
Copper coating functions:
•to assure a good electric contact between wire

and contact tip
•to assure a smooth feed of the wire through the
guide tube, feed rolls and contact tip (decrease
contact tube wear)

•to provide protection against corrosion
SAW Consumables
Welding fluxes:
• are granular mineral compounds mixed according to various
formulations
• shield the molten weld pool from the atmosphere
• clean the molten weld pool
• can modify the chemical composition of the weld metal
• prevents rapid escape of heat from welding zone

• influence the shape of the weld bead (wetting action)
• can be fused, agglomerated or mixed
• must be kept warm and dry to avoid porosity
SAW Consumables
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
SAW Consumables
SA Welding flux:
• must be kept warm and dry
• handling and stacking requires care
Fused fluxes are normally not hygroscopic but particles can
hold surface moisture
• only drying
Agglomerated fluxes contain chemically bonded water

• similar treatment as basic electrodes
• for high quality, agglomerated fluxes can be recycled with
new flux added
• if flux is too fine it will pack and not feed properly
• cannot be recycled indefinitely
SAW Consumables
Fused Flux
• Flaky appearance
• Lower weld quality
• Low moisture intake
• Low dust tendency
• Good re-cycling
• Very smooth weld

profile
Fused Flux:
Baked at high temperature, glossy, hard and black in colour,
cannot add ferro-manganese, non moisture absorbent and
tends to be of the acidic type
SAW Consumables
Fused welding fluxes
Components
Components are melted in Charge is
are dry mixed an electric cooled by:
furnace
Shooting the

melt through a
Product is stream of water
crushed and
Pouring melt
screened for
onto large chill
size
blocks
SAW Consumables
Fused fluxes advantages:
•good chemical homogeneity
•easy removal of fines without affecting flux
composition
•normally not hygroscopic  easy storage and
handling
•readily recycled without significant change in
particle size or composition

Fused fluxes disadvantages:
•difficult to add deoxidizers and ferro-alloys (due to
segregation or extremely high loss)
•high temperatures needed to melt ingredients limit
the range of flux compositions
SAW Consumables
Agglomerated Flux
• Granulated appearance
• High weld quality
• Addition of alloys
• Lower consumption
• Easy slag removal

• Smooth weld profile
Agglomerated Flux:
Baked at a lower temperature, dull, irregularly shaped, friable,
(easily crushed) can easily add alloying elements, moisture
absorbent and tend to be of the basic type
SAW Consumables
Agglomerated welding fluxes
Components The wet

Components
are powdered mix is
are bonded
and dry mixed pelletized

Pellets are broken
Pellets are
up and screened
baked
for size
SAW Consumables
Agglomerated fluxes advantages:

• easy addition of deoxidizers and alloying elements
• usable with thicker layer of flux when welding
• colour identification
Agglomerated fluxes disadvantages:

• tendency to absorb moisture
• possible gas evolution from the molten slag leading to
porosity
• possible change in flux composition due to segregation or
removal of fine mesh particles
SAW Consumables
Mixed fluxes - two or more fused or bonded fluxes are

mixed in any ratio necessary to yield the desired
results
Mixed fluxes advantages:
•several commercial fluxes may be mixed for highly
critical or proprietary welding operations
Mixed fluxes disadvantages:
•segregation of the combined fluxes during

shipment, storage and handling
•segregation occurring in the feeding and recovery
systems during welding
•inconsistency in the combined flux from mix to mix
Ceramic Backing
Ceramic backing:
•used to support the
weld pool on root
runs
•usually fitted on an
aluminium self
adhesive tape

•allow increased welding current without danger of burn-through
 increased productivity, consistent quality
•different profiles to suit different applications
•no backing/drying required
SAW Consumables
Any Questions

Questions
Welding Consumables:
QU 1. Why are basic electrodes used mainly on high strength
materials and what controls are required when using basic
electrodes?
QU 2. What standard is the following electrode classification

taken from and briefly discuss each separate part of the
coding? E 80 18 M
QU 3. Why are cellulose electrodes commonly used for the

welding of pressure pipe lines?

QU 4. Give a brief description of fusible insert and state two
alterative names given for the insert?
QU 5. What standard is the following electrode classification

taken from, and briefly discuss each separate part of the
coding ? E 42 3 1Ni B 4 2 H10
CSWIP 3.2 Welding Inspection
Welding Consumables
Inspection and Validation
TWI Training & Examination

Services
Inspection of consumables
Why? To assess whether the products are in

compliance with the requirements of the order or
not  see BS EN 10204
How?
Non-specific inspection Specific inspection
•carried out by the •carried out before delivery in

manufacturer in accordance accordance to product

with its own procedures specification
•the products inspected are •inspection is performed on the
NOT necessarily the products products to be supplied or on
supplied! test units of which the products
supplied are part
BS EN 10204-Type of documents
Non-specific
inspection
documents
Type 2.1 Type 2.2
• Name: Declaration of • Name: Test report

compliance with the order • Content: statement of
• Content: statement of compliance with the order

compliance with the order (include test results!)
(doesn’t include test results!) • Who validate it - the
• Who validate it - the manufacturer
manufacturer
BS EN 10204-Type of documents
Specific
inspection
documents
Type 3.1 Type 3.2
• Name: Inspection certificate 3.1 • Name: Inspection certificate 3.2

• Content: statement of compliance • Content: statement of compliance
with the order (include specific test with the order (include specific test

results!) results!)
• Who validate it - the manufacturer • Who validate it - the manufacturer
inspection (independent of inspection (independent of
manufacturing department!) manufacturing department!) +
purchaser’s/official designated
authorised inspector

Welding Consumables

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Course Reference WIS 5