Lesson 10

BASIC

WELDING FILLER METALTECHNOLOGY

A Correspondence Course

LESSON X

RELIABILITY OFWELDING FILLER METALS

©COPYRIGHT 2000 THE ESAB GROU

ESAB ESAB Welding &

Cutting Products

Lesson 1 The Basics of Arc

Welding

Lesson 2 Common Electric

Arc Welding Processes

Lesson 3 Covered Electrodes

for Welding Mild Steels


for Welding Low Alloy Steels

Lesson 5 Welding Filler Metals for Stainless Steels

Lesson 6 Carbon & Low Alloy Steel Filler Metals - GMAW,GTAW,SAW

Lesson 7 Flux Cored Arc

Electrodes Carbon Low Alloy Steels

Lesson 8 Hardsurfacing

Electrodes

Lesson 9 Estimating &

Comparing Weld Metal Costs

Lesson 10 Reliability of Welding

Filler Metals

of 1Lesson 10 - Reliability of Welding Filler Metals

12/3/03http://www.esabna.com/EUWeb/AWTC/Lesson10_1.htm

© COPYRIGHT 2000 THE ESAB GROU

TABLE OF CONTENTSLESSON X

RELIABILITY OF WELDING FILLER METALS

Section Nr. Section Title Page

10.1 INTRODUCTION ...................................................................................... 1

10.2 CODES, SPECIFICATIONS, AND STANDARDS .............................. 1

10.3 THE AMERICAN WELDING SOCIETY ................................................ 2

10.3.1 AWS Filler Metal Specifications ............................................................... 2

10.3.2 AWS Structural Code - Steel .................................................................... 3

10.4 THE AMERICAN SOCIETY FOR TESTING AND MATERIALS ...... 4

10.5 AMERICAN SOCIETY OF MECHANICAL ENGINEERS .................. 4

10.6 SHIP CLASSIFICATION SOCIETIES ................................................... 5

10.6.1 The American Bureau of Shipping ........................................................... 5

10.6.2 Lloyd’s Register of Shipping ..................................................................... 7

10.6.3 Det Norske Veritas .................................................................................... 7

10.7 MILITARY SPECIFICATIONS ................................................................. 8

10.8 STATE HIGHWAY ELECTRODE CERTIFICATION ........................... 9

10.9 TESTING PROCEDURES ...................................................................... 9

10.9.1 Chemical Composition Analysis Test ...................................................... 10

10.9.2 Soundness Test, All-Weld-Metal Tension Test and Impact Test ............ 10

10.9.3 Coating Moisture Test ................................................................................ 13

10.9.4 Guided Bend Tests .................................................................................... 13

10.9.5 Ferrite Test .................................................................................................. 15

10.9.6 Fillet Weld Test ........................................................................................... 16

10.10 CERTIFICATION OF ELECTRODES ................................................... 17

10.10.1 Typical Properties Certification ................................................................ 17

10.10.2 Actual Certifications ................................................................................... 17

10.11 QUALITY ASSURANCE ......................................................................... 19

Appendix A - TEST QUESTIONS .................................................................................. 26


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Page 1 of 1Lesson 10 - Reliability of Welding Filler Metals



LESSON X

RELIABILITY OF WELDING FILLER METALS

10.1 INTRODUCTION

Producing a weld by the arc welding process has often been compared to steelmaking on a

very small scale. The weld puddle is molten for a very short time and during that time, a

number of reactions must take place between the base plate, the filler metal, and the

electrode coating or shielding gas ingredients. These reactions must result in predictable

mechanical properties and chemical composition of the weld metal produced by each of

the great number of filler materials available. Reliable welding filler metals are the result of

the proper formulation, adherence to certain codes and specifications, and the result of a

good quality assurance program.

10.2 CODES, SPECIFICATIONS AND STANDARDS

The wide use of welding as a fabricating method requires that certain controls be exercised

to assure the safety and protection of persons and property exposed to structures and

equipment utilizing welded joints. As a result, various codes, specifications and standards

have been established by technical societies and professional organizations to assure safe,

sound welds. Among other things, these groups specify or recommend the base metal

requirements, joint design, filler metal, welding procedures, operator qualifications, required

weld tests, testing methods, and inspection of welds.

10.2.0.1 The professional technical societies or organizations have no way of enforcing

the codes, specifications or standards that they prepare. However, in many instances,

governing bodies of municipalities, counties, states or federal agencies may adopt all or

part of these documents as law. Private industry may require that work performed under

contract will conform to one or more of these codes or specifications, and therefore, they

become part of a legal document. Lastly, purchase orders issued for welding materials

may state that the terms are to meet a particular code or specification, and as such, these

purchase orders have legal implications.

10.2.0.2 The following is a description of the major societies and organizations whose

specifications and codes are widely used in the welding filler metals industry.


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LESSON X

10.3 THE AMERICAN WELDING SOCIETY (AWS)

The AWS publishes a number of specifications, standards and codes that have been

adopted by many governing bodies and industries. The AWS may be considered to be the

basic source of welding and welding engineering information in the USA. Many other

codes and specifications will include or refer to various AWS Filler Metal Specifications.

Electrode and welding filler metal manufacturers assign the appropriate AWS Classification

to their products wherever possible, as a means of standardization, according to the AWS

Filler Metal Specifications. The specifications prescribe the classification requirements

including such items such as chemical composition of the weld metal, radiographic (X-ray)

soundness tests, weld metal tension tests, impact tests, bend tests, and fillet weld tests

where applicable. The following is a complete list of the AWS Filler Metal Specifications for

ferrous and non-ferrous materials.

10.3.1 AWS Filler Metal Specifications

Specification No. Description

A5.1-91 Carbon Steel Covered Arc Welding Electrodes

A5.2-92 Iron & Steel Oxy Fuel Gas Welding Rods

A5.3-91 Aluminum & Aluminum Alloy Covered Electrodes

A5.4-92 Corrosion Resisting Chromium & Chromium-Nickel Steel

Covered Electrodes

A5.5-96 Low Alloy Steel Covered Arc Welding Electrodes

A5.6-84 Copper & Copper-Alloy Covered Electrodes

A5.7-84 Copper & Copper-Alloy Bare Welding Rods & Electrodes

A5.8-92 Brazing Filler Metals

A5.9-93 Corrosion-Resisting Chromium & Chromium-Nickel Steel

Bare & Composite Metal Cored &

Stranded Electrodes & Welding Rods

A5.10-92 Aluminum & Aluminum Alloy Bare Welding Rods & Electrodes

A5.11-90 Nickel & Nickel Alloy Covered Welding Electrodes

A5.12-92 Tungsten Arc Welding Electrodes

A5.13-80 Solid Surfacing Welding Rods & Electrodes

A5.14-89 Nickel & Nickel-Alloy Bare Welding Rods & Electrodes

A5.15-90 Welding Rods & Covered Electrodes for Welding Cast Iron

A5.16-90 Titanium & Titanium Bare Welding Rods & Electrodes


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Specification No. Description

A5.17-89 Carbon Steel Electrodes & Fluxes for Submerged ArcWelding

A5.18-93 Carbon Steel Filler Metals for Shielded Arc Welding

A5.19-93 Magnesium Alloy Welding Rods & Bare ElectrodesA5.20-95 Carbon Steel Electrodes for Flux Cored Arc Welding

A5.21-80 Composite Surfacing Welding Rods & Electrodes

A5.22-95 Flux Cored Corrosion Resistant Chromium &Chromium-Nickel Steel Electrodes

A5.23-90 Low Alloy Steel Electrodes & Fluxes for Submerged Arc

WeldingA5.24-90 Zirconium & Zirconium Alloy Bare Welding Rods &

Electrodes

A5.25-91 Consumables for Electroslag Welding of Carbon & HighStrength Low Alloy Steels

A5.26-91 Consumables for Electrogas Welding of Carbon & High

Strength Low Alloy SteelsA5.27-85 Copper and Copper Alloy Rods for Oxyfuel Gas Welding

A5.28-96 Low Alloy Steel Filler Metals for Gas Shielded Arc

WeldingA5.29-98 Low Alloy Steel Electrodes for Flux Cored Arc Welding

A5.30-79 Consumable Inserts

A5.31-92 Fluxes for Brazing and Braze Welding

10.3.1.1 These filler metal specifications also describe the classification requirements

concerning standardization such as electrode size and length, packaging, spooling, mark-

ing, labeling, and others.

10.3.2 AWS Structural Welding Code - Steel - The AWS Structural Welding Code -

Steel (AWS D1.1-96) covers the welding requirements applicable to welded steel structures

including buildings, bridges, and structures consisting of tubular shaped members. Factors

such as the design of welded connections, workmanship, welding procedure, welding

operator qualification, and inspection requirements are covered in this code. Previous to

the 1994 issue of this code, it also specified the tensile strength, yield strength, elongation,

and impact requirements for the low alloy flux cored electrodes, since no AWS Filler Metal

Specification existed for these electrodes. It is required that the user (contractor or fabrica-

tor) conduct tests to show that the low alloy weld metal would meet the mechanical proper-

ties mentioned above per the code.


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10.3.2.1 With the issuance of AWS A5.29-80, Specification for Low Alloy Steel Electrodes

for Flux Cored Arc Welding, the user now need only furnish the electrode manufacturer’s

certification that his product will meet the classification requirements of the latest edition of

AWS A5.29.

10.3.2.2 The AWS Structural Welding Code (AWS D1.1-96) does not prescribe such

design details as the location of parts or stress calculations to determine the size of

load-carrying members in a structure. These details will be covered in a general Building

Code that might state, “This structure is to conform to the American Institute of Steel

Construction (AISC) Specification for the Design, Fabrication and Erection of Structural

Steel For Buildings, and the AWS Structural Welding Code, AWS D1.1.” In this case, the

AWS Structural Welding Code becomes a part of a general building code that may be

adopted by a governing body.

10.3.2.3 The AWS publishes other specifications, standards and recommended practices

covering the welding of automotive parts, construction equipment, machinery, ships, and

water storage reservoirs. These, however, are less concerned with filler metal specification

and selection than they are with welding techniques, procedures, and operator qualifica-

tion.

10.4 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

The main objectives of the American Society For Testing & Materials are (1) to further the

knowledge of many types of materials, and (2) establish standardized specifications of and

standardized test methods for these materials.

10.4.0.1 The chemical and mechanical tests that apply to welding filler metals, as de-

scribed by the AWS and other professional organizations, are often based on the ASTM

standard testing methods.

10.5 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

The ASME is instrumental in establishing many codes and specifications. TheASME Boiler & Pressure Vessel Code is of primary importance for welding materials and

applications. This code is extensive, and is published in several different sections. Those

parts that refer to welding filler metals and welding requirements are:


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Section I. Power Boilers

Section II. Material Specifications

Section III. Nuclear Vessels

Section IV. Low Pressure Boilers

Section VIII. Unfired Pressure Boilers

10.5.0.1 Section II of the code, in which welding filler metals are specified, states that the

ASME has adopted the AWS Filler Metal Specifications verbatim (word for word). How-

ever, they do have their own specification designation. For example, AMSE SFA 5.5-96

Specification for Low Alloy Steel Covered Arc Welding Electrodes is the same as AWS

A5.5-96.

10.5.0.2 Under Section III of the code, the ASME issues a Quality System Certificate to

manufacturers of materials (including welding electrodes and wire) to be used under the

code. This certificate is issued only after an ASME plant audit and the manufacturer’s

entire quality assurance program is approved. Its issuance allows the manufacturer’s

products to be used in boiler and pressure vessel work, as well as on nuclear applications

as specified in the code. Details of the Quality System Certificate will be covered under the

Quality Assurance Section of this lesson.

10.6 SHIP CLASSIFICATION SOCIETIES

10.6.1 The American Bureau of Shipping (ABS) - The ABS is a non-profit, interna-

tional ship classification society. It certifies the structural integrity and mechanical fitness of

merchant ships, offshore drilling rigs, and other marine structures.

10.6.1.1 Annually, the Bureau publishes a listing entitled “Approved Welding Electrodes,

Wire-Flux and Wire-Gas Combinations.” The approvals of the filler metals are based upon

tests conducted to standards established by the Bureau or by other recognized agencies.

As requested by the manufacturer, filler metals may be approved to an AWS Filler Metal

Specification, and so listed, or approved to an ABS Grade as shown in Figure 1. In either

case, the approval testing must be made in the manufacturer’s facility in the presence of an

ABS representative. The extent of testing will vary, depending on the type of weld for which

the product is being qualified (fillet or butt), whether the filler material is being initially tested

as a new product, being tested annually, or whether the product is being upgraded at the

manufacturer’s request.

10.6.1.2 At the time of annual testing, the manufacturing facilities and quality control

procedures are subject to inspection also.


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LESSON X

10.6.1.3 Following are the various grade designations as assigned by the ABS.

MANUAL ELECTRODES FILLER METAL GRADES (SMAW)

Ordinary Strength 1 1Y

2 2Y

3 3Y

2H (Low Hydrogen)

3H (Low Hydrogen)

WIRE AND WIRE-GAS COMBINATION FILLER METAL GRADES (GMAW FCAW)

Ordinary Strength Higher Strength1SA, 1A, 1T 1YSA, 1YA, 1YT

2SA, 1A, 1T 2YSA, 2YA, 2YT

3SA, 1A, 1T 3YSA, 3YA, 3YT

ABS FILLER METAL GRADING SYSTEMFIGURE 1

TENSILESTRENGTH

YIELDSTRENGTH

ELONGATION 2"

ABSGRADE 1 2

IMPACT°F 68 32 14 -4 50 32 32 14 -4 14 -4 -22 -40

FT/LBS.MANUAL

SEMI-AUTO35 35 45 35 40 – 20 40 – 20 50 40 – 20

FT/LBS.AUTOMATIC 25 25 33 25 30 20 – 30 20 – 38 30 20 –

1,2,3 (see above) T Two pass automaticY Higher strength & impacts S Semi-automatic onlyH Low hydrogen electrode A Automatic onlyM Multi-pass automatic SA Semi-auto or automatic

20% MIN.

ORDINARY STRENGTH ABS FILLER METAL

HIGHER-STRENGTH ABS FILLER METAL

58,300TO

95,100 psi

71,000 TO

95,000 psi

Note: Where more than one test temperature is indicated for a specific grade, satisfactory testing according to any indicated temperature isacceptable.

GRADE NOTATIONS

ABS FILLER METAL MECHANICAL PROPERTY REQUIREMENTS

3 1Y 2Y 3Y

44,100 psi MIN. 54,000 psi MIN.

22% MIN.


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WIRE-FLUX COMBINATION FILLER METAL GRADES (SAW)

Ordinary Strength Higher Strength1TM, 1T, 1M 1YTM, 1YT, 1YM

2TM, 2T, 2M 2YTM, 2YT, 3YM

3TM, 3T, 3M 3YTM, 3YT, 3YM

10.6.1.4 By using the table and grade notations in Figure 1, you can see that the grade

ABS 2YSA signifies: (2Y) a tensile strength in the 71,000-95,000 psi range, a minimum

yield strength of 54,000 psi, and a minimum elongation of 20% in 2 inches, meets the

impact requirements of 20 ft.-lbs. at -4°F when welded semi-automatically, and 20 ft.-lbs. at

14°F when welded automatically: (SA) the wire-gas combination has been approved for

semi-automatic and automatic welding.

10.6.1.5 In the annual ABS Listing, the approved electrode or wire diameter, welding

position, shielding gas (if applicable) and type of welding current (AC or DC) are also listed.

Each electrode or filler metal must be re-approved annually.

10.6.2 Lloyd’s Register of Shipping (LRS) - Lloyd’s Register of Shipping is a British

ship classification society similar to the ABS. They also publish an annual approved filler

metal listing with test procedures very similar to the ABS.

10.6.3 Det Norske Veritas (DNV) - Det Norske Veritas is a Norwegian ship classifica-

tion society that operates very similarly to the American Bureau of Shipping and Lloyd’s

Register.

10.6.3.1 ESAB has a number of filler metals on the approved list of each of the three ship

classification societies. Since the listings change annually, they do not appear in this

instructional material. Information on the listings of any specific product may be secured by

contacting the Technical Services Department.


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10.7 MILITARY SPECIFICATIONS

Military specifications are issued by the Department of Defense and it is mandatory that all

work performed for that department be covered by the applicable military specification.

Military specifications are identified by a letter-number designation and the title. An ex-

ample is: MIL-E-22200/1E - Electrodes, Welding , Mineral Covered, Iron Powder, LowHydrogen, Medium and High Tensile Strength, As-Welded or Stress Relieved Applications.

10.7.0.1 In the example, MIL designates that it is a Military specification. The first letter E

stands for Electrode which is the significant word in the title. The number 22200/1 is the

serial number of the specification; the letter E at the end designates the revision letter and

will change as further revisions are made. The underlined portion is the title of the specifi-

cation.

10.7.0.2 A Military specification may cover only one or a number of electrodes or wires.

When the specification includes more than one item, a “type” designation is necessary. As

an example, an E8018-C3 low alloy electrode would be designated as MIL-E-22200/1E,

MIL 8018-C3.

10.7.0.3 The following is a partial list, along with a brief description, of the more common

military electrode specifications currently in use.

Specification No. DescriptionQQ-E-450a Covered Mild Steel Electrodes

MIL-E-13080 Covered Austenitic Steel Electrodes for Armor

Application

MIL-E-16053L Bare Aluminum Alloy Wires

MIL-E-16589 Covered Chrome-Molybdenum and Corrosion Resisting Steel

MIL-E-19933 Bare Chrome-Nickel Stainless Steel Wire

MIL-E-21562 Bare Nickel-Alloy Wires

MIL-E-22200/1F Covered, Iron Powder, Low Hydrogen, Medium and High

Tensile Steel Electrodes

MIL-E-22200/2C Covered Electrode, Austenitic Stainless Steel for

Corrosion and High Temperature Service

MIL-E-22200/3F Covered Electrode, Nickel-Base and Cobalt-Base Alloy

MIL-E-22200/4C Covered Electrode, Copper-Nickel Alloy

MIL-E-22200/5B Covered, Iron Powder, Low Hydrogen, Low Alloy Steel for

Hardening & Tempering

MIL-E-22200/6C Covered Electrode, Low Hydrogen, Medium and High Tensile

Steel


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MIL-E-22200/7B Covered Electrode, Molybdenum Alloy Electrodes

MIL-E-22200/8B Covered Electrode, Low Hydrogen, and Low Hydrogen Iron

Powder Alloy Steels and Corrosion Resisting Steels

MIL-E-22200/10B Covered, Iron Powder, Low Hydrogen, Medium and High

Tensile Steel Electrodes

MIL-E-23765/B (SH) Bare Solid Mild Steel Wires

MIL-E-24403/A (SH) Flux Cored Electrodes

MIL-E-19933E (SH) Bare Solid Chromium and Chromium-Nickel Steels

10.7.0.4 Some military specifications require varying degrees of testing by the manufac-

turer before a filler metal is submitted for use. These tests and testing procedures are

spelled out in the specification, and when successfully completed, the electrode or wire is

placed upon a Qualified Products List (QPL). Other specifications require the manufacturer

to submit an affidavit indicating the success of the testing of each specific shipment.

10.8 STATE HIGHWAY ELECTRODE CERTIFICATION

Electrodes and filler metals are approved for bridge and highway construction according to

the Federal Highway Administration Requirements. Electrodes are tested, and certification

is renewed annually to those states that maintain an approved list meeting Federal require-

ments. These listings vary annually, and the manufacturer should be consulted for verifica-

tion.

10.9 TESTING PROCEDURES

Test of welding filler metals per the specifications of the various societies, professional

organizations and governing bodies is time-consuming and expensive. However, accurate

testing is an important factor in producing quality welding filler metals. Test plates must be

welded according to the procedure stated in the specification, which in many instances

requires controlled preheat and interpass temperatures. The specimens must be carefully

machined from the proper portion of the test plate and held to very close dimensional

tolerances so that test results will be accurate. The test equipment must be kept in accu-

rate calibration.

10.9.0.1 The following are brief, partial descriptions of the more common types of tests

required by various specifications and codes. They are shown here to familiarize you with

the methods by which tests are conducted and are not to be construed as complete test

procedures.


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10.9.1 Chemical Composition Analysis Test - A weld pad for determining the chemi-

cal composition of a filler metal must be prepared as shown in Figure 2.

10.9.1.1 The base metal size and material is specified, and the weld metal is built up in

layers to the required height or number of passes to assure that the top surface has no

dilution with the base metal. The welds are deposited in the flat position. After welding, the

top surface is machined or ground smooth to remove all foreign matter. A sample is taken

from this surface for chemical analysis by a suitable method agreed upon between the

supplier and the purchaser.

10.9.2 Soundness (X-Ray) Test, All-Weld-Metal Tension Test and Impact Test - A

test plate is prepared according to the specification with a sufficient number of passes to fill

the groove, a sample of which is shown in Figure 3.

10.9.2.1 Some specifications require at least one stop and one start in the area of the

weld that is to be radiographed (X-rayed). The specification may also call for the test plate

to be preheated to a certain temperature before the first pass, and also specify an

interpass temperature. This means that the test plate must be allowed to cool to a certain

temperature range before the next pass is applied.

10.9.2.2 After the plate is completely welded, the test plate is prepared for radiographic

examination by machining off the backing strip from the root (bottom) of the weld, and also

TYPICAL WELDPAD FORCHEMICAL COMPOSITION ANALYSIS

Figure 2

CHEMICAL COMPOSITION SAMPLETAKEN FROM THIS SURFACE

SPECIFIED BY NUMBER OFLAYERS IN SOME SPECIFICATIONS


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LESSON X

the reinforcement or excess weld metal from the top (face) of the weld. The plate is then

radiographed to check for porosity or inclusions in the weld metal. The specification will

show several degrees and grades of acceptable porosity or inclusions.

10.9.2.3 Porosity and inclusion diagrams, as shown in Figure 4, are usually labeled as

fine, medium, assorted, and large. A representation of fine and large porosity is shown in

Figure 4. The allowable amount of porosity may vary for different filler metal specifications.

ALL WELD METAL TENSION SPECIMEN V-NOTCH IMPACT TEST SPECIMEN

DETAILS OF TEST ASSEMBLY FOR SOUNDNESS, TENSILE AND IMPACT TESTS

Figure 3


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LESSON X

10.9.2.4 After the test plate has been radiographed, the all-weld-metal tension specimen,

and the charpy V-notch impact specimen are machined from the center of the plate as

shown in Figure 3. Only the critical dimensions are shown in the sketches, and as you can

see, they must be held to rather close tolerances to obtain accurate test results.

10.9.2.5 The .500± .010" diameter of the tension specimen is all weld metal since it is

machined from the center of the weld. The area of the impact specimens in which the

notch is machined is all weld metal also.

10.9.2.6 The tensile specimen is placed in a tensile testing machine and pulled until it

fractures. (Refer to Lesson I, "Yield Strength".) The yield strength and ultimate tensilestrength are recorded on the tensile tester. After fracture, the two halves of the broken

specimen are fitted back together in a jig, and the distance between the two center punch

marks is accurately measured. If this distance is now 2.500", it tells us that the specimen

has stretched .500" or 25% of its original length before breaking. This figure is recorded as

the elongation in a 2" length of the weld metal specimen.

10.9.2.7 The five impact specimens are broken in a Charpy Impact Tester, as described in

Lesson I, "Charpy Impacts", and the energy absorbed in breaking each of them is re-

corded. In calculating the average impact value, the specimens with the highest and low-

est values are discarded. The average value of the three remaining specimens is recorded

as the impact value.

LARGE POROSITY OR INCLUSIONS3/64" to 1/16" DIAMETER OR LENGTH

MAXIMUM NUMBER IN ANY 6" OF WELD = 8

FINE POROSITY OR INCLUSIONS1/64" to 1/32" DIAMETER OR LENGTH

MAXIMUM NUMBER IN ANY 6" OF WELD = 30

SOUNDNESS TEST POROSITY AND INCLUSION STANDARDS

Figure 4


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10.9.3 Coating Moisture Test - The coating moisture test is conducted by removing a

small amount of the coating from the middle portions of three electrodes, all from the same

can or package. A small measured amount (4 grams) of this coating sample is tested in

sophisticated laboratory apparatus. The method of moisture testing satisfies AWS A5.5-96

and AWS D1.1 Specifications and is sensitive only to water. It is the most accurate and

reliable method of moisture determination currently in use.

10.9.4 Guided Bend Tests -

10.9.4.1 Transverse Face Bend, Root Bend and Side Bend Tests. The specifications for

some filler metals require that guided bend tests be made to evaluate the ductility and

soundness of a welded joint. The test plate is welded in the flat position and is made long

enough to produce the necessary number of specimens. See Figure 5.

10.9.4.1.1 The specimens are cut from the test plate, and the backing strip and weld

reinforcement machined flush with the face and root surfaces. If the test plate is greater

than 3/8" thick, it must be machined to 3/8" thickness, removing the metal from the root

surface for face bends, and from the face surface for root bends. In face bends, the face

of the weld is on the outside or convex surface of the specimen, and in root bends, the root

of the weld is on the outside or convex surface of the bend. The specimen is bent in a

guided bend test jig, the design of which is described in the specification, over a justified

radius (usually a 3/4" radius) through an angle of 180°. When removed from the jig, the

TRANSVERSE GUIDED BEND TESTSFIGURE 5

FACE OR ROOT BEND TEST SIDE BEND TEST PLATE

FACE BEND ROOT BEND SIDE BEND


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specimen will spring back to about the angle shown in Figure 5. In face and root bends,

defects in the surface of the weld are exposed as cracks, tears, or porosity.

10.9.4.1.2 Side bend tests are similar to face and root bend tests, except they are bent

so the side of the weld is on the outside or convex surface of the specimen. Side bends

expose defects in the interior and fusion zone of the weld.

10.9.4.2 Transverse Tension and Longitudinal Guided Bend Test. The transverse tension

test and longitudinal guided bend test may appear separately in some specifications; how-

ever, it is shown here (Figure 6) as they appear in AWS A5.20-95 (applicable only to the

single-pass electrodes of the E70T-2, E70T-3, E70T-10, and E70T-GS classifications.)

DETAILS OF TRANSVERSE TENSION AND GUIDED BEND TESTSFIGURE 6

10.9.4.2.1 An all-weld-metal tensile test, as shown in Figure 3, would not be meaningful

for single-pass electrodes because in single-pass welds, the weld metal is always substan-

tially diluted with the base metal. The bend test is prescribed for these electrodes because

they contain relatively high amounts of manganese and silicon that can reduce ductility

somewhat, and can cause cracking in the weld area when present in excessive amounts.


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LESSON X

10.9.4.2.2 The test plate must be a material having a minimum tensile strength equal to

that of the electrode being tested. The test plate is welded with one weld bead on each

side of the plate. This is considered a single-pass weld since each weld will be diluted with

the base material. The tensile specimen is cut from the plate, machined to the shape

shown in Figure 6, and pulled until fractured. A specimen that breaks in the base plate

shall be considered satisfactory.

10.9.4.2.3 The weld beads on the bend specimens are ground or machined smooth and

flush with the surface. The specimen is then uniformly bent over a 3/4" radius through an

angle of 180° in a suitable jig. The specimen, after bending, may show no crack exceeding

1/8" in length in any direction in the weld metal or the base metal.

10.9.5 Ferrite Test - In austenitic stainless steels, ferrite (as discussed in Lesson V) can

be beneficial in reducing cracking in some stainless steel weld metals, while in other envi-

ronments, it can reduce corrosion resistance. It can cause brittleness in high temperature

service, and can reduce toughness in cryogenic service. For these reasons, the amount of

ferrite in austenitic stainless steel weld metal must be established as accurately as pos-

sible. Ferrite content can be calculated by using the Schaeffler diagram or the WRC dia-

gram as shown in Lesson V, when the chemical analysis of the weld metal is known. It can

also be determined by the use of various magnetic sensing instruments.

10.9.5.1 To determine the ferrite level by instrument, a weld pad, as shown in Figure 7,

must be made.

10.9.5.2 The copper bars are used as a mold or form to build up the weld metal to the

proper height as shown. The welding procedure used in preparing test pad is carefully

spelled out in the specification as to welding direction, stops and starts, cleaning and

WELD PAD PREPARATION FOR FERRITE TEST

Figure 7

WELDDEPOSIT

1/2" TO 5/8"MINIMUMHEIGHT


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LESSON X

interpass temperature. The top surface of the completed pad is carefully filed by hand in

the direction of the weld. Six readings are taken along the top of the weld pad with a prop-

erly calibrated magnetic instrument. The six readings are averaged to a single value. This

average becomes the ferrite number.

10.9.6 Fillet Weld Test - Some specifications require the fillet weld test be prepared as

shown in Figure 8.

10.9.6.1 The weld specimen is made using the specified electrode size and plate thick-

ness. After welding, the plate is cut on the lines indicated, and one side of the 1" wide

section is polished and etched so that the weld bead is clearly visible. The largest possible

right triangle with equal leg lengths is carefully scribed within the fillet weld on this surface,

so that the fillet size, leg lengths, and convexity of the weld can be measured and com-

pared to the allowable deviations in the specification.

10.9.6.2 The welds in the two longer sections are broken by applying a force in the direc-

tion shown in the diagram. The broken surfaces are visually examined for evidence of

inclusions, gas pockets, or incomplete root fusion.

10.9.6.3 Fillet weld tests are especially required for all-position electrodes or wires, and

the specification will require that the test plates be welded in the vertical-up and overhead

positions.

FILLET WELD TEST SPECIMENFigure 8

LEG

CONVEXITY

LEG


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LESSON X

10.10 CERTIFICATION OF ELECTRODES

The certification of electrodes and welding wires has become more critical today, and the

number of test certifications requested has increased more than ten-fold in the last several

years. Conducting certification tests is a costly process, and all efforts must be made to

provide accurate information to the manufacturer, so that the end-user gets the material

tested to the necessary degree; no more, no less.

10.10.0.1 Welding filler metals may be certified by one of two methods: typical properties

certification or actual properties certification.

10.10.1 Typical Properties Certification - Certifications showing typical chemistry and

mechanical properties are provided with customer orders when so requested. These

typical properties are based on the results of many tests on similar materials and on a very

comprehensive, carefully controlled Quality Assurance System. An ESAB Typical Proper-

ties Certificate assures that the

products are tested in compliance

with AWS and ASME Filler Metal

Specifications. A copy of a Typical

Properties Certificate for Atom Arc

electrodes is shown in Figure 9.

Typical certifications are supplied by

the manufacturer, on a no-charge

basis, by request.

10.10.2 Actual Certifications -

Actual certification that each lot of a

particular product shipment will

meet a desired specification is

normally supplied by the manufac-

turer for a fee. In this case, pack-

ages of each lot number of the

product to be shipped will be

opened and tested according to the

customer’s request.

TYPICAL PROPERTIES CERTIFICATE

FIGURE 9


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LESSON X

10.10.2.1 In order to have the proper tests performed correctly and as inexpensively as

possible, the information that accompanies the order must contain all pertinent information

such as:

a. To what specification must the material conform and to what revision of that

specification?

b. Must all the tests as required by the specification be performed?

c. Are there any actual tests required in addition to those covered by the specifica-

tion?

d. Do special marking and packing requirements apply?

e. Is the material for a government contract?

f. Where is inspection to be performed and by whom?

g. What number of copies and distribution method is required for the certificates?

10.10.2.2 The American Welding Society publishes a document (AWS A5.01-93) entitled

“Filler Metal Procurement Guidelines”. This document (together with an AWS Filler Metal

Specification) is intended to assist the buyer in designating those testing requirements that

are applicable to his order. It consists of the following:

a. The AWS Filler Metal Classification.

b. Definition of lot classification (AWS A5.01-93 Section 2).

c. The intensity of testing schedule (i.e., number of tests to be conducted) (AWS

A5.01-93 Section 3).

10.10.2.3 A portion of Table 1, “Intensity of Testing” that applies to actual testing reads as

follows:

Intensity of Testing

Schedule H Chemical analysis only for each lot shipped.

I Tests called for in Table 2 “Required Tests” for each lot shipped.

J All tests that the classification called for in the pertinent AWS filler metal

specifications for each lot shipped.

K All tests specified by the purchaser, for each lot shipped.


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LESSON X

10.10.2.4 Table 2, referred to in Schedule I above, lists the “Required Tests” necessary

for actual certification, and in all cases, does not include all tests included in the applicable

AWS Filler Metal Specification. When the intensity of testing is not specified on an order,

the product will be tested to ESAB standard testing intensity which equals or exceeds those

tests required under Schedule I above.

10.10.2.5 As an example, stainless steel covered electrodes will only be tested for (1)

chemical analysis and (2) calculated ferrite content as required by the AWS Filler Metal

Procurement Guidelines A5.01-93. Any additional testing must be specified.

10.11 QUALITY ASSURANCE

ESAB has based its Quality Assurance Program around NCA 3800 of the ASME Boiler and

Pressure Vessel Code, Section III. This means that the program assures accurate docu-

mentation, close control of the raw materials including the steel and flux ingredients,

in-process controls and checks, and complete traceability of each lot of product produced.

It also includes close control of the inspection and measuring equipment which assures

accurate testing and certification of test results.

10.11.0.1 Both the Hanover, Pennsylvania and Ashtabula, Ohio Quality System Programs

have been accepted by the ASME as material manufacturers. This means that customers

using our products for nuclear and other applications to ASME requirements need not audit

our Quality Program. Copies of the ASME Quality System Certificates for both plants are

shown in figures 10 and 11. These certificates are issued only after an in-plant audit by an

ASME representative, and are valid for a three year period.

10.11.0.2 In addition, facilities in Hanover, PA; Ashtabula, OH; Niagara Falls, NY; and

Monterrey, Mexico have been certified to ISO 9002. This quality standard was first estab-

lished in 1987 by the International Organization for Standardization in Geneva, Switzerland.

Certification to this standard covers all areas of product manufacturing, including general

management, production, research, purchasing, engineering, human resources, and quality

assurance. Receipt of this certificate eliminates the costly time consuming audits normally

required by our customers. Copies of these certificates are shown in figures 12 through 15.


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LESSON X

QUALITY SYSTEM CERTIFICATE, ESAB HANOVER

FIGURE 10


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Lesson 10

Documents

Transcript of Lesson 10