Oxy-fuel Welding and Cutting

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals, respectively. French engineers Edmond Fouche and Charles Picard became the first to develop an oxygen-acetylene welding machine in 1903.^[1]

Oxy-fuel is one of the oldest welding processes, though in recent years it has become less popular in industrial applications. However, it is still widely used for welding pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artwork. Oxyfuel equipment is versatile, lending itself not only to some sorts of iron or steel welding but also to brazing, braze-welding, metal heating (for bending and forming), and also oxyfuel cutting.

In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded.

In oxy-fuel cutting, a cutting torch is used to heat metal to kindling temperature. A stream of oxygen then trained on the metal combines with the metal which then flows out of the cut (kerf) as an oxide slag ^[2].

Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel welding/cutting generally requires two tanks, fuel and oxygen). Most metals cannot be melted with a single-tank torch. As such, single tank torches are typically used only for soldering and brazing, rather than welding.

Uses

Oxy-gas torches are used for or have been used for:

• Welding metal: see below.
• Cutting metal: see below.
• Also, oxy-hydrogen flames are used:
  • In Stone Work for "flaming" where the stone is heated and a top layer crackles and breaks. A steel circular brush is attached to an angle grinder and used to remove the first layer leaving behind a bumpy surface similar to hammered bronze.
  • In the glass industry for "fire polishing".
  • In jewelry production for "water welding" using a "water torch". [1].
  • Formerly, to heat lumps of quicklime to obtain a bright white light called limelight, in theatres or optical ("magic") lanterns.
  • Formerly, in platinum works, as platinum is only fusible in the oxy-hydrogen flame and in an electric furnace.

[edit]

Apparatus

The apparatus used in gas welding consists basically of an oxygen source and a fuel gas source (usually cylinders), two pressure regulatorsand two flexible hoses (one of each for each cylinder), and a torch. This sort of torch can also be used for soldering and brazing. The cylinders are often carried in a special wheeled trolley.

There have been examples of oxyhydrogen cutting sets with small (scuba-sized) gas cylinders worn on the user's back in a backpack harness, for rescue work and similar.

There are also examples of pressurized liquid fuel cutting torches, usually using gasoline. These are used for their increased portability.

Welding Procedure Specification

A Welding Procedure Specification (WPS) is a formal document describing welding procedures. According to the American Welding Society (AWS), a WPS provides in detail the required welding variables for specific application to assure repeatability by properly trainedwelders and welding operators.

The American Society For Mechanical Engineers (ASME) similarly defines Welding Procedure Specification (WPS) as a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirements.

The American Welding Society defines welding Procedure Qualification Record (PQR) as a record of welding variables used to produce an acceptable test weldment and the results of tests conducted on the weldment to qualify a Welding Procedure Specification. The American Society of Mechanical Engineers (ASME), similarly defines welding Procedure Qualification Record (PQR) as a record of variables recorded during the welding of the test coupon. The record also contains the test results of the tested specimens.

Covered Arc-Welding Electrode

A covered arc welding electrode includes a steel core wire and a flux which is applied to the outside periphery of said steel core wire. The welding electrode can form a superior crack-resisting weld zone even if fluctuating stresses are continually applied to a base metal while the base metal is welded. The flux includes 40 to 60% metal carbonate, 10 to 25% metal fluoride and 4 to 25 metal oxide by weight. The flux comprises 24 to 32% of the total weight of said electrode. The composition of the welding electrode includes 0.005 to 0.05% carbon, 0.1 to 1.1% silicon, 1.5 to 2.5% manganese, not more than 0.007% sulfur and not more than 0.25% nickel by weight and the manganese/sulfur ratio is more than or equal to 350 to 1. In addition, the welding electrode can include 0.01 to 0.10% rare earth metal by weight. In which case, the Mn content may be 1.0 to 2.5% by weight and the manganese/sulfur ratio may be more than or equal to 270 to 1. In addition, the composition of the welding electrode can include titanium and zirconium, the total content of which may be less than or equal to 1.2% the total weight of the electrode, and/or aluminum and magnesium, the total content of which may be less than or equal to 1.2% of the total weight of the electrode.

1. A covered arc welding electrode comprising:
a flux including 40 to 60% metal carbonate, 10 to 25% metal fluoride and 4 to 25% metal oxide by weight; and a steel core wire, onto the outer periphery of which said flux is applied so as to comprise 24 to 32% of the total weight of said electrode, said electrode as a whole being comprised of 0.005 to 0.05% carbon, 0.1 to 1.1% silicon, 1.5 to 2.5% manganese, not more than 0.007% sulfur and not more than 0.25% nickel by weight and in which the manganese/sulfur ratio is more than or equal to 350 to 1.

2. A covered arc-welding electrode as set forth in claim 1, further comprising titanium and zirconium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

3. A covered arc-welding electrode as set forth in claim 2, further comprising aluminum and magnesium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

4. A covered arc-welding electrode as set forth in claim 1, further comprising aluminum and magnesium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

5. A covered arc-welding electrode comprising:
a flux including by weight 40 to 60% metal carbonate, 10 to 25% metal fluoride and 4 to 25% metal oxide; and a steel core wire, onto the outer periphery of which said flux is applied so as to comprise 24 to 32% of the total weight of said electrode;
said electrode as a whole being comprised of 0.005 to 0.05% carbon, 0.1 to 1.1% silicon, 1.0 to 2.5% manganese, not more than 0.007% sulfur, not more than 0.25% nickel and 0.01 to 0.10% rare earth metal by weight and in which the manganese/sulfur ratio is more than or equal to 270 to 1.

6. A covered arc-welding electrode as set forth in claim 5, further comprising titanium and zirconium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

7. A covered arc-welding electrode as set forth in claim 6, further comprising aluminum and magnesium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

8. A covered arc-welding electrode as set forth in claim 5, further comprising aluminum and magnesium, the total content of which is less than or equal to 1.2% of the total weight of the electrode.

Safety Issues

Welding can be a dangerous and unhealthy practice without the proper precautions; however, with the use of new technology and proper protection the risks of injury or death associated with welding can be greatly reduced.

[edit] Heat and sparks
Because many common welding procedures involve an open electric arc or flame, the risk of burns is significant. To prevent them, welders wear protective clothing in the form of heavy leather gloves and protective long sleeve jackets to avoid exposure to extreme heat, flames, and sparks.

[edit] Eye damage
The brightness of the weld area leads to a condition called arc eye in which ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes. Goggles and helmets with dark face plates are worn to prevent this exposure and, in recent years, new helmet models have been produced featuring a face plate that self-darkens upon exposure to high amounts of UV light. To protect bystanders, transparent welding curtains often surround the welding area. These curtains, made of a polyvinyl chloride plastic film, shield nearby workers from exposure to the UV light from the electric arc, but should not be used to replace the filter glass used in helmets.[26]
Those dark face plates must be much darker than those in sunglasses or blowtorching goggles. Sunglasses and blowtorching goggles are not adequate for arc welding protection.
In 1970, a Swedish doctor, Åke Sandén, developed a new type of welding goggles that used a multilayer interference filter to block most of the light from the arc. He had observed that most welders could not see well enough, with the mask on, to strike the arc, so they would flip the mask up, then flip it down again once the arc was going: this exposed their naked eyes to the intense light for a while. By coincidence, the spectrum of an electric arc has a notch in it, which coincides with the yellow sodium line. Thus, a welding shop could be lit by sodium vapor lamps or daylight, and the welder could see well to strike the arc. The Swedish government required these masks to be used for arc welding, but they were not used in the United States. They may have disappeared.[27]

[edit] Inhaled matter
Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-cored arc welding and shielded metal arc welding produce smoke containing particles of various types of oxides. The size of the particles in question tends to influence the toxicity of the fumes, with smaller particles presenting a greater danger. Additionally, many processes produce various gases (most commonly carbon dioxide and ozone, but others as well) that can prove dangerous if ventilation is inadequate. Furthermore, the use of compressed gases and flames in many welding processes pose an explosion and fire risk; some common precautions include limiting the amount of oxygen in the air and keeping combustible materials away from the workplace.[28]

[edit] Interference with pacemakers
Certain welding machines which use a high frequency AC current component have been found to affect pacemaker operation when within 2 meters of the power unit and 1 meter of the weld site[29].

Consumable Electrode Methods

One of the most common types of arc welding is shielded metal arc welding (SMAW), which is also known as manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or 'stick'. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that protects the weld area from oxidation and contamination by producing CO2 gas during the welding process. The electrode core itself acts as filler material, making a separate filler unnecessary. The process is very versatile, requiring little operator training and inexpensive equipment. However, weld times are rather slow, since the consumable electrodes must be frequently replaced and because slag, the residue from the flux, must be chipped away after welding.[16] Furthermore, the process is generally limited to welding ferrous materials, though specialty electrodes have made possible the welding of cast iron, nickel, aluminium, copper and other metals. The versatility of the method makes it popular in a number of applications including repair work and construction.[17]
Gas metal arc welding (GMAW) is a semi-automatic or automatic welding process that uses a continuous wire feed as an electrode and an inert or semi-inert shielding gas to protect the weld from contamination. When using an inert gas as shield it is known as Metal Inert Gas (MIG) welding. A constant voltage, direct current power source is most commonly used with GMAW, but constant current systems as well as alternating current can be used. GMAW welding speeds are relatively high due to the automatically fed continuous electrode, but is less versatile because it requires more equipment than the simpler SMAW process. Originally developed for welding aluminium and other non-ferrous materials in the 1940s, GMAW was soon applied to steels because it allowed for lower welding time compared to other welding processes. Today, GMAW is commonly used in industries such as the automobile industry, where it is preferred for its versatility and speed. Because it employs a shielding gas, however, it is rarely used outdoors or in areas of air volatility.[18]
A related process, flux-cored arc welding (FCAW), uses similar equipment but uses wire consisting of a steel electrode tube surrounding a powder fill material. This cored wire is more expensive than the standard solid wire and generates extra shielding gas and/or slag, but it permits higher welding speed and greater metal penetration.[19]
Submerged arc welding (SAW) is a high-productivity automatic welding method in which the arc is struck beneath a covering layer of flux. This increases arc quality, since contaminants in the atmosphere are blocked by the flux. The slag that forms on the weld generally comes off by itself and, combined with the use of a continuous wire feed, the weld deposition rate is high. Working conditions are much improved over other arc welding processes since the flux hides the arc and no smoke is produced. The process is commonly used in industry, especially for large products.[20] As the arc is not visible, it requires full automatization. In-position welding is not possible with SAW.

Power Supplies

To supply the electrical energy necessary for arc welding processes, a number of different power supplies can be used. The most common classification is constant current power supplies and constant voltage power supplies. In arc welding, the voltage is directly related to the length of the arc, and the current is related to the amount of heat input. Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding and shielded metal arc welding, because they maintain a relatively constant current even as the voltage varies. This is important because in manual welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and as a result, are most often used for automated welding processes such as gas metal arc welding, flux cored arc welding, and submerged arc welding. In these processes, arc length is kept constant, since any fluctuation in the distance between the wire and the base material is quickly rectified by a large change in current. For example, if the wire and the base material get too close, the current will rapidly increase, which in turn causes the heat to increase and the tip of the wire to melt, returning it to its original separation distance.[12]
The direction of current used in arc welding also plays an important role in welding. Consumable electrode processes such as shielded metal arc welding and gas metal arc welding generally use direct current, but the electrode can be charged either positively or negatively. In welding, the positively charged anode will have a greater heat concentration and, as a result, changing the polarity of the electrode has an impact on weld properties. If the electrode is positively charged, it will melt more quickly, increasing weld penetration and welding speed. Alternatively, a negatively charged electrode results in more shallow welds.[13] Non-consumable electrode processes, such as gas tungsten arc welding, can use either type of direct current (DC), as well as alternating current (AC). With direct current however, because the electrode only creates the arc and does not provide filler material, a positively charged electrode causes shallow welds, while a negatively charged electrode makes deeper welds.[14] Alternating current rapidly moves between these two, resulting in medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited after every zero crossing, has been addressed with the invention of special power units that produce a square wave pattern instead of the normal sine wave, eliminating low-voltage time after the zero crossings and minimizing the effects of the problem

STAINLESS STEEL AND SPECIAL ELECTRODES

1-SATINCROME 308L-17

Description and Applications:

Satincrome 308L-17 is a smooth running, rutile type stainless steel electrode manufactured by CIGWELD for the all positional (except vertical-down) fillet and butt welding of 19Cr/10Ni type stainless steels. The features of Satincrome 308L-17 include high AC arc stability, sound radiographic quality, smooth arc transfer characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to start-of-run porosity. Slag lift of Satincrome 308L-17 is enhanced in all welding positions, it is self peeling and non-spitting. Applications of Satincrome 308L-17 include the single and multi-pass welding of 19Cr/10Ni type stainless steel grades including 201, 202, 301, 302,303, 304, 304L, 305, 308 etc.

2-SATINCROME 309Mo-17

Description and Applications:

Satincrome 309Mo-17 is a rutile type, high alloy stainless steel electrode manufactured by CIGWELD for the all positional (except vertical-down) fillet and butt welding of 24Cr/13Ni type stainless steels. The features of Satincrome 309Mo-17 include high AC arc stability, sound radiographic quality, smooth arc transfer characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to start-of-run porosity. Slag lift of Satincrome 309Mo-17 is enhanced in all welding positions, it is self peeling and non-spitting. Applications of Satincrome 309Mo-17 include the single and multi-pass welding of matching 309 and 309L stainless steels. Satincrome 309Mo-17 is also suitable for the dissimilar welding of other “300 series” austenitic stainless steels and selected “400 series” ferritic grades to mild or low alloy steels such as 403, 405, 410, 416, 420, 430, 430F-Se, 446 etc and BHP 3CR12.

3-SATINCROME 316L-17

Description and Applications:

Satincrome 316L-17 is a low carbon, rutile type stainless steel electrode manufactured by CIGWELD for the all positional (except vertical-down) fillet and butt welding of 19Cr/10Ni type stainless steels. The features of Satincrome 316L-17 include high AC arc stability, sound radiographic quality, smooth arc transfer characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to start-of-run porosity. Slag lift of Satincrome 316L-17 is enhanced in all welding positions, it is self peeling and nonspitting. Applications of Satincrome 316L-17 include the single
and multi-pass welding of matching Molybdenum bearing stainless steels, 316 and 316L. Satincrome 316L-17 is also suitable for the general purpose welding of other “300 series” austenitic stainless steels including 301, 302, 303 and 304/304L, 305, 3CR12 types. The 2.5% Molybdenum content gives increased resistance to pitting corrosion and raises the creep strength for higher temperature applications.

4-SATINCROME 318-17

Description and Applications:

Satincrome 318-17 is a Niobium stabilised, rutile type stainless steel electrode manufactured by
CIGWELD for the all positional (except vertical-down) fillet and butt welding of stabilised and unstabilised 19Cr/10Ni type stainless steels, such as 316, 318 and 321. The features of Satincrome 318-17 include high AC arc stability, sound radiographic quality, smooth arc transfer
characteristics, very low spatter levels and excellent bead shape and contour. The advanced moisture resistant (MR) flux coating provides improved resistance to start-of-run porosity. Slag lift of Satincrome 318-17 is enhanced in all welding positions, it is self peeling and non-spitting. The Molybdenum content of Satincrome 318-17 gives improved resistance to pitting corrosion and the Niobium addition gives improved resistance to intergranular corrosion and good strength retention at elevated temperatures up to ≈ 700°C.

Steel industry

History of the modern steel industry, Global steel industry trends, Steel production by country, and List of steel producers

It is common today to talk about "the iron and steel industry" as if it were a single entity, but historically they were separate products. The steel industry is often considered to be an indicator of economic progress, because of the critical role played by steel in infrastructural and overall economic development.^[41]

The economic boom in China and India has caused a massive increase in the demand for steel in recent years. Between 2000 and 2005, world steel demand increased by 6%. Since 2000, several Indian ^[42] and Chinese steel firms have risen to prominence like Tata Steel (which bought Corus Group in 2007), Shanghai Baosteel Group Corporation and Shagang Group. ArcelorMittal is however the world's largest steel producer.

The British Geological Survey reports that in 2005, China was the top producer of steel with about one-third world share followed by Japan, Russia, and the USA.^[43]

In 2008, steel started to be traded as a commodity in the London Metal Exchange. At the end of 2008, the steel industry faced a sharp downturn that led to many cut-backs.^[44]

Steel

Steel is an alloy consisting mostly of iron, with a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most cost-effective alloying material for iron, but various other alloying elements are used such as manganese, chromium, vanadium, and tungsten.^[1] Carbon and other elements act as a hardening agent, preventing dislocations in the iron atom crystal lattice from sliding past one another. Varying the amount of alloying elements and form of their presence in the steel (solute elements, precipitated phase) controls qualities such as the hardness, ductility, and tensile strength of the resulting steel. Steel with increased carbon content can be made harder and stronger than iron, but is also more brittle.

Alloys with a higher carbon content are known as cast iron because of their lower melting point and castability.^[1] Steel is also distinguished from wrought iron, which can contain a small amount of carbon, but it is included in the form of slag inclusions. Two distinguishing factors are its increased rust-resistance and better weldability.

Though steel had been produced by various inefficient methods long before the Renaissance, its use became more common after more efficient production methods were devised in the 17th century. With the invention of the Bessemer process in the mid-19th century, steel became a relatively inexpensive mass-produced material. Further refinements in the process, such as basic oxygen steelmaking, further lowered the cost of production while increasing the quality of the metal. Today, steel is one of the most common materials in the world and is a major component in buildings, infrastructure, tools, ships, automobiles, machines, and appliances. Modern steel is generally identified by various grades of steel defined by various standards organizations.

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Steel Coil

Product Details
Larger photo Country of Origin: China (mainland) Primary Competitive Advantages: Guarantee/Warranty Price Product Features Prompt Delivery Quality Approvals Main Export Markets: Eastern Europe North America Mid East/Africa Central/South America Asia Western Europe Australasia	Wire Rod-type Steel Coil for Variety Uses Model Number:Wire Rod View basket Chat with supplier using: Key Specifications/Special Features: Manufacturer: Wu steel, An steel, Sha steel, and more Materials: Carbon construction steel: Q195 and Q215 Mild carbon steel: SWRM6, SWRM8, SWRM10, SWRM15, SWRM20, GM10Mn, and GM15Mn Fine carbon steel: 42A, 42B, 47A, WDT47A, and 47B High carbon steel: 62A, 62B, 67A, WDT67A, 67B, 72A, 72B, SWRH82A, WSWRH82B, 82MnA, 80MnA, W77MnA, and SYS72A Cold heading steel: SWRCH6A and SWRCH22A Welding steel: ER50-3B, WS03, H08A, H08MnA, H08Mn2Si, H08GX, H10Mn2, WER70S-6, WER44-8ò, WQ-1, WQ-2, WQ-3, and WQ-4 Payment Details: Payment Terms: Letter of Credit (LC, L/C)

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M.S. Welding Electrodes AWS E6013

Model No.: Welding Electrodes001-1 Location: China Minimum Order: 10T Minimum Order Price: competitive Posted Date: June 08, 2006

Description
Description: Mild Steel Welding Electrodes AWS E6013 is a low-carbon steel electrode with a high titaniume coating and can be used on A.C. or D.C. It has excellent welding technological properties. The arc is stable. The spatter is small. The slag viscosity is moderate. It can be used freely. The slag is easy to clean. The welded seam is smooth and fine and easy to restrike the arc. Application: Suitable for welding sheet metal structure made of low-carbon steel, such as ships, vehicles, building, and general machinery. Specifications: 2.0mm, 2.5mm, 3.0mm, 3.2mm, 4.0mm, 5.0mm Packing: 2.5kg/box or 5kg/box+plastic bag, 20kg/carton, 1000kg/pallet, or as per customers' requirements. Brand Name: GOLDEN MOUNTAIN Price Terms: FOB Qingdao, CIF Payment Terms: ...
Company Profile
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Haw Shin Product Co., Ltd (http://www.hs-hawshin.com) - Supplier of welding equipment and other industrial equipment such as Super Rite Flowmeter, Water Pumps, Safty Equipments, Pressure regulators, Air Freshener, Petroleum Series, Spray Gun Series, Industry Series, Construction Series and more. With more than 10 years expertises in this field, we always insist on providing the best products and services for our clients, at the most competitive price at the same time.

Danial Industries - Manufacturer of Leather Work/Safety Gloves, Mechanic & Welding Gloves & Other Types

Wenzhou Longwan Foreign Trade Co., Ltd - Manufacturer of Welding Machines, Welding Equipment & Supply

Special Electrodes

SATINCROME 308L-17

Rutile Type, Stainless Steel Electrode.
 Outstanding Operator Appeal!
 Now with Improved Slag Lift!
 All Positional (except vertical down)
Welding Capabilities.
 Advanced Moisture Resistant Flux

Coating.

Classifications:
AS/NZS 1553.3: E308L-17.
AWS/ASME-SFA A5.4: E308L-17.
Description and Applications:
Satincrome 308L-17 is a smooth running, rutile
type stainless steel electrode manufactured by
CIGWELD for the all positional (except
vertical-down) fillet and butt welding of 19Cr/10Ni
type stainless steels.

The features of Satincrome 308L-17 include high
AC arc stability, sound radiographic quality,
smooth arc transfer characteristics, very low
spatter levels and excellent bead shape and
contour. The advanced moisture resistant (MR)
flux coating provides improved resistance to
start-of-run porosity. Slag lift of Satincrome 308L-17
is enhanced in all welding positions, it is self
peeling and non-spitting.

Applications of Satincrome 308L-17 include the
single and multi-pass welding of 19Cr/10Ni type
stainless steel grades including 201, 202, 301, 302,
303, 304, 304L, 305, 308 etc.

Mild Steel Electrode

This mild steel electrodes, mild steel welding electrodes is a medium coated all position electrode for work of structural importance with medium penetration, soft arc and low spatter, easy to detach slag and can be used in both AC & DC. Typical applications of mild steel electrodes, mild steel welding electrodes is in Structures, Building Construction, Auto bodies, Railway wagons, Vessels, Tanks, Pipelines, Bridges, Ships, Trailers, Building up of shafts, Boilers, Grillls and General fabrication.

What is Welding Electrodes?

A device that emits, controls or receives electricity. Typically an end point or wire made of metal or some composite material, there are countless electrodes in electrical and electronics products. For example, in a vacuum tube, the cathode emitter is a "negative" electrode. The transparent wires made of indium-tin-oxide (ITO) that cross an LCD screen are electrodes.

ELECTRODE IDENTIFICATION

Arc welding electrodes are identified using the A.W.S, (American Welding Society) numbering system and are made in sizes from 1/16 to 5/16 . An example would be a welding rod identified as an 1/8" E6011 electrode.

The electrode is 1/8" in diameter

The "E" stands for arc welding electrode.

Next will be either a 4 or 5 digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 3 digits of a 5 digit number indicate the minimum tensile strength (in thousands of pounds per square inch) of the weld that the rod will produce, stress relieved. Examples would be as follows:

E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi

The next to last digit indicates the position the electrode can be used in.

1. EXX1X is for use in all positions
2. EXX2X is for use in flat and horizontal positions
3. EXX3X is for flat welding

The last two digits together, indicate the type of coating on the electrode and the welding current the electrode can be used with. Such as DC straight, (DC -) DC reverse (DC+) or A.C.
I won't describe the type of coatings of the various electrodes, but will give examples of the type current each will work with.

ELECTRODES AND CURRENTS USED

• EXX10 DC+ (DC reverse or DCRP) electrode positive.
• EXX11 AC or DC- (DC straight or DCSP) electrode negative.
• EXX12 AC or DC-
• EXX13 AC, DC- or DC+
• EXX14 AC, DC- or DC+
• EXX15 DC+
• EXX16 AC or DC+
• EXX18 AC, DC- or DC+
• EXX20 AC ,DC- or DC+
• EXX24 AC, DC- or DC+
• EXX27 AC, DC- or DC+
• EXX28 AC or DC+

CURRENT TYPES

SMAW is performed using either AC or DC current. Since DC current flows in one direction, DC current can be DC straight, (electrode negative) or DC reversed (electrode positive). With DC reversed,(DC+ OR DCRP) the weld penetration will be deep. DC straight (DC- OR DCSP) the weld will have a faster melt off and deposit rate. The weld will have medium penetration.
Ac current changes it's polarity 120 times a second by it's self and can not be changed as can DC current.

ELECTRODE SIZE AND AMPS USED

The following will serve as a basic guide of the amp range that can be used for different size electrodes. Note that these ratings can be different between various electrode manufactures for the same size rod. Also the type coating on the electrode could effect the amperage range. When possible, check the manufactures info of the electrode you will be using for their recommended amperage settings.

Electrode Table
ELECTRODE DIAMETER (THICKNESS)	AMP RANGE	PLATE
1/16"	20 - 40	UP TO 3/16"
3/32"	40 - 125	UP TO 1/4"
1/8	75 - 185	OVER 1/8"
5/32"	105 - 250	OVER 1/4"
3/16"	140 - 305	OVER 3/8"
1/4"	210 - 430	OVER 3/8"
5/16"	275 - 450	OVER 1/2"

Note! The thicker the material to be welded, the higher the current needed and the larger the electrode needed.

SOME ELECTRODE TYPES

This section will briefly describe four electrodes that are commonly used for maintenance and repair welding of mild steel. There are many other electrodes available for the welding of other kinds of metals. Check with your local welding supply dealer for the electrode that should be used for the metal you want to weld.

E6010 This electrode is used for all position welding using DCRP. It produces a deep penetrating weld and works well on dirty,rusted, or painted metals

E6011 This electrode has the same characteristics of the E6010, but can be used with AC and DC currents.

E6013 This electrode can be used with AC and DC currents. It produces a medium penetrating weld with a superior weld bead appearance.

E7018 This electrode is known as a low hydrogen electrode and can be used with AC or DC. The coating on the electrode has a low moisture content that reduces the introduction of hydrogen into the weld. The electrode can produce welds of x-ray quality with medium penetration. (Note, this electrode must be kept dry. If it gets wet, it must be dried in a rod oven before use.)

It is hoped that this basic information will help the new or home shop welder identify the various types of electrodes and select the correct one for their welding projects.

WELDING WIRE OR WELDING ROD

This invention relates to consumable welding rods or welding electrodes. More particularly, the invention relates to welding rods or welding electrodes of the type comprising a tubular metallic sheath enclosing a core or filling composed of grains or granules of inorganic welding materials belonging to one or more of the following groups: Alloying agents, fluxing agents, slag-forming agents, gas-forming agents and arc-stabilizing or electron-emitting agents.

Tubular welding wire or rods of the kind referred to are used in gas welding and in arc welding with nonconsumable electrode (carbon arc welding and TIG welding) as well as in the electroslag welding process (ES welding) and the consumable electrode welding process, in which last-mentioned processes the tubular wire or rod does itself constitute the consumable electrode. In automatic or semiautomatic consumable-electrode welding the wire is usually supplied as a coil, while in manual welding usually rod-shaped electrodes are employed. The wires or rods may be either bare or coated.

With the tubular wires or rods referred to, it is important to prevent material from dropping out at the electrode tip and to prevent voids from forming within the electrode. To secure this result it has been suggested to submit the core material to a high degree of compaction in the course of the manufacture, in order to convert it into a virtually solid body. This method does, however, not always secure the desired result. Also, it imposes particular restrictions on the manufacturing process. It has also been suggested to mix the powered material with a liquid bonding agent, for instance a sodium silicate solution, to a paste and to deposit or extrude a string of said paste in the trough-shaped strip. This method introduces, however, other complications.

Mild Steel Wire Rod 5.0mm, 6.0mm

Mild steel (MS) wire is a finished product which is directly used manufacture of various
engineering items. Generally, materials with diameter upto 4mm are considered to be
wire rods and materials below this size are classified as wire. MS wire has number of
applications such as for manufacturing fencing wire, wire nails, wire nettings, wire-ropes
etc.
Raw materials:
The major raw material required is mild steel wire rod of 6mm dia. or 8mm dia.