Welding Consumables

Contoh-contoh consumable seperti:
Shielded arc filler wires, lengths or rolls
Covered electrodes
Shielding gases
Separately supplied flux
Fusible inserts

Hal2 yang perlu diperhatikan pengecekan consumable:
-Size
-Classification / Supplier
-Condition
-Handling and storage
-Treatments e.g. baking / drying

Welding Consumable Standards

-MMA (SMAW)
BS 639: Steel electrodes 
BS EN 499: Steel electrodes
AWS A5.1 Non-alloyed steel electrodes
AWS A5.5 Alloyed  steel electrodes
AWS A5.4 Chromium electrodes


-MIG/MAG (GMAW) TIG (GTAW)
BS 2901: Filler wires 
BS EN 440: Filler wires
AWS A5.9: Filler wires
BS EN 439: Shielding gases

-SAW
BS 4165: Wire and fluxes
BS EN 756: Wire electrodes
BS EN 760: Fluxes
AWS A5.17: Wires and fluxes

Rutile electrodes

Used mainly on general purpose work

Low pressure pipework ( E6013), support brackets.

Flux constituents include:

Titanium dioxide, slag former

Clay - binding agent

Sodium silicate - main ionizer

Keuntungan rutile:

-Easy to use

-Low cost / control

-Smooth weld profiles

-Slag easily detachable

-High deposition possible with the addition of iron powder

Kelemahan rutile:

-High in hydrogen : >25ml

-High crack tendency

-Low strength

-Low toughness values

Cellulose electrodes

Used mainly for pipeline welding

Suitable for welding in all position especially vertical down, stove technique

They produce a gas shield high in hydrogen

Deep penetration/fusion characteristics

Flux constituents include:

Cellulose, natural organic compounds

Titanium dioxide - slag former

Sodium silicate/potassium silicate - main ionizers

Keuntungan Cellulose:

Deep penetration/fusion

Suitable for welding in all positions

Fast travel speeds 

Large volumes of shielding gas

Low control

Kelemahan Cellulose:

High in hydrogen : >85ml

High crack tendency

Rough cap appearance

High spatter contents

Low deposition rates

Basic electrodes:

Used mainly for high pressure work and for materials of high tensile strength

They are capable of producing welds of a low hydrogen content (<5ml)

Prior to use they may be baked to give a low hydrogen potential typically 300oC for 1 hour plus

Flux constituents include:

Limestone (calcium carbonate) - gas former

Fluorspar - slag former

Sodium silicate/potassium silicate - main ionizers

note:

-electrodes harus dibaked menurut manufactures recommendations. 
-vacuum packs tersedia dan tidak perlu untuk dipre-baking.
-electrodes harus digunakan dengan minimum weave.
-electrodes harus digunakan dengan minimum arc gap.
-parent material harus bebas dari moisture and contamination

Keuntungan Basic:
High toughness values
Low hydrogen contents
Low crack tendency
Kelemahan Basic:
High cost
High control
High welder skill required
Convex weld profiles
Poor stop/start properties

BS 639 Covered Electrodes standard

Electrodes classified as follows:
 E 35 - Min yield strength 355 N/mm2
Tensile strength 440 - 570 N/mm2
 E 38 - Min yield strength 380 N/mm2
Tensile strength 470 - 600 N/mm2 
 E 42 - Min yield strength 420 N/mm2
Tensile strength 500 - 640 N/mm2 
 E 46 - Min yield strength 460 N/mm2
Tensile strength 530 - 680 N/mm2 
 E 50 - Min yield strength 500 N/mm2
Tensile strength 560 - 720 N/mm2 

BS 639 Electrodes

AWS A5.5 Alloyed Electrodes standard

AWS A5.5 Electrodes

contoh AWS electrode flux types:
Cellulose flux- ends in 0,1 (No Baking)
E6010, E6011, E7010, E8011

Rutile flux-ends in 2,3,4 (Dry 120 Celcius)
E5012, E6012, E6013, E6014

Basic flux-ends in 5,6,7,8 (Backing 250 Celcius)
E6016, E7017, E8018, E9018