Welding consumables - Part 3

Job Knowledge
Part 1
Part 2
Part 4
Part 5

The last two articles covered the various types of manual metal arc consumables that are
available.
In order to be able to specify the type of flux coating, welding characteristics and chemical
composition of an electrode for a particular application, there needs to be some standardised
method of unique identification that is universally recognised.
This requirement has led to the writing of a series of consumable specifications that enable an
electrode to be easily and uniquely identified by assigning a consumable a 'classification'. The
two MMA electrode classification schemes that will be dealt with in this month's article are the
EN (Euronorm) and the AWS (American Welding Society) specifications. There is insufficient
space to cover in detail the whole range of compositions for MMA electrodes so the emphasis
here will be on the carbon steel filler metals.
The European specification for non-alloy and fine grained steel MMA electrodes is EN 499. This
divides the classification or designation number into two parts. Part 1 is a compulsory section
that requires symbols for the process, strength and elongation, impact strength, the chemical
composition and the type of flux coating. The second part is optional and includes that includes
symbols for the type of current and metal recovery, the welding position(s) that the electrode can
be used in and for the maximum hydrogen content of the deposited weld metal (NOT the
electrode).
The designation of a covered electrode begins with the letter 'E'. This tells us that this is a
covered electrode intended for MMA welding. The next two numbers give the minimum yield
strength that may be expected as shown in Table 1.
Table 1 Strength and elongation symbols
Min Yield Strength
N/mm

Symbol
35
38

355
380

Tensile Strength
N/mm
440 - 570
470 - 600

Minimum
Elongation %
22
20

42
46
50

420
460
500

500 - 640
530 - 680
560 - 720

20
20
18

The next symbol indicates the temperature at which an average impact value of 47J can be
achieved, as shown in Table 2.
Table 2 Impact value symbol
Symbol
Z
A
0
2
3
4
5
6

Temperature for
average of 47J C
No requirement
+20
0
-20
-30
-40
-50
-60

The third mandatory symbol is for the composition. Although the specification title (non-alloy
and fine grained steels) suggests that the electrodes have no alloying elements present, up to 3%
Ni and NiMo electrodes are included, see Table 3. (This symbol is only applied where the
electrode contains 0.3Mo or 0.6Ni).
Table 3 Chemical composition symbols
Symbol
No symbol
Mo
MnMo
1Ni
2Ni
3Ni
Mn1Ni
1NiMo
Z

Chemical composition % max or range

Mn
Mo
Ni
2.0
1.4
0.3 - 0.6
>1.4 - 2.0
0.3 - 0.6
1.4
0.6 - 1.2
1.4
1.8 - 2.6
1.4
>2.6 - 3.8
>1.4 - 2.0
0.6 - 1.2
1.4
0.3 - 0.6
0.6 - 1.2
Any other agreed composition

The fourth symbol indicates the type of flux coating - basic, rutile etc as shown in Table 4.
Table 4 Symbol for flux coating
Symbol

Coating

A
C
R
RR
RC
RA
RB
B

acid
cellulosic
rutile
thick rutile
rutile-cellulosic
rutile-acid
rutile-basic
basic

The next three symbols are not compulsory and give additional information on the percentage
weld metal recovery and the type of welding current on which the electrode can be operated
(Table 5); the welding position (Table 6) and the maximum hydrogen content of the deposited
weld metal if the electrodes are dried or baked as recommended by the manufacturer (Table 7).
Table 5 Symbol for weld metal recovery and current type
Symbol

Weld metal recovery %

1
2
3
4
5
6
7
8

<= 105
<= 105
>105<=125
>105<=125
>125<=160
>125<=160
>160
>160

Current type
AC or DC+
DC+ or DCAC or DC+
DC+ or DCAC or DC+
DC+ or DCAC or DC+
DC+ or DC-

Table 6 Symbols for welding position

Symbol
1
2
3
4
5

Welding position
All positions
All positions except V-down
Flat butt and fillet welds, HV fillet weld
Flat
V-down, flat butt, flat and HV fillet welds

Table 7 Symbol for hydrogen content in weld metal

Max Hydrogen
ml/100gms weld metal

Symbol
H5
H10

5
10

H15

15

A full designation may therefore read E42 2 B32H5. This describes a basic carbon manganese
steel electrode; weld metal yield strength of 420N/mm2, better than 47J at -20C, a weld metal
recovery of over 105%, capable of being used on AC or DC+ current in all positions except
vertical down and providing less than 5mls hydrogen in the weld metal.

The AWS specification equivalent to EN 499 is AWS A5.1 - Carbon Steel Electrodes for
Shielded Metal Arc Welding. The classification comprises five characters but in the 2004 edition
of the specification there are two separate schemes. A5.1, based on the US units of tensile
strength in pounds per square inch, Charpy -V values in foot-pounds and A5.1M, based on the SI
system, with strength in MPa, Charpy-V values in Joules.
It is thus possible to have virtually identical electrodes with different classifications, one using
US units, the other SI units. There is insufficient space within this brief article to describe fully
all of the 18 types covered by the specification except perhaps for the most commonly used
electrodes. For full details of the AWS scheme it is necessary to consult the specification.
To illustrate briefly how the electrodes are classified, the following gives a summary of the key
features.
The first character 'E' is common to both classifications and indicates that the electrode is a flux
coated manual metal arc electrode. The next two digits indicate the tensile strength. In the A5.1
designation this is either '60',indicating a UTS of 60ksi and a yield strength of 48ksi, or '70',
indicating a UTS of 70ksi and a yield strength of 58ksi. In the A5.1M designation these are 43 or
49, indicating a UTS of 430MPa, yield strength of 330MPa or 490MPa UTS,400MPa yield
respectively.
The last two digits give information on flux coating type, welding position, current type and
polarity and Charpy-V impact strength, if required. Those electrodes suffixed XX10 or XX11
have cellulosic coatings; those suffixed XX12,XX13, XX14, XX19 or XX24 have rutile coatings
and those suffixed XX15, XX16, XX18, XX28 and XX48 are basic low hydrogen. XX18, XX28
and XX48 all have iron powder additions and are therefore high recovery electrodes.
Listed below are those EN and AWS specifications that prescribe the requirements for ferrous
electrodes.
BS EN 499
BS EN 757
BS EN 1599
BS EN 1600
AWS A5.1/A5.1M
AWS A5.4

Non-alloyed and fine grained steel electrodes

High strength steels
Creep resisting steels
Stainless and heat resisting steels
Carbon Steel Electrodes for SMAW
Stainless Steel Electrodes for SMAW

AWS A5.5

Low Alloy Steel Electrodes for SMAW

This article was written by Gene Mathers.