AWS UGFM-2010 AWS User s Guide to Filler Metals.pdf

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1、AWS UsersGuide to FillerMetalsAWS UGFM:2010AWS Users Guide to Filler MetalsText Compiled ByT.M. MustaleskiAWS President, 200304Edited ByRakesh Gupta, Senior Staff EngineerRosalinda ONeill, Senior Publications ManagerAWS Technical Services DivisionSecond Edition 2010(Supersedes UGFM:1995)AWS UGFM:201

2、0iiInternational Standard Book Number: 978-0-87171-765-8American Welding Society 550 N.W. LeJeune Road; Miami, FL 33126 2010 by American Welding SocietyAll rights reservedPrinted in the United States of AmericaThe AWS Users Guide to Filler Metals is a collection of commentary information selected fr

3、om the 30 technical standards written by the AWS Committee on Filler Metal. The Users Guide provides descriptions of specific filler metals and their intended usage, as well as methods for classification, welding procedures, and safety considerations.Although reasonable care has been taken in the co

4、mpilation and publication of the Users Guide to insure authenticity ofthe contents, no representation is made as to the accuracy or reliability of this information. The Users Guide is intendedsolely as a supplement to the AWS Filler Metal Comparison Charts, and should not be regarded as a substitute

5、 for thevarious AWS specifications to which it refers. This publication is subject to revision at any time.AWS UGFM:2010iiiPersonnelAWS A5 Committee on Filler Metals and Allied MaterialsJ. S. Lee, Chair ChevronH. D. Wehr, Vice Chair Arcos Industries LLCJ. J. DeLoach Jr, 2nd Vice Chair Naval Surface

6、Warfare CenterR. K. Gupta, Secretary American Welding SocietyT. Anderson ESAB Welding bare solid and tubular wires on spools,coils, and drums, or in straight lengths; and solid and sintered strip electrodes. It applies to all fusion welding processes,except brazing, braze welding, and thermal sprayi

7、ng, or granular metallic or mineral products, such as submerged arcfluxes, or other such products used in fusion welding processes.The specification makes use of both U.S. Customary Units and the International System of Units (SI). The measure-ments are not exact equivalents; therefore, each system

8、must be used independently of the other without combining in anyway. The specification with the designation A5.02 uses U.S. Customary Units. The specification A5.02M uses SI Units.2.4 General Safety Considerations. Safety and health issues and concerns are beyond the scope of these standards and,the

9、refore, are not fully addressed herein. Some safety and health information can be found in the following paragraphs.Safety and health information is available from other sources.2.4.1 Ventilation During Welding. Five major factors govern the quantity of fumes in the atmosphere to whichwelders and we

10、lding operators are exposed during welding; they are:(1) the dimensions of the space in which welding is performed (with special regard to the height of the ceiling)(2) the number of welders and welding operators working in that space(3) the rate of evolution of fumes, gases, or dust, according to t

11、he materials and processes used(4) the proximity of the welders or welding operators to the fumes as they issue from the welding zone, and to thegases and dusts in the space in which they are working(5) the ventilation provided to the space in which the welding is performed.American National Standar

12、d Z49.1, Safety in Welding, Cutting and Allied Processes (published by the AmericanWelding Society), discusses the ventilation that is required during welding and should be referred to for details. Attentionis drawn particularly to the section of that document on health protection and ventilation. S

13、ee also AWS F3.2 ventilationguide for weld fume, for more detailed descriptions of ventilation options.The Safety and Health Fact Sheets listed below are published by the AWS. They may be downloaded and printeddirectly from the AWS website at http:/www.aws.org. The Safety and Health Fact Sheets are

14、revised and additionalsheets added periodically.2.4.6 AWS Safety and Health Fact Sheets Index (SHF)No. Title1 Fumes and Gases2 Radiation3 Noise4 Chromium and Nickel in Welding Fume5 Electrical Hazards6 Fire and Explosion Prevention7 Burn Protection8 Mechanical Hazards9 Tripping and Falling10 Falling

15、 Objects11 Confined Spaces12 Contact Lens Wear13 Ergonomics in the Welding Environment14 Graphic Symbols for Precautionary Labels15 Style Guidelines for Safety and Health Documents16 Pacemakers and Welding17 Electric and Magnetic Fields (EMF)18 Lockout/TagoutAWS UGFM:2010219 Laser Welding and Cuttin

16、g Safety20 Thermal Spraying Safety21 Resistance Spot Welding22 Cadmium Exposure from Welding therefore, storage or conditioning above ambient temperature may dry themtoo much and adversely affect their operation (see Table 4.2.)4.4.10 Core Wire. The core wire for all the electrodes classified in the

17、 specification is usually a mild steel having atypical composition which may differ significantly from that of the weld metal produced by the covered electrodes.4.4.11 Coverings4.4.11.1 Electrodes of some classifications have substantial quantities of iron powder added to their coverings. Theiron po

18、wder fuses with the core wire and the other metals in the covering, as the electrode melts, and is deposited as partof the weld metal, just as is the core wire. Relatively high currents can be used since a considerable portion of theelectrical energy passing through the electrode is used to melt the

19、 thicker covering containing iron powder. The result isthat more weld metal may be obtained from a single electrode with iron powder in its covering than from a singleelectrode of the same diameter without iron powder.4.4.11.2 Due to the thick covering and deep cup produced at the arcing end of the

20、electrode, iron powder electrodescan be used very effectively with a “drag” technique. This technique consists of keeping the electrode covering in contactwith the workpiece at all times, which makes for easy handling. However, a technique using a short arc length ispreferable if the 3/32 or 1/8 in

21、2.5 mm or 3.2 mm electrodes are to be used in other than flat or horizontal fillet weldingpositions or for making groove welds.4.4.11.3 The E70XX E49XX electrodes were included in this specification to acknowledge the higher strengthlevels obtained with many of the iron powder and low-hydrogen elect

22、rodes, as well as to recognize the industry demandAWS UGFM:20107for electrodes with 70 ksi 490 MPa minimum tensile strength. Unlike the E70XX-X E 49XX-X classification in AWSA5.5, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding, these electrodes do not containdeliberate a

23、lloy additions, nor are they required to meet minimum tensile properties after postweld heat treatment.4.4.11.4 E70XX E49XX low-hydrogen electrodes have mineral coverings which are high in limestone and otheringredients that are low in moisture and hence produce weld deposits “low in hydrogen conten

24、t.” Low hydrogenelectrodes were developed for welding low alloy high-strength steels, some of which were high in carbon content.Electrodes with other than low-hydrogen coverings may produce “hydrogen-induced cracking” in those steels. Theseunder bead cracks occur in the base metal, usually just belo

25、w the weld bead. Weld-metal cracks may also occur. Low-hydrogen electrodes should be used when welding high-sulfur or enameling steels. Other electrodes are likely to causeporosity and/or cracks in high-sulfur steels. With enameling steels, the hydrogen that escapes after welding with otherthan low-

26、hydrogen electrodes produces holes in the enamel.4.4.12 Amperage Ranges. Table 4.3 gives amperage ranges which are satisfactory for most classifications.4.5 Description and Intended Use of Electrodes4.5.1 E6010 E4310 Classification4.5.1.1 E6010 E4310 electrodes are characterized by a deeply penetrat

27、ing, forceful, spray-type arc and readilyremovable, thin, friable slag which may not seem to completely cover the weld bead. Fillet welds usually have a relativelyflat weld face and have a rather coarse, unevenly spaced ripple. The coverings are high in cellulose, usually exceeding30% by weight. The

28、 other materials generally used in the covering include titanium dioxide, metallic deoxidizers such asferromanganese, various types of magnesium or aluminum silicates, and liquid sodium silicate as a binder. Because oftheir covering composition, these electrodes are generally described as the high-c

29、ellulose sodium type.4.5.1.2 These electrodes are recommended for all welding positions, particularly on multiple-pass applications in the vertical and overhead welding positions and where welds of good soundness are required. They frequently areselected for joining pipe and generally are capable of

30、 welding in the vertical position with either uphill or downhillprogression.4.5.1.3 The majority of applications for these electrodes is in joining carbon steel. However, they have been used toadvantage on galvanized steel and on some low-alloy steels. Typical applications include shipbuilding, buil

31、dings, bridges,storage tanks, piping, and pressure vessel fittings. Since the applications are so widespread, a discussion of each is impractical.Sizes larger than 3/16 in 5.0 mm generally have limited use in other than flat or horizontal-fillet welding positions.4.5.1.4 These electrodes have been d

32、esigned for use with dcep (direct current, electrode positive). The maximumamperage that can generally be used with the larger sizes of these electrodes is limited in comparison to that for otherclassifications due to the high spatter loss that occurs with high amperage.4.5.2 E6011 E4311 Classificat

33、ion4.5.2.1 E6011 E4311 electrodes are designed to be used with ac current and to duplicate the usabilitycharacteristics and mechanical properties of the E6010 E4310 classification. Although also usable with dcep, a decreasein joint penetration will be noted when compared to the E6010 E4310 electrode

34、s. Arc action, slag, and fillet weldappearance are similar to those of the E6010 E4310 electrodes.4.5.2.2 The coverings are also high in cellulose and are described as the high-cellulose potassium type. In additionto the other ingredients normally found in E6010 E4310 coverings, small quantities of

35、calcium and potassiumcompounds usually are present.4.5.2.3 Sizes larger than 3/16 in 5.0 mm generally have limited use in other than flat or horizontal-fillet weldingpositions.4.5.3 E6012 E4312 Classification4.5.3.1 E6012 E4312 electrodes are characterized by low penetrating arc and dense slag, whic

36、h completely coversthe bead. This may result in incomplete root penetration in fillet welded joints. The coverings are high in titania, usuallyexceeding 35% by weight, and usually are referred to as the “titania” or “rutile” type. The coverings generally alsocontain small amounts of cellulose and fe

37、rromanganese, and various siliceous materials such as feldspar and clay withsodium silicate as a binder. Also, small amounts of certain calcium compounds may be used to produce satisfactory arccharacteristics on dcen (direct current, electrode negative).AWS UGFM:20108AWS UGFM:20109Table 4.3Typical A

38、mperageRangesE6018,ElectrodeE6010,E6027,E7015,E7018M,E7024,DiameterA5.1E6011E6012E6O13E6019E6020E6022E7027E7014E7016E7018E7028E7048E4318,A5.1A5.1ME4310,E4327,E4915,E4918M,E4924,(in)(mm)A5.1ME4311E4312E4313E4319E4320E4322E4927E4914E4916E4918E4928E49481/161.620 to 4020 to 405/642.025 to 6025 to 6035 t

39、o 553/32a2.4a,2.5a40 to 8035 to 8545 to 9050 to 9080 to 12565 to 11070 to 110100 to 1451/83.275 to 12580 to 14080 to 13080 to 140100 to 150110 to 160125 to 185110 to 160100 to 150105 to 155140 to 19080 to 1405/324.0110 to 170110 to 190105 to 180130 to 190130 to 190140 to 190160 to 240150 to 210140 t

40、o 200130 to 200180 to 250150 to 2203/165.0140 to 215140 to 240150 to 230190 to 250175 to 250170 to 400210 to 300200 to 275180 to 255200 to 275230 to 305210 to 2707/325.6170 to 250200 to 320210 to 300240 to 310225 to 310370 to 520250 to 350260 to 340240 to 320260 to 340275 to 3651/46.0210 to 320250 t

41、o 400250 to 350310 to 360275 to 375300 to 420330 to 415300 to 390315 to 400335 to 4305/168.0275 to 425300 to 500320 to 430360 to 410340 to 450375 to 475390 to 500375 to 475375 to 470400 to 525aThis diameter is not manufactured in the E7O28 E4828 classification.4.5.3.2 Fillet welds tend to have a con

42、vex weld face with smooth even ripples in the horizontal welding position,and widely spaced rougher ripples in the vertical welding position which become smoother and more uniform as the sizeof the weld is increased. Ordinarily, a larger size fillet must be made in the vertical and overhead welding

43、positionsusing E6012 E4312 electrodes compared to welds with E6010 E4310 and E6011 E4311 electrodes of the samediameter.4.5.3.3 The E6012 E4312 electrodes are all-position electrodes and usually are suitable for welding in the verticalwelding position with either the upward or downward progression.

44、However, more often the larger sizes are used in theflat and horizontal welding positions rather than in the vertical and overhead welding positions. The larger sizes are oftenused for single-pass, high-speed, high-current fillet welds in the horizontal welding position. Their ease of handling, good

45、fillet weld face, and ability to bridge wide root openings under conditions of poor fit, and to withstand high amperagesmake them very well suited to this type of work. The electrode size used for vertical and overhead position welding isfrequently one size smaller than would be used with an E6010 E

46、4310 or E6011 E4311 electrode.4.5.3.4 Weld metal from these electrodes is generally lower in ductility and may be higher in yield strength (1 ksito 2 ksi 0.7 MPa to 1.4 MPa) than weld metal from the same size of either the E6010 E4310 or E6011 E4311electrodes.4.5.4 E6013 E4313 Classification4.5.4.1

47、E6013 E4313 electrodes, although very similar to the E6012 E4312 electrodes, have distinct differences.Their flux covering makes slag removal easier and gives a smoother arc transfer than E6012 E4312 electrodes. This isparticularly the case for the small diameters 1/16, 5/64, and 3/32 in 1.6 mm, 2.0

48、 mm, and 2.5 mm. This permitssatisfactory operation with lower open-circuit ac voltage. E6013 E4313 electrodes were designed specifically for lightsheet metal work. However, the larger diameters are used on many of the same applications as E6012 E4312 electrodesand provide low penetrating arc. The s

49、maller diameters provide a less penetrating arc than is obtained with E6012E4312 electrodes. This may result in incomplete penetration in fillet welded joints.4.5.4.2 Coverings of E6013 E4313 electrodes contain rutile, cellulose, ferromanganese, potassium silicate as abinder, and other siliceous materials. The potassium compounds permit the electrodes to operate with ac at lowamperages and low open-circuit voltages.4.5.4.3 E6013 E4313 electrodes are similar to the E6012 E4312 elect