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Basic Knowledge of Welding Electrodes
2014-07-09
The electrode consists of core wire and coating. That is to say, painting the skin (coatings) on metallic cores and forming outer uniform makes an electrode. The materials of core wire vary from different types of electrode. The core wire is the inner. In order to ensure the quality and performance of the weld, there are strict requirements on the contents of metal elements in the core, especially on the harmful impurities (such as sulfur, phosphorus) content,which should be limited strictly. And the material of the weld should be superior to base metal.
Generally,the core is a kind of wire with a certain length and diameter.When welding,welding core has two functions: firstly,conduct the welding current and form an electronic arc,thusconvert the it into heat energy; secondly,the core itself is a melting metal as the formation of the weld filler metal.The skin on the surface of the electrode is the coating, which plays an extremely important role in the welding process.Without coating, the oxygen and nitrogen in the air will intrude in the molten bare metal while welding,thus will oxidize or nitride iron element and other useful elements,such as carbon,silicon and manganese and left in the weld,causing the weld slag or crack.Meanwhile,the gas that has melted into the welding pool may produce a large number of pores in the weld.All the above factors can reduce the mechanical propeties (strength,shock value) of the weld greatly,and also may brittle the weld. The function of coating is to isolate oxygen outside from the weld, thus forming a protection cover. The bare electrode without coating is not suitable for arc welding. This is because the arc welding has a poor stability,more splash and bad weld.Through longterm practice, the welders gradually found out that paiting some mineral material (namely the coatings) in core wire,the performance of electrodes can be improved greatly.
According to the different condition, elding electrodes can be divided into three categories: classifying by the purposes of welding rod, by the main chemical composition property of coatings, and by the slag of the melting coatings.
(1)In accordance with the uses of electrodes, the electrodes can be divided into structural steel electrode,heat resistant steel electrode, stainless steelelectrode, surfacing electrode, low temperature steel electrode, cast iron electrode, nickel and nickel alloy electrode,copper and copper alloy electrode,aluminum and aluminum alloy electrode and electrodes with special purposes.
(2) In accordance with the main chemical composition property of coatings,welding electrodes can be divided into titanium oxide type electrode,titanium calcium type electrode, ilmenite electrode, iron oxide type electrode,cellulose type electrode, low hydrogen electrode, graphite electrode and base type electrode.
(3) In accordance with slag of melting coatings,welding electrodes can be divided into acidic electrode and basic electrode. The main component of coating of acidic electrode is acidic oxide, such as silica, titanium dioxide, ferric oxide etc.On the other side, the main component of base electrode is basic oxide, such as marble, fluorite etc.
How to test the quality of welding electrodes?
(1) From the appearance of electrode. The surface of coating should be smooth without porosity or mechanical damage, and the coating is uneccentric and core wire should be without corrosion.
(2) From the strength of coating. Raise a single electrode into about a metre high, then loose your hand and let it free fall on the smooth thick steel plate.If the coating is not peeling,it proves that the strength of coating is up to quality requirements.
(3) From the process of actual welding.That's to say verifying the quality of welding electrodes through the actual operation. The electrodes with good quality have stable arc while welding, and both core and coating will be melted evenly with rare splash, good weld and easy removal of slag.
Generally,the core is a kind of wire with a certain length and diameter.When welding,welding core has two functions: firstly,conduct the welding current and form an electronic arc,thusconvert the it into heat energy; secondly,the core itself is a melting metal as the formation of the weld filler metal.The skin on the surface of the electrode is the coating, which plays an extremely important role in the welding process.Without coating, the oxygen and nitrogen in the air will intrude in the molten bare metal while welding,thus will oxidize or nitride iron element and other useful elements,such as carbon,silicon and manganese and left in the weld,causing the weld slag or crack.Meanwhile,the gas that has melted into the welding pool may produce a large number of pores in the weld.All the above factors can reduce the mechanical propeties (strength,shock value) of the weld greatly,and also may brittle the weld. The function of coating is to isolate oxygen outside from the weld, thus forming a protection cover. The bare electrode without coating is not suitable for arc welding. This is because the arc welding has a poor stability,more splash and bad weld.Through longterm practice, the welders gradually found out that paiting some mineral material (namely the coatings) in core wire,the performance of electrodes can be improved greatly.
According to the different condition, elding electrodes can be divided into three categories: classifying by the purposes of welding rod, by the main chemical composition property of coatings, and by the slag of the melting coatings.
(1)In accordance with the uses of electrodes, the electrodes can be divided into structural steel electrode,heat resistant steel electrode, stainless steelelectrode, surfacing electrode, low temperature steel electrode, cast iron electrode, nickel and nickel alloy electrode,copper and copper alloy electrode,aluminum and aluminum alloy electrode and electrodes with special purposes.
(2) In accordance with the main chemical composition property of coatings,welding electrodes can be divided into titanium oxide type electrode,titanium calcium type electrode, ilmenite electrode, iron oxide type electrode,cellulose type electrode, low hydrogen electrode, graphite electrode and base type electrode.
(3) In accordance with slag of melting coatings,welding electrodes can be divided into acidic electrode and basic electrode. The main component of coating of acidic electrode is acidic oxide, such as silica, titanium dioxide, ferric oxide etc.On the other side, the main component of base electrode is basic oxide, such as marble, fluorite etc.
How to test the quality of welding electrodes?
(1) From the appearance of electrode. The surface of coating should be smooth without porosity or mechanical damage, and the coating is uneccentric and core wire should be without corrosion.
(2) From the strength of coating. Raise a single electrode into about a metre high, then loose your hand and let it free fall on the smooth thick steel plate.If the coating is not peeling,it proves that the strength of coating is up to quality requirements.
(3) From the process of actual welding.That's to say verifying the quality of welding electrodes through the actual operation. The electrodes with good quality have stable arc while welding, and both core and coating will be melted evenly with rare splash, good weld and easy removal of slag.