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Types of Welding Electrodes explained
Welding electrode is mainly classified into ii broad categories
1. Non-consumable electrodes and
2. Consumable electrodes
Non-consumable or Refractory Electrodes
Non-consumable electrodes are those which attain non melt away or consumed during the welding process. These electrodes involves the usage of high melting betoken materials such equally carbon - MP 6700 bird Fahrenheit, pure tungsten MP 6150 bird Fahrenheit, or alloy tungsten.
Main features of non-consumable welding electrode
- While welding amongst these electrodes a filler metallic is needed to fill upwardly up the gap betwixt the ii metallic parts.
- These are used inward carbon arc welding together with Tungsten Inert Gas (TIG) welding .
- Tungsten electrodes are much costlier than carbon or graphite electrodes. Tungsten alloy electrodes are costlier.
Consumable Electrodes
This electrodes are depression melting betoken electrodes. When electrode together with chore is struck the arc starts to melt the goal of the electrode. The molten electrode is transferred to the chore inward the cast of metallic droplets.
Main features of Consumable welding electrode
- these are to a greater extent than thermally efficient than non consumable electrodes.
- They are made of dissimilar materials depending upon the ask together with the chemic composition of metals to endure joined.
- These are used inward MIG welding inward the cast of bare electrode.
- Most normally used nub cloth is mild steel, depression alloy steel together with nickel steel.
1. Bare electrodes: They don't cause got whatsoever flux coating alone the alloy or the metallic wire.
2. Light coated electrodes: These are electrodes having coating factor of 1.25 . coating factor = diameter of the electrode / diameter of the nub wire .
illustration : Citobest electrode from AO or Advani Oerlikon.
3. Medium coated electrodes: These cause got coating factor of most 1.45 .
illustration : Overcord
4. Heavily coated electrode : Coating factor is betwixt 1.6 together with 2.2 . illustration : citofine .
Covered electrodes tin give notice endure classified equally follows :
- electrodes having cellulose
- Rutile (titania)
- Electrode having Fe oxide
- Electrode amongst Fe powder
- Low hydrogen electrode
Welding Electrode Explained inward details
- Need of filler metal
Depending upon the cloth of the electrode, it may melt together with render filler metal; if it is non-consumable, a carve upwardly filler metallic add-on becomes necessary.
- Core Wire composition
The nub wire is prepared past times keeping inward hear the type of metallic to endure welded. The composition of nub wire is dissimilar for each metal. When mild steel is needed to endure welded the nub wire must cause got cause similar composition to larn a homogeneous weld joint.
- The size together with length of the welding electrode
The size (diameter) of the electrode nub wire totally depends on the amount of metallic deposition needed together with the type of gap betwixt the ii metallic plates to endure joined. The length of the nub depends of the electrical resistance, rigidity together with diameter of the electrode. Typical coated electrode dimensions are 150 to 460 mm (6 to eighteen in.) inward length together with 1.5 to 8 mm (j to in.) inward diameter. As the thickness of the sections to endure welded decreases, the required electrical current together with electrode diameter also decrease.
- Current Requirements
If bigger diameter welding electrodes are used thence the requirement of the electrical current volition also endure higher.
Specifications for electrodes together with for filler metals, including dimensional tolerances, character command procedures, together with processes, are stated past times the American Welding Society (AWS) together with the American National Standards Institute (ANSI); some seem inward the Aerospace Materials Specifications (AMS) past times the Society of Automotive Engineers (SAE).
Electrodes are identified past times numbers together with letters (Table 27.2), or past times colouring code, especially if they are equally good pocket-sized to imprint amongst identification.
- Specification of the welding electrodes
Specifications for electrodes together with for filler metals, including dimensional tolerances, character command procedures, together with processes, are stated past times the American Welding Society (AWS) together with the American National Standards Institute (ANSI); some seem inward the Aerospace Materials Specifications (AMS) past times the Society of Automotive Engineers (SAE).
- Welding electrode numbering system
Electrodes are identified past times numbers together with letters (Table 27.2), or past times colouring code, especially if they are equally good pocket-sized to imprint amongst identification.
Among other requirements, the specifications solid soil that
(a) the wire diameter must non vary to a greater extent than than 0.05 mm (0.002 in.) from nominal size, and
(b) the coatings must endure concentric amongst the wire.
Welding Electrode is sold past times weight together with are available inward a broad multifariousness of sizes together with specifications. Selection together with recommendations for electrodes for a exceptional metallic together with its application tin give notice endure establish inward supplier literature together with inward the diverse handbooks
(a) the wire diameter must non vary to a greater extent than than 0.05 mm (0.002 in.) from nominal size, and
(b) the coatings must endure concentric amongst the wire.
Welding Electrode is sold past times weight together with are available inward a broad multifariousness of sizes together with specifications. Selection together with recommendations for electrodes for a exceptional metallic together with its application tin give notice endure establish inward supplier literature together with inward the diverse handbooks
- Electrode coating
Claylike materials are used to coat the electrodes. These materials include silicate binder equally good equally powdered materials such equally diverse oxides, metallic alloys, fluorides together with carbonates together with cellulose. Cellulose includes cotton wool cellulose together with woods flour.
Brittle electrode coatings has some functions together with they accept component inward complex interactions at the fourth dimension of welding. The basic functions are
a) they attention inward stabilizing the arc.
b) Act equally shield against the surrounding surroundings past times producing gases. The gases produced are mainly carbon dioxide CO2 together with H2O vapor together with pocket-sized amounts of carbon monoxide CO together with Hydrogen.
c) They command the charge per unit of measurement at which the electrode melts.
d) Act equally a flux together with protect the weld articulation against the formation of oxides together with other inclusions. The resulting slag also protects the molten weld pool.
e) These coatings add together alloying elements inward the weld zone together with enhances the properties of the weld joint. Deoxidizers attention the articulation from becoming brittle.
To ensure a skilful weld the deposited coating or slag must endure removed later on each pass. Influenza A virus subtype H5N1 wire brush tin give notice endure used for cleaning the deposited coating.
Bare electrodes are also available which are made of stainless steel of aluminum alloys.