Indian Standard I: Covered Electrodes For Manual Metal Arc Welding of Carbon and Carbon Manganese Steel - Specification
Indian Standard I: Covered Electrodes For Manual Metal Arc Welding of Carbon and Carbon Manganese Steel - Specification
Indian Standard I: Covered Electrodes For Manual Metal Arc Welding of Carbon and Carbon Manganese Steel - Specification
Indian Standard i
;
COVERED ELECTRODES FOR MANUAL METAL
ARC WELDING OF CARBON AND CARBON
MANGANESE STEEL — SPECIFICATION
(Sixth Revision) :,
;:
{
ICS 25.160 .20;77.080.20
0 BIS 2004
,* .-
Welding General Sectional Committee, MTD 11
FOREWORD
This Indian Standard (Sixth Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by
the Welding General Sectional Committee had been approved by the Metallurgical Engineering Division Council.
This standard was first published in 1957 and subsequently revised in 1963, 1967, 1970, 1974 and 1991. While
reviewing the standard in the light of experience gained during these years, the Committee decided to revise it to
bring it in line with the present practices being followed by the Indian and overseas industry.
In this revision, the following changes have been made:
.
a) Semibasic type of covering has been included.
b) Chemical analysis of basic and semibasic classification has been provided.
c) Percentage elongation for ‘O’ designating digit has been included.
In the formulation of this standard due weightage has been given to international co-ordination among the standards
prevailing in different countries in addition to relating it to the practices in the field in this country. This has been
met by deriving assistance from the following publications:
a) ISO 2560:1973 Covered electrodes for manual arc welding of mild steel and low alloy steel—
Code of symbols for identification
b) BS 639:1986 Covered carbon and carbon manganese steel electrodes for manual metal arc
welding
c) ANSUAWSA 5.1-1991 Covered carbon steel arc welding electrodes — Specification
In reporting the results of a test or analysis, made in accordance with this standard, if the final value, observed or
calculated, is to be rounded off, it shall be done in accordance with IS 2:1960 ‘Rules for rounding off numerical
values (revised’.
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IS 814:2004
Indian Standard
COVERED ELECTRODES FOR MANUAL METAL
ARC WELDING OF CARBON AND CARBON
MANGANESE STEEL — SPECIFICATION
(Sixth Revision)
1 SCOPE IS No. Title
This standard specifies the requirements for covered 1608:1995 Mechanical testing of metals —
carbon and carbon manganese steel electrodes for Tensile testing (second revision)
carbon and carbon manganese steel, including 1757:1988 Method for charpy impact test
hydrogen controlled electrodes for manual metal arc (V-notch) for metallic materials
welding of mild and medium tensile steels including (second revision)
structural steels, depositing weld metal having a tensile 1977:1996 Low tensile structural steel (third
strength not more than 610 MPa. revision)
Electrodes designed specifically for repair welding, 2002:1992 Steel plates for pressure vessels for
often marketed in India as ‘low heat input’ electrodes intermediate and high temperature
are not covered in this standard. service including boilers (second
revision)
Ilmenite type electrodes are being used fairly widely
2062:1999 Steel for general structural purposes
in few other countries. There appears to be a trend to
@fib revision)
use ihnenite as an ingredient of the covering in our
country also. Provision for a separate class for such 2879:1998 Mild steel for metal arc welding
electrode may be considered at a later stage. electrodes (third revision)
NOTE — For weld metal with tensile strength higher than 3039:1988 Structural steel for construction of
610 MPa, a reference maybe made of IS 1395. hulls of ship (second revision)
2 REFERENCES 8500:1991 Structural steel—Micro-alloyed
(medium and high strength qualities)
The following standards contain provisions which — Specification (jlrst revision)
through reference in this text constitute provision of
11802:1986 Method for determination of
this standard. At the time of publication, the editions
diffusible hydrogen content of
indicated were valid. All standards are subject to
deposited weld metal from covered
revision and parties to agreements based on these electrodes in welding mild and low
standards are encouraged to investigate the possibility alloy steels
of applying the most recent editions of the standards
indicated below: 13043:1991 Covered manual metal arc welding
electrodes — Determination of
IS No. Title efficiency, metal recovery and
812:1957 Glossary of terms relating to welding depositim coefficient
and cutting of metals 13851:1993 Storage and redrying of covered
1182:1983 Recommended practice for electrodes before use —
radiographic examination of fusion Recommendations
welded butt joints in steel plates 3 TERMINOLOGY
(second revision)
For the purpose of this standard, the definitions given
1387:1993 General requirements for the supply
in IS 812 and the following definitions shall apply.
of metallurgical materials (second
revision) 3.1 Weld Slope — It is the angle formed between the
1395:1982 Low and medium alloy steel covered lines of the weld root and a horizontal reference plane.
electrodes for manual metal arc Slope may be measured either clockwise or
welding (third revision) artticlockwise and either above or below the horizontal
plane between 0° and 90°.
1599:1985 Method for bend test (second
revision) 3.2 Weld Rotation —The rotation of weld is the angle
1
IS 814:2004
formed between upper portion of vertical reference c) Letter ‘X’ indicating the radiographic quality
plane passing through the weld root and a point on the (see 5.9).
face of weld equidistant from both the edges of weld. NOTE — Examples illustrating for establishing electrodes
Rotation may be measured either clockwise or coding from the initial test results have been given in
anticlockwise between 0° and 180°. Annex A.
3.3 Weld Position — The welding position is given 5.2 Type of Covering
by the combination of weld slope and weld rotation Type of covering shall be indicated by the following
(see 5.5.1). letters:
4 SUPPLY OF MATERIALS A – Acid
B – Basic
General requirements relating to the supply of covered C – Cellulosic
electrodes for metal arc welding shall be as laid down R – Rutile
in IS 1387. RR – Rutile, heavy coated
SB – Semibasic
5 CLASSIFICATION
NOTE — The characteristics of each type of the covering and
5.1 Coding coating ratio are described in Annex B for guidance only.
I
follows:
5.1.2 Additional Coding a) All positions;
The following letters indicating the additional properties b) All positions except vertical down;
J
of the electrodes maybe used, if required: c) Flat butt weld, flat fillet weld and horizontal/
a) Letters H 1, H2 and H3 indicating hydrogen vertical fillet weld;
controlled electrodes (see 5.7); d) Flat butt weld and flat fillet weld;
b) Letters J, K and L indicating increased e) Vertical down, flat butt, flat fillet and horizontal
metal recovery, as effective electrode; and vertical fillet weld; and
‘Efficiency (EE)’ as per IS 13043 in the o Any other position or combination of positions
following range (see 5.8) not classified above.
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IS 814:2004
and overhead positions, it maybe considered that sizes 5.6 Welding Current and Voltage Conditions
larger than 4 mm are not normally used for welding in
The welding current and open circuit voltage conditions
these positions.
on which the electrodes can be ollerated as
5.5.3 An electrode shall not be coded as suitable for a recommended by the manufacturer shall be indicated
particular welding position unless it is possible to use by the appropriate designation digits as given in
it satisfactorily in the position to comply with test Table 3. Welding current and voltage conditions have
requirements of this standard. been described in Annex D.
o 16 No impactrequirements
1 20 47 JI+27T
2 22 41 J/+OY
3 24 47 JI-20%2
4 24 27 J/-3O”C
o 16 No impact requirements
1 18 47 JI+27W
2 18 47 J/+O”C
3 20 47 JI-2WC
4 20 27 JI-3WC
5 20 27 JI-4CW
6 20 27 J/-46”c
NOTE — ~S7 is the cross-sectional area of test piece.
3
IS 814:2004
5.7 Hydrogen Controlled Electrodes from covering for enabling it to be gripped by the
electrode’s holder as specified below:
The letters H 1, H2 and H3 shall be included in the
classification as a suffix for those electrodes which Electrode Size Bare Length
will give diffusible hydrogen in ml/100 g when
determined in accordance with IS 11802 as given Minimum Maximum
below: mm mm mm
H 1 = Up to 15 ml diffusible hydrogen 1.6t03.15 15 30
4.0 to 8.0 20 40
H2 = Up to 10 ml diffusible hydrogen
H3 = Up to 5 ml diffusible hydrogen 7.2.2 Arc Striking End
NOTE — For F13,glycerin method shall not be used. The arc striking end of the electrode shall be bare and
permits easy striking of the arc. The distance from the
5.8 Increased Metal Recovery arc end to the first point where the fill cross-section of
the covering prevails shall not exceed the following
The letters J, K and L shall be included in the
limits:
classification as a sufllx for those electrodes which have
appreciable quantities of metal powder in their coating For all classifications — 1/2 core wire diameter or
and give increased metal recovery with respect to that 2.0 mm, whichever is less
of core wire melted in accordance with the range given
in 5.1.2(b). Table 4 Sizes and Lengths of Electrode
(Clauses 7.1 and 7.1.2)
The metal recovery shall be determined as effective
electrode efficiency (EE as per the method given in Size Length
Is 13043). mm mm
(1) (2)
5.9 Radiographic Quality Electrodes
1.6 150 or 200 or 250
The letter ‘X’ shall be included in the classification as 2.0 200 or 250 or 300 or 350
a suffix for those electrodes which deposit radiographic 2.5 250 or 300 or 350
quality welds (see 9.6).
3.15 350 or 450
6 CORE WIRE FOR ELECTRODES 4.0 350 or 450
5.0 350 or 450
The core wire used for the manufacture of electrodes
shall conform to IS 2879. 6.3 350 or 450
8.0 350 or 450
7 DIMENSIONS AND TOLERANCES
7.1 Size and Length 7.3 Concentricity of Flux Covering with Core
Wire — Tolerance
The size of an electrode shall be designated by the
nominal diameter of the core wire expressed in The flux covering on the electrode shall be uniform
millimetres. Sizes of electrode and corresponding and concentric with the core wire. The tolerance for
lengths of electrodes shall be as given in Table 4. concentricity of the covering (see Fig. 1) shall be such
that the maximum core pltis one covering dimension
7.1.1 The tolerance on the specified diameter of core shall not exceed the minimum core plus one covering
wire shall be+ 0.05 mm. The tolerance on the specified dimension by more than:
length of electrode shall be *3 mm.
a) 5 percent of the mean of two dimensions for
7.1.2 Sizes and lengths of electrode other than those EBXXXX and ESBXXXX class electrodes,
mentioned in Table 4 may be supplied subject to b) 4 percent of the mean of two dimensions for
mutual agreement between the manufacturer and the ERXXXX, ERRXXXX and EAXXXX class
purchaser. The tolerance in such cases shall be agreed electrodes, and
to between the manufacturer and the purchaser.
c) 3 percent of the mean of two dimensions for
7.2 Bare Length ECXXXX class electrodes.
7.2.1 Contact End 7.4 Core wire and coverings shall be free from defects
which would interfere with the uniform welding
The contact end of the electrode shall be clean and free performance of the electrode.
IS 814:2004
ECXXXX do
ERXXXX do
ERRXXXX do
EBXXXX 0.12 1.6 0.75 0,035 0.035 0.30 0.20 0.30 0.08 1.75
5
,.
1
IS 814:2004
among the initial tests (see 8.2) and are meant to be maintained for quality control, for ensuring that the
repeated at intervals to provide evidence that the composition and quality of all the electrodes currently
electrodes currently produced possess the properties produced are similar to those electrodes subjected to
proved in the initial tests: initial and periodic check tests.
a) All weld metal mechanical tests for tensile or 8.6 Additional Tests
impact (see 9.1); and
Subject to agreement with the manufacturer, the
b) Running performance test (for sizes up to and purchaser may request for additional tests to be made
including 2.5 mm) (see 9.3). or certificates to be provided for each batch of electrodes
Such tests shall be conducted at least once in a year. supplied. If so, the tests and batch definition shall be
These tests shall not apply to the electrodes not agreed between the manufacturer and the purchaser.
manufactured during the year. When production of a 9 DETAIL OF TESTS
particular type of electrode after stoppage of production
for more than six months is restored, the periodic tests 9.1 All Weld Metal Mechanical Tests for Tensile and
shall be conducted. Impact
By means of suitable system of control, the Two all weld test assemblies shall be prepared, one
manufacturer shall satis~ himself that the composition using 4.0 mm and the other using the highest size
and quality of all the electrodes currently produced are manufactured in accordance with the method described
similar to those electrodes which were subjected to in Annex F. If the highest size produced by any
initial tests. He shall ensure that the result of quality manufacturer is 4.0 mm, then two weld test assemblies
control tests and date of manufacture of electrodes is using 4.0 and 3.15 mm size respectively shall be
traced from the batch number of the relevant details, or prepared.
both. NOTE — 1sscase 3.15 mm is tire highest size manufactured,
only one weld test assembly shall be prepared with this size.
NOTES
1 For the purpose of this standard, a batch is defined as a lot 9.L2 All Weld Tensile Tests
of covered electrodes of any one size and classification
produced from coating identified by a dry mix or more than Two all weld tensile test specimens, one from each of
one dry mix of controlled chemical composition and core wire the assemblies as given in 9.1.1, shall be prepared and
identified by a heat number or controlled chemical tested in accordance with the method described in
composition.
Annex F. The ultimate tensile strength and yield stress
2 Identification of electrode core wire: shall comply with the values given in Table 6. When
a) Solid core wire for manufacture of electrodes particular ductile properties are claimed or specified,
identified by heat number shall consist of material the minimum percentage elongation shall comply with
from a single heat of metal.
the appropriate value given in Table 6.
b) Solid core wire identified by controlled chemical
NOTE-The all weld tensile test is for qrrrditycontrol purpose
composition rather than by heat number, shall consist
of mill coils of one or more heat from which samples only. It is not intended to imply that values obtained in atl
weld tests should be used for design purposes.
have been taken for chemical analysis. The results of
the analysis must be within the composition limits as 9.1.3 All Weld Impact Tests
specified in IS 2879.
3 Identification of covering mix: Five charpy V-notch impact test specimens shall be
a) A dry mix is the quantity of dry coating ingredients machined fkom the same test assembly and tested in
mixed at one time in one mixing vessel. A dry mix accordance with the metlmd described in Annex F at
may be divided into smaller quantity for production the temperature specified in Table 6 and shall comply
of wet mixes in using a liquid binder. with the values given in Table 6 at specified
b) Covering identified by a dry mix shall consist of temperature. The results of the impact test from
electrode produced from a single dry mix of coating five test specimens shall be assessed as specified
ingredients.
in 9.1.3.1,9.1.3.2 and 9.1.3.3.
c) Covering identified by controlled composition rather
than by dry mix shall consist of one or more dry mixes 9.1.3.1 When computing the average values of the
and shall be subjected to sufficient tests to assure that impact properties fkom the set of five specimens, the
all dry mixes within the lot are equivalent. These tests lowest value and the highest value obtained shall be
shall include chemical analysis of the weld metal, the
results of which must fall within the manufacturers disregarded.
acceptance limits. The identification of the test
9.1.3.2 For classification EXX 1XX, EXX2XX and
procedure and the test results shall be recorded.
EXX3XX, two of the three remaining values shall be
8.5.1 The manufacturer on request shall make available greater than the specified 47 joules; one of the three
to the approving and certifying authorities the records values may be lower but shall not be less than41 joules.
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IS 814:2004
The computed average value of the three values shall 9.3 Running Performance Test (for Electrode Sizes
be equal to or greater than 47 joules. Up to and Including 2.5 mm)
9.1.3.3 For classification EXX4XX, EXX5XX and This test is to be carried out for electrodes of 2.5 mm
EXX6XX, two of the three remaining values shall be size and below to assess the welding performance. The
greater than the specified 27 joules; one of the three test shall be conducted using three electrodes as per the
values may be lower but shall not be less than 23 joules. details given in Annex H. The bead should be visually
The computed average value of the three values shall inspected and should be free from porosities, slag
be equal to or greater than 27 joules. inclusions, cracks, etc, in the main portion of the bead
as given in Annex H. The bead shall be reasonably
9.2 Butt Weld Bend Test
straight and evenly rippled. The slag should be removed
Butt weld assemblies shall be prepared in different with little effort.
welding positions for the various electrode
classifications as per the recommendations given in 9.4 Increased Metal Recovery Test
Table 7 and the procedures given in Annex G. If 2.5 The metal recovery shall be determined for the
mm size electrode is manufactured then this size shall electrodes classified under EXXXXXJ, EXXXXXK
be used for the root run for the butt weld assembly and EXXXXXL or EXXXXXHJ, EXXXXXHK and
wherever option of 2.5 or 3.15 mm is given in Table 7. EXXXXXHL on the largest size electrode
9.2.1 From each butt weld assembly two bend tests, manufactured but not lower than 4.0 mm in accordance
one with face and one with root in tension shall be with the method given in IS 13043. The value obtained
carried out. The test specimens shall be bent through by the method shall be rounded off to the nearest
180° over a mandrel having a diameter equal to three multiple of 5.
times the thickness of the specimen in accordance with
The rounded recovery figure shall conform to
IS 1599. The electrode shall be deemed to be
the requirements of 5.1.2(b) for the respective
satisfactory, if on completion of the test no crack or
classification.
defect at the outer surface of the test specimen is greater
than 3 mm measured across the test specimen or 1.5 9.5 Diffusible Hydrogen Evaluation Test
mm measured along the length of the test specimen.
Premature failure at comers of the test specimen shall This test shall be carried out for all electrodes classified
not be considered as a case for rejection. under EXXXXXH and EXXXXXHL preferably using
NOrE — In view of the possible scatter in welding and testing, the upper limit of ultimate tensile strengths may be exceeded
by 40 MPa.
7
IS 814:2004
Table 7 Welding Procedure for Preparation of Butt Weld Bend Test Pieces
(Clauses 9.2 and G-1.4)
EXXX6X As required In all positions a) If the position comes nearer to flat position:
specified by the 1) First run with 3.15 mm or 4.0 mm
manufacturer 2) Subsequent runs (except last two layers) with
4.0mmor5.Omm
3) Last two layers with the largest size
submitted for approval
4s
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IS 814:2004
3.15 mm or 4.0 mm size. The test shall be carried out prepared by using electrode from the same batch
inaccordance with IS 11802. wherever possible and submitted only for the tests in
which failure occurred. The electrode shall not be
9.6 Radiographic Test accepted as having passed that test unless the tests on
All welded test assemblies after the removal of backing additional specimen are satisfactory.
strip, shall be machined or ground smooth so as to avoid
11 PACKING AND STORAGE
difficulty in interpretation ofradiograph ofweld. It shall
then be subjected to radiographic test as per IS 1182. 11.1 The net mass of an individual bundle or carton of
The radiograph shall not show crack or incomplete electrodes shall not exceed 7 kg.
fusion. The radiograph acceptance standard in respect
of porosity and slag inclusions is indicated in Table 8. 11.2 Electrodes shall be suitably packed to guard
againstany damage duringtransportation.The packing
In making the evaluation for radiographic acceptance shall be suitableto ensurethatundernormal storeroom
standard, a length of 25 mm of the welded assembly conditions, the electrodes shall, for a period of six
shall be excluded from both ends. months atler the date of manufacture, be capable of
10 RETESTS giving results in accordance with the provisions of this
standard and that if the flux covering is a type requiring
Where any test specimen fails to fulfil the test special protection during storage, the details of such
requirements, twice the number of the test specimens special protection shall be furnished by the
made for that test for the initial or periodic test shall be manufacturer and reference to this should be included
-- .—
A
!
IS 814:2004
in the marking of bundle or carton of electrodes. The clearly marked with the following information:
electrodes shall be stored in a dry room condition (see a) Classification (see 5);
also IS 13851).
b) Indication of the source of manufacture;
11.3 The batch of electrodes represented by the c) Trade name and brief description of the
electrodes tested shall not be certified as complying electrodes;
with this standard unless the test results obtained satisfy
the requirements specified in 8.3 and the manufacturer d) Size and quantity of electrodes;
has performed the tests at intervals in accordance with e) Batch number;
the requirements of this standard. f) Recommended current range, polarity and open
circuit voltage;
12 TEST RESULTS
g) Date of manufacture;
12.1 On request, as evidence that the electrodes supplied h) Recommendation for special storage conditions
comply with the requirements of this standard, the and redrying temperature; and
manufacturer shall produce the results of most recent
periodic check tests on electrodes representative of the j) A cautionary notice on safety during welding.
electrodes supplied. 13.1.2 BIS Certl~cation Marking
12.2 If required by the purchaser, the manufacturer The bundle or carton of electrodes may also be marked
shall furnish a test certificate for each batch of electrode with Standard Mark. .
supplied.
13.1.2.1 The use of the Standard Mark is governed by
13 MARKING the provisions of Bureau ofIndian Standar& Act, 1986
13.1 As agreed to between the manufacturer and the and the Rules and Regulations made thereunder. The
purchaser, brand name/classification shall be printed details of conditions under which the licence for the
on all the electrodes. use of Standard Mark maybe granted to manufacturers
or producers maybe obtained from the Bureau of Indian
13.1.1 Each bundle or carton of electrodes shall be Standards.
ANNEX A
(Clause 5.1.2)
EXAMPLES OF ELECTRODE CLASSIFICATIONS
A-1 The examples given in A-2 and A-3 illustrate the sets of impact tests at +27°C, O°Cand –20°C in order to
way in which the coding and the complete classification determine the appropriate classification.
is expressed.
A-3 EXAMPLE 2
A-2 EXAMPLE 1
A covered electrode having a basic covering with an
The electrode is a covered electrode having a light rutile increased metal recovery of 120 percent and depositing
covering. weld metal containing 7 millilitres of diffusible
hydrogen per 100 g of deposited weld metal.
The electrQde maybe used for welding in all positions
and it weld satisfactorily on a.c. with a minimum open The electrode may be used for welding in all positions
circuit voltage of 50 V and on d.c. with both positive except vertical down and operate on a.c. with a
and negative polarity. minimum open circuit voltage of 70 V and on d.c. with
positive polarity. The electrode deposit weld metal gives
The electrodes are not designed to give hydrogen radiographic quality weld.
controlled weld metal. The electrode is not meant for
The electrode deposits weld metal with the properties
radiographic application.
given in Table 10 when tested in accordance with this
The electrode deposits weld metal with the properties standard and when the manufacturer submits 6.3 mm
given in Table 9, when tested in accordance with electrode as the maximum size to be classified. The
standard and when the manufacturer submits 8 mm table of results shows that the manufacturer carried out
electr~de as the maximum size to be classified. The sets of impact tests at –30°C and 40”C in order to
table oi wsults shows that the manufacturer carried out determine the appropriate classification.
10
IS 814:2004
Ultimate tensile 480 465 410-510 510-610 Satisfactory for EX4XXX but
strength, MPa unsatisfactory for EX5XXX class
Yield strength, 365 350 330 Min 360 &fin Satisfactory for both
Mpa EX4XXX and EX5XXX classes
Impact strength
at –20”C, J
(average)
Elogation, percent
at 5.65 ~
46,45
40,40
35
26
40,37
33,32
30
25
47 Min
22 Min
47 Min
18 Min
Unsatisfactmy for both
EX4XXX and EX5XXX classes
ER4 21
COVERED ELECTRODE JI
11 “
-“? , —.
.
7
IS 814:2004
Ultimate tensile 570 550 410-510 510-610 Satisfactory for EX5XXX but
strength, MPa unsatisfactory for EX5XXX class
Yield strength, 420 400 330 Min 360 A4in Satisfactory for both
MPa EX4XXX and EX5XXX classes
NOTES
1 Elogation incorporated here from Table 3 after establishment of impact property at specified temperature.
2 So is the cross-sectional area of test piece.
EB54 26i J x
COVERED
TYPE
mm-
OF COVERING -(BASIC )
I‘
STRENGTH C.HARACTERISTICS-OJTS= 5Kl- MPa AND
YS=360 MPa min.)
.
12
-?.. —
IS 814:2004
ANNEX B
(Clause 5.2)
CHARACTERISTICS OF COVERING AND COATING RATIO
ANNEX C
(Clause 5.5.1)
WELDING POSITION
14
,= .&.”
,e+
IS 814:2004
90°
SLOPE
ROTATION
Y
FIG. 3 HoruzomdVmmcN- POSITION
(f 0° 0°
0° SLOPE
SLOPE
ROTATION O TO 180° ROTATION O TO 180°
0°
180-
ROTATION
15
IS 814:2004
ANNEX D
(Clause 5.6)
STANDARD WELDING CURRENT AND VOLTAGE CONDITION
D-1 STANDARD WELDING CURRENT AND to size of the electrode. Table 12 applies to the sizes 2.5 mm
VOLTAGE CONDITION and above. The reference size for coding of welding current
and voltage condition should be 4 mm or 5 mm. If electrodes
Specific welding current and open circuit voltage of size less than 2.5 mm are used, a high voltage may be
necessary. Within the range of sizes 2.5 mm to 8 mm, the
conditions are denoted by symbols given in Table 12. open circuit voltage necessary may be expected to vary
When an electrode is meant for use with either d.c. or approximately as follows:
a.c., combination of symbols given in Table 12 shall
be used. Code Voltage Variation in Voltage
NOTES v v
1 The electrode may not function satisfactorily at a lower 90 100 to 80
voltage than that for which it is classified but a higher voltage
may be used in service with advantage. 70 80 to 60
2 The open circuit voltage for striking the arc varies according 50 60 to 40
Description Symbol
(1) (2)
16
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IS 814:2004
ANNEX E
(Clauses 8.1.3, F-1.1 and F-1 .2)
PARENT METAL FOR TEST PIECES
17
/.. A..... -
IS 814:2004
ANNEX F
(Clauses 9.1.1,9.1.2,9.1.3, G-1.l andH-1.1)
ALL WELD TESTS FOR TENSILE AND IMPACT
F-1 PREPARATION OF TEST PIECES F-2.4 Each electrode shall be consumed completely
up to a stub end of not more than 50 mm. - -
F-1.l Parent Metal
F-2.5 The welding current used shall always be less
The parent metal for plates used in test pieces shall be
than the maximum value and within the range
in accordance with Annex E. The test specimens shall
recommended by the manufacturer. The open circuit
not be subjected to any mechanical or thermal treatment
voltage shall not be less than that specified by the
other than that required under this Annex.
manufacturer.
F-1.2 All weld metal test pieces shall be prepared by
depositing weld metal between the chamfered edges of The welding current shall be a.c., if the electrode can
two plates placed on a backing strip as shown in Fig. 7. be used with both a.c. or d.c, The welding current shall
The backing strip shall be tack welded to the test be d.c. with positive polarity, if the electrode can be
assembly. used with d.c. positive or negative polarity.
The backing strip shall also be made from the material F-2.6 If it is necessary to interrupt the welding
used for all weld metal assemblies described in procedure, the assembly shall be allowed to cool in still
Annex E. air to room temperature. When welding is resumed,
the assembly shall be preheated to a temperature of
F-1.3 The dimensions of test assembly are shown in 110+ 15°c.
Fig. 7 and given in Table 14. The length of the plate
shall be enough to accommodate a tensile test specimen F-2.7 When the assembly has been welded completely,
and at least six charpy V-notch impact test specimens it shall be allowed to cool in still air to room
as shown in Fig. 7. temperature. The portion including the weld shall then
be removed by cutting away the excess plate at the
F-1.4 The plate edges shall be bevelled by machining places indicated in Fig. 9. Cutting along the chain lines
or machine gas cutting. In the later case, any remaining (shown by ---- -) may be done mechanically or by
scale should be removed from bevelled edges. The machine gas cutting. Along the longitudinal boundaries
surface of the backing strip should be free from rust or (shown by broken lines rts(--------------------
scale. --- -) of the parts to be machined into impact test pieces
F-1.5 In order to counteract shrinkage deformation, cutting should be done by mechanical methods only.
the test assembly should be preset as shown in Fig. 8 in
F-3 HEAT TREATMENT OF ALL WELD
such a way so that afler completion of welding a level
TENSILE TEST PIECE
joint is obtained.
F-3.1 The all weld test pieces shall be heat treated in a
F-2 WELDING PROCEDURE
furnace at a temperature of 250”C for a period of
F-2,1 The assembly shall be welded in flat position 12+1 hrs. After the soaking period, the specimen shall
unless the electrode is not recommended in the flat be withdrawn from the furnace and allowed to cool
position in which case welding position shall be one slowly, protected from drought and chilling.
that is recommended by the manufacturer.
F-3.2 The purpose of heat treatment is to remove
F-2.2 The test assembly shall be preheated to hydrogen from weld metal.
110 + 15“C. Welding shall be continued with an
interpass temperature of not less than 11O°C and not F-3.3 The impact test pieces shall not be heat treated.
more than 180”Cas measured by temperature indicating F-4 ALL WELD TENSILE TEST
crayons or surface thermometers at the area specified
in Fig. 7. The tensile test specimen shall be machined from the
weld metal test pieces in accordance with IS 1608, care
F-2.3 Pass Sequence being taken that the longitudinal axis of the test
The weld metal shall be deposited in layers made up of specimen coincides with the central line of the weld
two passes as shown in Fig. 9. The welding speed shall and the mid thickness of the plate (see Fig. 10). The
be adopted to obtain the number of layers given in Table dimensions of the specimen shall be as shown in
15. The direction of welding to complete a pass and a Fig. 11 and Fig. 12. The specimen shall be tested
layer shall be same. The direction of deposition of each in accordance with IS 1608.
layer shall alternate from each end of the plate. F-5 ALL WELD IMPACT TEST
NOTE — The test specimens to be located on the centre
line A-A. The impact test specimen shall be machined from
18
*.,,-..
IS 814:2004
the weld metal test pieces to the dimensions given centre of the weld and is to be cut on the face of the
in Table 16 in accordance with IS 1757. Care being test piece perpendicular to the surface of the plate
taken that the longitudinal axis of the specimen (see Fig.13A, 13B and 13C)thetests are to be conducted
are perpendicular to the weld axis and upper surface at the test temperature on an approved impact
of the plate. The notch shall be positioned in the machine.
8.0 1 to top 2 8 to 12
55* 0.6 10+0.11 10* O.11 45” * 2“ 0.25 ● 0.025 8+0.11 27.5 * 0.42
19
,
1
IS 814:2004
.-
k-. -----
T
i
_, _
____ _ _-,
r
li-
1- --
\r
F -. -- —_. ---
IV
25 )0
F -- ___ --- -_ -
l!! 50 ‘ —
—
— 10
--
-TENSILE TEST
e ---, SPECIMEN
( I 1.
ISCARD
&
mm i min
1-
1.-
k- (.
I
OFTESTASSEMBLYANDPOSITIONOFCmG
FIG. 7 DIMENSIONS OFTESTPIECES
FIG. 8 PRESETTING
OFTESTASSEMBLY
20
IS 814:2004
A
FIG. 9 WELDGEOMETRY
FIG. 10 CUTITNG
OFTENSILETESTPIECE
- PARALLEL LENGTH 60 mm ~
70 mm min -
P
FIG.12 TENSILETESTPtECEFORSUES3.15 mm
21
- ,... .>.
IS 814:2004
T/2
. ~: I
1,2
4 I
55 9
A Position of Test Assembly
10 /
F!zE?
10 \
27.5 27.5
55
~ C Dimensions of V-Notch
ANNEX G
(Clause 9.2)
BUTT WELD BEND TEST
G-1 PREPARATION OF TEST PIECE root bend test specimen as indicated in Fig. 15. The
specimen shall then be subjected to a temperature of
G-1.1 Parent Metal
250”C for a period of 12 + 1 h for hydrogen removal
The parent metal for plates used in preparing test pieces prior to testing. After the soaking period, the specimen
shall be in accordance with Annex F. The test specimen shall be withdrawn from the furnace and allowed to
shall not be subjected to any mechanical or thermal cool slowly, protected from droughts and chilling.
treatment other than that required under this Annex.
G-2 BEND TEST
G-1.2 Test pieces shall be prepared as shown in
Fig. 14 by welding together two plates of suitable length G-2.1 Each bend test specimen shall be 30 mm in
to allow the cutting out of test specimens of specified width. The upper and lower surface of the weld shall
size. The dimensions of test assembly are given in be filed ground or machined level with the respective
Table 17. original surface of the plates, where the surface of the
plates are not level with each other, provided that the
G-1.3 Plates may be preset to allow for slight distortion thickness of the plate is not reduced by more than a
after welding. total of 1 mm. Tool marks should be avoided as they
G-1.4 Welding Procedure lead to localization of stresses and may cause premature
failure. For this reason, direction of machining of
The welding procedure followed in making the test surfaces should be along the specimen and transverse
pieces should be as set out in Table 7 according to the of the weld. The sharp comers of the test specimens
position of welding. In all cases the backing runs shall shall be rounded to a radius not exceeding 10 percent
be made with 4.0 mm electrodes in the weld position of the specimen thickness.
applicable to each test piece after cutting out a groove
to a depth of 3 mm if such groove is considered G-2.2 The test specimen shall be bent through an angle
necessary (see Fig. 15). of 180° in accordance with IS 1599. Method for bend
test over a mandrel having a diameter equal to three
G-1.5 The welding current used shall be within the
times the thickness of the specimen. One test specimen
appropriate range recommended by the manufacturers.
should be tested with face of the weld in tension and
The open circuit voltage shall not be less than that
one with the root of the weld in tension. The electrode
specified by the manufacturer. The welding current shall
should be deemed to be satisfactory, if on completion
be a.c. if the electrode can be used with positive polarity,
of the test no crack or defect at the outer surface of the
when the electrode can be used with both d.c. negative
test specimen is greater the 3 mm measured across the
and positive polarity.
test specimen or 1.5 mm measured along the length of
G-1.6 After welding the test piece shall be cut by the test specimen. Premature failure at comers of the
sawing or machining to form one face bend and one specimen shall not be considered a cause for rejection.
22
,...
1
IS 814:2004
m
w ● ●
w -
DISCARD 60 max.
DISCARD 60max.
G4k
FIG. 14 PREPARATION
OFBENDTESTPJECE
6mm max —
FIG. 15 GROOVE
PREPARATION
FORDEPOSITION
OFSEALING
RUN
23
,.. .. ...
IS 814:2004
ANNEX H
(Clause 9.3)
RUNNING PERFORMANCE TEST
H-1 PREPARATION OF TEST PIECE Three fill electrodes of the particular size keeping not
more than 50 mm stub end should be burnt over the
H-1.1 Parent Metal
parent metal by using a suitable current within the
The parent material should be chosen from any of the current range prescribed by the manufacturer. When
steels prescribed in Annex F. The length of parent the electrode can be used both on d.c. and a.c; a.c. should
material for this test should be such that at least one be used with OCV not less than that prescribed by the
full straight run of the electrode can easily be manufacturer. When the electrode can be used in d.c.
accommodated on it. The thickness of the piate/sheet only, the d.c. positive polarity should be adopted. If all
should be within 2 to 3 times the diameter of the core the three beads are made on the same plate/sheet, care
wire of the electrode. If sheet of suitable thickness is should be taken that no portion of any bead overlaps
not available, plates can be shaped to desired thickness. with any portion of other beads. The electrodes maybe
The plate/sheet should be free from any rust, dirt, redried before welding as directed by the manufacturer.
moisture, oil, grease or any other contamination before
H-2 RUNNING PERFORMANCE TEST
welding.
H-1.2 Welding Procedure The beads shall be visually inspected and shall be free
from porosities, slag inclusions, cracks, etc, in the main
Welding should be done in downhand position by portion of the beads given in Fig. 16. The beads should
stringer bead or, light weaving technique either by touch be fairly straight and evenly rippled. The slag should
welding or by keeping the arc slightly open. The be removed with little effort. A length of 15 mm from
weaving should be restricted to 1.5 times the diameter the start and from finish of the bead should not be
of the electrode (the final diameter including coating). considered for visual inspection.
15mm 15mm
I ‘((((~(’((([v I
FIG. 16 RUNNINGPERFORMANCE
TEST
24
- . . ....
Bureau of Indian Standards
BIS is a statutory institution established under the Bureau ofhdian Standards Act, 1986 to promote harmonious
development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.
Copyright
B1S has the copyright of all its publications. No part of these publications may be reproduced in any form
without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing
the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to
copyright be addressed to the Director (Publication), BIS.
Amendments are issued to standards as the need arises cm the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘B1S Catalogue’ and ‘Standards: Monthly Additions’.
This Indian Standard has been developed from Dot: No. MTD 11 (4455).
.4. . . .
AMENDMENT NO. 1 OCTOBER 2005
TO
1S 814:2004 COVERED ELECTRODES FOR
MANUAIJ METAL ARC WELDING OF CARBON AND
CARBON MANGANESE STEEL — SPECIFICATION
(SiAIh Revision)
[ Foreword, para 3(a) ] –- Substitute the following for the existing line:
‘Semibasic type (SB) of covering has been included and ‘S’ type of covering has I
been deleted.’
( Foreword, paru 3 ) — Add ‘d)’ as follows:
‘d) Transverse bend test has been deleted’ I
[ Page 2, clause !I1.2(a), and page 4, clause 5.7 ] — Substitute ‘HI, Hz,
H3’jbr ‘H 1, H2 and H3’ wherever it appears. $1
~
[ Page 2, clause 5.1.2(b), lines 1 to 4 ] — Substitute the following for the
t
existing: ‘
‘letters J, K and L. indicating increased metal recovery, as ‘effective electrode t
effkiency (EE)’ asp& IS 13043 in the following range (see 5.8)”.
( Page 2, cfause 5.5 ) — Substitute ‘1,2,3 ... .....’ for ‘a ),b),c), ... . ...’.
( Page .5, Table5,CO12 ) — Substitute ‘ASpermsn.facturers declaration’~b’ ‘Not
specified’.
( Page 6, c)ause 8,4, line 2 ) -—Substitute ‘see 8.3’ Jor ‘see 8.2’.
[ Page 6, clause 8.4(a)] — Substitute ‘tensile and impact’ for ‘tensile or
.
impact’ .
A
( Page 7, Table 6, CO1 3 ) — Substitute ‘400’ for ‘360’ for all
EX5 . .. .....classifidations.
( Page 9, Table 8,CO11 and 2 ) — Substitute the following for the existing
classifications:
EA 42 xx
*
EB542 X
EB542
EB362 X GIYKtel
EB 562 X
EB 541 X
EB 552 X
.
Amend No. 1 to IS 814:2004
EC4XI0 -x
EC 4X16-X
ER4XXX -X
ERR4 XXX - X
ER 5 XXX - JX Grade 2
ERR 5 XXX - Jx
ERR 5 XXX - KX
ERR 5 XXX - LX
Ef35 XXX - HXX
f3B5 XXX - HLX
ER41 XX Not
ER 42 XX required
( Page 12, Table 10, CO16, row 1 ) — Substitute the following for the
existing:
‘Satisfactory
for both EX4.XXX and EX5XXX classes’
,
( Page 12, Table 10, COI6, row 4 ) — Substitute the following for the
existing:
‘tJnsatisfactory for both EX5XXX and EX4XXX classes’
( Page 12, Table 10, CO11, row 5 ) — Substitute ‘Elongation’ for ‘Elongation’.
.
AmendNo. 1 to IS 814:2004
( Page 12, Table 10, last line below line diagram ) — SubstiMe ‘EB 5426 w
JX’ for ‘Ill 5426H1 LIX”.
( Page 18, Armex F,,ciause F-2.7, line 5 ) — Substitute ‘Fig. 10’for ‘Fig. 9’.
( page i 9, i7able ]6, CO16, heading ) — Substitute ‘DepthBelow Notch’ for
‘Depth Between Notch’.
*
,,
4
(MTDli)
Reprography IJnit, BIS, New Delhi, India
3
.,
.
..