Welding Processes 51

Table 1.10 Comparison of four types of electrodes

Electrode class Rutile Gas shielded iron oxide silicate Basic

Ductility
Penetration
Absence of undercut
Absence of spatter
Deposition efficiency
Deposition rate
Soundness
Ease of handling
Ease of re-striking
Resistance to cracking
4 2 3 1
4 1 2 3
1 4 3 2
2 4 1 3
1 4 3 2
2 4 1 3
3 4 1 2
1 3 4 2
1 2 3 4
2 3 4 1

Note : 1 indicates the best results; 4 the worst.

The division of electrode coatings into four main types gives only a general
picture of coatings and it is worthwhile considering further subdivisions or
combinations of these types:
(a) Cellulosic electrodes : Little variation is possible with this major type of
electrode. The original coatings restrict use to direct current; however, minor
additions or arc stabilisers allow the use of a.c. with some electrodes. Spatter
losses remain high and the weld bead is coarse with uneven ripples.
Mechanical properties of the weld are good.
(b) Medium rutile electrodes : With an average coating thickness i.e., outer diameter
less than one and a half times the core wire diameter, it is based on titanium
dioxide, with around 15 per cent of cellulosic material present in the covering
to give some gas shielding. These electrodes are suitable for positional
welding. Hot cracking can occur with small throat thicknesses although
the weld metal is not so susceptible as iron oxide/silicate deposits.
(c) Heavy rutile electrodes : Thicker coverings with less, below 5 per cent, cellulosic
additions result in a heavy compact self detaching slag. The weld appearance
is smooth and mechanical properties are quite good.
(d) Iron oxide acid electrodes : These electrodes have a medium to heavy covering
that produces an iron oxide, manganese oxide-silica acidic slag. Further,
the covering contains deoxidizers (generally ferromanganese) to give sound
weld deposits with good mechanical properties. The solid slag has a
characteristic honey comb structure and is readily detached. Deposition
rates are high and deep penetration can be achieved with thick coverings.
Though the welds can be made in all positions, the nature of the molten
slag (voluminous and often fluid) makes these electrodes best suited in the
flat position.
Weld deposits from these electrodes are more susceptible to hot cracking
than from other types and care must be taken with the parent material.
Carbon content should not exceed 0.24 per cent nor sulphur content exceed
0.05 per cent for killed steels or 0.06 per cent for rimmed steels. Crack
susceptibility is most marked in horizontal-vertical or vertical fillet welds.
(e) Rutile acid electrodes : With replacement of iron and/or manganese oxide by
titania upto a maximum of 30 per cent, a somewhat more fluid acid slag is