WELDING ENGINEERING and QA

Checking SMAW electrode ovens

and electrode handling at Suppliers

SQE, Materials and Welding | July 28, 2018

Overview

 Many foundries and fabricators for Sulzer use SMAW (Shielded

Metal Arc Welding also known as “Stick Welding”) to perform weld
repairs and fabrication.

 SMAW is a good welding process. SMAW is very simple, robust,

and versatile.

 But there are some problems that can happen with the electrodes.

 This presentation is to be a general guide of what we should do as

Supplier Quality Engineers when we check on the electrode baking
and handling.
 For specific questions, check with a welding specialist or welding engineer.

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The goals

 Help our suppliers reduce weld rework.

 Ensure welds have the properties needed by Sulzer, especially

 Weld toughness
 Freedom from cracks
 No defects received by the factories.

 Make sure our customer expectations are met.

 Help prevent mixed-metal errors.

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Problems – “Why check at all?”

 SMAW electrodes (or “rods” or “the sticks”) have flux coating that
likes to soak up water.
 Water contains hydrogen (H2) and Oxygen (O). H and O are bad for
the welds.
 Possible welding problems include:
 Porosity
 Cracking
 Lower toughness
 For this reason, many national codes including AWS / ASME have
requirements about how the electrodes are to be baked and
handled.
 My personal background is ASME, but the practice is good for
others.

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Some definitions

 Electrodes, or “rods” or “sticks” or “stick rods”

 Electrode Ovens

 Heated Quivers – they go with the welders

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A picture of the problem

Over time,
water goes
in here.

Then the
water goes
in the weld.

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Keeping the sticks dry
Step 1, receiving the sticks

 There are 2 ways that electrode manufacturers package electrodes.

 Hermetically-sealed cans like beer cans – air-tight.

 Plastic or paper packages – not air-tight.

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Keeping the sticks dry

 Electrodes received in hermetically sealed containers may be used

right away without being baked.
 They need to be stored in a holding oven or heated quiver at 100-
120°C unless used immediately (within 4 hours).

 Electrodes received in non-airtight packages require high

temperature baking for 1-2 hours at ~300-350°C before use.
 Then they need to be used immediately or held in a holding oven or
heated quiver.
 Too much time at the high temperature damages the rods.

 Please notice that this means that 2 ovens are needed. A small
oven for the 1-2 hour baking, and a larger holding oven for holding
the electrodes at the lower temperature.
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Eric, do you mean all SMAW electrodes ?? …

 Actually not all electrodes.

 Carbon steel, low alloy steel, martensitic and ferritic stainless, and
duplex all require baking and holding in heated ovens or quivers.
 WCB, LCB, CA15, CA6NM, 3A, 4A, 5A, WC9, and more…
 Anything strongly magnetic.

 Austenitic stainless steel and nickel-base rods usually do not

require baking or holding in ovens or quivers.
 CF3M, ENiCrMo-3, CF8, etc, Hastelloy, Monel, etc …
 Anything non-magnetic or very weakly magnetic.

 Always look at manufacturer instructions.

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Risk factors

 Main risk factor is hand and finger burns.

 Ovens and electrodes should be hot. Always be careful with your

hands and fingers.

 Approach things that should be hot slowly.

 Be careful with arc flash and fumes.

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Overview of checks

 Checks of weld bays are quick checks. Usually 3-5 minutes, no

more.

 Usually just a quick check. Not an in-depth audit.

 Might be some exceptions, like Nuclear.

 Checks in 2 parts:
 Visual overview
 Hands-on

 There is no substitute for a hands-on check.

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ROD OVENS – The Visual Check

 Are there separate ovens for baking and holding?

 Are the ovens labeled as such?

 Do the ovens work?

 Can you read the thermometer? Is it 100-120°C?

 Is the thermometer calibrated? It should be.

 Do the doors close securely?

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ROD OVENS – The hands-on check #1

 Carefully check with your hand to see if the rods are hot.
 Sometimes they are just warm. Check to see if they feel 100-120°C. Usually
can tell from around 6mm away. Do not need to do a temperature
measurement unless you really think something is wrong and the supplier does
not agree, then it might be good to try a measurement.

 Take a look and make sure the rod shelves are labeled with
electrode type or alloy type.

 If heat-lot traceability is required by contract specifications, are the

rods in the oven traceable?

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ROD OVENS – The hands-on check #2

 Do a spot check of a few electrodes on the shelves to make sure

they are the right alloy type for that shelf.

 Wrong rod type on shelf? Major problem. Could easily cause

mixed-metal error. Meaning, wrong weld metal could be used.

 If the shelves are labeled with alloy type (like WCB or 3A), ask how
the person loading the shelves knows which electrodes to load on
that shelf.

 If you need to know the electrode type to weld a casting grade

(example, CF3M uses E316L), ask to see the WPS or other shop
written instructions that tell you this. It must be easily available in
the shop.

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ROD OVENS – Final check

 Visually inspect (quick check) of the insulation strip around the

furnace door. It should be complete with no gaps.
 Gaps allow air to move through the furnace (air drafts).

 Does the door open, close, and latch correctly?

 After closing the oven door, move your hand around the top ½ of
the furnace door to check for temperature spikes.
 Temperature spikes indicate drafts.

 Step back and look at the whole thing.

Does something look wrong?

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QUIVERS – What to check #1

 Is the quiver plugged in and turned on?

 Check to make sure the quiver door is closed, and the latch is good.

 Is the door and whole quiver in good condition? Or is it beat-up

and leaky?

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QUIVERS – What to check #2

 Gently and carefully check the side walls of the oven or quiver to
see if it is warm, and the same temperature all over.
 It seems that round quivers with little plastic wheels heat from the bottom, so
they need to be stored standing up to make sure the top is hot enough.

 Open the quiver. Does the temperature seem to be 100-120°C?

 Does the door close correctly?

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WHAT IS THAT ROD? – Oopsie!

 Hey!!
What are these loose rods doing?!
 What are they? How long have they been out?

 Remember, welders love to hide rods around the place.

 Old weird rods…

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The End – Thank You!

 There is a lot of detail here.

 Just take it slow. Allow yourself to learn over time.

 Don’t worry if you miss something or don’t feel perfect.

 Check a few things. Have a try.

 Ask questions.

 Thanks for your attention.

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