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Reg. 94
MATERIALS OF CONSTRUCTION

COVERED ELECTRODES FOR METAL ARC WELDING OF MILD STEEL

General requirements

(1) Application.- The following Regulations apply to electrodes of sizes 3/32 inch (12 S.W.G.) and larger in diameter for metal arc welding of carbon steels having ultimate tensile strength not exceeding 33 tons per square inch and Sulphur and Phosphorus contents not greater than 0.06 per cent each. Electrodes less than 3/32 inch in diameter shall not be used in boilers.

The electrodes shall comply with the requirements of physical tests prescribed for each class.

Their characteristics and behaviour under ordinary working conditions shall be such that satisfactory weld deposits can be made by a welder of average skill and experience and that the following characteristics are also obtained:-

(a)

a relative ease in the control of the slag and weld metal during welding;

(b)

a good degree of stability of the arc and of the fusing of the covering;

(c)

no undue degree of spatter;

(d)

a fair rate of deposition and depth of penetration;

(e)

easy removability of the slag;

(f)

no undue tendency to under-cut;

(g)

a fair contour of the weld deposits; and

(h)

a low internal porosity of the weld metal.

(2) Classification.- The electrodes shall be classified into:

(a)

normal penetration electrodes for use in one or more welding positions; and

 

(b)

 

deep penetration electrodes for close unprepared butt-welding in the flat position and/or fillet welding, in the flat and horizontal – vertical positions.

(3) Manufacture.- Electrodes may be made by any method that shall yield a product conforming to the requirements of these Regulations.

(4) Size of Electrodes.- The nominal size of the electrodes shall refer to the diameter of the core wire and the length shall not exceed 18 inches. Provision shall be made for end or centre gripping.

The tolerances on the specified diameter of the core wire of the electrodes shall be plus or minus 0.002 inch.

(5) Covering.- The flux covering shall be sufficiently robust to withstand the normal conditions of transport, storage, handling and use, without damage and shall be uniform in thickness all over so that it fuses evenly. The variation in the thickness shall not exceed 3 per cent.

(6) (a) Packing and storage.- Electrodes shall be suitably packed to guard against damage during transportation. When stored, the electrodes shall be kept in their original bundles or packings in a dry store room and under such conditions, the electrodes shall for a period of at least six months be capable of giving results similar to those which they would have given on the date of their despatch from the manufacturer.

(b) Marking.- Each package shall be marked with the following information:-

Name of the Manufacturer.
Trade name of the Electrodes.
Size and quantity of Electrodes.
Batch number.
Recommended current range.
Classification as per Indian Boiler Regulations.

(7) Tests.- The electrodes shall be subjected to Initial tests, Periodic check tests and Production control to ensure that the requirements of these Regulations are fulfilled.

Electrodes intended for use with more than one type of current or polarity shall be tested using each type of current and polarity.

Where any test specimen fails to satisfy the requirements of any particular test, two further test specimens shall be prepared using the electrodes from the same batch and submitted to the same test.

The batch of electrodes shall be accepted as having passed the test provided that the tests of both the additional specimens are satisfactory.

(8) Test Certificates.- The manufacturers shall, when called upon, produce the results of the most recent Periodic check tests carried out within the preceding 12 months, on electrodes representative of the electrodes supplied.

 
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