arc welding electrodes (product catalogue)

""

'I;1" ~

. ~, ,;I ,~I

I

!

I

~~

Itj!';,",

.~

'"', ',~":

;; ~

"""

f'< ~

I~;i~

1

",

'

"

,'

,~,:,

*

",

'

:

~

,,

"

"'

"(/

t'rri!,\

/ i-')~f !1,'~J,~'j~, ~:

'\'iW.i," ','""'"CcntrHllnarkclin!: omcc :

r"'~1

".39"3~~nkatarmnan.,~lrcct.

"T"Naear.CHcn;;~j- 60{) 017(l) '.,.~ tt044 824 0781

~f"~1);,,

Fax,r ~~O44 823 k062

Ii

t1'Y?

'J ,!f~

"

PRODUCT ~ATALOGUE~0'

,"

I'I/' ',',

'ARC W'ELDING ELECTRODES:' 0\1 ,."..

r" ~ . '. .

.~

,b

i;o

~

o::r

ti,1

~

If{i

ip1

iI,j

~'Ii

Q ~:!

M

~~i

:--.'f:i$§I

~,~1\

I~

;:c:

:!r' ~-~

.I

!is

m~,.

~

:'!"

"'"

~

tl.,

~\

H

~,

fI~~ ~

~~;:

!t'i;(o

!1!

/I

'J.;:;t'

~

'':'1-

tf:J

{J

.J

.IIIUMIlETI11Im

m

IiI

If you have any specific requirements not covered

in our range, please feel free to write to our WORKS.

We would be too glad to develop the electrodes to

your specification.

4th Edition)

~

( \ II-DET NORSKE VERITAS

QUALITY SYSTEM CERTIFICATE

\j' r1 ~Certificate No. QSC - 5H56

\ . t,?-JJ~ Thisistocertifythat(/ theQualitySystem

~1Y1 '1.iAILAM MET~LOGEN (P) LTD.

~-at

Pondid1erry. india

Has been found to conform to the Quality System Standa'rd:

ISO 9002,1994

This Certificalt! is valid for the follou"ng prod1ld or seroia ranges:

Manufacture and Supply of Welding Consumables.

Piau arid dah.

Rotterdam, January 31st, 1997

71,i.1 Cmifratl is valid u7UiL-

January 31st, 2000

1.

'"tIu Acm</iUd Unil:

--

"

_

ORSKE VERIT

..

AS

,

B'V"

E NETIiERLANDS

(--~-----~ ,-" ---,

_uRon} Meijer

Managrmn~ &prt'smtallut

DI'iV Mt\NAC;U.fE~TSY~n't:M CERITFICA'110N

~ On'ginal Cmification @k'

January 31st, 1997

Accreditedhy lhe RvA

f'Lackof fulfilment of conditions a~ set out ill the Appendix Ulay render tlm Ct'rtificatc invalid.

1':{.I(:~i.U..:-.l!t!.Ii.

DIT NORSKE VERITAS SV. H~a\lrc(hmra.a[ 7, ~OiO DC ROItt'rd<tI1J, -nIt' NC'lherJ.uul" TEL I~'T +31 10 ,179 86OQ, FAX +:51 101797111

~CONTENTS

Page No.

1. MILD STEEL ELECTRODES

2. LOW ALLOY AND HIGH TENSILE STEELELECTRODES5

3. PIPE WELDING ELECTRODES11

4. HARDFACING ELECTRODES13

5. STAINLESS AND HEAT RESISTING STEELELECTRODES17

6. CAST IRON ELECTRODES25

7. CUTTING AND GOUGINGELECTRODES27

8. MAINTENANCE ELECTRODES29

9. GUIDEFOR IS DESIGNATIONS35

10. GUIDEFOR AWS DESIGNATIONS38

11. CHEMICALCOMPOSITIONREIlUIREMENTSFORSTAINLESSSTEELWELDMETAL 39

12. HARDNESS CONVERSIONTABLE41

13. CONVERSIONTABLE FORWELDING ENGINEERS43

15. ELECTRODEAPPROVAL CHART45

16. ELECTRODECARE AND CONDITIONING48

.J

MAILAM METALLOGEN (P) LTD

TYPICAL WELDCURRENT AND PACKING DATA

METAL PROPERTIES

Chemical Physical Size Length Current Pieces Pieces% mm mm (Amps) per per

carton box

C - 0.06YS : 400 N/mm2 2.50 350 60 - 90 175 875

Mn - 0.20UTS: 500 N/mm2 3.15 450 90 - 130 105 525

Si - 0.02E : 24%{L=4d} 4.00 450 140 - 180 65 325CVN at RT 60 J 5.00 450 180 - 220 40 200

AC, DC(-)

C - 0.10 YS : 400 N/mm2 2.50 350 60 - 90 200 1000Mn - 0.40 UTS: 480 N/mm2 3.15 450 90 - 120 125 625Si - 0.15 E . 27%{L=4d} 4.00 450 140 - 180 80 400

eVN at RT 60 J 5.00 450 170 - 220 55 275

AC, DC(-)

YS : 400 N/mm22.50 350 60 - 90 200 1000e - 0.10 3.15 350 90 - 140 125 625Mn - 0.40 UTS: 490 N/mm24.00 450 140' - 190 80 400Si - 0.15 E : 26%{L=4d}5.00 450 180 - 240 55 275eVN at oDe 60 J6.30 450 230 - 310 35 175

AC, DC(-)

2.00 300 40 - 60 250 1250C - 0.08 YS : 390 N/mm2 2.50 350 60 - 90 150 750Mn - 0.45 UTS: 480 N/mm2 3.15 450 100 - 140 100 500Si - 0.17 E : 28%{L=4d} 4.00 450 140 - 190 70 350

eVN at OOC70J 5.00 450 180 - 250 40 2006.30 450 250 - 330 25 125

AC,DC(-)

- .J

IIWIIIIT IUJiII

PRODUCT DESCRIPTION

MAILOFINEA heavy coated, mild steel electrode giving a deposit of pure

iron which is made highly resistant to corrosion by molten zinc.The weld deposit is ductile with very low impurities. The arc issmooth and the slag is easily detachable.

MAILARC -12A medium rutile coated general purpose electrode for all posi-

tion welding including vertical down with easy detachable slag.Used for welding in general fabrication, ship building, storagetanks, busbodies, frame works etc, .

MAILARC -13PLUSA medium coated, all position electrode with medium penetra-

tion, low spatter and easy detachable slag. Used for weldingtanks, ralls, coaches, boilers, ships, pipes and various fabrica-tion jobs. Operates in all positions including vertical down.

MAILARC -13RA medium heavy coated, rutile type, all position electrodegiving good penetration, low spatter and easy peeling slagWeld deposit is of radiographic quality. Application includespressure pipes, tubes, boilers etc., Best suited for sheet metalwelding.

MILD STEEL

CODING &CLASSIFICA TION

IS 814ES 4122

IS 814ER4112AWS A51E 6012

IS 814ER 4212AWS A5.1E 6013

IS 814ER 4222XAWS A5.1E 6013

ELECTRODES

I .2

PRODUCT DESCRIPTION CODING &CLASSIFICA TION

MAILARC -13RRA heavy coated, rutile type electrode giving radiographic welds IS 814with negligible spatter, very smooth arc and a self peeling slag. ERR 4222XCan be used as a touch electrode and gives an excellent bead AWS A5.1appearance. Ideal for automobile frames, storage tanks, rail E 6013coaches, boilers etc.,

MAILARC -14An all position iron powder mild steel electrode giving radio- IS 814graphic welds. The deposition efficiency is 110% approximately. ERR 5222XJAn ideal mild steel electrode for obtaining higher welding output AWS A5.1with very high current. E 7014

MAILARC -24A super heavy coated, iron powder electrode havillg a metal IS 814recovery of 140% approximately. Suitable for fast downhand ERR 5242XKand horizontal fillet welding giving excellent weld bead finish. AWS A5.1Gives radiographic quality welds. E 7024'

.MAILARC -18A heavy coated, low hydrogen, iron powder type electrode with IS 814an extremely smooth arc, medium penetration and least spatter. EB 5426H2JXIdeally suited for producing tough and ductile welds of radi\>- AWS A5.1graphic quality in boilers, pressure vessels and heavy structures E 7018subjected to dynamic loading. Deposition efficiency is 115%approximately.


METAL PROPERTIES

Chemical Physical Size Length Current Pieces Piecesmm mm (Amps) per per

~!carton box

YS : 390 N/mm22.50 350 60 - 90 120 600

C - 0.08 UTS: 480 N/mm2 3.15 450 100 - 140 80 400Mn - 0.48 E : 29%{L=4d} 4.00 450 140 - 190 50 250Si - 0.18 CVN at OOC90 J 5.00 450 180 - 250 35 175

6.30 450 250 - 330 20 100AC, DC(-)

YS : 450 N/mm2C - 0.08 UTS. 540 N/mm2 3.15 450 100 - 140 105 525Mn - 0.60 E : 26%{L=4d} 400 450 150 - 200 65 325Si - 0.18 CVN at OOC80 J 5.00 450 200 - 250 40 200

AC, DC(-)

C - 0.08YS :470 N/mm2 3.15 450 150 - 170 50 250

Mn - 0.80 UTS: 540 N/mm2 4.00 450 200 - 250 35 175

Si E : 26%{L=4d) 5.00 450 250 - 290 25 125- 0.18 CVN at OOC80 J

AC, DC(-)

YS : 470 N/mm2 2.00 300 40 - 70 150 750C - 0.06 UTS: 550 N/mm2 2.50 350 60 - 100 100 500Mn - 125 E : 28%{L=4d} 3.15 450 100 - 140 75 375Si - 0.42 CVN at -30°C 70J 4.00 450 150 - 200 50 250

5.00 450 200 - 240 30 1506.30 450 270 - 360 20 .100

'\C(70V), DC(+)

I -

\811111111I11III

.J

MILD STEEL

3

ELECTRODES

4

TYPICAL WELD CURRENT AND PACKING DATAMETAL PROPERTIES


% carton box

YS : 490 N/mm22.50 350 60 - 90 120 600

C - 0.08 3.15 450 100 - 140 80 400Mn - 1.20 UTS: 550 N/mm2

4.00 450 140 - 190 60 300Si - 0.45 E : 26%{L=4d}

5.00 450 190 - 240 40 200CVN at -30DC 1OOJ 6.30 450 250 - 340 25 125

AC(70V), DC(+)]

2.50 350 60 - 90 120 600C - 0.08 YS : 450 N/mm2 3.15 450 100 - 140 80 400Mn - 1.00 UTS: 520 N/mm2 4.00 450 140 - 180 60 300Si - 0.50 E : 26%{L=4d} 5.00 450 180 - 230 40 200

CVN at -30DC80 J 6.30 450 240 - 320 25 125

AC(70V), DC(+)

2.50 350 60 - 90 100 500

C - 0.08YS : 500 N/mm2 3.15 450 90 - 140 75 375

Mn 1.40UTS: 550 N/mm2 4.00 450 140 - 180 50 250

- E : 28%{L=4d} 5.00 450 180 - 250 30 150Si - 0.35 CVN at -46DC50 J 756.30 450 270 - 320 15AC(90V),DC(+)

C - 0.08 YS : 500 N/mm2 2.50 350 60 - 90 100 500

Mn - 1.50 UTS: 600 N/mm2 3.15 450 90 - 140 75 375

Si - 0.45 E : 28%{L=4d} 4.00 450 140 - 180 50 250

Ni - 0.60 5.00 450 180 - 250 30 1506.30 450 270 - 320 20 100

AC(90V),DC(+)

--_U'-'_._"--' ~'--'-"-'"-- -

~ ~ ~ ~-~

8IIIUIIIIIIlI&I LOW ALLOY & HIGH TENSILE

PRODUCT DESCRIPTION

MAILARC -16A medium heavy coated, low hydrogen all position electrodegiving X-ray quality welds for welding of mild steel, mediumhigh tensile steel and low alloy steel. The deposit acts as abuffer before hardfacing and has excellent impact properties.Slag is quite easy to remove. Ideal for joining mild steel tocast steel and for depositing non-machinable welds on castiron.

MAILARC - 165A medium heavy coated, low hydrogen, all position electrodegiving X-ray quality welds. Ideal for welding cast steel,steels with very high carbon and sulphur contents, low alloysteel and steels of unknown composition. Weld metal hashigh impact properties and high resistanceJo cracking.

MAILARC -18(5PECIAL)An iron powder, low hydrogen type electrode. giving radio-graphic welds with excellent impact properties at sub-zerotemperatures. Ideal for welding rigid restrained structures,pressure vessels, carbon steels etc.,

MAILARC -88GA medium heavy coated, low hydrogen, iron powder typeelectrode giving a weld metal containing 1.5% Mn and 0.6%Ni.Specially developed for welding of high tensile fine grainedsteels used for tankages, pressure vessels, penstocks etc.,The electrode gives smooth arc, medium penetration andlow spatter. The welds are of radiographic quality.

5

II

CODING &CLASSIFICATION

IS 814EB 5426H)<AWS A5.1E 7016

IS 814EB 5426H)<AWS A5.1E 7016

IS 814EB 5529H2JX

AWS A5.1

E 7018 - 1

IS 1395E 55BG129FeAWS -: A5.5

E 8018G

.JSTEEL ELECTRODES

6

>4

PRODUCT DESCRIPTION CODING &CLASSIFICATION

MAILARC - 98GA low hydrogen, iron powder electrode giving radiographic welds IS 1395with a smooth arc and least spatter. Ideal for welding heavy E 63BG129Feduty structures, high tensile steels involving dynamic loading

AWS A5.5penstocks, earthmoving equipments etc.,

E 9018G

MAILARC - 108M

An all position, low hydrogen electrode ideally suited for IS 1395welding high 'tensile steels, earthmoving equipments, USS-T1 E 68BM229Festeels etc., The weld metal is of radiographic quality. Tendency AWS A5.5for hydrogen induced cracking is reduced by the low hydrogen E 10018Mlevel in the deposit.

.

MAILARC - 118MA heavy coated, all position, low hydrogen electrode, for IS 1395

welding high tensile steels like USS-T1'steel ,earthmoving E 76BM329Fe

equipments, quenched and tempered steels. The weld metal AWS A5.5is of radiographic quality and yields high impact value at sub- E 11018Mzero temperatures upto -51°C

MAILARC - MoA heavy coated, all position, low hydrogen, iron powder type

IS 1395electrode. Deposit has 0.5% Mo and hence ideal for welding

E 49BA126Fe0.5% Mo 1% Cr steels. The weld metal has good creep resistingAWS A5.5properties. Also ideal for welding boiler plates, tubes, pipelines at

elevated temperature upto 540°C. Deposit is of radiographic E 7018 - A1quality .


Size Length Current Pieces PiecesChemical Physical

mm mm (Amps) per perIii carton box

2.50 350 60 - 90 100 500C - 007 YS : 600 N/mm2

3.15 450 90 - 140 75 ~75Mn - 1.40 UTS. 650 N/mm2 4.00 450 140 - 180 50 250Si - 0.45 E . 24%{L=4d} 5.00 450 180 - 250 30 150Ni - 0.65 CVN at -30°C 50J 6.30 450 260 - 320 15 75

AC(90V),DC(+)

2.50 350 60 - 90 100 500C - 0.07 YS : 630 N/mm2

90 - 140 75 375UTS . 740 N/mm2 3.15 450

Mn - 1.20 4.00 450 140 - 180 50 250Si - 0.45 E 20%{L=4d}

5.00 450 180 - 250 30 150Ni - 1.80 CVN at -51°C 40 J

6.30 450 260 - 320 15 75Cr - 023Mo - 0.30 AC(90V),DC(+)

YS : 730 N/mm2 2.50 350 60 - 90 100 500C - 0.06

90 - 140 75 3751.40 UTS: 810 N/mm2 3.15 450Mn - 50 250

- 0.40 E : 22%{L=4d} 4.00 450 140 - 180Si30 150

Ni - 2.10 CVN at -51°C 40 J 5.00 450 180 - 250

0.30 6.30 450 260 - 320 15 75Cr -Mo - 0.30 AC(90V),DC(+)

YS : 460 N/mm2 2.50 350 60 - 90 120 600C - 0.06

100 - 130 80 400UTS . 560N/mm2 3.15 450Mn - 0.65 250Si - 0.30 E : 26%{L=4d} 4.00 450 140 - 190 50

CVN at RT 140J 5.00 450 190 - 250 40 200Mo - 0.50 6.30 450 250 - 300 20 100

AC(70V), DC(+)

~.MIUIIIITAU.m

._~ ~~._--

LOW ALLOY & HIGH TENSILE

7

STEEL.J

ELECTRODES

8

TYPICAL WELD CURRENT AND PACKING DATA.METAL PROPERTIES


%carton box

C - 0.06 YS : 520 N/mm2 2.50 350 60 - 90 100 500

Mn - 0.65 UTS: 600 N/mm2 3.15 450 100 - 130 75 375Si - 0.35 E : 22%{L=4d} 4.00 450 140 - 180 50 250Cr - 1.20 CVN at RT 100J 5.00 450 190 - 250 30 150

Mo 0.50 6.30 450 250 - 310 20 100-

AC(70V).DC(+)

2.50 350 60 - 90 100 500C - 0.07 YS : 560 N/mm2 3.15 450 100 - 130 75 375Mn - 0.65 UTS: 650 N/mm2 4.00 450 140 - 180 50 250Si - 0.35 E : 22%{L=4d} 5.00 450 190 - 240 30 150Cr - 2.25 CVN at RT 50 J 6.30 450 250 - 310 20 100Mo - 1.00

AC(70V),DC( +)

C - 0.08 YS : 510 N/mm2 3.15 450 90 - 140 75 375Mn - 1.00 UTS: 600 N/mm2 4.00 450 140 - 1'80 50 250Si - 0.40 E : 22%{L=4d} 5.00 450 180 - 250 30 150Ni - 0.60 CVN at -18°C 50 JCr - 0.55 AC(90V),DC( +)Cu - 0.50

C - 0.08 YS : 510 N/mm2 2.00 300 40 - 70 175 875Mn - 1.00 UTS: 600 N/rrim2 2.50 350 60 - 90 120 600Si - 0.40 E : 22%{L=4d} 3.15 450 100 - 130 80 400Ni - 0.60 CVNat -18°C40 J 4.00 450 140 - 180 50 250Cr - 0.55 5.00 450 190 - 240 35 175Cu - 0.50

AC(70V),DC(-)

--".vc ~ ,- . ~--"._~._-'_.._----

.J

LOW ALLOY & HIGH TENSILE ELECTRODESMIIWIIITIllOOII

PRODUCT DESCRIPTION

MAILARC -1CRA heavy coated, all position, low hydrogen, iron powder elec-

trode, with excellent creep and heat resisting properties at.

elevated temperature upto 550° C. Deposit is of radiographicquality. Ideal for welding boiler and refinery chrome moly platesand pipe lines.

MAILARC -2CRA heavy coated, all position, low hydrogen, iron powder typeelectrode. Deposit is of radiographic quality and has approxi-mately 1% Mo and 2.25% Cr and has very good creep andoxidation resistance upto 575°C. Ideal for welding boiler,refinery pipelines and plat~s of chemical plants having similarCr-Mo compositions.

MAILARC -aawA medium heavy coated, low hydrogen electrode giving adeposit of radiographic quality. The weld metal offers excellentresistance to atmospheric corrosion. Ideal for welding hightensile steels and weathering steels like CORTEN - A,CORTEN - B etc.

MAILARC -aaWR

A heavy coated all position rutile type, low alloy, high tensileelectrode giving a deposit of radiographic quality. Has anexcellent atmospheric corrosion resistance. Ideal for weldinghigh tensile steels and weathering steels like CORTEN - A,CORTEN- B etc.,

9

STEELCODING &

CLASSIFICATION

IS 1395E 55BB226Fe

AWS A5.5

E8018-B2

IS 1395E 63BB326Fe

AWS A5.5

E 9018 - B3

IS 1395E 55BG129FeAWS A5.5

E8018-W2

IS 1395E 55RG125AWS A5.5

E 8013 - W2

10


METAL PROPERTIES

Chemical Physical Size Length Current Pieces Pieces

r'mm mm (Amps) per per

IIcarton box

YS : 400 N/mm2 2.50 350 40 - 70 200 1000C - 0.10

UTS. 480 N/mm2 315 350 70 - 120 125 625Mn - OAO

E . 25%{L=4d} 4.00 350 120 - 160 80 400Si - 0.22 CVN at -29°C 60J 500 350 140 - 210 55 275

OC(+)

C - 0.10 YS 470 N/mm' 2.50 350 40 - 70 200 1000Mn - 0.50 UTS 530 N/mm' 315 350 70 - 130 125 625Si - 018 E . 26%{L=4d} 400 350 120 - 180 80 400Ni - 051 500 350 140 - 220 55 275

OC( +)

C - 0.12YS : 510 N/mm2 2.50 350 40 - 70 200 1000

Mn - 0.60 3.15 350 70 - 130 125 625UTS : 590 N/mm2Si - 0.15 4.00 350 120 - 180 80 400E : 24%{L=4d }Ni - 0.25 5.00. 350 140 - 220 55 275Mo - 0.40

OC(+)

C - 0.11 YS : 430 N/mm2 2.50 350 60 - 90 200 1000

Mn OA5 UTS : 510 N/mm2 3.t5 350 75 - 140 125 625-400Si - 0.36 E : 27%{L=4d} 4.00 350 120 - 180 80

5.00 350 140 - 230 55 275Mo - OA8

OC(+)

-8 r

IIIIIIIITIIUIII PIPE WELDING ELECTRODESPRODUCT DESCRIPTION

MAILARC -10A cellulosic type electrode for all position welding includingvertical down with a powerful penetrating arc and easily de-tachable slag. Ideally suited for achieving excellent penetra-tion in root (;Jassesin cross country pipeline with conventionalor stove pipe technique. The weld deposit is of radio-graphic quality.

MAILARC -10GA c"lIulosic type electrode ideally suited for all position weldingincluding vertical down. Gives a smooth penetrating arc. Theweld deposit is of radiographic .quality and has excellentmechanical properties. Ideal for welding pipeline of highstrength pipe steel, storage tanks, drill platforms etc., usingdown hill travel.

MAILARC -10G1A cellulosic, all position, medium coated electrode givinga very smooth arc. Specially designed for high strengthpipeline welding, using both stove pipe and conventionaltechniques. The slag is quick freezing and easily removable.Weld metal is of radiographic quality.

MAILARC -10MoA medium coated, cellulosic type electrode, ideally suited forwelding in all position including vertical down. Gives a deeppenetrating arc with a thin friable slag. Weld metal is ductileand gives creep resistant 0.5 % Mo deposit which is of radio-graphic quality. Ideal for pipeline applications using stovepipe or conventional techniques.

II

.!


IS 814E C4310X

AWS A51E 6010

AWS A5.5E 7010G

AWS A5.5

E 8010G

AWS A55

E 7010-A1

12

PRODUCT DESCRIPTION APPLICATIONS

/

MAILHARD -RI -J Ideal for rail crossings,A rutile type electrode giving a machinable deposit of hardness gear shafts, hammers,

axles etc.,250 BHN approximately.

/MAILHARD -RII

,,/Typical applications

A rutile type electrode giving a deposit of hardness 350 BHN include drive sprockets,wheels, shafts, pullies,approximately and has good resistance to impact. It has goodaxles, rail crossings, etc. ,sliding properties.

MAILHARD -Rill Ideal for hardfacingapplications on canes,

A rutile type electrode giving a non machinable deposit of and bamboo . cuttinghardness 600 BHN approximately. An initial buffer layer knives, shear blades,of Mailex - 18/8/6 is recommended while using on austenitic crusher hammers,manganese steels. sprockets etc.,

MAILHARD -BIIILH Application includes

A heavy coated, basic type, hydrogen controlled iron powder bamboo, chipper knives,sprockets, conveyorelectrode with a smooth are, medium penetration and leastbuckets, crusher jaws.spatter. Gives a hard and non-machinable deposit which cancane cutting knives. oilwithstand very high abrasion and impact and can only be ground.expeller worms etc.,

MAILHARD - BVApplications includes

A medium heavy coated basic type electrode with a smooth arc cement die rings, oiland least spatter and works easily even at low currents: Gives expellerworrns, concretean air hardening alloyed cast iron deposit which is extremely mixer blades, screwhard and resists very high abrasion and moderate impact. Ideal conveyors, muller tyresfor hardfacing. application requiring resistance to scratching or

bucket lips etc.,mild grin9ing abrasions.

CURRENT AND PACKING DATA

WELD METAL Size Length Current Pieces PiecesPROPERTIES mm mm (Amps) per per

carton box

3.15 450 100 - 120 100 500AS WELDED 4.00 450 140 - 180 70 350Hardness on 3 layers 5.00 450 180 - 220 40 200250 BHN (approx.)

AC,DC( - )

3.15 450 100 - 120 100 500AS WELDED 400 450 140 - 180 70 350Hardness on 3 layers 5.00 450 180 - 220 40 200350 BHN (approx.)

AC, DC( - )

AS WELDED 3.15 450 100 - 120 100 500Hardness on 3 layers 4.00 450 140 - 180 70 350

5.00 450 180 - 220 40 200600 BHN (approx.)

AC, DC( - )

3.15 450 100 - 140 75 375AS WELDED 4.00 450 140 - 180 50 250Hardness on 3 layers 5.00 450 190 - 240 30 150550 BHN (approx.) AC(70V),DC(+)

AS WELDED 3.15 450 90 - 110 80 400Hardness on 3 layers 4.00 450 120 - 150 60 300600BHN (approx.) 5.00 450 140 - 190 40 200

AC ,DC(+)

(I ,J

HARDFACINGMIUIIII1I1.lIm

13

r

ELECTRODES

14

CURRENT AND PACKING DATAWELD METALPROPERTIES Size Length Current Pieces Pieces

mm mm (Amps) per percarton box

AS WELDED 3.15 450 100 - 120 75 375Hardness - 200 BHN 4.00 450. 140 - 180 50 250(approx) increases to 5.00 450 180 - 220 30 150500 BHN under impactin service. AC(70V),DC( +)

AS WELDED 3.15 450 100 - 130 75 375Hardness on 3 layers 4.00 450 140 - 180 50 250200 BHN (approx) 5.00 450 180 - 220 30 150increases to 500 BHNunder impact in service.

AC(70V),DC{ +)

AS WELDED 315 350 100 - 130 } }Hardness on 2 layer 4.00 350 130 - 170 } 2 Kgs. } 10 Kgs.600 BHN (approx) 5.00 350 170 - 210 } }

AC,DC( + )

- HARbFACING ELECTRODESMAIJII METIUIIGEII

PRODUCT DESCRIPTION

MAILMANGAN -12A heavy coated, basic type electrode with mild steel core wiregiving a deposit of 12% Mn. Gives a smooth are, least spatter and

also gives a weld deposit of hardness 200 BHN in as weldedcondition which work hardens to over 500 BHN under impact.

MAILMANGAN - 14/4A heavy coated, low hydrogen type austenitic manganese steel

electrode depositing 14% Mn and 4% Ni. The deposit is ofworkhardening type. Hardness increases from 200 BHN in aswelded condition to 500 BHN under impact. For hardfacingapplications on mild steel and low alloy steel a buffer layer ofMailex 18/8/6 is recommended.

MAILHARD - 35CRA basic coated electrode giving a deposit of 3.5% C and 35%Cr for hardfacing applic:ations. The deposit is highly resistant toabrasion. It also resists oxidation even upto 10000C and hasa hardness of 600 BHN.

15

APPLICATIONS

Typical application in-cludes rock crushers,steel rails, cement grinding

rings, ball mills, manga-nese steel parts of earthmoving equ.ipments,surfacing of hammers,dredger bucketteeth etc.,

Ideal for manganesesteel rails, cementgrinding rings, rockcrusher. jaws, crushermantles, hammers,muller tyres etc.,

Application includesceramic handlingequipments, sandblasting equipment,conveyor screws, tubemill, rolling mill guides,plough shares, cokechutes etc.,

16


Chemical Physical Size Length Current Pieces Piecesmm mm (Amps) per per%

carton box

C 0.05 UTS: 590 N/mm2 2.00 300 30 - 50 150 750-

50 - 70 100 500Mn - 1.50 : 40%{L=4d} 2.50 350E3.15 350 70 - 100 60 300Si - 0.45 FN = 54.00 350 100 - 140 45 225Cr - 19.00

140 - 180 30 150Ni - 10.00 5.00 350

AC,DC( +)

2.00 300 30 - 50 150 750C - 0.05 UTS: 620 N/mm22.50 350 50 - 70 100 500Mn - 1.50 E : 36%{L=4d}3.15 350 70. - 100 60 300Si - 0.60 FN = 74.00 350 100 - 140 45 225Cr - 19.20 5.00 350 140 - 180 30 150Ni - 10.00

Nb - 0.60

AC,DC( +)

C - 0.03 2.00 300 30 - 50 150 750Mn - 1.50 UTS: 590 N/mm2 2.50 350 50 - 70 100 500Si - 0.45 E :40%{L=4d} 3.15 350 70 - 100 60 300Ni - 10.00 FN = 5 4.00 350 100 - 140 45 225Cr - 19.50 5.00 350 140 - 180 30 150

AC,DC(+)

8 .!

IIAllAUnillOGfli STAINLESS AND HEAT RESISTING STEEL ELECTRODES

PRODUCT DESCRIPTION

MAILEX - AA rutile coated stainless steel electrode yielding a deposit of19% Cr and 10% Ni and having an excellent resistance to corro-sion upto 8000 C. Ideal for welding stainless steel jobs ofsimilar composition like AISI 301, 302, 304, 308 etc.,

MAILEX- ANbA rutile coated stainless steel electrode yielding a deposit of19% Cr 10%Ni and about 0.5% Nb with maximum resistanceto cracking, corrosion and high temperatures upto 8000C.Presence of Niobium prevents intergranular corrosion. Idealfor welding of AISI 304, 304L, 321,347 steels and also forwelding stabilised stainless steel of process equipment infood and chemical industries.

MAILEX -ALAn extra low carbon, rutile coated stainless steel electrodegiving a deposit of 19% Cr and 10% Ni. Has excellentresistance to intergranular corrosion and also to cracking,oxidation and scaling at elevated temperatures. Ideal forwelding of stainless steel of similar composition like 304L,308L etc., with low carbon level.

17


IS 5206E 19.9.R 26

AWS A5.4

E 308 - 16

IS 5206E 19.9.NbR 26

AWS A5.4E347-16

IS 5206E 19.9LR 26AWS A5.4E 308L - 16

18

TYPICAL WELD CURRENT AND PACKING DATAMETAL PROPERTIES ,", ,', ..

Size Length Current PiecesChemical Physical Pieces(oo mm mm (Amps) per per(

carton box

;;. .'.I

C - 0.05 2.00 300 30 - 50 150 750Mn . 1.50 UTS . 59.0N/mm2 2.50 350 50' - 70 100 ~OOSi - 0.50 E : 4Q%{L=4d} 3.15 350 70' - 100" 60 300'Ni - 1250, FN = 6 4,00 350 100 - 140 45 225Cr - 19.00

.::..5.00 350 140 - 180 30 150

Mo . 2.4 0 AC,DC( +)..,

C 0.05",

-Mn - 1.50" UTS . 630 N/mm2 1.",~.90 300 30,., 50 150 750Si - 050. E .: 37%{J-=4d}

, 2.5Q 35Q 5Q, 70 100 500Ni - 12.70 FN = 6 1- 3.15., .350 70 - 100 60 300Cr - 18.80 4.00 350 100 - 140 45 225Mo .. 2.50 5.00 350 140 - 180 30 150Nb .. 0.60 AC,DC( +),.

"

C - 0.03 2.00Mn 1.50 300 30 .. 50 150 750

- UTS : 600 N/mniSi .. 0.50 2.50 350 50 .. 70 100 500

E :40%{L=4d} 3.15) 350 70 -100;~ 60 300Ni - 13.00 FN = 5 4.00. r 350'"

100 -140 45 225Cr - 19.00Mo .. 2.50 5.00 )' 350' 140- 180 30 150 t,

AC,DC( +)

.('.' ',;;

C - 0.08 2.00 300 30 .. 50 150 -750 'Mn 1.60 UTS.: 570 N/mm2 2.50 350 50 .. 70 100 90GSi - 0.50 E : 40%{1. =4dJ 3.15,. 350 70 .100" 60 300"Cr - 23.50 4.00 3S0 100- 140c 45 225Ni - 13.00 5.00 350 140 - 180 30 150

AC,DC( +),

_.~ "._,-_._--MAllAMMETIllOGlll STAINLESS AND

PRODUCT DESCRIPTION

MAILEX - MoA rutile coated stainless steel electrode giving a deposit of 19%Cr, 13%Ni and 2.5% Mo. Electrode offers excellent creepstrength and maximum resistance to cracking, corrosion andscaling at elevated temperature even as high as 850°C.

MAILEX - MoNbA rutile type stainless steel electrode giving niobium stabilised18% Cr 13% Ni and 2.5% Mo weld metal. The weld metalpossesses good resistance to corrosion and pitting and improvedcreep strength. The weld metal has excellent resistance to inter-granular corrosion. Most suitable for welding AISI 316, 317 and318 types when maximum resistance to corrosion is required.

MAILEX - MoLAn extra low carbon rutile coated stainless steel electrodegiving 18%Cr,13%Ni and 2.5% Mo. Has excellent resistanceto intergranular corrosion and also to cracking and oxidationat elevated temperatures. Ideal for welding stainless steel ofsimilar composition like 316L, 317L etc., with low carbonlevel.

MAILEX - 25/12A rutile type stainless steel electrode giving 25%Cr,12%Nideposit. Weld metal offers excellent resistance to corrosionat high temperatures upto 11OooC. Ideal for welding AISI309 grade steels, cladding of 18/8 clad steels and steels ofdissimilar composition.

19

~ ~.,.~-~-~-<~O.'-'-~-- - "'.

HEAT,.I

RESISTING STEE~ :f:LECTRODES

CODING &. CLASSIFICATION

IS 5206E 19.12.2.R26

AWS A 5.4

E 316 -16

IS 5206E 19.12.2NbR 26

AWS A 5.4

E 318 - 16

IS 5206E 19.12.2.LR26

AWS A 5.4

E 316L - 16

IS 5206E 23.12.R 26AWS A 5.4

E 309 - 16

20

TYPICAL WELDCURRENT AND PACKING DATAMETAL PROPERTIES

Chemical Physical Size Length Current Pieces Pieces% mm mm (Amps) per per

carton box

...C ... 0.03 2.00 300 30 - 50 150 750Mn ... 1.60 UTS: 590 N/mm2 2.50 350 50 - 70 100 500Si ... 0.50 E : 38%{L=4d} 3.15 350 70 - 100 60 300Ni ... 13.00 4.00 350 100 - 140 45 225Cr - 23.50 5.00 350 140 - 180 30 150

AC,DC( +)

C ... 0.06200 300 30 - 50 150 750Mn ... 1.60 UTS: 620 N/mm2 2.50 350 50 - 70 100 500Si ... 0.50 E : 35%{L=4d} 3.15 350 70 - 100 60 300Ni - 13.00 4.00 350 100 - 140 45 225Cr - 23.50 5.00 350 140 - 180 30 150Mo - 2.50

AC,DC( +)

C ... 0.10 .2.00 300 30 - 50 150 750Mn .. 2.00 UTS: 590 N/mm2 2.50 350 50 - 70 100 500Si ... 0.50 E : 35%{L=4d} 3.15 350 70 - 100 60 300Ni - 20.50 4.00 350 100 - 140 45 225Cr - 25.50 500 350 140 - 180 30 150

AC,DC( +)

C ... 0.09Mn ... 5.50 UTS: 600 N/mm2 2.50 350 100 - 120 85 425Si ... 0.50 E : 38%{L=4d} 3.15 350 150 - 170 50 250Cr - 19.00 4.00 350 200 - 220 35 175Ni 9.00 5.00 350 240 - 280 25 125..

AC,DC(-)

I)MIlAMIIIIUM STAINLESS AND

PRODUCT DESCRIPTION

MAILEX -25/12LAn extra low carbon, rutile type stainless steel electrode giving

25%Cr and 12%Ni deposit. Weld metal has excellent resis-tance to corrosion and scaling at high temperatures. Ideallysuited for welding of 18/8 stainless steels,to carbon steeland for welding clad side of 18/8 clad stainless steels.

MAILEX -25/12MoA rutile type stainless steel electrode yielding a deposit of 25%Cr, 12% Ni and 2.5% Mo, Has excellent resistance to oxidationupto 1100° C. Ideal for welding 309 Mo steels and as bufferlayer in welding dissimilar steels.

MAILEX - 25/20

A rutile type stainless steel electrode giving 25%Cr -20% Nideposit. Weld metal offers excellent resistance to oxidation atelevated temperatures upto 12000C. Ideal for welding steels ofcomposition like AISI 310. Also best suited for welding Cr-Mosteels, clad steels, fumace retorts etc.,

MAILEX -18/8/6

A low hydrogen type electrode with mild steel core wire butgiving a deposit of 18%Cr 8%Ni 6%Mn. Weld metal is highly

resistant to corrosion and heat at elevated temperatures. Idealfor welding difficult steels such as harden able steels, armourplates, for joining austenitic manganese steel to mild steeland for laying buffer layer before hardfacing.

21

HEAT


IS 5206E 23.12:LR26AWS A 5.4E 309L - 16

IS 5206E 23.12.2R 26AWS A 5.4E 309Mo - 16

IS 5206E 25.20.2R 26XAWS A 5.4E 310 ~16

IS 5206E 18.8.MnR26

-..,

RESISTING STEEL ~ELECTRODES

t

22

PRODUCT DESCRIPTIONCODING &

CLASSIFICATION

MAILEX - 18/8/655A heavy coated electrode with stainless steel core wire giving IS 5206

a deposit of 18%Cr, 8%Ni and 6% Mn. The deposit has excellent E 18.8 MnR20

resistance to heat and corrosion. Best suited for joining austeni-tic manganese steel to mild steel, welding of difficult steels suchas high alloy steels, armour plates etc., and for laying bufferlayer before hardfacing.

MAILEX -13CRA basic coated electrode giving a deposit of 13% Cr of radio- AWS A 5.4

graphic quality. Ideal for joining materials having similar alloy E410 -15

composition and for surfacing applications in turbine parts, valveseats etc., Best suited for joining straight chromium steels.



(j~) carton box

C - 0.09 UTS' 600 N/mm2 2.50 350 50 - 70 100 500

Mn - 600 E . 38%{L=4d) 3.15 350 80 - 110 60 300

Si - 0.50 4.00 350 110 - 130 45 225

Ni - 900 5.00 350 150 - 200 30 150

Cr - 19.00 AC,DC( +)

C - 0.08 2.50 350 50 - 70 85 425Mn - 0.75 UTS: 550 N/mm2 3.15 350 70 , 130 50 250Si - 0.55 E : 20%{L=4d} 4.00 350 130 - 160 35 175Cr - 13 00 5.00 350 160 - 220 25 125Ni - 0.60 DC(+)

-IIIIJIIIIHIU.Ir.III STAINLESS AND HEAT

23

,J

RESISTING STEEL ELECTRODES

f

\~

24

ELECTRODESTYPICAL WELD

CURRENT AND PACKING DATAMETAL PROPERTIES

Chemical Physical Size Length' Current Pieces Pieces% mm mm (Amps) per per

carton box

2.50 350 60 - 90 120 6003.15 450 100 - 130 80 4004.00 450 140 - 180 60 300500 450 190 - 240 40 200

AC(90V),DC(+)

C - 0.75 HARDNESS 2.50 350 40 - 60 ) )Ni - 63.00 160 - 190 BHN

3.15 350 80 - 100 II Kg. 112 Kgs.Fe - 4.00 400 450 110 - 140 } }Cu - Bal

5.00 450 140 - 170

AC, DC(+)

C - 0.75 HARDNESS 2.50 350 40 - 60 } IFe - 4.00 160 - 190 BHN 3.15 350 70 - 90 } I Kg. } 12 Kgs.Ni - Bal 4.00 350 100 - 120 } }5.00 350 140 - 170

AC,DC(+)

L

I C - 0.80 HARDNESS 2.50 350 50 - 70 I INi - 55.00 170 - 190 BHN 3.15 350 70 - 110 f I Kg. } 12 Kgs.Fe - Bal 4.00 350 110 - 130 I }

5.00 350 140 - 180

AC,DC(+)

~ -IIIUIIIIT Il1fIa

IIIIi

PRODUCT DESCRIPTION

MAILOCASTA basic coated electrode for producing non-machinable welds

on cast iron and for joining cast iron to mild steel.

MAILOMONELA medium coated electrode with monel core wire giving amachinable deposit of Ni-Cu alloy for welding of cast iron. Nopreheating is needed. Ideal for repair work on cast ironcastings. filling up of cracks etc.,

MAILONICKELA medium coated electrode with nickel core wire giving asoft and machinable deposit of nickel for welding of castiron. No preheating is required. Ideal for repair jobs on castiron casting, surfacing or wornout castings, filling up of cracksetc.,

MAILOCAST - FNA medium heavy coated electrode with ferro nickel wire givinga soft and machinable deposit of iron-nickel alloy for welding ofcast iron. Ideal for producing crack free weld joints on castiron and for joining cast iron to mild steel. No preheating isnecessary.

25

CAST IRON


AWS A5.15ESt

AWS A5.15E NiCu-B

AWS A5.15E Ni-C!

AWS A5.15E NiFe-CI

.J

26

I

In<V.... xU (l) 0

.!!! Q..Q

« a.I-«c en eQ)

L... 0(!) U<1Jt

!!! Q. CUZ a. u

~u

en« cU)Q.

<1JQ.

W C t: EZ ~«

C «o~

0 I-ZW .c

o:: a::: o,Ea::: ~Et- :J -.J

U U

~EW U5E..JW

C) enzZ 0~- «C) u

:::::;

::J Q.Q.

0 «C)

---..------ _.~,-

Cz«C)z-t-t- z::) 0~U Q.

52uenwcI-U:JC0.. a:::Q.

r/

(81~ .

00001/)0I/)C")N

000~I"--V

--000 I

('1")r--1,{)-NNC") 0

I I 0000 01/)01/) «""'-NN

0001,{)1,()1.O

"f"f"f

1/)00<r-OQ

M~..n

- -""-0)""""0

~ ~ ~ .~g 0

O'Ja.O"O::t::..cC 0 "-::J .~ Q)

eU"OOU3:~CD -c:~UU)~

'.3. 5 CU «S ]1 Qj'u U

-g=U)~(/)~~C'O~~.QQ)E~~g> u ..0 co'E: 'n;.- - "0-t:Qj "0 <1JO"O::JQ) -cO')--

Q)

~ t) § ro'E @ OJ ~E a :5 J!! ~ ~ ~ ~rn.QE.E.Q~ E~ro~ E<1Jo-J;!o-urn o u

,,"~!i'1:~'~~~~~'

01/)1/)

I/)f'-.N

('\IT'""""-

\Il

oml.[)l,()("")N

0 00 +'OCX>I/) ~N NC") 0

I I I 0000 c.5~~~ «

000L{)l()1,{)

C")C")C")

1/)00., 00C")"fl/)

CX>N

-g.~ .9 ~ ~'ffi

rn~-gEo~- rn 3:

C'J"* - V) g'.~ rn.§ Q).8 -c 'en .~Q)U)Q)Oj::J'S:2Eee3: Qj~~ .8.g Q) '0 ~ Q)

()rnt)~ ~gUcu~~<1Jrn

o-w>c.Eodi~~Qj~

~2 <1J ~ ~'n;rn '01: 1) e Z. E<lJ5",E<lJQ)"o:2c).,~~:5~~

U enc crn .S!CJ)e ~.- 0

~ c-Ernto c: .....c .- e0

'"Q)

S~~"0

0 0CI) e.c

'"CI CI

~.c:C0>--0-g8e

O::~E~W Q)"'.cLL

Qj 8:!:II1II:: "0 ::J 3:III: Q)"O e« iii e ~:I: 0 a.

U ~ 09 .~>"'010'-=:3eo

5., .c rn 0

en xQ)e ::J- a..- q::

c( ::Jg>Q)II1II::1/1 o.cc:; « CI ~

f'-.N

-Q)

rn"O15,g-ri

~~"*'0

Q) Q)

.~ ~~0."" >

"C '" 0e.9!CIrn.ce

~~:E.-

Q) Q)t: CI CI::Jc-~~50 o.co.~Q) Q) 3:"O.r;-g~~~ en~Qj

5 0

-gE~iii ~:c- 0 a.-

~ 0_111

0 E Iiifii0 .2 .5 iD...J a!.!!1-

c( E~i3:E<Eo9


APPLICATIONSSize Length Currentmm mm (Amps) Minimum Packing

Best suited for fabrication of storage 3.15 350 90 - 140 Available in 3 Kg.tanks, automobile chassis, rail coaches. 4.00 350 120 - 170 PackingVery ideal for rebuilding wornout 5.00 350 180 - 220rollers and sugar mill trunions etc.,

AC,DC( + )

For joining and building up of low andmedium carbon steels. Ideal for joining

3.15 350 90 - 140 Available in 3 Kg.dissimilar joints and oil soaked parts.Used as cushioning alloy under 4.00 350 120 - 170 Packing

hardfacing deposits. Also finds appli- 500 350 180 - 240

cations in pressure vessels, pipes, steel AC,DC(+)casting, heavy machinery parts etc.,

For joining and surfacing of highcarbon, low and high alloy steels,

2.50 350spring steels, manganese steels, case 50 - 75

hardening steels, high speed steels, 3.15 350 75 - 120 Available in 3 Kg.

cast steels, and difficult to weld steels 4.00 350 90 ...;150 Packing

and unidentified steels. Can be used 5.00 350 130 - 180

as buffer layer before hardfacing and AC,DC(+)also for welding parts subjected to wear,corrosion and impact.

For welding of austenitic manganesesteel, materi~ls of difficult weldability, 2.50 350 50 - 70

manganese steel to mild steel, armour 315 350 70 - 100 Available in 3 Kg.steels. Ideal for providing cushioning 4.00 350 100 - 140 Packinglayer before hardfacing. Repairing 500 350 140 - 180cracks in austenitic manganese steelcastings, surfacing manganese steel AC,DC(+)rails etc.,

(IIIWIIIIIIllfSII

.!MAINTENANCE

PRODUCT DESCRIPTION

MAILMAIN -135A maintenance electrode giving a smooth uniform bead which

is of radiographic quality. For welding of thin sheets, lowercurrent is to be used to avoid distortion.

MAILMAIN -185A maintenance electrode giving an extremely ductile and crack

resistant deposit. The weld bead has good appearance andis of radiographic quality.

MAILEX -29/9

A maintenance electrode giving a deposit of 29%Cr, 9%Ni. The

weld metal is crack resistant, ductile, shock proof and tough.Gives smooth arc and least spatter.

MAILMAIN -4370

A maintenance electrode depositing austenitic stainless steel.

The weld metal is resistant to corrosion by atmosphere. seawater, weak acids and has excellent heat resistance.

29

ELECTRODES

-

30


APPLICATIONSSize Length Currentmm mm (Amps) Minimum Packing

For joining of cast ironto steel.Welding 2.50 350 40 - 80

and surfacing of cast iron. Can be 3.15 350 60 -120 Available in 3 Kg.

successfully used on rusty,corroded 4.00 350 90 - 140 Packing

and oil soaked parts. 5.00 350 150 -180

AC,DC(+)

For building up of parts Hardnesssubjected to friction wear 320 BHN 3.15 450 100 - 130 Available in 3 Kg.and shocks. Forging dies,

4.00 450 130 -170 Packingstriking tools,carbon steel

5.00 450 170 -210rails, rims, die plates etc.,

AC, DC(+)

For building up of partsHardnesssubjected to wear by abra- 3.15 450 100 -120 Available in 3 Kg.

sion and shocks, worm 600 BHN 4.00 450 140 - 180 Packingscrews, beaters, crusher 5.00 450 180 - 220jaws, buckets, fan blades,dredger teeth, repair of AC, DC(+)cutting tools etc.,

For hardfacing of parts sub-jected to heavy abrasion,and Hardness 315 350 100 - 130 Available in 3 Kg.metal to metal wear with 600 BHNmoderate impact. Suitable 4.00 350 130 - 170 Packing

for cement press screws, 500 350 170 -210

dredging buckets, edgerunner bottom, knife, palm AC, DC(+)nut screws, boring bits,blast furnace bells andhoppers.

- MAINTENANCEIIIUII1I!111l11GEM

PRODUCT DESCRIPTION

MAILMAIN - CINMA maintenance electrode giving a non-machinable deposit for

welding of cast iron to steel. Close colour match betweendeposit and base material is possible. Has good bondingproperties even on difficult-to-weld cast iron.

MAILMAIN - 320A maintenance electrode with good welding properties in allpositions. Thick deposits can be made without buffer layers.Weld metal is resistant to shock and impact stresses.

MAILMAIN - 550

A maintenance electrode giving a non-machinable deposit of

600 BHN approximately. Has excellent resistance to abrasionwith smooth appearance and superior weld beads.

MAILCARB

A maintenance electrode with high metal recovery and exceptional

abrasion resistance at high temperatures.

31

~

ELECTRODES

32


APPLICA TIONSSize Length Currentmm mm (Amps) Minimum Packing

For wear resistant surfacingof mild and low alloy steels.

3.15 350 90 -110 Available in 3 Kg.Building machines, con- Hardness 4.00' 350 110 -140 Packingveyor screws, scrapper600 BHN 5.00 350 150 -180blades, muller tyres,

trampers etc.,AC. OC(+)

For welding and surfacing of copper.3.15 350 80 - 110 Available in 3 Kg.brass and bronze, joining copper and 4.00 350 110 - 140 Packingbronze to cast iron overlays and steel.5.00 350 130 - 180Filling cavities in copper alloy castings.

AC, OC(+)

For cutting and piercing of carbon steel

Available in 3 Kg.cast iron, copper, aluminium, brass 3.15 450 150 - 240and other metals and alloys. Ideal for 4.00 450 190 - 280 Packingcutting of unwanted materials with- 5.00 450 240 - 360out the use of oxyacetylene or com-pressed air. AC, OC(-)

-iFor chamfering and gouging of low alloy 3.15 350 'T50- 200 Available in 3 Kg.steels, stainless steel, cast iron, carbon 4.00 350 230 - 280 Packingsteels etc.,and to remove defects in 5.00 350 270 - 350weld metal without the use of oxyacety-lene. AC, OC(+)

For welding joints as well as surfacing2.50 350 40 - 70 Available in 3 Kg.and repairs of machine frames, housings,3.15 350 60 - 100 Packingbearing blocks, cylinder blocks, sugar4.00 350 80 - 120mill rollers, cast iron dies etc.,

AC, OC(+)

-<~'~~-

8 MAINTENANCEMII.IMIIITIIUJra

PRODUCT DESCRIPTION

MAILMAIN - 600A maintenance electrode giving a hard wear resistant deposit.

MAILMAIN - BRONZEA maintenance electrode for welding of copper and bronze.The weld deposit is free from porosity and crack. The weldbead is smooth and uniform.

MAILMAIN CUTA maintenance electrode for cutting and piercing of all metals

MAILMAIN-GRU

A maintenance electrode used for chamfering and for producingsmooth grooves.

MAILMAIN-CINIA maintenance electrode for cold welding of cast iron andfor joining cast iron to mild steel.

33

.!

ELECTRODES

34

Designation Ultimate Tensile Yield Strength (Min)Digit Strength -N/mm2 N/mm2

4 410 - 510 3305 510 - 610 360

(IIIAIlJIIIITIWIIiII

GUIDE FOR IS DESIGNATIONS OF MANUALARC WELDING ELECTRODES

(AS PER IS 814: 1991)

MAIN CODINGFirst prefix letter 'E' indicates a covered electrode manufactured by extrusion process.

Second prefix letter indicates the type of covering.

A

B

C

R

RR

S

Acid

Basic

Cellulosic

Rutile

Rutile, heavy coated

Any other type not mentioned above

The flIst digit indicates ultimate tensile strength in combination with the yield stress.

The second digit indicates the percentage elongation in combination with the impact values.

DesignationDigit

Percentage Elongation

Minon 5.65.;soImpact Strength

in Joules (Min) at °c

For tensile01234

410 -510 N/mm2

No elongation and impact requirements20 47 J / + 27"C22' 47 J / OOC24 47 J / - 2O"C24 27 J / - 3O"C

range

35

.!

For tensile range 510- 610 N/mm2

a123456

47 J/ + 27°C

47J/ aoc47J/ - 20°C

27J/ - 30°C

27 J/ - 40°C

27J/ - 46°C

No elongation and impact requirements

18

18

20

20

20

20

The third digit indicates welding position

1. All positions2. All positions except vertical down3. Flat butt weld, flat fillet weld and horizontal/vertical fillet weld4. Flat butt weld and flat fillet weld.

.

5. Vertical down,. flat butt, flat fillet and horizontal/vertical fillet weld.6. Any other posItion or combination of positions not classified above.

The fourth digit indicates the current condition in which electrode to be used

Welding current and voltage conditions:

Digit D.C. RecommendedElectrode polarity

(2)

A.C., OCVV-min

(3)(1)

0

1

2

345

6

78

91)

2)

+ Not recommended

50

50

507070

70

9090

90

+ or-

++ or-

+

+ or-

+Symbol 0 reserved for electrodes exclusively used on D.C.

Positive polarity +. Negative polarity-

36

8111.111111I10OIII

ADDITIONAL CODINGPerformance characteristics

IThe letter and figure H1, H2 and H3 for hydrogencontrolled electrode. IH1 =

H2 =H3 =

Upto 15 ml of diffusible Hydrogen per 100 gms of deposited metal.



I The letter indicating increased metal recovery as effective electrode efficiency. J

J

K

L

110 - 129 percent

130 - 149 percent

150 percent and above=

JIThe i",:'er indicating the radiographic quality.

The letter 'X' shall be included in the classification as a suffix for those electrodeswhich deposit radiographic quality welds.

37

,,!

GUIDE FOR AWS DESIGNATIONS OF

MANUAL ARC WELDING ELECTRODES

The prefix "E" designates arc welding electrode

The first two digits of four digit numbers and the first three digits of five digit number

indicate minimum tensile strength.

E-60xx - 60,000 psi. Minimum tensile strength



The next to last digit indicates position.

E-xx 1x - All positions

E-xx2x - Flat position and horizontal fillets

The last two digits indicate the types of electrode covering, current and polarity. All low

hydrogen type covering (those ending in EXX -15, EXX- 16 and EXX-18) must be kept

in an oven at 250'C minimum before use.

The su1'tix(Example: EXXX - A1) indicates the approximate alloy composition in the weld

deposits.

A1 - 0.50% Mo

B1 - 0.50% Cr 0.5% Mo

B2 - 1.25% Cr 0.5% Mo

B3 - 2.25% Cr 1.0% Mo

B4 - 2.00% Cr 0.5% Mo

B5 - 0.50% Cr 1.0% Mo

B6 - 5.00% Cr 0.5% Mo 0.4% Ni

B7 - 7.00% Cr 0.5% Mo 0.4% Ni

B8 - 9.00% Cr 1.0% Mo 0.4% Ni

B9 - 9.00% Cr 1.0% Mo 1.0% Ni

G - 1.00% Mn(min), 0.8%Si (min), 0.5% Ni (min) 0.3% Cr(Min),

0.2% Mo(Min), 0.1% V(Min), 0.2% Cu(Min).

(Atleast one of the elements listed to meet the minimum values.) Additional chemical

requirements may be as agreed between supplier and purchaser)

C1

C2

C3

C4

C5

01,02

03

-2.5% Ni.

-3.5% Ni

- 1.0% Ni 0.3% Mo 0.15% Cr

-1.5% Ni

-6.5%Ni

- 0.25 - 0.45% Mo, 1.75% Mn

- 0.40 - 0.65% Mo, 1.75% Mn

38

UMllMMmllDGll emlca

Weight Percenta,b

Cu\,

Mn Si P 5 N

UNsd C Cr NI Mo Cb(nb)

AWS Plus Ta

Classification" Number

0.90 004 003 0.10.030 075

95-12.0 15.30 40 - 70

E209-XX' W3221 0 006 205-240 010-030 0.7580 .100 100 0.04 003

19.0-21.5 55- 70 0.75 0.03 010-030 0.75

E219-XX W32310 006 105.12.5 1.00 004

170-190 4.0-60 075 0.75

E240.XX W32410 0.06 004 003

9.0-107 05- 153.30.475 0.90

E307 .XX W30710 0.04-014 18.0-215 0.03 07505 - 25 090 004

0.08 18.0-210' 9.0-110 075 0.90 004 003 075

E308-XX W30810 0.5 - 2.5

W30810 004-008 18.0-210 9.0-110 0.75 0-03 075

E308H-XX 05.25 090 00490-110 0.75 075

E308L-XX W30813 004 180-210 05.25 090 004 00320 - 30 0.75 i

E308Mo-XX W30820 008 180-21.0 90-120 05 - 2 5 090 004 003

0.04 180-210 9.0-120 20- 30 004 003 075

308MoL-XX W30823 12.0-140 075 05 - 2 5 090 075

E309-XX W3091 0 0.15 22 0-250 05- 2 5 090 004 003

0.04 22.0-25.0 120-140 0.75 004 003 0.75

'"E309L-XX W30913 12.0-14.0 0.75 0.70 - 100 05 - 2.5 0.90 0.75

CD E309Cb-XX W30917 0.12 22.0-250 0.5 - 2.5 090 004 0.03

22.0-250 12.0-14.0 20- 30 003 0.75

E309Mo-XX W30920 012 0.5 - 2.5 0.90 0.04

0.04 22.0-25.0 12.0-14.0 20 - 3 0 0.75 0.03 0.03 075

E309MoL-XX W30923 0.75 1.0 - 25 0750 08-0 20 250-280 20.0-22.5 0.75 0.03 003

E310-XX W31010 200-225 0.75 1.0 - 25 0.75

E310H-XX W31015 0 35-045 25.0-280 (1.70 - 1.00 1.0 - 25 0.75 0.03 0.03

250-280 200-220 0.75 003 0.75

E310Cb-XX W31017 0.12 1.0.2.5 0.75 003

25.0-280 200-22.0 20 - 30 0.03 0.75

E310Mo-XX W31020 012 0.5 - 2.5 0.90 0.04

28.0-32.0 80-10.5 0.75 003 0.75

E312-XX W31310 0.15 05- 2.5 090 004

17.0-200 11.0-14.0 20-30 0.03 075

E316-XX W31610 0.06 0.5 - 2.5 0.90 0.04

004-0'08 170-200 11.0-14.0 20- 30 0.90 0.04 003 075

E316H-XX W31610 20-300.5 - 25 0.75

E316L-XX W31613 0.04 17.0-20.0 110-14.0 05-25 090 0.04 0.03

0.08 160-21.0 120-14.0 30 - 4.0 0.04 0.03 0.75

E317 .XX W31710 05-25 0.90

0.04 18.0-210 12.0-14.0 30 - 4.0 0.04 003 0.75

E317L-XX W31713 11.0-14.0 20-30 6xC, min 05 - 2 5 090

E318-XX W31910 0.08 170-200to 1.00 max 30 - 40

axc, min 05.25 060 004 003

0.07 19.0-210 320-360 20- 3 0E320-XX W88021 to '.00 max

Weight Percent a,b

f.

AWS UNSdC Cr Ni Mo Cb(Nb) Mn Si P S N . Cu

Classification" Number Plus T a

E320LR-XX W88022 0.03 19.0-210 32.0-360 2.0.3.0 8xC. min 1.5 - 2.5 0.30 0.02 0.015 3.0-4.0

to 0.40 max

E330-XX W88331 0.18-0.25 14.0-170 33 0-37.0 0.75 1.0- 2.5 0.90 0.04 0.03 0.75

E330H-XX W88335 0.35-0.45 14.0-17.0 330-370 0.75 1.0.2.5 0.90 0.04 0.03 0.75

E347-xx W34710 0.08 18.0-21.0 9.0-11.0 0.75 8xC, min 0.5-2.5 0.90 0.04 0,03 0.75

to 1.00 max

E349-XX''. W34910 0.13 18,0-210 8.0-10.0 0.35-0,65 0.75 -1,20 0,5

- 2.5 0.90 0.04 0,03 0.75

E383-XX W88028 0.03 265- 29,0 30.0-33.0 3.2 - 4.2 0.5 - 2.5 0.90 0.02 0,02 0,6-1.5

E385-XX W88904 003 195-215 24.0-260 42 - 5.2 1,0-

2,5 0,75 0.03 0.02 1.2-20

E410-XX W41010 0.12 11.0-13.5 0.7 0.75 1,0 0.90 O.O~ 0,03 0.75

E410NiMo-XX W41016 0.06 11.0-12.5 4,0-5.0 0.40-0.70 1.0 0.90 0,04 0.03 - 0.75

E430-XX W43010 0.10 15.0.180 0.6 0.75 1,0 0.90 0.04 0.03 0.75

E502.XX W5021 0 0.10 4.0 -6,0 04 0,45.0.65 1.0 0,90 0.04 0,03 0.75

E505.XX W50410 010 80.10,5 0,4 0,85.1,20 1.0 0,90 0.04 0.03 0.75

E630.XX W37410 0.05 160-16,75 4,5.5.0 0.75 0.15 -0.30 0,25.0,75 0.75 0,04 0,03 3.25-4,0

E16.8-2.XX W3681 0 0.10 14.5'16.5 7.5.9.5 1,0 -2.0 0,5 . 2.5 0,60 0,03 0.03 0,75

E7Cr-XX W50310 0.10 6.0 - 8.0 0.4 0.45-0.65 1.0 0.90 0.04 0.03 0,75

E2209-XX W39209 0.04 21,5-23.5 85-10.5 2.5 - 3.5 0.5.2.0 0.90 0.0., 0,03 0.08.0.20 0.75

E2553.XX W39553 0,06 24.0-27.0 6.5-85 2.9 - 3.9 0.5 -1.5 1,00 -0,04 0,03 0.10.0.25 1,50-2.5

Notesa) Analysis shall be made for elements for which specific values are shown in the table. If, however, the presence of other

elements is indicated in the course of routine analysis. further analysis shall be made to determine that the total of theseother elements. except iron, is not present in excess of 0.50 percent.

b) Single values are maximum percentages.c) Classification suffix -XX may be 15 - 16 - 17 . 25 or -26.

d) SAE/ASTM Unified Number System for Metals and Alloys.e) Vanadium shall be 0,10 to 0,30 per cent.f) Titanium shall be 0,15 percent maximum,g) Tungsten shall be from 1.25 percent to 1.75 percent.

.

(ICh I Composition Requirements for Stainless Steel Weld Metal

Chemical Composition Requirements for Stainless Steel Weld Metal

~0

-

ROCKWELL VICKERS BRINELL HARDNESS ROCKWELL VICKERS BRINELL HARDNESS

HARDNESS HARDNESS HARDNESS HARDNESS

~~"0 a, "00,

C Cic:: c ii

c:

00

EIII 'i

f EIII ru

~Ct.!! CD

""

C.tJii U).- tn.!!

ID

""

c:.tJii in.-

OIl"", ! IPC)'t"" ! 4)

::Jt.C .)1:;: C:.- III GI III :it. C ::Jt.;: C.- IIIQ,I UI

0 E ","0 - Q. 0 E (11'0 - Q.

0 ~0"0 ~:e 'i 'iii 0

0 ~0'C ~:e -; 'Uj 0

.0"0 ~~EIt

U)"D~~E

It

or to cu""

GI a.... IV cu

"'"

Q) Co

. 0 .- >- :J C'O ;n, 0 .- >0 ~cu u; GI 0

UJ IIIJ CIl.. I-U.....,.. U J ED J CIl. I-U ""''1'''"

67 ..' 918 820 .... 20 98.9 240 231 225 107

66 884 796 19 98.1 235 226 220 106

65 852 774 18 97.5 231 222 215 103

64 822 753 17 969 227 218 210 102

~63793 732 16 96.2 223 214 206 100

62 ... 765 711 15 955 219 210 201 99

61 740 693 14 94.9 215 206 197 97

60 717 675 ... 13 94.1 211 202 193 95

59 694 657 .. 12 93.4 207 199 190 93

58 ... 672 639 11 926 203 195 186 91

57 650 621 10 91.8 199 191 183 90

56 630 604 9 912 196 187 180 89

55 611 588 8 90.3 192 184 177 88

54 592 571 7 897 189 180 174 87

53 573 554 283 6 890 186 177 171 85

52 556 538 273 5 883 183 174 168 84

51 539 523 500 264 4 875 179 171 165 83

50 523 508 488 256 3 87.0 177 169 162 82

49 508 494 476 246 2 860 173 165 160 81

48 493 479 464 237 1 85.5 171 163 158 80

47 ) 479 465 453 231 0 845 167 159 154 78

46 465 452 442 221 832 162 153 150 76

45 452 440 430 215 820 157 148 145 74

44 ... 440 427 419 208 80.5 153 144 140 72

. ~--

43 ... 428 415 40842

201 ... 79.0 149 140417 405 398 194

136 70

4177.5 143 134 131

406 394 387 188 76.068

40139 130 127

... 396 385 377 18166

3974.0 135 126 122

386 375 367 17664

3872.0 129 120 117

.., 376 365 357 17062

37 36770.0 125 116 113 60

356 347 165 68.036 '."

120 111... 357 346 337

108 58

35160 .., 66.0 116 107 104

348 337 327 155 64.056

34 339... 112 104 100 54

... 329 318 14933

610 108 100330 319

96 52

32309 147 58.0 104 95

... 321 310 301 14292 50

3155.0 99 91 87

... 312 302 294 13948

30 30451.0 95 86 83 46

293 286 13629

47.0 91 83 79296 286

44

28 -279 132 44.0 88 80

... 288 27876 42

27272 129 39.0 84 76

281 27172 40

:. 26265 126 35.0 80 72

N 274 26468 38

25259 123 30.0 76 67

267 258 253 12064 36

2424.0 72 64

261 25260 34

23247 118 20.0 69 61

-.. 255 246 24157 32

115 11.022 100.2 250

65 57 53 30241 235 112 0

21 99.5 24562 54 50 28

236 230 110

(III1II.111 M£11U.tra

HARDNESS CONVERSION TABLE (Approx.)

8 .J

I111J11II1I11J18

USEFUL CONVERSION TABLE FOR WELDING ENGINEERS

Quantity 81 Units To convert from To Multiply by

Mass Kilogram (kg) kg Ib 2.205

1 tonne = 103kg tonne(t) ton (long) 0.984ton (short) 1.102

Force newton (N) kN Ibf 224.81N = 1kgm/sec2 kgf, kp 102.0

Stress pascal (Pa) kgf/mm2. kp/mm2 0.102ksi 0.145

1 pa = 1N/m2 N/mm(MPa) pa 1.0x1OS

Pressure pascal (Pa) bar Ibf/in2 14.5

1 bar = 105 Pa kgf/cm2 1.02

= 10-1N/mm-2 atm 0.987

Energy joule (J) J ft Ibf 0.73761J = 1 Nm kgfm 0.10201J = 0.1 daJ

kgfm, kpm ft Ibf 7.2331kgfm/cm2 ftlb* 5.7864

Speed mm/sec mm/sec inch/min 2.362m/hr 3.60

Dep Rate kg/hr kg/hr Ib/hr 2.205

Flow Rate litre/min litre/min ft3/hr 2.119m3/hr 0.(>6

Heat Input JIm kJ/mm kJ/in 25.4

* True for standard Charpy V-notch impact specimen

43

DIAMETERLENGTHmm SWG in mm in

1.6 16 1/16 250 10

2.0 14 5/64 300 122.5 12 3/32 350 143.15 10 1/8 400 16

4 8 5/32 450 185 I'; 3/16 600 24

6 4 1/4 700 287 2 9/32

8 5/16

ELECTRODE SIZE EQUIVALENTS

44

AWS#BIS LRS ABS IRS BV DNV BAX CIB MNDSI. TYPE

CLASSIFICATION

MAILARC-13 PLU~ E 6013 . . . . . . .1

E6013 . . . . . . . . .2 MAILARC - 13R

MAILARC - 13RR E 6013 . . . .3

4 MAILARC -10 E 6010

5 MAILARC -10G E 7010G

E 7016 . . . .6 MAILARC -16

7 MAILARC - 168 E 7016

MAILARC -18 E 7018 . . . . . . . . .8

MAILARC - 18 8PL E7018-1 . . .9

MAILARC -24 E 7024 . .10

11 MAILARC - 88G E 8018G

12 MAILARC -88W E 8018W

13 MAILARC - 98G E 9018G

14 MAILARC -Mo E7018-A1 .15 MAILARC - 118M E 11018M

16 MAILHARD -R III -17 MAILOCUT -

E308-16 .18 MAILEX -A

19 MAILEX -ANb E 347 -16

E 308L - 16 .20 MAILEX-AL

E 316L. 16 .21 MAILEX.Mol,

E 309- 16 .22 MAILEX -25/12

23 MAILEX - 13CR E410-16

24 MAILEX - 18/8/6 -

.J

APPROVAL CHARTSI. MMD ROSQ ElL PDIL UHDE BHEL BHEL BHEL BHPV

TNEB HSL WART FICHIDEA

TRY HYD RPT VIZAG NLC

.* * *2 * * * * .

* * * * * * *3* * *4

* * * *5*

6 * * *7:I:

8 * * * * . * . * * .* * * *9 * * * * * * *10

*11

*12*13

14

15* *16

*17

*18* * :I:

* :(:*19

*20* *21* *22 * * * * *23

*24

*46

~-

, ~-

I)MAILAMII£TAlIlii« ELECTRODE

# For abbreviation see overleaf 45

TYPETEMPERATURE( AWSClassification) TIME

DC

6012,6013,701490 - 100 1 Hr.'

6010, 7010G, 7010-:\1, 8010G70 - 80 1 Hr.

7024, ENiCu-B, ENi-C:, ENiFe-CI150 - 180 1 Hr.

7016, Hardfacing, Low alloyElectrodes and Stainless SteelElectrodes

200 - 250 2 Hrs.7018,7018-1, and otherHydrogen controlled electrodes

300 2 Hrs.

I;I

I 8I1W11II1I1U1111

BIS

LRS

ABS

IRS

BV

DNV

BAX

CIB

MND

MMD

RDSO

ElL

POlL

IDEA

UHDE

BHEL, TRY.

BHEL, HYD.

BHEL, RPT

BHPV, VIZAG.

NLC

TNEB

HSL

WART

FICH

. BUREAU OF INDIAN STANDARDS

. LLOYD'S REGISTER OF SHIPPING

- AMERICAN BUREAU OF SHIPPING

- INDIAN REGISTER OF SHIPPING

- BUREAU VERITAS

- DET NORSKE VERITAS

- BAXCOUNSEL

- CHIEF INSPECTOR OF BOILERS

- M.N. DASTUR & COMPANY LIMITED

- MERCANTILE MARJNE DEPARTMENT

- RESEARCH DESIGN AND STANDARDS ORGANISATION

- ENGINEERS INDIA LIMITED

- PROJECTS & DEVELOPMENT INDIA LTO.. INTERNATIONAL DEVELOPMENT AND ENGG. ASSOCIATED LTD.,

- UHDE INDIA LIMITED.. BHARAT HEAVY ELECTRICALS LIMITED, TRICHY.

- BHARAT HEAVY ELECTRICALS LIMITED, HYDERABAD.

- BHARAT HEAVY ELECTRICALS LIMITED, RANIPET.

- BHARAT HEAVY PLATE & VESSELS LIMITED,VISAKHAPATTINAM.

- NEYVELI LIGNITE CORPORATION

- TAMILNADU ELECTRICITY BOARD

- HINDUSTAN SHIPYARD LIMITED

- WARTSILA NSD CORPORATION

- FICHTNER CONSULTING ENGINEERS (INDIA) PVT. LTD.,

47

.!

ELECTRODE CARE AND CONDITIONING

There is a tendency for the I .moisture if exposed or durin' I e ectrodes to Pick up

atmosphericwelds and poor performan

g~n~

storage This may lead to faulty

hydrogen electrOdesce 0 e ectrodes. This ISmore so with low

at the lowest Th I'where the hydrogen level is expected to be

moisture m.

de ow hydrogen electrodes if allowed to catch U

Pay evelop underbead k'heavy restraint Joints In all su h crac Ing In the heat affected zone of

must and the recom~en c cases, the. redrYlng of electrdes is a

is given below:ded temperature for different range of electrodes

48

arc welding electrodes (product catalogue)

Documents