Welding Electrode Formulation,Then and Now


    Achieving the production formulation of welding consumables such as coated electrodes and submerged arc welding powder is a time-consuming, costly process and requires many calculations and tests. But you can understand the basic principles by describing the process in a simplified way, and then moving on to more complex content to get the answer.

    The formulation of welding materials means the exact weight percentage of different chemical and mineral compounds, which has been contracted in this formula due to a specific purpose.

    If we look at the chemical analysis of a pure welded metal, we must pay attention to the fact that each of these elements is derived from the origin of the electrode coating or core wire in the Covered Electrode in the SMAW process or derived from Flux or Wire in Welding Flux in SAW Process.

    In the Figure Below you Can find The Pick-Up and Burn off Manganese element which is in the Formula of Covered Electrode  ENiCrMo6.

    As can be seen, the source of this element in the weld metal can be powders used in coating or core wire.A percentage of this element is lost through the presence of slag, spatter and gas.

    Manganese in Welding Electrode Formula

    In another example, in the photo below, look at submerged arc welding, in which the presence of silicon is investigated.

    Silicon in Welding Flux Formula

    another example, in the photo below, look at flux-cored arc welding, in which the presence of nickel is investigated. in this example, for gas protection ,there is no slag on the surface of weld bead and the waste of element is reduced.

    Nickel in the Formula of Flux Cored Arc Welding Wire