- Keywords Welding electrodes, welding ANSI/AWS A5.15-90 rods, cast iron, filler metal An American National Standard specifications, flux cored arc welding electrodes, shielded Approved by metal arc welding electrodes American National Standards Institute gas metal arc welding electrodes March 14,1990 Specification for Welding Electrodes and Rods for Cast Iron Superseding ANSIIAW S AS. 15-82 Prepared by AWS Committee on Filler Metal Issued 1956: Revised, 1965, 1969, 1982 Under the Direction of Technical Activities Committee Approved by AWS Board of Directors Abstract The chemical composition requirements for electrodes and rods for welding cast iron are specified. Copper- base rods used for braze welding of cast iron are not included. Major topics include general requirements, testing, packaging, and application guidelines. American Welding Society 550 N.W. LeJeune Road, P. 0. Box 351040, Miami, Florida 33135 (This Foreword is not a part of ANSIIAWS A5.15-90, Specification for Welding Electrodes and Rods for Cast Zron, but is intended for information purposes only.) The first specification for electrodes and rods for welding cast iron was published more than thirty years ago as a joint ASTM/AWS document. The first revision that was exclusively an AWS specification was published in 1969 and revised in 1982. Evolution of the document is as shown below: ASTM A398-56T Tentative Specification for Welding Rods and Covered Electrodes for AWS A5.15-56T Welding Cast Iron. AWS A5.15-65T Tentative Specification for Welding Rods and Covered Electrodes for ASTM A3 9 8-6 5T Cast Iron AWS A5.15-69 Specification for Welding Rods and Covered Electrodes for Welding ANSI W3.15-1973 Cast Iron ANSIIAWS AS. 15-82 Specification for Welding Rods and Covered Electrodes for Cast Iron Comments and suggestions for improvement of this standard are welcome. They should be sent to the Secretary, Filler Metal Committee, American Welding Society, 550 N.W. LeJeune Road, P. 0. Box 35 1040, Miami, Florida, 33 135. V AWS Committee on Filler Metal W. L. Wilcox, Chairman Consultant D. J. Kotecki, 1st Vice Chairman The Lincoln Electric Company D. F. Betz, 2nd Vice Chairman Crane Midwest W. A. Dierschow, Secretary American Welding Society Z. Al-Hillal Liquid Carbonic D. R. Amos Westinghouse Turbine Plant B. E. Anderson Alcotec K. E. Banks Teledyne McKay J. B. Bolton Kennametal, Incorporated. R. S. Brown Carpenter Technology Corporation J. Caprarola, Jr. Alloy Rods Corporation L. J. Christensen* Consultant R. J. Christofel Consultant D. A. DelSignore Westinghouse Electric Company P. B. Dickerson* Consultant H. W. Ebert Exxon Research and Engineering Company D. A. Fink The Lincoln Electric Company J. Gonzalez The Lincoln Electric Company G. Hallstrom, Jr. USNRC-RII R. L. Harris* R. L. Harris Associates D. C. Helton Consultant W. S. Howes National Electrical Manufacturers Association (NEMA) J. P. Hunt Inco Alloys International R. B. Kadiyala Techalloy Maryland, Incorporated P. A. Kammer* Eutectic Corporation G. A. Kurisky Maryland Specialty Wire R. A. LaFave Elliott Company N. E. Larson Union Carbide Corporation A. S. Laurenson Consultant G. H. MacShane Stoody Deloro Stellite Incorporated L. M. Malik* Arctec Canada Limited W. F. McLaughiin Chrysler Corporation M. T. Merlo Tri-Mark, Incorporated G. E. Metzger WRDC/MLLS J. W. Mortimer Consultant *Advisor ... 111 w. L. Mott Hobart Brothers Company C. L. Null Naval Sea Systems Command Y. Ogata* Kobe Steel, Limited J. Payne Schneider Services International R. L. Peaslee Wall Colmonoy Corporation E. W. Pickering Combustion Engineering, Incorporated S. D. Reynolds, Jr.* Westinghouse Electric Company L. F. Roberts Canadian Welding Bureau D. Rozet Consultant P. K. Salvesen American Bureau of Shipping H. S. Sayre* Consultant 0. W. Seth Chicago Bridge and Iron Company R. W. Straiton Bechtel Group, Incorporated R. D. Sultan L-Tec Welding and Cutting Systems R. A. Swain Welders Supply J. W. Tackett Haynes International R. D. Thomas, Jr. R. D. Thomas and Company R. Timerman* CONARCO, S.A. R. T. Webster Teledyne Wah Chang A. E. Wiehe* Consultant W. A. Wiehe Arcos Divisions, Hoskins Manufacturing Company F. J. Winsor* Consultant K. G. Wold Welding Consultants USA T. J. Wonder VSE Corporation AWS Subcommittee on Electrodes and Rods for Welding Cast Iron K. E. Banks, Chairman Teledyne McKay R. A. Bushey, Vice Chairman Alloy Rods Corporation W. A. Dierschow, Secretary American Welding Society R. A. Bishel Inco Alloys International M. B. Dillman Consultant D. 0. Drossman Wear Management Services E. R. Kuch Cooper Industries J. C. Margerie* Centre Technique des Industries J. W. Matush Consultant P. J. Mikelonis* Grede Foundries, Incorporated A. H. Miller* DISC L. W. Myers Dresser Industries, Incorporated W. F. Ridgway Eutectic and Castolin Institute M. T. Rowley* Consultant C. F. Walton* Consultant 'Advisor iv . Page No ... Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i ll Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v ii List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v ii 1 . Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Part A .G eneral Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . Units of Measure and Rounding-Off Procedure . . . . . . . . . . . . . . . . . . . . . . . . 1 Part B .T ests. Procedures. and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6 . Summary ofTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 . Retest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 . Weld Test Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9 . Chemical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Part C .M anufacture. Identijkation. and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 6 10. Welding Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1 1 . Shielded Metal Arc Welding Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 12 . Gas Metal Arc and Flux Cored Arc Welding Electrodes . . . . . . . . . . . . . . . . . . . 8 Appendix .G uide to A WS A5.15-90, Specijication for Welding Electrodes and Rods for Cast Iron 15 Specification for Welding Electrodes and Rods for Cast Iron 1. Scope not to prohibit their use with any other process for which they are found suitable. This specification prescribes requirements for the classification of the following: 3. Acceptance (1) Rods for oxyfuel gas welding (2) Electrodes for gas metal arc welding Acceptance* of the welding electrodes shall be in (3) Electrodes for flux cored arc welding accordance with the provisions of ANSIIAWS (4) Electrodes for shielded metal arc welding A5.0 1, Filler Metal Procurement Guidelines.’ These filler metals are suitable for welding gray cast iron, malleable cast iron, nodular cast iron, compacted graphite cast iron, and certain alloy cast 4. Certification irons. I By affixing the AWS specification and classifica- tion designations to the packaging, or the classifica- Part A tion to the product, the manufacturer certifies that General Requirements the product meets the requirements of this spe~ification.~ 2. Classification 5. Units of Measure and Rounding- Off Procedure 2.1 The electrodes and rods covered by this specifi- cation are classified according to chemical compo- 5.1 U.S. Customary Units are the standard units of sition, as specified in Tables lA, lB, and 1C. measure in this specification. The SI Units are given as equivalent values to the U.S. Customary 2.2 Electrodes and rods classified under one classi- Units. The standard sizes and dimensions in the fication shall not be classified under any other clas- two systems are not identical, and for this reason, sification in this specification. 2.3 The electrodes and rods classified under this 2. See section A3 (in the Appendix) for further informa- specification are intended for oxyfuel gas welding, tion concerning acceptance, testing of the material shipped, and ANSI/A WS A5.01, Filler Metal Procure- shielded metal arc welding, gas metal arc welding, ment Guidelines. or flux cored arc welding, as applicable, but that is 3. AWS standards can be obtained from the American Welding Society, 550 N.W. LeJeune Road, P.O. Box 1. Copper-base filler metals frequently used in the braze 351040, Miami, Florida 33135. welding of cast iron are no longer included in this specifi- 4. See section A4 (in the Appendix) for further informa- cation. For information pertaining to these materials see tion concerning certification and the testing called for to A7.6 in the Appendix. meet this requirement. 1 2 conversion from a standard size or dimension in value shall be rounded to the “nearest unit” in the one system will not always coincide with a standard last right-hand place of figures used in expressing size or dimension in the other. Suitable conver- the limiting value in accordance with the rounding sions, encompassing standard sizes of both, can be off method given in ANSIIAWS A1 .I , Metric Prac- made, however, if appropriate tolerances are tice Guide for the Welding Industry. applied in each case. 5.2 For the purpose of determining conformance with this specification, an observed or calculated Table lA* Chemical Composition Requirements for Undiluted Weld Metal for Shielded Metal Arc and Flux Cored Arc Welding Electrodes Weight PercenPbqe Other AWS UNS Elements, Classificationd Numbef C Mn Si P S Fe Ni‘ Mo Cug A1 Total Shielded Metal Arc Welding Electrodes ENi-CI W8200I 2.0 2.5 4.0 - 0.03 8.0 85 min. - 2.5 1.0 1. o ENi-CI-A W82003 2.0 2.5 4.0 - 0.03 8.0 85 min. - 2.5 1.0-3.0 1.0 ENiFe-CI W82002 2.0 2.5 4.0 - 0.03 Rem. 45-60 - 2.5 1.0 1. o ENiFe-CI-A W82004 2.0 2.5 4.0 - 0.03 Rem. 45-60 - 2.5 1.0-3.0 1.0 ENiFeMn-CI W82006 2.0 10-14 1.0 - 0.03 Rem. 35-45 - 2.5 1.0 1. o ENiCu-A W84001 0.35-0.55 2.3 0.75 - 0.025 3.0-6.0 50-60 - 35-45 - 1 .O ENiCu-B W84002 0.35-0.55 2.3 0.75 - 0.025 3.0-6.0 60-70 - 25-35 - 1. o Flux Cored Arc Welding Electrodes ENiFeT3-CIh W82032 2.0 3.0-5.0 1.0 - 0.03 Rem. 45-60 - 2.5 1.0 1 .o *See notes on following page. Table lB* Chemical Composition Requirements for Core Wire for Shielded Metal Arc Welding Electrodes Weight Percentab*‘ Other AWS UNS Elements, Classificationd Numbef C Mn Si P S Fe Ni Mo Cu A1 Total Shielded Metal Arc Welding Electrodes ESt KO1520 0.15 0.60 0.15 0.04 0.04 Rem. - - - - - *See notes on following page. (Continued) 3 Table 1C Chemical Composition Requirements for Rods and Bare Electrodes Weight PercentPqbqc Other AWS UNS Elements, Classificationd Numbere C Mn Si P S Fe Ni‘ Mo Cug Mg A1 Ce Total Cast Iron Welding Rods for OFW RCI F10090 3.2-3.5 0.60-0.75 2.7-3.0 0.50-0.75 0.10 Rem. Trace Trace - - - - - RC‘I-A F10091 3.2-3.5 0.50-0.70 2.0-2.5 0.20-0.40 0.10 Rem. 1.2-1.6 0.25-0.45 - - - - - RCI-B F10092 3.2-4.0 0.10-0.40 3.2-3.8 0.05 0.015Rem. 0.50 - - 0.04-0.10 - 0.20 - Electrodes for Gas Metal Arc Welding ERNi-CI NO2215 1.0 2.5 0.75 - 0.03 4.0 90 min. - 4.0 - - - I. o ERNiFcMn-CI NO2216 0.50 10-14 1.0 - 0.03 Rem. 35-45 - 2.5 - 1.0 - 1.0 Notes: a. The weld metal, core wire, or the filler metal, as specified, shall be analyzed for the specific elements for which values are shown in this table. If the presence of other elements is indicated, in the course of this work, the amount of those elements shall be determined to ensure that their total does not exceed the limit specified for “Other Elements, Total” in the last column of the table. b. Single values shown are maximum, unless otherwise noted. c. “Rern.” stands for Remainder. d. Copper-base filler metals frequently used in the braze welding of cast irons are no longer included in this specification. For information pertaining to these materials see A7.6. e. SAE/ASTM Unified Numbering System for Metals and Alloys. f. Nickel plus incidental cobalt. g. Copper plus incidental silver. h. No shielding gas shall be used for classification ENiFeT3-CI. Part B of both tests shall meet the requirement. Specimens Tests, Procedures, and Requirements for retest may be taken from the original test assem- bly or sample, or from new test assemblies or sam- ples. For chemical analysis, retest need only be for 6. Summary of Tests those specific elements that failed to meet the test requirement. Chemical analysis, as specified in Table 2, of the filler metal or rod stock from which the filler metal is made, or the core wire, or the undiluted weld 8. Weld Test Assembly metal is the only test required for classification of a product under this specification. 8.1 One test assembly is required. It is the weld pad 7. Retest in Figure 1 for chemical analysis of undiluted weld metal from electrodes for shielded metal arc or flux If the results of any test fail to meet the require- cored arc welding electrodes, except for the ESt ment, that test shall be repeated twice. The results classification for which the core is analyzed. 4 9. Chemical Analysis Table 2 Required Tests 9.1 For solid filler metal classified in Table 1A , and Chemical the core wire for electrodes classified in Table 1B , a Chemical Analysis of Analysis sample of the filler metal, core wire, or the rod stock AWS Undiluted Weld Metal of Filler from which the filler metal or core wire is made, Classification from Weld Pad’ Metal’ shall be prepared for chemical analysis. Solid filler metal, when analyzed for elements that are present ENi-Cl Required N.R. in a coating (copper flashing, for example), shall be ENi-CI-A Required N.R. analyzed without removing the coating. When the EN i Fe-CI Required N.R. filler metal is analyzed for elements other than ENiFe-CI-A Required N.R. those in the coating, the coating shall be removed if ENiFeMn-CI Required N.R. ENiCu-A Required N.R. its presence affects the results of the analysis for ENiCu-B Required N.R. other elements. Rod stock analyzed for elements ENiFeT3-CI Required N.R. not in the coating may be analyzed prior to apply- RCI N.R. Required ing the coating. RCI-A N.R. Required RCI-B N.R. Required ERNi-CI N.R. Required 9.2 For electrodes classified in Table IA, a sample ERNiFeMn-Cl N.R. Required shall be analyzed in the form of weld metal, not ESt N.R. RequiredZ filler metal. The sample for analysis shall be taken from weld metal obtained with the filler metal. The sample shall come from a weld pad as shown in Figure 1. The top surface of the pad described in Notes: 8.3 and shown in Figure 1 shall be removed, dis- 1. “N.R.” means that the test is not required. carded, and a sample for analysis shall be obtained from the underlying metal by any appropriate 2. Chemical requirements for the ESt classification are mechanical means. The sample shall be free of slag. based on the composition of the core wire without any For covered electrodes 1/8 in. (3.2 mm) and flux coatings. smaller and flux cored electrodes .052 in. (1.3 mm) diameter and smaller, the sample shall be taken at least 71 16 in. (1 1 mm) from the nearest surface of the base metal. For covered electrodes larger than 8.2 Preparation of the weld test assembly shall be 118 in. (3.2 mm) diameter and flux cored electrodes as prescribed in 8.3 and Figure 1. The base metal larger than .052 in. (1.3 mm), the sample shall be for the assembly shall be gray iron, nodular iron, or taken at least 9/16 in. (14 mm) from that surface. carbon steel. Testing of the assembly shall be as prescribed in 9.2 and 9.3 9.3 The sample shall be analyzed by accepted ana- lytical methods. The referee method shall be the 8.3 Weld Pad. When required by Table 2, a weld appropriate one of the following: pad shall be prepared as specified in Figure 1. Base metal of any convenient size, of the type specified (1) ASTM E39, Standard Method for Chemi- in 8.2, shall be used as the base for the weld pad. cal Analysis of Nickel The surface of the base metal on which the filler metal is deposited shall be clean. The pad shall be (2) ASTM E76, Standard Methods for Chem- welded in the flat position with multiple beads and ical Analysis of Nickel-Copper Alloys multiple layers to obtain undiluted weld metal. The preheat temperature shall not be less than 60°F (3) ASTM E350, Standard Method for Chem- (16°C) and the interpass temperature shall not ical Analysis of Carbon Steel, Low-Alloy Steel, exceed 300°F (150OC). The slag shall be removed Silicon Electrical Steel, Ingot Iron and Wrought after each pass. The pad may be quenched in water Iron between passes. The dimensions of the completed pad shall be as shown in Figure 1, for each size of 5. ASTM standards can be obtained from the American electrode. Testing of this assembly shall be as speci- Society for Testing and Materials, 19 16 Race Street, Phil- adelphia, Pennsylvania 1 90 13. fied in 9.2. 5 Shielded Metal Arc Welding Flux Cored Arc Weldine ~ Minimum Minimum Minimum Minimum Min. No. of Electrode Diameter Height (H) Length (L) Electrode Diameter Height (H) Length (L) Layers 118 in. (3.2 mm) 1/2 in. (13 1-1/2 in. .052 in. (1.3 mm) 518 in. (1 6 3 in. 4 and less mm) (38 mm) and less mm) (76 mm) Greater than 1/8 7/8 in. (22 2 in. Greater than .052 1 in. 4 in. 4 in. (3.2 mm) mm) (51 mm) in. (1.3 mm) (25 mm) (102 mm) Notes: The width (W) of the weld metal shall be sufficient for the method of analysis. No shielding gas shall be used for classification ENiFeT3-CI. Figure 1-Pad for Chemical Analysis of Undiluted Weld Metal