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Welding consumables are the filler metal — and the flux or coating that protects it — melted into a weld. For carbon steel they are covered electrodes for manual arc welding, solid wire for MIG/MAG and TIG, flux-cored wire and submerged-arc wire with flux, each classified so that the weld metal matches the strength and toughness of the steel being joined.
Every arc-welding process needs filler metal and a way to keep air away from the molten pool. In manual metal arc (MMA or 'stick') welding the electrode is a steel core wire with a mineral coating that melts into a gas shield and a slag. MIG/MAG (GMAW) welding feeds solid wire through a gun with a shielding gas; TIG (GTAW) adds filler rod by hand to a tungsten arc; flux-cored wire (FCAW) carries its flux inside a tube; and submerged-arc welding (SAW) runs a bare wire under a blanket of granular flux for thick, long welds.
Consumables are classified by the strength and toughness of the weld metal they deposit and by how they are used. In the AWS system E7018 means an electrode (E) for 70 ksi (490 MPa) weld metal, usable in all positions (1), with a basic, low-hydrogen iron-powder coating (8). ER70S-6 is a solid wire or rod (ER) of the same strength with the higher manganese and silicon (6) that tolerate mill scale. The ISO systems say the same in metric terms — ISO 2560-A E 42 4 B 42 H5, for example.
Rutile electrodes such as E6013 weld easily and look neat and are used for light fabrication and maintenance. Basic low-hydrogen electrodes such as E7018 give tough, crack-resistant welds and are required for structural, pressure and pipeline work; they absorb moisture and must be kept dry and baked before use. Cellulosic E6010 and E8010 electrodes are used for the root runs of pipeline welds.
The GCC's construction, oil and gas, petrochemical and shipyard work uses large volumes of consumables, imported from Europe, Asia and the Middle East and approved by each project's welding procedure. Welds on GCC oil, gas and pressure equipment are qualified to ASME Section IX, AWS D1.1 or API 1104, and the consumable is part of the qualified procedure: changing the brand or classification means checking the procedure first.
Consumables are ordered by classification and standard, diameter and packing. For electrodes the packing matters as much as the rod: low-hydrogen electrodes are supplied in hermetically sealed tins or vacuum packs, and once opened must go into a holding oven.
| Region | Standard | What it covers |
|---|---|---|
| USA | AWS A5.1/A5.1M AWS |
Carbon steel electrodes for shielded metal arc welding — E6010, E6013, E7016, E7018 |
| USA | AWS A5.18/A5.18M AWS |
Carbon steel electrodes and rods for gas shielded arc welding — ER70S-2, ER70S-6, E70C metal-cored |
| USA | AWS A5.20/A5.20M AWS |
Carbon steel electrodes for flux cored arc welding — E71T-1, E70T-5 and others |
| USA | AWS A5.17/A5.17M AWS |
Carbon steel electrodes and fluxes for submerged arc welding — EL12, EM12K wire with F6/F7 fluxes |
| USA | AWS A5.5/A5.5M AWS |
Low-alloy steel electrodes for shielded metal arc welding — E8018-C1, E8010-P1 and others |
| International | ISO 2560 ISO |
Covered electrodes for manual metal arc welding of non-alloy and fine grain steels — system A (yield and impact) and system B (tensile, AWS-style) |
| International | ISO 14341 ISO |
Wire electrodes and weld deposits for gas shielded metal arc welding of non-alloy and fine grain steels |
| International | ISO 636 ISO |
Rods, wires and deposits for tungsten inert gas welding of non-alloy and fine-grain steels |
| International | ISO 17632 ISO |
Tubular cored electrodes for gas shielded and non-gas shielded metal arc welding of non-alloy and fine grain steels |
| International | ISO 14171 ISO |
Solid wire electrodes, tubular cored electrodes and electrode/flux combinations for submerged arc welding of non-alloy and fine grain steels |
| China | GB/T 5117 SAC |
Covered electrodes for manual metal arc welding of non-alloy and fine grain steels (E4303, E5015, E5016) |
| India | IS 814 BIS |
Covered electrodes for manual metal arc welding of carbon and carbon-manganese steel |
Grade equivalents and the standards bodies: Steel grades & standards
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