Академический Документы
Профессиональный Документы
Культура Документы
SFA-5.6
2. Acceptance 6. Retest
Acceptance of the material shall be in accordance with
If any test fails to meet its requirement, that specific
the provisions of AWS A5.01, Filler Metal Procurement
test must be repeated twice. The results of both tests shall
Guidelines.
meet the requirement. Specimens for retest may be taken
from the original test assembly or from one or two new
3. Certification test assemblies.
The manufacturer certifies by affixing the marking For chemical analysis, retest shall be for the specific
required in Section 18 that the material, or representative element which failed to meet the requirement.
153
Cu Total
AWS UNS Common Including Other
Classification Numberc Name Ag Zn Sn Mn Fe Si Nid P Al Pb Tl Elements
ECu W60189 Copper Remainder f f 0.10 0.20 0.10 f f 0.10 0.02 — 0.50
ECuSi W60656 Silicon bronze Remainder f 1.5 1.5 0.50 2.4 to 4.0 f f 0.01 0.02 — 0.50
(copper silicon)
ECuSn-A W60518 Phosphor bronze Remainder f 4.0–6.0 f 0.25 f f 0.05 to 0.35 0.01 0.02 — 0.50
ECuSn-C W60521 冧 (copper-tin) 冦 Remainder f 7.0–9.0 f 0.25 f f 0.05 to 0.35 0.01 0.02 — 0.50
ECuNie W60715 Copper nickel Remainder f f 1.00–2.50 0.40–0.75 0.50 29.0–33.0 0.020 — 0.02 0.50 0.50
(70/30)
154
ECuAl-A2 W60614 Aluminum bronze Remainder f f f 0.50–5.0 1.5 f — 6.5 to 9.0 0.02 — 0.50
ECuAl-B W60619 Aluminum bronze Remainder f f f 2.5–5.0 1.5 f — 7.5 to 10.0 0.02 — 0.50
2004 SECTION II
ECuNiAl W60632 Nickel aluminum Remainder f f 0.50–3.5 3.0–6.0 1.5 4.0–6.0 — 6.0 to 8.5 0.02 — 0.50
bronze
ECuMnNiAl W60633 Manganese-nickel Remainder f f 11.0–13.0 2.0–6.0 1.5 1.0–2.5 — 5.0 to 7.5 0.02 — 0.50
NOTES:
a. Analysis shall be made for the elements for which specific values or an “f” are shown in this 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 these other elements is not present in excess of the limits specified for ‘total other elements’ in the last column in the table.
b. Single values shown are maximum.
c. SAE/ASTM Unified Number System for Metals and Alloys.
d. Includes cobalt.
e. Sulfur shall be restricted to 0.015 percent for the ECuNi classification.
f. Those elements must be included in total of other elements.
PART C — SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.6
TABLE 2
SUMMARY OF MATERIALS REQUIRED FOR TESTING
Base Metala (ASTM Specifications and UNS Numbers)
AWS Transverse Guided
Classification Chemical Analysis Tension Testb Bend Testb
B152 or B11
ECu B152 or B11 C12200 B152 or B11 C12200 C12200
B96 or B97
ECuSi B96 or B97 C65500 B96 or B97 C65500 C65500
ECuSn-A B103 C51100 B103 C51100 B103 C51100
ECuSn-C B130 C52100 B130 C52100 B130 C52100
ECuNic B122 C71500 B122 C71500 B122 C71500
ECuAl-A2 B169 C61400 B169 C61400 B169 C61400
ECuAl-B B148 C95400 B148 C95400
ECuNiAl B148 C95800 B148 C95800 B148 C95800d
ECuMnNiAl B148 C95700 B148 C95700 B148 C95700d
NOTES:
a. Tests are required only where base metals are designated. All welding for chemical analysis, all-weld-
metal tension tests, and transverse guided-side-bend tests shall be done with the test plates in the flat
position.
b. When desired, steel, A36 or equivalent, may be substituted for the designated copper alloy. When this
is done, surfacing welds shall be applied to the groove faces of the joint. Surfacing shall be accomplished
with electrodes of the same classification as those being tested and may be done in the flat position.
c. Groove weld usability tests shall be conducted for the ECuNi classification as per Fig. 3.
d. Bend radius shall be in accordance with 11.
7. Weld Test Assemblies as shown in Fig. 2 using base metal of the appropriate
type specified in Table 2 and the Tension test and Bend
Two test assemblies are required for all except ECuNi
test columns of Table 2. Testing of this assembly shall
classification. This classification requires three test
be as specified in Sections 9 and 10.
assemblies as follows:
(1) A weld pad, Fig. 1, for chemical analysis of the 7.3 Groove Weld for Usability Test. A test assembly
undiluted weld metal shall be prepared for electrodes of the ECuNi classifica-
(2) A groove weld, Fig. 2, for mechanical properties tion and welded as shown in Fig. 3, using base metal of
and soundness of the weld metal the appropriate type specified in Table 2 including Notes.
(3) A groove weld, Fig. 3, for usability of ECuNi The welding position shall be as specified in the Usability
electrodes test column of Table 3 for the different sizes of electrodes
of the ECuNi classification. Testing of the assembly shall
7.1 Weld Pad. Base metal of a convenient size, of
be as specified in Section 11.
the type specified in Table 2, and in the Chemical Analysis
Column of Table 2 (including Note b to that Table), shall
be used as the base for the weld pad shown in Fig. 1. 8. Chemical Analysis
The surface of the base metal on which the weld metal 8.1 Details of the test are specified in 8.2 and 8.3.
is deposited shall be clean.
The pad shall be made with multiple passes and layers 8.2 Weld deposits or fractured portions of all-weld-
of weld metal deposited in the flat position. The slag metal tension test specimens may be employed for the
shall be removed after each pass. The temperature of the determination of weld metal chemical analysis. Weld
base metal shall be not less than 60°F (16°C) prior to metal shall be deposited in layers in the flat position using
welding, and the interpass temperature shall not exceed the base material specified in Table 2. In case of dispute,
300°F (150°C). The dimensions of the completed pad deposit dimensions shall be as specified in Fig. 1.
shall be as shown in Fig. 1 for each size of electrode.
8.3 Samples for analysis shall be free from all foreign
Testing of this assembly shall be as specified in Section 8.
matter. To avoid dilution, a minimum height of 5⁄8 in.
7.2 Groove Weld for Mechanical Properties and (16 mm) of weld metal shall remain after removal of the
Soundness. A test assembly shall be prepared and welded sample for analysis.
155
--`,,```,,,,````-`-`,,`,,`,`,,`---
8.4 Weld metal analysis may be made by any suitable 9.3 The test assemblies shall be prepared and evalu-
method. In case of dispute, the chemical analysis proce- ated in accordance with 9.3.1, 9.3.2, and 9.3.3.
dure in the latest edition of the following ASTM specifi- 9.3.1 The weld shall merge smoothly with the sur-
cations shall be the referee method: face of the plate. Any reinforcement must be reasonably
E62-XX Photometric Methods for Chemical Analysis uniform and shall not exceed 3⁄32 in. (2.4 mm).
of Copper and Copper-Base Alloys
E75-XX Chemical Analysis of Copper-Nickel and 9.3.2 In preparation for radiography, the backing
Copper-Nickel-Zinc Alloys strip and any excessive reinforcement shall be removed
from the test assembly. Any surface irregularities that
might mask or be confused with radiographically
9. Radiographic Test rejectable indications shall be removed from the face and
9.1 Radiographic examination for classification is root of the weld by any suitable mechanical means.
required only for ECuNi electrodes. 9.3.3 The weld shall be radiographed in accordance
9.2 The groove weld for radiographic test shall be with ASTM Method E142, Controlling Quality of Radio-
made in accordance with Fig. 3. Test assemblies for the graphic Testing. The sensitivity level shall be 2-2T.
3
⁄32 in. (2.4 mm) and 1⁄8 in. (3.2 mm) electrodes shall be 9.3.4 The usability of the electrode is acceptable
welded in the vertical position. Test assemblies for the if the radiograph shows no cracks, no zones of incomplete
5
⁄32 in. (4.0 mm) and 3⁄16 in. (4.8 mm) diameter electrodes fusion, and no rounded indications in excess of those
shall be welded in the flat position. The groove weld for permitted by Figs. 4A, B, C and D according to the
tensile and bend tests for 5⁄32 in. (4.0 mm) and 3⁄16 in. thickness of the test assembly. A rounded indication is
(4.8 mm) electrodes (Fig. 2) may be radiographed in lieu an indication whose length is no more than three times
of the assembly in Fig. 3. its width on the radiograph. Rounded indications may be
156
circular, elliptical, conical, or irregular in shape, and they shown in Fig. 2. The welding shall be done in the flat
may have tails. The size of a rounded indication is the position, as stated in Table 2. Tension tests shall be con-
largest dimension of the indication, including any tail ducted in the as-welded condition and in accordance with
that may be present. Slag indications shall be evaluated the tension test section of the latest edition of AWS B4.0.
as porosity. When evaluating the radiograph, 1 in. (25 Standard Methods for Mechanical Testing of Welds. Test
mm) on each end of the weld, and rounded indications specimen dimensions shall be as shown in Fig. 5.
less than 1⁄64 in. (0.4 mm) shall be disregarded.
157
158
--`,,```,,,,````-`-`,,`,,`,`,,`---
TABLE 3
MECHANICAL PROPERTY REQUIREMENTS
Tensile
Strength,
Min
AWS Elongation in. 4 ⴛ D
Classification ksi MPa Gage Length, Percent, Min.
ECu 25 170 20
ECuSi 50 350 20
ECuSn-A 35 240 20
ECuSn-C 40 280 20
ECuNi 50 350 20
ECuAl-A2 60 410 20
ECuAl-B 65 450 10
ECuNiAl 72 500 10
ECuMnNiAl 75 520 15
11.2 When required in Table 2, test specimens (in 13. Standard Sizes and Lengths
the as-welded condition) shall be bent in conformance
with the side-bend test sections of the latest edition of Standard sizes and lengths of electrodes shall be as
AWS B4.0, Standard Methods for Mechanical Testing shown in Tables 4 and 5. In all cases, standard size refers
of Welds. A 3⁄8 in. (9.5 mm) thick specimen shall be to the diameter of the core wire.
uniformly bent through 180 degrees over 3⁄4 in. (19 mm)
radius in any suitable jig except that ECuAl-A2, ECuNiAl 14. Core Wire and Covering
and ECuMnNiAl specimens shall be uniformly bent using
14.1 Diameter of the core wire shall not vary more
the radius specified in Fig. 6. Positioning of the specimens
than ±0.003 in. (±0.08 mm) from the standard size speci-
for bending shall be such that the welded joint will con-
fied. Length shall not vary more than ±3⁄8 in. (±10 mm).
form to this radius after bending. The side of the bend
with the greater discontinuities, if any, shall be in tension, 14.2 The core wire and covering shall be concentric
and the weld shall be at the center of the bend. Figures to the extent that the maximum core-plus-one covering
7A and 7B show two typical bending jigs from the latest dimension shall not exceed the minimum core-plus-one
edition of AWS B4.0 and are dimensioned for bending covering dimensions by more than 7 percent of the mean
a 3⁄8 in. (9.5 mm) thick specimen over a 2T radius. dimension for 3⁄32 in. (2.4 mm); 5 percent of the mean
dimension for sizes 1⁄8 and 5⁄32 in. (3.2 and 4.0 mm); and
11.3 After bending in accordance with 11.2, the con-
4 percent of the mean dimension for 3⁄16 in. (4.8 mm). The
vex surface of the transverse guided-side-bend test speci-
concentricity may be measured by any suitable means.
mens shall exhibit no cracks or open discontinuities in
the weld metal exceeding 1⁄8 in. (3 mm) measured in any 14.3 Core wire and covering shall be free of defects
direction. Small checks or cracks at the edges of the test which would interfere with uniform performance of the
specimen shall be disregarded. electrode.
11.3.1 The guided-bend test jig. Fig. 7B is recom-
mended when steel is used as base metal for the test 15. Exposed Core
assembly (see Table 2, Note b).
15.1 The exposed core on the grip end (for making
contact with the electrode holder) shall be as shown in
Table 6.
PART C — MANUFACTURE, IDENTIFICATION,
AND PACKAGING 15.2 The arc end of each electrode shall be sufficiently
bare and the covering sufficiently tapered to permit easy
12. Method of Manufacture
striking of the arc. The covering shall cover the core wire
The welding materials classified by this specification for at least one-half of the circumference of the electrode
may be made by any method yielding product conforming at a distance of two-thirds the diameter of the core wire,
to the requirements of this specification. or 3⁄32 in. (2.4 mm), whichever is smaller.
159
FIG. 4A ACCEPTANCE STANDARD FOR 1⁄4 in. (6.4 mm) TEST PLATE
160
--`,,```,,,,````-`-`,,`,,`,`,,`---
FIG. 4B ACCEPTANCE STANDARD FOR 3⁄8 in. (9.5 mm) TEST PLATE
161
--`,,```,,,,````-`-`,,`,,`,`,,`---
FIG. 4C ACCEPTANCE STANDARD FOR 1⁄2 in. (12.7 mm) TEST PLATE
162
FIG. 4D ACCEPTANCE STANDARD FOR 3⁄4 in. (19 mm) TEST PLATE
163
164
--`,,```,,,,````-`-`,,`,,`,`,,`---
FIG. 6 NOMOGRAM FOR SELECTING MAXIMUM BEND RADIUS FOR ALLOWABLE SPECIMEN THICKNESS (FOR
CLASSIFICATIONS ECuAl-A2, ECuNiAl AND ECuMnNiAl)
165
ELECTRIC SHOCK can kill. W Wear correct eye, ear, and body protection.
WARNING: W Do not touch live electrical parts.
W Read and understand the manufacturer’s instructions W See American National Standard Z49.1 Safety in Weld-
and your employer’s safety practices. ing and Cutting published by the American Welding
W Keep your head out of the fumes. Society, 550 N.W. LeJeune Rd., P.O. Box 351040,
W Use enough ventilation, exhaust at the arc, or both to Miami, Florida 33135; OSHA Safety and Health Stan-
keep fumes and gases away from your breathing zone, dards, 29 CFR 1910, available from U.S. Government
and the general area. Printing Office, Washington, DC 20402.
166
--`,,```,,,,````-`-`,,`,,`,`,,`---
167
168
TABLE 4
STANDARD SIZES OF ELECTRODES
Standard Sizes, Diameter of Core Wire,
in. (mm)
3 1 5 3
AWS ⁄32 ⁄8 ⁄32 ⁄16
Classification (2.4) (3.2) (4.0) (4.8)
冧
ECu
ECuSi
ECuSn-A X X X X
ECuSn-C
ECuNi
ECuAl-A2 X X X X
ECuAl-B — X X X
ECuNiAl — X X X
ECuMnNiAl X X X X
TABLE 5
STANDARD LENGTHS OF ELECTRODES
Diameter of Core Wire Standard Length
in. mm in. mm
冦
3 9 and 230 and
⁄32 (0.093) 2.4
12 300
3.2
冧
1
⁄8 (0.125)
5 4.0 14 350
⁄32 (0.156)
3 4.8
⁄16 (0.187)
TABLE 6
EXPOSED CORE ON GRIP END OF THE ELECTRODE
Distance From
Grip End to
Full Thickness
Bare Portion of Covering
Electrode Diameter (minimum) (maximum)
in. mm in. mm in. mm
5 1 1
⁄32 and 4.0 ⁄2 13 1 ⁄4 30
smaller
3 3
⁄16 4.8 ⁄4 19 11⁄2 40
169
Appendix
Guide to AWS Classification of Copper and Copper Alloy
Arc Welding Electrodes
(This Appendix is not a part of AWS A5.6-84 Specification for Covered Copper and Copper Alloy Arc Welding Electrodes, but is included for
information only.)
170
A3.1.4 The proximity of the welder or welding A4.4 ECuSn Classification (Phosphor Bronze).
operator to the fumes as they issue from the welding ECuSn electrodes are used to join phosphor bronzes of
zone, and to the gases and dusts in the space in which similar compositions. They are also useful for joining
the welder or welding operator is working. brasses and, in some cases, for welding them to cast iron
A3.1.5 The ventilation provided to the space in and carbon steel.
which the welding is done. ECuSn weld metals tend to flow sluggishly, requiring
preheat and interpass temperatures of at least 400°F
A3.2 American National Standard Z49.1, Safety in (205°C) on heavy sections. Postweld heat treatment may
Welding and Cutting (published by the American Weld- not be necessary, but it is desirable for maximum ductil-
ing Society), discusses the ventilation that is required ity, particularly if the weld metal is cold worked.
during the welding, and should be referred to for details.
A4.4.1 ECuSn-A electrodes are used primarily to
Attention is particularly drawn to the Section of that
join base metal of similar composition. They also may
document entitled “Ventilation.”
be used to weld copper if the resultant weld metal has
adequate electrical conductivity and corrosion resistance
A4 Description and Intended Use of Filler Metal for the specific application.
A4.1 Copper and copper alloy covered electrodes A4.4.2 ECuSn-C electrodes have higher tin content
generally operate with dcep and the coverings often are resulting in weld metals of higher hardness, tensile and
hygroscopic. yield strength than ECuSn-A weld metal.
A4.1.1 The supplier should be consulted regarding: A4.5 ECuNi Classification (Copper-Nickel). Elec-
(a) Specific operating parameters and positions trodes of the ECuNi classification are used for shielded
(b) Recommended storage conditions and recondi- metal arc welding of wrought or cast 70⁄30, 80⁄20, and 90⁄10
tioning temperatures copper-nickel alloys to themselves or to each other. They
A4.1.2 The weld area shall be free from moisture also are used for welding the clad side of copper-nickel
and other contaminants. clad steel. Preheating generally is not necessary.
A4.2 ECu Classification (Copper Electrodes). ECu A4.6 ECuAl Classification (Aluminum Bronze)
electrodes are generally manufactured from deoxidized A4.6.1 The copper-aluminum electrodes are used
copper wire (essentially pure copper with small amounts only in the flat position. For butt joints, a 90 degree single
of deoxidizers added) and may be used for shielded metal V-groove is recommended for plate thicknesses up to and
arc welding of deoxidized coppers, oxygen-free coppers, including 7⁄16 in. (11 mm), and a modified U- or double V-
and tough pitch (electrolytic) coppers. The electrodes are groove is recommended for the heavier plate thicknesses.
also used to repair or surface these base metals as well Preheat and interpass temperature should be as follows:
as to surface steel and cast iron. Mechanically and metal-
lurgically sound joints can best be made in deoxidized A4.6.1.1 For iron-base materials, 200 to 300°F
coppers. Reactions with hydrogen in oxygen-free copper, (95 to 150°C).
and the segregation of copper oxide in tough pitch copper A4.6.1.2 For bronzes, 300 to 400°F (150 to
may detract from joint efficiency. However, when highest 210°C).
quality is not required, ECu electrodes may be success-
A4.6.1.3 For brasses, 500 to 600°F (260 to
fully used on these base metals. ECu electrodes may also
315°C).
be used for clad restoration on copper-clad vessels if
precautions are taken to minimize dilution effects. Pre- A4.6.2 ECuAl-A2 electrodes are used in joining
heats to 1000°F (540°C) may be required. aluminum bronzes of similar composition, high strength
copper-zinc alloys, silicon bronzes, manganese bronzes,
A4.3 ECuSi Classification (Silicon Bronze). ECuSi
some nickel alloys, many ferrous metals and alloys, and
electrodes contain approximately three percent silicon
combinations of dissimilar metals. The weld metal is
plus small percentages of manganese and tin. They are
also suitable for surfacing wear- and corrosion-resistant
used primarily for welding copper-silicon alloys. ECuSi
bearing surfaces.
electrodes are occasionally used for the joining of copper,
dissimilar metals, and some iron-base metals. Silicon A4.6.3 ECuAl-B electrodes deposit weld metal
bronze weld metal seldom is used to surface bearing having higher tensile strength, yield strength, and hard-
surfaces, but often is used to surface areas subjected to ness with a correspondingly lower ductility than ECuAl-
corrosion. A2 weld metal. ECuAl-B electrodes are used for repairing
171
aluminum bronze and other copper alloy castings. ECuAl- requiring high resistance to corrosion, erosion, or cavita-
B weld metal also is used for high strength surfacing of tion in salt and brackish water.
wear- and corrosion-resistant bearing surfaces. A4.6.5 ECuMnNiAl electrodes are used to join
A4.6.4 ECuNiAl electrodes are used to join or or repair cast or wrought manganese-nickel-aluminum
repair cast or wrought nickel-aluminum bronze materials. bronze materials. These weld metals exhibit excellent
These weld metals also may be used for applications resistance to corrosion, erosion and cavitation.
--`,,```,,,,````-`-`,,`,,`,`,,`---
172