SPECIFICATION FOR ALUMINUM AND ALUMINUM- ALLOY ELECTRODES FOR SHIELDED METAL ARC WELDING

Transcription

1 SPECIFICATION FOR ALUMINUM AND ALUMINUM- ALLOY ELECTRODES FOR SHIELDED METAL ARC WELDING A00 SFA-5.3 (Identical with AWS Specification A5.3/A5.3M-99.) 1. Scope This specification prescribes requirements for the classification of aluminum and aluminum-alloy electrodes for shielded metal arc welding. 2.3 The following ISO standard 3 is referenced in the mandatory sections of this document: (a) ISO 544, Filler Materials for Manual Welding Size Requirements. 3. Classification PART A GENERAL REQUIREMENTS 2. Normative References 2.1 The following ANSI/AWS standards 1 are referenced in the mandatory sections of this document: (a) ANSI/AWS A5.01, Filler Metal Procurement Guidelines. (b) ANSI/AWS B4.0, Standard Methods for Mechanical Testing of Welds. 2.2 The following ASTM standards 2 are referenced in the mandatory sections of this document: (a) ASTM E 29, Standard Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications. (b) ASTM E 34, Standard Methods for Chemical Analysis of Aluminum and Aluminum Alloys. (c) ASTM B 209, Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate. 3.1 The electrodes covered by the A5.3/A5.3M specification are classified using a system that is independent of U.S. Customary Units and the International System of Units (SI). Classification is according to the chemical composition of the core wire, as specified in Table 1, and mechanical properties of a groove weld. 3.2 An electrode classified under one classification shall not be classified under any other classification in this specification. 4. Acceptance Acceptance 4 of the electrode shall be in accordance with the provisions of ANSI/AWS A5.01, Filler Metal Procurement Guidelines. 5. Certification By affixing the AWS specification and classification designations to the packaging, or the classification to 1 AWS Standards can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL ASTM Standards can be obtained from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA ISO Standards can be obtained from the American National Standards Institute (ANSI), 11 West 42nd Street, New York, NY See Section A3, Acceptance (in Annex) for further information concerning acceptance, testing of the material shipped, and ANSI/ AWS A5.01, Filler Metal Procurement Guidelines. 53

2 SFA SECTION II TABLE 1 CHEMICAL COMPOSITION REQUIREMENTS FOR CORE WIRE Weight Percent a,b Other Elements AWS UNS Classification f Designation c Si Fe Cu Mn Mg Zn Ti Be Each Total Al E1100 A91100 (d) (d) min e E3003 A Remainder E4043 A Remainder NOTES: a. The core wire, or the stock from which it is made, 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 work, the amount of those elements shall be determined to ensure that they do not exceed the limits specified for Other Elements. b. Single values are maximum, except where otherwise specified. c. SAE/ASTM Unified Numbering System for Metals and Alloys. d. Silicon plus iron shall not exceed 0.95 percent. e. The aluminum content for unalloyed aluminum is the difference between percent and the sum of all other metallic elements present in amounts of percent or more each, expressed to the second decimal before determining the sum. f. Refer to Table A1 for Proposed ISO Designations. 54

3 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 the product, the manufacturer certifies that the product meets the requirements of this specification Units of Measure and Rounding-Off Procedure 6.1 This specification makes use of both U.S. Customary Units and the International System of Units (SI). The measurements are not exact equivalents; therefore, each system must be used independently of the other without combining in any way. The specification with the designation A5.3 uses U.S. Customary Units. The specification A5.3M uses SI Units. The latter are shown in appropriate columns in tables or within brackets [ ] when used in the text. 6.2 For the purpose of determining conformance with this specification, an observed or calculated value shall be rounded to the nearest 1000 psi [10 MPa] for tensile strength, and to the nearest unit in the last righthand place of figures used in expressing the limiting value for other quantities in accordance with the rounding-off method given in ASTM E 29, Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications. PART B TESTS, PROCEDURES, AND REQUIREMENTS 7. Summary of Tests The tests required for each classification are specified in Table 2. The purpose of these tests is to determine the chemical composition of the core wire and the mechanical properties of the weldment. The base metal for the weld test assemblies, the welding and testing procedures to be employed, and the results required are given in Sections 9 through Retest 8.1 If the results of any test fail to meet the requirement, that test shall be repeated twice. The results of both tests shall meet the requirement. Specimens or samples for retest may be taken from the original test assembly or sample, or from a new test assembly or sample. For chemical analysis, retest need be only for those specific elements that failed to meet the test requirement. 5 See Section A4, Certification (in Annex) for further information concerning certification and the testing called for to meet this requirement. 8.2 If the results of one or both retests fail to meet the requirement, the material under test shall be considered as not meeting the requirements of this specification for that classification. 8.3 In the event that, during preparation or after completion of any test, it is clearly determined that prescribed or proper procedures were not followed in preparing the weld test assembly or test specimens or in conducting the test, the test shall be considered invalid, without regard to whether the test was actually completed, or whether the test results met, or failed to meet, the requirement. That test shall be repeated, following the proper prescribed procedures. In this case the requirement for doubling the number of test specimens does not apply. 9. Weld Test Assembly 9.1 One weld test assembly is required as specified in Table 2. It is the groove weld in Fig. 1 for mechanical properties. 9.2 Preparation of the weld test assembly shall be as prescribed in 9.3, Fig. 1, and Table 2 [Notes (5) and (6)] using base metal of the appropriate type specified in Table 3. Testing of the assembly shall be as specified in Sections 11, Tension Test, and 12, Bend Test. The assembly shall be tested in the as-welded condition. 9.3 The test assembly shall be preheated to a temperature between 350 and 400 F [175 and 200 C], and shielded metal arc (SMA) welded from one side, in the flat position. The test assembly should be precambered or restrained so that warping due to welding will not cause the finished test assembly to be out-of-plane by more than 5 degrees. If the completed test assembly is more than 5 degrees out-of-plane it shall be straightened at room temperature. 10. Chemical Analysis 10.1 A sample of the core wire, or the stock from which it is made, shall be prepared for chemical analysis The sample shall be analyzed by accepted analytical methods. The referee method shall be ASTM E 34, Standard Methods for Chemical Analysis of Aluminum and Aluminum Alloys The results of the analysis shall meet the requirements of Table 1 for the classification of electrode under test. 55

4 SFA SECTION II TABLE 2 REQUIRED TESTS Electrode Size AWS Classification in. mm Chemical Analysis a Tension Test b Bend Test c Required Not Required d Not Required d 2.5 Required Not Required d Not Required d Required Not Required d Not Required d Required Required e Required e E1100, E3003, Required Not Required d Not Required d and E Required Not Required d Not Required d 6.0 Required Required f Required f Required Required f Required f Required Not Required d Not Required d Required Not Required d Not Required d NOTES: a. Chemical analysis of the core wire or the stock from which it is made. b. See Section 11. c. See Section 12. d. If the product is not produced in the sizes listed for required tensile tests and bend tests, then the size closest but not greater than the size specified to be tested, shall be subject to the required tests. e. Electrodes 5 32 in. (4.0 mm) and smaller shall be classified on the basis of the results obtained with the 5 32 in. (4.0 mm) size of the same classification. f. Electrodes 3 16 in. (4.8 mm) and larger shall be classified on the basis of the results obtained with the 1 4 in. (6.4 mm) size of the same classification. 11. Tension Test 11.1 Two transverse rectangular tension test specimens shall be machined from the groove weld described in Section 9, Weld Test Assembly, and shown in Fig. 1. The dimensions of the specimens shall be as specified in the tension test section of AWS B4.0, Standard Methods for Mechanical Testing of Welds. All dimensions shall be the same as shown in the AWS B4.0 figure for transverse rectangular tension test specimens (plate) except the reduced section radius shall be 2 in. [50 mm] The specimens shall be tested in the manner described in the tension test section of ANSI/AWS B4.0, Standard Methods for Mechanical Testing of Welds The results of the tension test shall meet the requirements specified in Table Bend Test 12.1 One transverse face and one transverse root bend specimen, as required in Table 2, shall be machined from the groove weld test assembly described in Section 9 and shown in Fig. 1. The dimensions of these bend specimens shall be the same as those shown in the bend test section of AWS B4.0 in the figure for transverse face and transverse root-bend specimens (plate) The specimens shall be tested in the manner described in the guided bend test section of ANSI/ AWS B4.0 by bending them uniformly through 180 degrees over a in. [32 mm] radius in any suitable jig. Typical bend test jigs as shown in bend test section of AWS B4.0 shall be used. Positioning of the facebend specimen shall be such that the face of the weld is in tension. Positioning of the root-bend specimen shall be such that the root of the weld is in tension. For both types of transverse bend specimen, the weld shall be at the center of the bend Each specimen, after bending, shall conform to the in. [32 mm] radius, with an appropriate allowance for spring back, and the weld metal shall show no crack or other open defect exceeding 1 8 in. [3.2 mm] measured in any direction on the convex surface, when examined with the unaided eye. Cracks that occur on the corners of a specimen during testing and which show no evidence of inclusions or other fusion-type discontinuities, shall be disregarded. 56

5 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 C Discard L B A A B Tension specimen Root-bend specimen Face-bend specimen Tension specimen ALLOWABLE FOR ALL SAW CUTS (S) DIMENSIONS in. mm A B C, min L, min R, radius S T V W, min /4 1/4 3/8 3/ C Discard Z, min 1 25 See Detail A Warping 5 max W/2 T W 60 V GENERAL NOTES: 1. Root opening = 1/16 in. (1.6 mm). 2. Backing material shall be the same alloy as the base metal. It may be rolled or extruded. 3. Test material blanks shall be removed from the locations shown. S Z R Detail A FIG. 1 GROOVE WELD TEST ASSEMBLY FOR MECHANICAL PROPERTIES 57

6 SFA SECTION II TABLE 3 BASE METAL FOR TEST ASSEMBLIES Electrode Base Metal AWS Aluminum ASTM UNS Classification Alloy a Specification Designation E B209 A91100 E3003, E b B209 A93003 NOTES: a. Aluminum Association, Inc. registration numbers. b. When welding 3003 with E4043 electrodes, (annealed temper) plate is preferred. TABLE 4 TENSION TEST REQUIREMENTS Tensile Strength, Min. a AWS Classification psi MPa E E E NOTE: a. Fracture may occur in either the base metal or the weld metal. PART C MANUFACTURE, IDENTIFICATION, AND PACKAGING 13. Method of Manufacture The electrodes classified according to this specification may be manufactured by any method that will produce electrodes that meet the requirements of this specification. 14. Standard Sizes and Lengths 14.1 Standard sizes (diameter of the core wire) and lengths of electrodes are shown in Table 5. Other sizes and lengths meet the requirements of this specification when agreed by the purchaser and supplier The diameter of the core wire shall not vary more than in. [ 0.05 mm] from the diameter specified. The length shall not vary more than 1 4 in. [ 6 mm] from that specified. 15. Core Wire and Covering 15.1 The core wire and covering shall be free of defects that would interfere with uniform deposition of the electrode The core wire and the covering shall be concentric to the extent that the maximum core-plus-onecovering dimension shall not exceed the minimum core-plus-one-covering dimension by more than the following: (a) Seven percent of the mean dimension in sizes 3 32 in. [2.4 and 2.5 mm] (b) Five percent of the mean dimension in sizes 1 8 and 5 32 in. [3.2 and 4.0 mm] (c) Four percent of the mean dimension in sizes 3 16 in. [4.8 mm] and larger Concentricity may be measured by any suitable means The coverings shall be such that they are not readily damaged by ordinary handling and the coverings shall not blister when heated to 400 F [200 C]. They shall be consumed uniformly during welding, and they also shall not blister or melt back from the core wire. The flux residue they produce shall be readily removable. 16. Exposed Core 16.1 The grip end of each electrode shall be bare (free of covering) for a distance of not less than 1 2 in. [12 mm], nor more than in. [30 mm] for electrodes 5 32 in. [4.0 mm] and smaller, and not less than 3 4 in. [19 mm] nor more than in. [38 mm] for electrodes 3 16 in. [4.8 mm] and larger, to provide for electrical contact with the electrode holder The arc end of each electrode shall be sufficiently bare and the covering sufficiently tapered to permit easy striking of the arc. The length of the bare portion (measured from the end of the core wire to the location where the full cross-section of the covering is obtained) shall not exceed 1 8 in. [3 mm] or the diameter of the core wire, whichever is less. Electrodes with chipped coverings near the arc end, baring the core wire no 58

7 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 TABLE 5 STANDARD SIZES Diameter of Core Wire Standard Lengths AWS Classification in. mm in. mm 3 32 (0.094) 2.4 a (0.098) (0.125) (0.156) E1100, E3003, 3 16 (0.188) 4.8 a and E4043 (0.197) 5.0 (0.236) (0.250) 6.4 a NOTE: a. These sizes are not included in ISO (0.312) (0.375) 9.5 a more than the lesser of 1 4 in. [6 mm] or twice the diameter of the core wire, meet the requirements of this specification, provided no chip uncovers more than 50% of the circumference of the core. 17. Electrode Identification All electrodes shall be identified as follows: 17.1 At least one imprint of the electrode classification shall be applied to the electrode covering within in. [65 mm] of the grip end of the electrode The numbers and letters of the imprint shall be of bold block type of a size large enough to be legible The ink used for imprinting shall provide sufficient contrast with the electrode covering so that, in normal use, the numbers and letters are legible both before and after welding The prefix letter E in the electrode classification may be omitted from the imprint In lieu of imprinting, electrodes may be identified by the following: (a) Attaching to the bare grip end of each electrode a pressure sensitive tape bearing the classification number (b) Embossing the classification number on the bare grip end of each electrode. In this case, a slight flattening of the grip end will be permitted in the area of the embossing. 18. Packaging 18.1 Electrodes shall be suitably packaged to protect them from damage during shipment and storage under normal conditions Standard package net weights shall be 1 lb [0.5 kg], 5 lb [2.5 kg], and 10 lb [5 kg]. Other package weights meet the requirements of this specification when agreed by the purchaser and supplier. 19. Marking of Packages 19.1 The following product information (as a minimum) shall be legibly marked on the outside of each unit package: (a) AWS specification and classification designations (year of issue may be excluded) (b) Supplier s name and trade designation (c) Size and net weight (d) Lot, control, or heat number 19.2 The following precautionary information (as a minimum) shall be prominently displayed in legible print on all packages of electrodes, including individual unit packages enclosed within a larger package. WARNING: PROTECT yourself and others. Read and understand this information. FUMES AND GASES can be hazardous to your health. 59

8 SFA SECTION II ARC RAYS can injure eyes and burn skin. ELECTRIC SHOCK can KILL. O Before use, read and understand the manufacturer s instructions, Material Safety Data Sheets (MSDSs), and your employer s safety practices. O Keep your head out of the fumes. O Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases away from your breathing zone and the general area. O Wear correct eye, ear, and body protection. O Do not touch live electrical parts. O See American National Standard ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126; and OSHA Safety and Health Standards, available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC Phone: (202) DO NOT REMOVE THIS INFORMATION 60

9 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 Annex Guide to Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding (This Annex is not a part of AWS A5.3/A5.3M-99, Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding, but is included for information purposes only). A1. Introduction The purpose of this guide is to correlate the electrode classifications with their intended applications so the specification can be used effectively. Reference to appropriate base metal specifications is made whenever that can be done and when it would be helpful. Such references are intended only as examples rather than complete listings of the materials for which each filler metal is suitable. A2. Classification System A2.1 The system for identifying the electrode classifications in this specification follows the standard pattern used in other AWS filler metal specifications. The letter E at the beginning of each classification designation stands for electrode. The numerical portion of the designation in this specification conforms to the Aluminum Association registration for the composition of the core wire used in the electrode. A2.2 An international system for designating welding filler metals is under development by the International Institute of Welding (IIW) for use in future specifications to be issued by the International Standards Organization (ISO). Table A1 shows the proposed designations for aluminum filler metals. In that system the initial E designates a covered electrode, the letter A the alloy system, followed by a four-digit number. For wrought aluminum alloys, the four-digit number is the same as that commonly recognized worldwide. A3. Acceptance Acceptance of all welding materials classified under this specification is in accordance with ANSI/AWS A5.01, Filler Metal Procurement Guidelines, as the specification states. Any testing a purchaser requires of the supplier, for material shipped in accordance with this Specification, shall be clearly stated in the purchase order, according to the provisions of ANSI/AWS A5.01. In the absence of any such statement in the purchase order, the supplier may ship the material with whatever testing normally is performed on material of that classification, as specified in Schedule F, Table 1, of ANSI/ AWS A5.01. Testing in accordance with any other Schedule in that Table shall be specifically required by the purchase order. In such cases, acceptance of the material shipped shall be in accordance with those requirements. A4. Certification The act of placing the AWS specification and classification designations on the packaging enclosing the product, or the classification on the product itself, constitutes the supplier s (manufacturer s) certification that the product meets all of the requirements of the specification. The only testing requirement implicit in this certification is that the manufacturer has actually conducted the tests required by the specification on material that is representative of that being shipped and that material met the requirements of the specification. Representative material, in this case, is any production run of that classification using the same formulation. Certification 61

10 SFA SECTION II TABLE A1 DESIGNATION REFERENCE GUIDE AWS Composition Proposed ISO AWS Classification Designation a UNS Number Designation b Number c 1100 A91100 EA1100 E A93003 EA3003 E A94043 EA4043 E4043 NOTES: a. AWS chemical composition designation is that of the core wire and is the same as the Aluminum Association designation number. b. The proposed ISO designation number (IIW doc. XII ) contains the last four digits of the UNS number for wrought alloys, preceded by EA, E to signify a covered electrode and A to signify an aluminum base alloy. c. The AWS classification number is the AWS chemical composition designation preceded by an E to signify an electrode which carries the electrical current. is not to be construed to mean that tests of any kind were necessarily conducted on samples of the specific material shipped. Tests on such material may or may not have been conducted. The basis for the certification required by the specification is the classification test of representative material cited above, and the Manufacturer s Quality Assurance Program in ANSI/AWS A5.01. A5. Ventilation During Welding A5.1 Five major factors govern the quantity of fumes in the atmosphere to which welders and welding operators are exposed during welding: (a) Dimensions of the space in which welding is done (with special regard to the height of the ceiling) (b) Number of welders and welding operators working in that space (c) Rate of evolution of fumes, gases, or dust, according to the materials and processes used (d) The proximity of the welders or welding operators to the fumes as the fumes issue from the welding zone, and to the gases and dusts in the space in which they are working (e) The ventilation provided to the space in which the welding is done. A5.2 American National Standard ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes (published by the American Welding Society), discusses the ventilation that is required during welding and should be referred to for details. Attention is drawn particularly to the Section of that document on Health Protection and Ventilation. A6. Welding Considerations A6.1 Welding aluminum by the shielded metal arc process is a well established practice. However, development of the gas shielded arc welding processes and the many advantages these processes offer has caused a shift away from the use of covered electrodes. When shielded metal arc welding, a flux-covered electrode is held in the standard electrode holder, and welding is done with direct current, electrode positive (DCEP). Important factors to be considered when welding aluminum with covered electrodes are moisture content of the electrode covering, and cleanliness of the electrode and base metal. Preheat is usually required to obtain good fusion and to improve soundness of the weld. Residual flux removal between passes is required to provide improved arc stability and weld fusion. Complete removal of the residual flux after welding is necessary to avoid corrosive attack in service. A6.2 The presence of moisture in the electrode covering is a major cause of weld porosity. Dirt, grease, or other contamination of the electrode can also contribute to porosity. The absorption of moisture by the covering can be quite rapid, and the covering can deteriorate after only a few hours exposure to a humid atmosphere. For this reason, the electrodes should be stored in a dry, clean location. Electrodes taken from previously opened packages or those exposed to moisture should be conditioned by holding them at 350 to 400 F [175 to 200 C] for an hour before welding. After conditioning, they should be stored in a heated cabinet at 150 to 200 F [65 to 95 C] until used. A6.3 The minimum base metal thickness recommended for shielded metal arc welding of aluminum 62

11 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 is 1 8 in. [3.2 mm]. For thicknesses less than 1 4 in. [6.4 mm], no edge preparation other than a relatively smooth, square cut is required. Material over 1 4 in. [6.4 mm] should be beveled to a single-v-groove with a 60 to 90-degree included angle. On very thick material, U-grooves may be used. Depending upon base metal gauge, root-face thicknesses range between 1 16 and 1 4 in. [1.6 and 6.4 mm]. A root opening of 1 32 to 1 16 in. [0.8 to 1.6 mm] is desirable for all groove welds. A6.4 Because of the high thermal conductivity of aluminum, preheating to 250 to 400 F [120 to 200 C] is nearly always necessary on thick material to maintain the weld pool and obtain proper fusion. Preheating will also help to avoid porosity due to too rapid cooling of the weld pool at the start of the weld. On complex assemblies, preheating is useful in avoiding distortion. Preheating may be done by torch using oxygen and acetylene or other suitable fuel gas, or by electrical resistance heating. Mechanical properties of 6XXX series aluminum-alloy weldments can be reduced significantly if the higher preheating temperatures, 350 F [175 C] or higher, are applied. A6.5 Single-pass SMA welds should be made whenever possible. However, where thicker plates require multiple passes, thorough cleaning between passes is essential for optimum results. After the completion of any welding, the weld and work should be thoroughly cleaned of residual flux. The major portion of the residual flux can be removed by mechanical means, such as a rotary wire brush, slag hammer, or peening hammer, and the rest by steaming or a hot-water rinse. The test for complete removal of residual flux is to swab a solution of five-percent silver nitrate on the weld areas. Foaming will occur if residual flux is present. A6.6 Interruption of the arc when shielded metal arc welding aluminum can cause the formation of a fused flux coating over the end of the electrode. Reestablishing a satisfactory arc is impossible unless this formation is removed. A7. Description and Intended Use of Electrodes 7.1 Electrodes of the E1100 classification produce weld metal of high ductility, good electrical conductivity, and a minimum tensile strength of psi (80 MPa). E1100 electrodes are used to weld 1100, 1350(EC), and other commercially pure aluminum alloys. A7.2 Electrodes of the E3003 classification produce weld metal of high ductility and a minimum tensile strength of psi [95 MPa]. E3003 electrodes are used to weld aluminum alloys 1100 and A7.3 The E4043 classification contains approximately five-percent silicon, which provides superior fluidity at welding temperatures, and for this reason is preferred for general purpose welding. The E4043 classification produces weld metal with fair ductility and a minimum tensile strength of psi [95 MPa]. E4043 electrodes can be used to weld the 6XXX series aluminum alloys, the 5XXX series aluminum alloys (up to 2.5- percent Mg content), and aluminum-silicon casting alloys, as well as aluminum base metals 1100, 1350(EC), and A7.4 For many aluminum applications, corrosion resistance of the weld is of prime importance. In such cases, it is advantageous to choose an electrode with a composition as close as practical to that of the base metal. For this use, covered electrodes for base metals other than 1100 and 3003 usually are not stocked and must be specially ordered. For applications where corrosion resistance is important, it may be advantageous to use one of the gas shielded arc welding processes for which a wider range of filler metal compositions is available. A8. Special Tests It is recognized that supplementary tests may be required for certain applications. In such cases, tests to determine specific properties such as corrosion resistance, electrical conductivity, mechanical properties at elevated or cryogenic temperatures, and suitability for welding different combinations of aluminum base alloys may be required. A9. Chemical Analysis The accepted and most widely used method for chemical analysis is found in ASTM E 227, Optical Emission Spectrometric Analysis of Aluminum and Aluminum Alloy by the Point-to-Plane Technique. This method analyzes a bulk sample and all elements simultaneously. The ASTM E 34, Test Method for Chemical Analysis of Aluminum and Aluminum Alloy, prescribes individual test methods for which each element is tested. The ASTM E 34 test methods are used as a referee method if a dispute arises concerning a specific element analysis. 63

12 SFA SECTION II A10. General Safety Considerations A10.1 Burn Protection. Molten metal, sparks, slag, and hot work surfaces are produced by welding, cutting, and allied processes. These can cause burns if precautionary measures are not used. Workers should wear protective clothing made of fire-resistant material. Pant cuffs, open pockets, or other places on clothing that can catch and retain molten metal or sparks should not be worn. High-top shoes or leather leggings and fire-resistant gloves should be worn. Pant legs should be worn over the outside of high-top shoes. Helmets or hand shields that provide protection for the face, neck, and ears, and a head covering to protect the head should be used. In addition, appropriate eye protection should be used. When welding overhead or in confined spaces, ear plugs to prevent weld spatter from entering the ear canal should be worn. Goggles or equivalent should also be worn to protect eyes. Clothing should be kept free of grease and oil. Combustible materials should not be carried in pockets. If any combustible substance has been spilled on clothing, a change to clean, fireresistant clothing should be made before working with open arcs or flame. Aprons, cape-sleeves, leggings, and shoulder covers with bibs designed for welding service should be used. Where welding or cutting of unusually thick base metal is involved, sheet metal shields should be used for extra protection. Mechanization of highly hazardous processes or jobs should be considered. Other personnel in the work area should be protected by the use of noncombustible screens or by the use of appropriate protection as described in the previous paragraph. Before leaving a work area, hot work pieces should be marked to alert other persons of this hazard. No attempt should be made to repair or disconnect electrical equipment when it is under load. Disconnection under load produces arcing of the contacts and may cause burns or shock, or both. (Note: Burns can be caused by touching hot equipment such as electrode holders, tips, and nozzles. Therefore, insulated gloves should be worn when these items are handled, unless an adequate cooling period has been allowed before touching.) The following sources are for more detailed information on personal protection: (a) ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL (b) Code of Federal Regulations, Title 29 Labor, Chapter XVII, Part 1910, OSHA General Industry Standards available from the U.S. Government Printing Office, Washington, DC (c) ANSI/ASC Z87.1, Practice for Occupational and Educational Eye and Face Protection, American National Standards Institute, 11 West 42nd Street, New York, NY (d) ANSI Z41, American National Standard for Personal Protection Protective Footwear, American National Standards Institute, 11 West 42nd Street, New York, NY A10.2 Electrical Hazards. Electric shock can kill. However, it can be avoided. Live electrical parts should not be touched. The manufacturer s instructions and recommended safe practices should be read and understood. Faulty installation, improper grounding, and incorrect operation and maintenance of electrical equipment are all sources of danger. All electrical equipment and the workpieces should be grounded. The workpiece lead is not a ground lead. It is used only to complete the welding circuit. A separate connection is required to ground the workpiece. The workpiece should not be mistaken for a ground connection. The correct cable size should be used, since sustained overloading will cause cable failure and result in possible electrical shock or fire hazard. All electrical connections should be tight, clean, and dry. Poor connections can overheat and even melt. Further, they can produce dangerous arcs and sparks. Water, grease, or dirt should not be allowed to accumulate on plugs, sockets, or electrical units. Moisture can conduct electricity. To prevent shock, the work area, equipment, and clothing should be kept dry at all times. Welders should wear dry gloves and rubber soled shoes, or stand on a dry board or insulated platform. Cables and connections should be kept in good condition. Improper or worn electrical connections may create conditions that could cause electrical shock or short circuits. Worn, damaged, or bare cables should not be used. Open-circuit voltage should be avoided. When several welders are working with arcs of different polarities, or when a number of alternating-current machines are being used, the opencircuit voltages can be additive. The added voltages increase the severity of the shock hazard. In case of electric shock, the power should be turned off. If the rescuer must resort to pulling the victim from the live contact, nonconducting materials should be used. If the victim is not breathing, cardiopulmonary resuscitation (CPR) should be administered as soon as contact with the electrical source is broken. A physician should be called and CPR continued until breathing has been restored, or until a physician has arrived. Electrical burns are treated as thermal burns; that is, clean, cold (iced) compresses should be applied. Con- 64

13 PART C SPECIFICATIONS FOR WELDING RODS, ELECTRODES, AND FILLER METALS SFA-5.3 tamination should be avoided; the area should be covered with a clean, dry dressing; and the patient should be transported to medical assistance. Recognized safety standards such as ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes; the National Electrical Code; and NFPA No. 70, available from National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269, should be followed. A10.3 Fumes and Gases. Many welding, cutting, and allied processes produce fumes and gases which may be harmful to health. Fumes are solid particles which originate from welding filler metals and fluxes, the base metal, and any coatings present on the base metal. Gases are produced during the welding process or may be produced by the effects of process radiation on the surrounding environment. Management, personnel and welders alike should be aware of the effects of these fumes and gases. The amount and composition of these fumes and gases depend upon the composition of the filler metal and base metal, welding process, flux, current level, arc length, and other factors. Fluxes, used for oxyfuel gas welding of aluminum alloys, are composed primarily of chlorides plus small fluoride additions. The coatings used in covered electrodes of the types shown in this specification A5.3/A5.3M contain both chlorides and fluorides. The possible effects of overexposure range from irritation of eyes, skin, and respiratory system to more severe complications. Effects may occur immediately or at some later time. Fumes can cause symptoms such as nausea, headaches, dizziness, and metal fume fever. The possibility of more serious health effects exists when especially toxic materials are involved. In confined spaces, the fumes might displace breathing air and cause asphyxiation. One s head should always be kept out of the fumes. Sufficient ventilation, exhaust at the arc or flame, or both, should be used to keep fumes and gases from your breathing zone and the general area. In some cases, natural air movement will provide enough ventilation. Where ventilation may be questionable, air sampling should be used to determine if corrective measures should be applied. All aluminum electrodes possess a compositional control of percent maximum beryllium content. This provides a check by the manufacturer that the filler metal is essentially free of this element and thus avoids the presence of concentrations of this highly toxic metallic particulate during the filler metal transfer across the arc. Since the electrode core wire is fabricated as drawn, wrought aluminum wire, the same beryllium control has been applied to all filler metals covered by this ANSI/AWS A5.3/A5.3M specification. Thus all electrodes possess a percent beryllium maximum limit. More detailed information on fumes and gases produced by the various welding processes may be found in the following: (a) The permissible exposure limits required by OSHA can be found in CFR Title 29, Chapter XVII Part The OSHA General Industry Standards are available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC (b) The recommended threshold limit values for these fumes and gases may be found in Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment, published by the American Conference of Governmental Industrial Hygienists (AC- GIH), 1330 Kemper Meadow Drive, Suite 600, Cincinnati, OH (c) The results of an AWS-funded study are available in a report entitled, Fumes and Gases in the Welding Environment, available from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL A10.4 Radiation. Welding, cutting, and allied operations may produce radiant energy (radiation) harmful to health. One should become acquainted with the effects of this radiant energy. Radiant energy may be ionizing (such as x-rays), or nonionizing (such as ultraviolet, visible light, or infrared). Radiation can produce a variety of effects such as skin burns and eye damage, depending on the radiant energy s wavelength and intensity, if excessive exposure occurs. A Ionizing Radiation. Ionizing radiation is produced by the electron beam welding process. It is ordinarily controlled within acceptance limits by use of suitable shielding enclosing the welding area. A Nonionizing Radiation. The intensity and wavelengths of nonionizing radiant energy produced depend on many factors, such as the process, welding parameters, electrode and base metal composition, fluxes, and any coating or plating on the base metal. Some processes such as resistance welding and cold pressure welding ordinarily produce negligible quantities of radiant energy. However, most arc welding and cutting processes (except submerged arc when used properly), laser beam welding and torch welding, cutting, brazing, or soldering can produce quantities of nonionizing radiation such that precautionary measures are necessary. Protection from possible harmful effects caused by nonionizing radiant energy from welding include the following measures: 65

14 SFA SECTION II (a) One should not look at welding arcs except through welding filter plates which meet the requirements of ANSI/ASC Z87.1, Practice for Occupational and Education Eye and Face Protection, published by American National Standards Institute, 11 West 42nd Street, New York, NY It should be noted that transparent welding curtains are not intended as welding filter plates, but rather are intended to protect passersby from incidental exposure. (b) Exposed skin should be protected with adequate gloves and clothing as specified in ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL (c) Reflections from welding arcs should be avoided, and all personnel should be protected from intense reflections. (Note: Paints using pigments of substantially zinc oxide or titanium dioxide have a lower reflectance for ultraviolet radiation.) (d) Screens, curtains, or adequate distance from aisles, walkways, etc., should be used to avoid exposing passersby to welding operations. (e) Safety glasses with UV-protective side shields have been shown to provide some beneficial protection from ultraviolet radiation produced by welding arcs. A Ionizing radiation information sources include: (a) AWS F2.1-78, Recommended Safe Practices for Electron Beam Welding and Cutting, available from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL (b) Manufacturer s product information literature. A Nonionizing radiation information sources include: (a) Hinrichs, J.F., Project Committee on Radiation- Summary Report. Welding Journal, January (b) Nonionizing Radiation Protection Special Study No , Evaluation of the Potential Hazards from Actinic Ultraviolet Radiation Generated by Electric Welding and Cutting Arcs, available from the National Technical Information Service, Springfield, VA 22161, ADA (c) Nonionizing Radiation Protection Special Study No , Evaluation of the Potential Retina Hazards from Optical Radiation Generated by Electric Welding and Cutting Arcs, available from the National Technical Information Service, Springfield, VA 22161, ADA (d) Moss, C. E., and Murray, W. E. Optical Radiation Levels Produced in Gas Welding, Torch Brazing, and Oxygen Cutting. Welding Journal, September (e) Optical Radiation Levels Produced by Air-Carbon Arc Cutting Processes. Welding Journal, March (f) ANSI/ASC Z136.1, Safe Use of Lasers, published by American National Standards Institute, 11 West 42nd Street, New York, NY (g) ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL (h) ANSI/ASC Z87.1, Practice for Occupational and Educational Eye and Face Protection, published by American National Standards Institute, 11 West 42nd Street, New York, NY (i) Moss, C. E. Optical Radiation Transmission Levels through Transparent Welding Curtains. Welding Journal, March