A5 3
A5 3
A5 3
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Key Words- Covered aluminum electrodes, AWS A5.3/A5.3M:1999
aluminum welding electrodes, An American National Standard
shielded metal arc welding,
filler metal specifications Approved by
American National Standards Institute
February 11,1999
Specification for
Aluminum and Aluminum-Alloy
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Prepared by
AWS Committee on Filler Metals and Allied Materials
Approved by
AWS Board of Directors
Abstract
This specification prescribes requirements for the classification of covered (flux coated) E1100, E3003, and E4043
aluminum-alloy electrodes forshielded metal arc welding. Tests conducted for classification are chemical analysis of the
core wire as well as tensile and bendtests from groove weld test assemblies fabricated with each oftwo sizes of electrode
for each classification. Standard electrode sizes, electrode identification, and chemical composition limits arespecified.
This specification makes use of both U.S. Customary Units and the International System of Units (SI). Sincethese are
not equivalent, each system must be used independently of the other.
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Statement on Use of AWS Standards
All standards (codes, specifications, recommended practices,methods, classifications, and guides) of the American
Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the Ameri-
can National Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are
included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry
the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the gov-
ernmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases,
these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where
this contractual relationship exists,changes in or deviations from requirements of an AWS standard must be by agree-
ment between the contracting parties.
Note: The primary purpose of AWS is to serve and benefit its members. To this end, AWS provides a forum for the ex-
change, consideration, and discussion of ideas and proposals that are relevant to the welding industry and the consensus
of which forms the basis for these standards. By providing such a forum, AWS does not assume any duties to which a
user of these standards may be required to adhere. By publishing this standard, the American Welding Society does not
insure anyone using the information it contains against any liability arising from that use. Publication of a standard by
the American Welding Society does not carry with it any right to make, use, or sell any patented items. Users of the in-
formation in this standard should make an independent, substantiating investigation of the validity of that information
for their particular use and the patent statusof any item referred to herein.
Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in
writing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL
33126 (See Annex B). With regard to technical inquiries made concerning AWS standards, oralopinions on AWS stan-
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dards may be rendered. However,such opinions represent only the personal opinions of the particular individuals giving
them. These individuals do not speak on behalf of AWS, nordo these oral opinions constitute official or unofficial opin-
ions or interpretations of AWS. In addition, oral opinions are informal and should not be used as asubstitute for an offi-
cial interpretation.
This standard is subject to revision at any time by theAWS Committee on Filler Metals and Allied Materials. It must be
reviewed every five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations,
additions, or deletions)and any pertinent data that may beof use in improving this standard are requested and should be
addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS Committee on Filler
Metals and Allied Materials and the author of the comments will be informed of the Committee’s response to the com-
ments. Guests are invited to attend all meetings of the AWS Committee on Filler Metals and Allied Materials to express
their comments verbally. Procedures for appeal ofan adverse decision concerning all such comments are provided in the
Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American
Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
Photocopy Rights
Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or
educational classroom use only of specific clients, is granted by the American WeldingSociety (AWS) provided that the
appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-
8400; online: http://www.copyright.com
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Personnel
AWS Committee on Filler Metals and Allied Materials
R. A. LaFave,Chair Elliott Company
J. F! Hunt, Ist Mce Chair Consultant
D. A. Fink, 2nd Mce Chair The Lincoln Electric Company
R. K. Gupta, Secretary American Welding Society
*R. L. Bateman Electromanufacturas,S.A.
R. S.Brown Carpenter Technology Corporation
R. A. Bushey ESAB Weldingand CuttingProducts
J . Caprarola,JI: Consultant
*L. J. Christensen Consultant
R. J. Christoffel Consultant
D. D. Crockett The Lincoln Electric Company
R. A. Daemen Consultant
D. A. DefSignore Consultant
R. L. Drury I l l Caterpillar, Incorporated
H. W Ebert ExxonResearchand EngineeringCompany
J. G. Feldstein Foster Wheeler Energy Corporation
S.E. Ferree ESAB Weldingand CuttingProducts
L. Flasche Delphi Delco Electronic Systems
R. D.Fuchs Böhler Thyssen Welding USA, Incorporated
C. E. Fuerstenau Alloy Ring Service
G. Hallstrom,Jr. Hallstrom Consultants
J . A. Henning Deltak, Incorporated
R. B. Kadiyala Techailoy Maryland, Incorporated
F? J. Konkol ConcurrentTechnologiesCorporation
D.J. Kotecki The Lincoln Electric Company
D. I:Ku AmericanBureau of Shipping
N. E. Larson Consultant
A. S. Laurenson Consultant
J. S. Lee Chicago BridgeandIronCompany, Incorporated
G. H. MacShane MAC Associates
W A. Marttila DaimlerChrysler
R. Menon Stoody Company
M, i? Merlo Select Arc, Incorporated
A. R. Mertes Ampco Metal, Incorporated
M.D. Morin ABB Power Generation
C. L. Null Department of the Navy
J. J.Payne Consultant
R. L. Peaslee Wall Colmonoy Corporation
E. W Pickering, Jr. Consultant
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...
III
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* E J . Winsor Consultant
K. G. Wold Siemens Power Corporation
iv
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Foreword
(This Foreword is not a part of AWS A5.3/A5.3M:1999,Specifcation forAluminum and Aluminum-Alloy Electrodes
for Shielded Metal Arc Welding, but is included for information purposes only.)
This document represents the sixth revision of the first aluminum covered electrode specification issued in 1943. The
original document was prepared by ajoint AWS/ASTM Committee and publishedas an ASTM Standard.
During the mid-to-late 1960s, ASTM agreed to accept AWS as the sole agency responsible for the development and
publication of filler metal specifications. In recent years, AWS filler metal specifications have been recognized by the
American National Standards Institute as shown below:
AWS/ASTM B184-43T Tentative Specifications for Aluminum and Aluminum-Alloy Metal Arc-Welding Electrodes
AWS A5.3-62T Tentative
Specification for Aluminum
and
Aluminum-Alloy
Arc-Welding Electrodes
ASTM B184-62T
AWS
A5.3-69
Specification
for Aluminum and
Aluminum-Alloy
Arc-Welding
Electrodes
ANSI W3.3-1973
ANSI/AWS A5.3-80SpecificationforAluminumandAluminum-AlloyCoveredArc-Welding Electrodes
ANSI/AWS A5.3-88Specification for AluminumandAluminum-AlloyElectrodes for ShieldedMetal Arc Welding
ANSI/AWS A5.3-91SpecificationforAluminumandAluminum-AlloyElectrodes for ShieldedMetal Arc Welding
Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,
AWS Committee on Filler Metals and Allied Materials, American Welding Society, 550 N.W. LeJeune Road, Miami, FL
33126.
Official interpretations of any of the technical requirements of this standard may be obtained bysending a request, in
writing, to the Managing Director TechnicalServices Division, American Welding Society.A formal reply will be issued
after it has been reviewed by the appropriate personnel following established procedures.
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V
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Table of Contents
Page No.
...
Personnel .................................................................................................................................................................... I II
Foreword ..................................................................................................................................................................... V
...
List of Tables ............................................................................................................................................................ VIII
...
List ofFigures .......................................................................................................................................................... VIII
1. Scope ...................................................................................................................................................................... 1
Part A"Genera1 Requirements.................................................................................................................................... 1
2. Normative References............................................................................................................................................ 1
3. Classification .......................................................................................................................................................... 1
4. Acceptance ............................................................................................................................................................. 1
5. Certification ............................................................................................................................................................ 1
6 . Units of Measure and Rounding-Off Procedure ..................................................................................................... 2
Part B-Tests, Procedures, and Requirements ............................................................................................................. 2
7. Summary of Tests ................................................................................................................................................... 2
8. Retest ...................................................................................................................................................................... 2
9. Weld Test Assembly ............................................................................................................................................... 3
10. Chemical Analysis.................................................................................................................................................. 3
11. Tension Test ............................................................................................................................................................ 3
12. Bend Test................................................................................................................................................................ 5
Part C d a n u f a c t u r e , identifcation, and Packaging.................................................................................................. 5
13. Method of Manufacture .......................................................................................................................................... 5
14. Standard Sizesand Lengths .................................................................................................................................... 5
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15. Core Wire and Covering ......................................................................................................................................... 5
16. Exposed Core .......................................................................................................................................................... 6
17. Electrode Identification .......................................................................................................................................... 6
18. Packaging ............................................................................................................................................................... 7
19. Marking of Packages .............................................................................................................................................. 7
Annex A - C u i d e t oAWS Specification for Aluminum and Aluminum-AlloyElectrodes for
Shielded Metal ArcWelding......................................................................................................................... 9
Al . Introduction ........................................................................................................................................................... 9
A2. Classification System ............................................................................................................................................ 9
A3. Acceptance............................................................................................................................................................. 9
A4 . Certification ........................................................................................................................................................... 9
AS . Ventilation During Welding ................................................................................................................................. 10
vi
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Page No .
A6. Welding Considerations .......................................................................................................................................
10
A7 . Description and Intended Use of Electrodes ....................................................................................................... 11
A8. Special Tests........................................................................................................................................................ 11
A9. Chemical Analysis............................................................................................................................................... 11
A10 . General Safety Considerations .......................................................................................................................... 11
Annex B-Guidelines forPreparation of Technical Inquiries for AWS Technical Committees ................................. 15
B1. Introduction .......................................................................................................................................................... 15
B2. Procedure ............................................................................................................................................................. 15
B3. Interpretation of Provisions of the Standard ........................................................................................................ 15
B4. Publication of Interpretations............................................................................................................................... 16
B5. Telephone Inquiries.............................................................................................................................................. 16
B6. The AWS Technical Committee.......................................................................................................................... 16
AWS Filler Metal Specifications by Material and Welding Process .......................................................................... 17
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List of Tables
Table Page No.
1 Chemical Composition Requirements for Core Wire ................................................................................... 2
2 Tests ...............................................................................................................................................
Required 3
3 BaseMetal for Test Assemblies ................................................................................................................... 5
4 TensionTestRequirements ........................................................................................................................... 5
5 Standard Sizes ............................................................................................................................................... 6
Al Designation Reference Guide ..................................................................................................................... 10
List of Figures
Figure Page No.
1 Groove WeldTest Assembly for MechanicalProperties ............................................................................... 4
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...
Vlll
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AWS A5.3/A5.3M:1999
3. Classification
3.1 The electrodes covered by the A5.31A5.3M specifi-
Part A cation are classified using a systemthat is independent of
General Requirements U.S. Customary Units and the International System of
Units (SI). Classification is according to the chemical
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composition of the core wire, as specified in Table 1, and
2. Normative References mechanical properties of a groove weld.
2.1 The following ANSIIAWS standards' are referenced 3.2 An electrode classified under one classification shall
not be classified under any other classification in this
in the mandatory sections of this document:
specification.
(1) ANSIIAWSA5.01, Filler Metal Procurement
Guidelines.
( 2 ) ANSIJAWS B4.0, Standard Methods for Mechan-
ical Testing of Welds. 4. Acceptance
2.2 The following ASTM standards2 are referenced in Acceptance4 of the electrode shall be in accordance
the mandatory sections of this document: with the provisions of ANSIIAWS A5.01, Filler Metal
Procurement Guidelines.
(1) ASTM E 29, Standard Practice for Using Signif-
cant Digits in Test Data to Determine Conformance with
Specifications.
(2) ASTM E 34, Standard Methods for Chemical 5. Certification
Analysis of Aluminum and Aluminurn Alloys. By affixing the AWS specification and classification
(3) ASTM B 209, Standard Specification for Alumi- designations to the packaging, or the classification to the
num and Aluminum-Alloy Sheetand Plate.
1
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AWS A5.3/A5.3M:1999
Table 1
Chemical Composition Requirements for Core Wire
Weight Percentash
~~ ~ ~~~
Other
Elements
AWS UNS
Classification‘
DesignationC
Si Cu Fe Mn Al Total
Mg Each ZnBe Ti
Ell00 A91100 (d) (d) 0.05-0.20 0.05 - 0.10 - 0.0008 0.05 0.15
99.00 mine
E3003
A93003 0.6 0.7 0.05-0.20 1.0-1.5 - 0.10 - 0.0008 0.05 0.15 Remainder
E4043
A94043
4.5-6.0 0.8 0.30 0.05 0.05 0.10 0.20 0.0008 0.05 0.15 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 pres-
ence of other elements is indicated i n 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 100.00 percent aud the sum of all other metallic elements presenl in
amounts of 0.010 percent or more each, expressed to the second decimal before determining the sum.
f. Refer to Table AI for Proposed IS0 Designations.
Off Procedure
6.1 This specification makes use of both U.S. Customary The tests required for each classification are specified
Units and the International System of Units (SI). The in Table 2. The purpose of these tests is to determine the
measurements are not exact equivalents; therefore, each chemical composition of the core wire and the mechani-
system must be used independently of the other without cal properties of the weldment. The base metal for the
combining in any way. The specification with the desig- weld test assemblies, the welding and testing procedures
nation A5.3 uses U.S. Customary Units. The specifica- to be employed, and the results required are given in Sec-
tion A5.3M uses SI Units. The latter are shown i n tions 9 through 12.
appropriate columns in tables or within brackets [ ] when
used in the text.
6.2 For the purpose of determining conformance with 8. Retest
this specification, an observed or calculated value shall
be rounded to the nearest 1000 psi [lo MPa] for tensile 8.1 If the results of any test fail to meet the requirement,
strength, and to the “nearest unit” in the last right-hand that test shall be repeated twice. The results of both tests
place of figures used in expressing the limiting value for shall meet the requirement. Specimens or samples forre-
other quantities in accordance with the rounding-off test may be taken from the original test assembly or sam-
method given in ASTM E 29, Practice for Using Signifi- ple, or from a new test assembly or sample. For chemical
cant Digits in Test Data to Determine Conformance with analysis, retest need be only for those specific elements
Specifications. that failed to meet thetest requirement.
8.2 If the results of one or both retests fail to meet the re-
5. See SectionA4, Certification (in AnnexA) for further infor- quirement, the material under test shall be considered as
mation concerningcertificationand the testingcalled for to not meeting the requirementsof this specification for that
meet this requirement. classification.
2
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AWS A5.3iA5.3M A999
Table 2
Required Tests
Electrode Size
AWS Classification
in. mm Chemical Analysisa Tension Testh Bend TestC
a. Chemical analysis of the core wireor 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 smallershallbeclassifiedonthe basis of theresultsobtained with the 5/32 in. [4.0 mm] size of thesame
classification.
f. Electrodes 3/16 in. [4.8mm] and larger shall be classified on the basis of the results obtained with the 114 in. (6.0 or 6.4 mm] size of thesame
classification.
8 3 In the event that, during preparationor after comple- tion. The test assembly should be precambered or re-
tion of any test, it is clearly determined that prescribed or strained so that warping dueto welding will not cause the
proper procedures were not followed in preparing the finished test assembly to be out-of-plane by more than
weld test assembly or test specimens or in conducting the 5 degrees. If the completed test assembly is more than
test, the test shall be considered invalid, without regard 5 degrees out-of-plane it shall be straightened at room
to whether the test was actually completed, or whether temperature.
the test results met, or failed to meet, the requirement.
That test shall be repeated, following the proper pre-
scribed procedures. In this case the requirement for dou- 10. Chemical Analysis
bling the number of test specimens doesnot apply.
10.1 A sample of the core wire, or the stock from which
it is made, shall be prepared for chemical analysis.
9. Weld Test Assembly 10.2 The sampleshall be analyzed by accepted analytical
9.1 One weld test assembly is required as specified in methods. The referee method shall be ASTM E 34, Stan-
Table 2. It is the groove weld in Figure 1 for mechanical dard Methodsfor Chemical Analysisof Aluminum and
properties. Aluminum Alloys.
9.2 Preparation of the weld test assembly shall be as pre- 10.3 The results of the analysis shall meet the require-
scribed in 9.3, Figure 1, and Table 2 (Notes eand f) using ments of Table 1 for the classification of electrode under
base metal of the appropriate type specified in Table 3. test.
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. 11. Tension Test
9.3 The test assembly shall be preheated to a temperature 11.1 Two transverse rectangular tension test specimens
between 350" and 400°F [175" and 2OO"C], and shielded shall be machined from the groove weld described in
metal arc (SMA) welded from one side, in the flat posi- Section 9, Weld Test Assembly, and shown in Figure 1.
3
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AWS A5.3/A5.3M:1999
t
”i
DISCARD
L I
I
I
TENSION SPECIMEN I DIMENSIONS
mm in.
”
A 1.5 38
A I ROOT-BEND SPECIMEN- 2 B 50
45 C, MIN
1.8
L, MIN
300 12
A I FACE-BEND
SPECIMEN R, RADIUS 114 6.5
A II S6.5 114
t TENSION SPECIMEN
I T W8 9.5
V 3116 5
250 W
10, MIN
DISCARD C
t Z, MIN 1 25
SEE DETAIL “ A
General Notes:
1. Root Opening = 1116 in. [1.6 mm].
2. Backing material shallbe the same alloy
as the base metal. It may be rolled or extruded.
shown.
3. Test material blanks shall be removed from the locations
DETAIL A
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AWS A5.3/A5.3M:1999
Table 5
Standard Sizes
of Diameter Core Wire Lengths
Standard
15.2 The core wire and the covering shall be concentric the full cross-section of the covering is obtained) shall
to the extent that the maximum core-plus-one-covering not exceed 1/8 in. [3 mm] or the diameter of the core
dimension shall not exceed the minimum core-plus-one- wire, whichever is less. Electrodes with chipped cover-
covering dimensionby more than the following: ings near the arc end, baring the core wire no more than
(1) Sevenpercent ofthemeandimension in sizes the lesser of 1/4 in. [6 mm] or twice the diameter of the
3/32 in. [2.4 and 2.5 mm] core wire, meet the requirements of this specification,
(2) Five percent ofthemean dimension in sizes 1/8 provided no chip uncovers more than50% of the circum-
and 5/32 in. [3.2 and 4.0 mm] ference of the core.
(3) Four percent of themeandimension in sizes
3/16 in. [4.8 mm] and larger
Concentricity may be measured by any suitable means. 17. Electrode Identification
15.3 The coveringsshall be such that they are not readily All electrodes shall be identified as follows:
damaged by ordinary handling and the coverings shall
not blister when heated to 400°F [200°C]. They shall be 17.1 At least one imprint of the electrode classification
consumed uniformly during welding, and they also shall shall be applied to theelectrode covering within 2-1/2 in.
not blister or melt back from the core wire. The flux resi- [65 mm] of the grip end of the electrode.
due they produce shall be readily removable. 17.2 The numbers and letters of the imprint shall be of
bold block type ofa size large enough to be legible.
16. Exposed Core 17.3 The ink used for imprinting shall provide sufficient
contrast with the electrode covering so that, in normal
16.1 The grip end of each electrode shall be bare (free of use, the numbers and letters are legible both before and
covering) for a distance of not less than 1/2 in. [12 mm], after welding.
nor more than 1-1/4 in. [30 mm] for electrodes 5/32 in.
[4.0 mm] and smaller, and not less than 3/4 in. [19 mm] 17.4 The prefix letter E in the electrode classification
nor more than 1-1/2 in. [38 mm] for electrodes 3/16 in. may be omitted from the imprint.
[4.8 mm] and larger, to providefor electrical contact with 17.5 In lieu of imprinting, electrodes may be identified
the electrode holder. by the following:
16.2 The arc end of each electrode shall be sufficiently (1) Attaching to the bare grip end of each electrode a
bare and the covering sufficiently tapered to permit easy pressure sensitive tape bearing the classification number
striking of the arc. The length of the bare portion (mea- (2) Embossing the classification number on the bare
sured from the end of thecore wire to the location where grip end of each electrode. In this case, a slight flattening
6
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= 0784265 0511335 545 AWS A5.3IA5.3M :1999
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by the purchaser and supplier.
Keep your head out of the fumes.
Use enough ventilation, exhaust at the arc, or both, to
19. Marking of Packages keep fumes and gases away from your breathing zone
and the general area.
19.1 The following product information (as a minimum)
shall be legibly marked on the outside of each unit Wear correct eye, ear, and body protection.
package: Do not touch live electrical parts.
(1) AWS specification and classification designations
(year of issue may be excluded) See American National Standard ANSI 249.1, Safety
(2) Supplier’s name and trade designation in Welding, Cutting, and Allied Processes, published
(3) Size and net weight by the American Welding Society, 550 N.W. LeJeune
(4) Lot, control, or heat number Road, Miami, FL33126; and OSHA Safety and Health
Standards, available from the Superintendent of Doc-
19.2 The following precautionary information(as a mini- uments, U.S. Government Printing Office, Washing-
mum) shall be prominently displayed in legible print on ton, DC 20402. Phone: (202) 512-1800.
all packages of electrodes, including individual unit
packages enclosedwithin a larger package. DO NOT REMOVE THIS INFORMATION
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AWS A5.31A5.3M :1999
Annex A
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:1999, Specification for Aluminum and Aluminum-Alloy Electrodes for
Shielded Metal Arc Welding, but is included for informationpurposes only).
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9
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AWS A5.31A5.3M:1999
Table A l
Designation Reference Guide
A W S Composition Designationa UNS Number Proposed IS0 Designationh A W S Classification NumberC
to be construed to mean that tests of any kind were nec- ment of the gas shielded arc welding processes and the
essarily conducted on samples of the specific material many advantages these processes offer has caused a shift
shipped. Tests on such material may or may not have away from the use of covered electrodes. When shielded
been conducted. The basis for the certification required metal arc welding, a flux-coveredelectrode is held in the
by the specification is the classification test of "represen- standard electrode holder, and welding is done with di-
tative material" cited above, and the "Manufacturer's rect current, electrode positive (DCEP). Important fac-
Quality AssuranceProgram" in ANSI/AWS A5.01. tors 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
A5. Ventilation During Welding improve soundness of the weld. Residual flux removal
A5.1 Five major factors govern the quantity of fumes in between passes is required to provide improved arc sta-
the atmosphere to which welders and welding operators bility and weld fusion. Complete removal of the residual
are exposed duringwelding: flux after welding is necessary to avoid corrosive attack
(1) Dimensions of the space in which welding is done in service.
(with special regard to the height of the ceiling)
(2) Number of welders and welding operators work- A6.2 The presence of moisture in the electrode covering
ing in that space is a major cause of weld porosity. Dirt, grease, or other
(3) Rate of evolution of fumes, gases, or dust, accord- contamination of the electrode can also contribute to po-
ing to the materials and processes used rosity. The absorption of moisture by the covering canbe
(4) The proximity of the welders or welding opera- quite rapid, and the covering can deteriorate after only a
tors to the fumes as the fumes issue from the welding few hours exposure to a humid atmosphere. For this rea-
zone, and to the gases and dusts in the space in which son, the electrodes should be stored in a dry, clean loca-
they are working tion. Electrodes taken from previously opened packages
(5) The ventilation provided to the space in which the or those exposed to moisture should be "conditioned" by
welding is done. holding them at 350" to 400°F [175" to 2OO"C] for an
hour before welding. After conditioning, they should be
A5.2 American National StandardANSI 249.1, Safety in stored in a heated cabinet at 150" to 200°F 165" to 95"CJ
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A root opening of 1/32 to 1/16 in. [0.8 to 1.6 mm] is de- the 5XXX series aluminum alloys (up to 2.5-percent Mg
sirable for all groove welds. content), and aluminum-silicon casting alloys, aswell as
aluminum base metals 1100, 1350(EC), and 3003.
A6.4 Because of the high thermal conductivity of alumi-
num, preheating to 250" to 400°F [120" to 200°C] is A7.4 For many aluminum applications, corrosion resis-
nearly always necessary on thick material to maintain the tance of the weld is of prime importance. In such cases, it
weld pool and obtain proper fusion. Preheating will also is advantageous to choose an electrode with a composi-
help to avoid porosity due to too rapid cooling of the weld tion as close as practical to that of the base metal. For
pool at the start of the weld. On complex assemblies, pre- this use, covered electrodes for base metals other than
heating is useful in avoiding distortion. Preheating may be 1100 and 3003 usually are not stocked and must be spe-
done by torch using oxygen and acetylene or other suit- cially ordered. For applications where corrosion resis-
able fuel gas, or by electrical resistance heating. Mechani- tance is important, it may be advantageous to use one of
cal properties of 6XXX seriesaluminum-alloy weldments the gas shielded arc welding processes for which a wider
can be reduced significantly if the higher preheating tem- range of filler metal compositions is available.
peratures, 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 AS. Special Tests
passes, thorough cleaning between passes is essential for
optimum results. After the completion of any welding, It is recognized that supplementary tests may be re-
the weld and work should be thoroughly cleaned of quired for certain applications. In such cases, teststo de-
residual flux. The major portion of the residual flux can termine specific propertiessuch as corrosion resistance,
be removed by mechanical means, such as a rotary wire electrical conductivity, mechanical properties at elevated
brush, slag hammer, or peening hammer, and the rest by or cryogenic temperatures, and suitability for welding
steaming or a hot-water rinse. The test for complete re- different combinations of aluminum base alloys may be
moval of residual f l u x is to swab a solution of five- required.
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 A9. Chemical Analysis
welding aluminum can cause the formation of a fused
flux coating overthe end of the electrode. Reestablishing The accepted and most widely used method for chem-
a satisfactory arc is impossible unless this formation is ical analysis is found in ASTM E 227, Optical Emission
removed. Spectrometric Analysis of Aluminum and Aluminum
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Alloy by the Point-to-Plane Technique. This method ana-
lyzes a bulk sample and all elements simultaneously. The
ASTM E 34, Test Method for Chemical Analysis of Alu-
A7. Description and Intended Useof minum and Aluminum Alloy, prescribes individual test
Electrodes methods for which each element is tested. The ASTM E
A7.1 Electrodes of the EllOO classification produce 34 test methods are used as a referee method if a dispute
weld metal of high ductility, good electrical conductivity, arises concerning a specific element analysis.
and a minimum tensile strength of 12 O 0 0 psi (80 MPa).
EllOO electrodes are used to weld 1100, 1350(EC), and
other commerciallypure aluminum alloys. Alo. General Safety Considerations
A7.2 Electrodes of the E3003 classification produce
A1O.l Burn Protection. Molten metal, sparks, slag, and
weld metal of high ductility and a minimum tensile
hot work surfaces are produced by welding, cutting, and
strength of 14 O00 psi [95 MPa]. E3003 electrodes are
allied processes. These can cause burns if precautionary
used to weld aluminum alloys 1100 and 3003.
measures are not used. Workers should wear protective
A7.3 The E4043 classification contains approximately clothing made of fire-resistant material.Pant cuffs, open
five-percent silicon, which provides superior fluidity at pockets, or other places on clothing that can catch and re-
welding temperatures,and for this reason is preferred for tain molten metal or sparks should not be worn. High-top
general purpose welding. The E4043 classification pro- shoes or leather leggings and fire-resistant gloves should
duces weld metal with fair ductility and a minimum ten- be worn. Pant legs should be worn over the outside of
sile strength of 14 O00 psi [95 MPa]. E4043 electrodes high-top shoes. Helmets or hand shields that provide pro-
can be used to weld the 6XXX series aluminum alloys, tection for the face, neck, and ears, and a head covering
11
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to protect the head should be used. In addition, appropri- All electrical equipment and the workpieces should be
ate eye protection should be used. grounded. The workpiece lead is not a ground lead. It is
When welding overhead or in confined spaces,ear used only to completethe welding circuit. A separatecon-
plugs to prevent weld spatter from entering the ear canal nection is required to ground the workpiece. The work-
should be worn. Goggles or equivalent should also be piece should not be mistaken for a ground connection.
worn to protect eyes. Clothing should be kept free of The correct cable size should be used, since sustained
grease and oil. Combustible materials should not be car- overloading will cause cable failure and result in possible
ried in pockets. If any combustible substance has been electrical shock or fire hazard. All electrical connections
spilled on clothing, a change to clean,fire-resistant cloth- should be tight, clean, and dry. Poor connections can
ing should be made before working with open arcs or overheat and even melt. Further, they can produce dan-
flame. Aprons, cape-sleeves, leggings, and shoulder cov- gerous arcs and sparks. Water, grease, or dirt should not
ers with bibs designed for welding service should be be allowed to accumulate on plugs, sockets, or electrical
used. units. Moisture can conductelectricity. To prevent shock,
Where welding orcutting of unusually thick base the work area, equipment, and clothing should bekept
metal is involved, sheet metal shields should be used for dry at all times. Weldersshould wear dry gloves and rub-
extra protection. Mechanization of highly hazardous pro- ber soled shoes, or stand on a dry boardor insulated plat-
cesses or jobs should beconsidered. Other personnel in form. Cables and connections should be kept in good
the work area should be protected by the use of noncom- condition. Improper or worn electrical connections may
bustible screens or by the use of appropriate protection as create conditions that could cause electrical shock or
described in the previous paragraph. Before leaving a short circuits. Worn, damaged, or bare cables should not
work area, hot work pieces should be marked to alert be used. Open-circuit voltage should be avoided. When
other persons of this hazard. No attempt should be made several welders are working with arcs of different polari-
to repair or disconnect electrical equipment when it is ties, or when a number of alternating-current machines
under load. Disconnection under load produces arcing of are being used, the open-circuit voltages can be additive.
the contacts and may cause burns or shock, or both. The added voltages increase the severity of the shock
(Note: Burns can be caused by touching hot equipment hazard.
such as electrode holders, tips, and nozzles. Therefore, In case of electric shock, the power should be turned
insulated gloves should be worn when these items are off. If the rescuer must resort to pulling the victim from
handled, unless an adequate cooling periodhas been al- the live contact, nonconducting materials should be used.
lowed before touching.) If the victim is not breathing, cardiopulmonary resuscita-
The following sources are for more detailed informa- tion (CPR) should be administered as soon as contact
tion on personal protection: with the electrical source is broken. A physician should
(1) ANSI 249.1, Safely in Welding, Cutting, and Allied be called and CPR continued until breathing has been re-
Processes, published by the American Welding Society, stored, or until a physician has arrived. Electrical burns
550 N.W. LeJeune Road, Miami, FL 33126. are treated as thermal burns; that is, clean, cold (iced)
(2) Code of FederalRegulations, Title 29 Labor, compresses should be applied. Contamination should be
Chapter XVII, Part 1910, OSHA General Industry Stan- avoided; the area should be covered with a clean, dry
dards available from the U.S. Government Printing Of- dressing; and the patient should be transported to medi-
fice, Washington, DC 20402. cal assistance.
(3) ANSIIASC 287.1, Practice for Occupational and Recognizedsafety standards such as ANSI 249.1,
Educational Eye and Face Protection, American Na- Safely in Welding, Cutting, andAllied Processes;the Na-
tional Standards Institute, 11 West 42nd Street, New tional Electrical Code;and NFPA No. 70, available from
York, NY 10036-8002. National Fire Protection Association, 1 Batterymarch
(4) ANSI 241, American National Standard for Per- Park, Quincy, MA 02269, should be followed.
sonal ProtectionDrotective Footwear, American Na-
A103 Fumes andGases. Many welding, cutting, and al-
tional Standards Institute, 11 West 42nd Street, New
York, NY 10036-8002. lied processes produce fumes and gases which may be
harmful to health. Fumes are solid particles which origi-
A10.2 Electrical Hazards. Electric shock can kill. How- nate from welding filler metals and fluxes, the base
ever, it can be avoided. Live electrical parts should not metal, and any coatings present on the base metal. Gases
be touched. The manufacturer’s instructions and recom- are produced during the welding process or may be pro-
mended safe practices should be read and understood. duced by the effectsof process radiation on the surround-
Faulty installation, improper grounding, and incorrect ing environment. Management, personnel and welders
operation and maintenance of electrical equipment are all alike should be aware of the effects of these fumes and
sources of danger. gases. The amount and composition of these fumes and
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gases depend upon the composition of the filler metal A10.4 Radiation.Welding, cutting, and allied operations
and base metal, welding process, flux, current level, arc may produce radiant energy (radiation) harmful to
length, and other factors. Fluxes, used for oxyfuel gas health. One should become acquainted with the effects of
welding of aluminum alloys, are composed primarily of this radiant energy.
chlorides plus small fluoride additions. The coatings Radiant energy may be ionizing (such as x-rays), or
used in covered electrodes of the types shown in this nonionizing (such as ultraviolet, visible light, or infra-
specification A5.3IA5.3M contain both chlorides and red). Radiation can produce a variety of effects such as
fluorides. skin burns and eye damage, dependingon the radiant en-
The possible effects of overexposure range from irri- ergy’s wavelength and intensity, if excessive exposure
tation of eyes, skin, and respiratory system to more se- occurs.
vere complications. Effects may occur immediately or at
some later time. Fumes can cause symptoms suchas nau- A10.4.1IonizingRadiation. Ionizing radiation is
sea, headaches, dizziness, and metal fume fever. The produced by the electron beam welding process. It is or-
possibility of more serious health effects exists when es- dinarily controlled within acceptance limits by use of
pecially toxic materials are involved. In confined spaces, suitable shielding enclosing the welding area.
the fumes mightdisplace breathing air and cause asphyx-
iation. One’s head should always be kept out of the
A10.4.2NonionizingRadiation. The intensity and
fumes. Sufficient ventilation, exhaust at the arc or flame,
wavelengths of nonionizing radiant energy produced de-
or both, should be used to keep fumes and gases from
pend on many factors, such as the process, welding pa-
your breathing zoneand the general area.
rameters, electrode and base metal composition, fluxes,
In some cases, natural air movementwillprovide
and any coating or plating on the base metal. Some pro-
enough ventilation. Where ventilation may be question-
cesses such as resistance welding and cold pressure
able, air sampling should be used to determine if correc-
welding ordinarily produce negligible quantities of radi-
tive measures shouldbe applied.
ant energy. However, most arc welding and cutting pro-
All aluminum electrodes possessacompositional cesses (except submerged arc when used properly), laser
control of 0.0008 percent maximum beryllium content. beam welding and torch welding, cutting, brazing, or sol-
This provides a checkby the manufacturer that the filler dering can produce quantities of nonionizing radiation
metal is essentially free of this element and thus avoids such that precautionary measures are necessary.
the presence of concentrations of this highly toxic metal-
Protectionfrompossibleharmful effects caused by
lic particulate during the filler metal transfer across the
nonionizing radiant energy from welding include the fol-
arc. Since the electrode core wire is fabricated as drawn,
lowing measures:
wrought aluminum wire, the same beryllium control has
been applied to all filler metals covered by this ANSI/ (1) One should not look at welding arcs except
AWS A5.3IA5.3M specification. Thus all electrodes pos- through welding filter plates which meet the require-
sess a 0.0008 percentberyllium maximum limit. ments of ANSVASC 287.1, Practice for Occupational
More detailed information on fumes and gases pro- and Education Eye and Face Protection, published by
duced by the various welding processesmay be found in American National Standards Institute, 11 West 42nd
the following: Street, New York, NY 10036-8002. It should be noted
that transparent welding curtains are not intended as
(1)Thepermissibleexposure limits required by
OSHA can be found in CFR Title 29, Chapter XVII Part welding filter plates, but rather are intended to protect
passersby from incidental exposure.
1910. The OSHAGeneral Industry Standards are avail-
able from the Superintendent of Documents, U.S. Gov- (2) Exposed skin should be protected with adequate
ernment Printing Office, Washington, DC 20402. gloves and clothing as specified in ANSI 249.1, Safety in
(2) Therecommended threshold limit values for Welding, Cutting, and Allied Processes, published by
these fumes and gases may be found in Threshold Limit American Welding Society, 550 N.W. LeJeune Road,
Values for ChemicalSubstances and Physical Agents in Miami, FL 33126.
the Workroom Environment, published by the American (3) Reflections from welding arcs should be avoided,
Conference of Governmental Industrial Hygienists and all personnel should be protected from intense re-
(ACGIH), 1330 Kemper Meadow Drive, Suite 600, Cin- flections. (Note: Paintsusing pigments of substantially
cinnati, OH 45240-1643. zinc oxide or titanium dioxide have a lower reflectance
(3) The results of an AWS-funded study are available for ultraviolet radiation.)
in a report entitled, Fumes and Gases in the Welding (4) Screens, curtains, or adequatedistance from
Environment, available from the American Welding aisles, walkways, etc., should be used to avoid exposing
Society, 550 N.W. LeJeune Road, Miami, FL 33126. passersby to welding operations.
13
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( 5 ) Safety glasses with UV-protective side shields Hazards from Optical Radiation Generatedby Electric
have been shown to provide some beneficial protection Welding and Cutting Arcs, available from the National
from ultraviolet radiation produced by welding arcs. Technical Information Service, Springfield, VA 22161,
ADA-043023.
A10.4.3 Ionizing radiation information sources
(4) Moss, C. E., and Murray, W. E. Optical Radiation
include:
Levels Produced in Gas Welding, Torch Brazing, and
(1) AWS F2.1-78, Recommended Safe Practices for Oxygen Cutting. Welding Journal, September 1979.
Electron Beam Welding and Cutting, available from the
(5) Optical
Radiation
Levels
Produced by Air-
American Welding Society, 550 N.W. LeJeune Road,
Carbon Arc Cutting Processes, Welding Journal, March
Miami, FL 33126,
1980.
(2) Manufacturer’s product information literature.
(6) ANSI/ASC 2136.1,Safe Use of Lasers, published
A10.4.4 Nonionizing radiation information sources by American National Standards Institute, 11 West 42nd
include: Street, New York, NY 10036-8002.
(1) Hinrichs, J. F., Project Committee on Radiation- (7) ANSI 249.1, Safety in Welding, Cutting, and Allied
summary report. Welding Journal, January 1978. Processes, published by the American Welding Society,
(2) Nonionizing Radiation Protection Special Study 550 N.W. LeJeune Road, Miami, FL 33126.
No. 42-0053-77, Evaluation of the Potential Hazards (8) ANSI/ASC 287.1,Practice for Occupational and
from Actinic Ultraviolet Radiation Generated by Electric Educational Eye and Face Protection, published by
Welding and Cutting Arcs, available from the National American National Standards Institute, 11 West 42nd
Technical Information Service, Springfield, VA 22161, Street, New York, NY 10036-8002.
ADA-033768. (9) Moss, C. E. Optical Radiation Transmission Lev-
(3) Nonionizing Radiation Protection Special Study els through Transparent Welding Curtains, WeldingJour-
No. 42-0312-77, Evaluation of the Potential Retina nal, March 1979.
14 --`,,`,``,,```,``,,,``````,``,-`-`,,`,,`,`,,`---
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Annex B
Guidelines for Preparation of Technical Inquiries for
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AWS Technical Committees
(This Annex is not a part of ANSIJAWS A5.3JA5.3M:1999, Specification for Aluminum and Aluminum-Alloy Elec-
trodes for Shielded Metal Arc Welding, but is included for informationpurposes only).
B1. Introduction the edition of the standard that contains the provisions or
that the Inquirer isaddressing.
The AWSBoardof Directors has adopted a policy
whereby all official interpretations of AWS standards B2.2 Purpose of the Inquiry. The purpose of the inquiry
will be handled in a formalmanner. Under that policy, all must be stated in this portion of the inquiry. The purpose
interpretations are made by the committee that is respon- can be either to obtain an interpretation of a Standard re-
sible for the standard. Official communication concern- quirement, or to request the revision of a particular pro-
ing an interpretation is through the AWS staff member vision in the Standard.
who works with that committee. The policy requires that B2.3 Content of the Inquiry. The inquiry should be
all requests for an interpretation be submitted in writing. concise, yet complete, to enable the committee to quickly
Such requests will be handled as expeditiously as possi- and fully understand the point of the inquiry. Sketches
ble but due to the complexity of the work and the proce- should be used when appropriate and all paragraphs, fig-
dures that must be followed, some interpretations may ures, and tables (or the Annex), which bear on the in-
require considerabletime. quiry must be cited. If the point of the inquiry is to obtain
a revision of the Standard, the inquiry must provide tech-
nical justification for that revision.
B2. Procedure B2.4 Proposed Reply. The inquirer should, as a pro-
All inquiries must be directed to: Managing Director, posed reply, state an interpretation of the provision that is
Technical Services, American Welding Society, 550 the point of the inquiry, or the wording for a proposed re-
N.W. Ldeune Road, Miami, FL 33126. vision, if that is what inquirer seeks.
All inquiries must contain the name, address, and af-
filiation of the inquirer, and they must provide enough
information for the committee to fully understand the B3. Interpretation of Provisions of
point of concern in the inquiry. Where that point is not the Standard
clearly defined, the inquiry will be returned for clarifica-
tion. For efficient handling, all inquiries should be type- lnterpretations of provisions of the Standard aremade
written and should also be in the format used here. by the relevant AWS Technical Committee. The secre-
tary of the committee refers all inquiries to the chairman
B2.1 Scope. Each inquiry must address one single provi- of the particular subcommitteethat has jurisdiction over
sion of the Standard, unless the point of the inquiry in- the portion of the Standard addressed by the inquiry. The
volves two or more interrelated provisions. That provision subcommittee reviews the inquiry and the proposed reply
must be identified in the Scope of the inquiry, along with to determine what the response to the inquiry should be.
15
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Following the subcommittee’s development of the re- an official interpretation of any A W S Standard with the
sponse, the inquiry and the response arepresentedtothe information that such an interpretation can be obtained
entire committee for review and approval. Upon ap- onlythrougha written request. TheHeadquarters Staff
proval by the committee, the interpretation willbean of- cannotprovide consulting services. The staff can, how-
ficial interpretation of the Society, andthe secretary will ever, refer a caller to any of those consultants whose
transmit the response to the inquirer andtothe Welding names are on file at A W S Headquarters.
Journal for publication.
16
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AWS Filler Metal Specifications by Material and Welding Process
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AWS A5.31A5.3M :1999
A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic
Steel Weld Metal Produced by Arc Welding
A5.01 Filler Metal Procurement Guidelines
A5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
A5.2 Specification for Carbon and Low-Alloy Steel Rods for Oxyfuel Gas Welding
A5.31A5.3M Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding
A5.4 Specification for Stainless Steel Welding Electrodes for Shielded Metal Arc Welding
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~~
A5.5 Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
A5.6 Specification for Covered Copper and Copper Alloy Arc Welding Electrodes
A5.7 Specification for Copper and Copper Alloy Bare Welding Rods and Electrodes
A5.8 Specification for Filler Metals for Brazing and Braze Welding
A5.9 SDecification for Bare Stainless Steel Welding Electrodes and Rods
A5.10 Specification for Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods
A5.11/A5.11M Specification for Nickel and Nickel-Alloy Welding Electrodes for Shielded Metal Arc Welding
A5.12/A5.12M Specification for Tungsten and Tungsten Alloy Electrodes for Arc Welding and Cutting
A5.13 Specification for Solid Surfacing Welding Rods and Electrodes
A5.141A5.14M SDecification for Nickel and Nickel-Allov Bare Welding Electrodes and Rods
A5.15 SDecification for Welding Electrodes and Rods for Cast Iron
,4516 SDecification for Titanium and Titanium Allov Welding Electrodes and Rods
A5.17/A5.17M Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
A5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding
A5.19 Specification for Magnesium Alloy Welding Electrodes and Rods
A5.20 Specification for Carbon Steel Electrodes for Flux Cored Arc Welding
A5.21 Specification for Composite Surfacing Welding Rods and Electrodes
A5.22 Specification forStainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for
Gas Tungsten Arc Welding
A5.23/A5.23M Suecification for Low-Allov Steel Electrodes and Fluxes for Submerged Arc Welding
A5.24 Specification for Zirconium and Zirconium Allov Welding Electrodes and Rods
A5.251A5.25M SDecification for Carbon and Low-Allov Steel Electrodes and Fluxes for Electroslae Welding
A5.26/A5.26M Specification for Carbon and Low-Alloy Steel Electrodes for Electrogas Welding
A5.28 Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding
A5.29 Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding
A5.30 Specification for Consumable Inserts
A5.31 Specification for Fluxes for Brazing and Braze Welding
A5.32/A5.32M Specification for Welding Shielding Gases
For ordering information, contact the AWS Order Department, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
Telephones: (800) 334-9353, (305) 443-9353, ext. 280; FAX (305) 443-7559.
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Copyright American Welding Society Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/10/2004
Provided by IHS under license with AWS 08:19:42 MDT Questions or comments about this message: please call the Document
Policy Group at 303-397-2295.