10803

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( Reaffirmed 1995 )

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IS:10803 1984

I izd ianStandard

METHOD OF SAMPL ING AND PREPARATlONOF WELD PAD FOR CHEMICAL ANALYSIS

OF WELD METAL FROM COVERED

ELECTRODES FOR MANUAL

METAL ARC WELDING

Welding General Sectional Committee, SMDC 14

Chairman

SHRID. S. HONAVAR

Members

SERI S. R. JANA ( Alternate toShri D. S. Honavar )

SHRI J. K. AHLUWAL~ASHRI T. K. Basu ( Alternate )

SHRI H. N. AHUJ A

SHRIK. BALMANOHARSHRI R. V. KALE ( Aksrnate )

!& RI S. K. BASU

Representing

D & H Secheron Electrodes Pvt Ltd. Indore

Stewarts & Lloyds of India Ltd. Calcutta

Directorate General of Employment and Training,New Delhi

SHRI R. BANERJ EEAlternate )SHRI S. C. BHOWAL

SHRI K. L. BARIJ I AI ternnte )SHRI S. K. BURMAN

Hindustan Shipyard Ltd, Vishakhapatnam

Indian Oxygen Ltd, Calcutta

National Test House, Calcutta

M. N. Dastur & Co Pvt Ltd, CalcuttaSHRI D. B. GHOSH( Al ternate I )SHRI B. B. SAHA ( Alternate II )

SHRI S. C. DEY Central Boilers Board, New Delhi

DIRECTOR M & C ), RDSO Ministry of RailwaysLUCKNOWCHEMIST& METALLURGIST-2,

RDSO, LUCKNOW ( Alternate I )PRODUCTION NGINEER, CF, MADRAS

( Alternate II )SHRI C. C. GIROTRA Assoc&t$n of Indian Engineering Industry, New

SHRI R. S. AGOARWAL ( Alternate )SHRI M. T. KANSE DirecDc;;te General of Supplies & Disposals, New

SHRI S. N. BASU ( Alternate )

( Conti nued on page 2 )

@ Copyright 1984

INDIAN STANDARDS INSTITUTION

This publication is protected under the I ndian Copyright Act ( XIV of 1957) and

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I S: 10803 -1984

( Continued fr om page 1 )

Members Representing

SHRI R. KRISHNAMURTHY Bharat Heavy Electricals Ltd, HardwarSHRIN. K. SETHI ( Al ternate I )SHRI K. POORANCHANDRARAO( Alternate II)

SHRI S. MAJUMDAR Directorate Geueral of Technical Development,New DelhiSHRI S. K. BHATIA ( Alfernate )

SHRI A. V. MULAY Tata Engineering and Locomotive Co Ltd,Jamshedour

SHRI . S. JOSHI ( Alternate >SHRI N. MUM M~~RTHY Engineers-in-Chief’s Branch, Army HeadquartersSHRI . D. PANDA Dalmia Institute of Scientific and Industrial

Research. RaiaangaurSHRIRAJINDRA NATH ( Al ternate I )SHRI S. L. V. RANGAN( Alternate I I )

SHRI ANIL PANDYA Steel Authority of India Ltd ( Bokaro SteelPlant ), Bokaro Steel City

SHRI K. M. POLE Walchandnagar Industries, WalchandnagarSHRI G. D. APTE ( Alternate )

SHUI R. D. PENNATHUR Bharat Heavy Plate and Vessels Ltd.

DR S. PRASANNAKUMARVishakhapatnam

Larsen & Toubro Ltd. BombavSHRI . K. NANDA (Alternate )

SHRI J. R. PKASnER Engineers India Ltd, New DelhiSHRIN. RADHAKRISHNAN Binny Ltd, MadrasSHRI B. RAMASWAMY Indian Hume Pipes Co Ltd, BombayDR V. RAMASWAMY Steel Authority of India Ltd ( Research &

SHRI S. K. CHOUDHURY Alternate )Development Organization ), Ranchi

SHRI P. B. RAOSHRIA. L. LALA ( Alternate )

Ministry of Defence ( DGI-)

SHR~ V. S. G. RAOSHRI L. M. TOLANI ( Alternate )

Department of Atomic Energy, Bombay

DR R. H. G. RAUSHRI C. R. GHOSH ( Alternate )

Mukand Iron & Steel Works Ltd, Bombay

REPRESENTATIVE Jessop & Co Ltd, CalcuttaSHRI H. K. TANEJA Indian Register of Shipping, Calcutta

SHRI S . CHANDRA Alternate )SHRI J. R. UPADHYAY Apar Pvt Ltd, Bombay

SI~RI PATWARDHAN Alternate )SHRI E. K. VENKATARAMANSHRI . S. VISVANAIH

Peico Electronics & Electricals Ltd, BombayAdvani-Oerliken Ltd. Bombay

SHRIK. RAGHAVENDRAN,Director ( Strut & Met )

Director General, ISI ( Ex-off icio M ember)

Secretary

SHRI P. DAKSHINA MURTY

Senior Deputy Director ( Metals ), IS1

( Continued on page 8 )

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IS : 10803 - 1984

Indian Standard

METHOD OF SAMPL ING AND PREPARATION

OF WELD PAD FOR CHEMfCAL ANALYSIS

OF WELD METAL FROM COVERED

ELECTRODES FOR MANUAL

METAL ARC WELDING

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institutionon 2 January 1984, after the draft finalized by the Welding GeneralSectional Committee had been approved by the Structural and MetalsDivision Council.

0.2 This standard is meant to be a guide specifying a uniform method ofpreparing the weld pad for chemical analysis of weld metal from coveredelectrodes for manual metal arc welding.

0.3 In the preparation of this standard assistance has been derived fromISO/DIS 6847 ‘Manual metal arc deposition of a weld metal pad forchemical analysis’, issued by the International Organization for Standard-ization.

0.4 In reporting the result of a test or analysis made in accordance withthis standard, if the final value, observed or calculated, is to be roundedoff, it shall be done in accordance with IS : 2-1960*.

1. SCOPE

1.1 This standard describes the method of preparation of weld padobtained by deposition from electrodes for manual metal arc welding andspecifies the method of taking out chips for chemical analysis purposes.This standard does not cover estimation of gases in weld metal.

1.2 Electrodes Size and Type - This standard applies to manual arcwelding electrodes of all ferrous metals and nickel and nickel-base alloys iuthe sizes from 1’6 mm to 6’3 mm diameter.

*Rules for FgJpJ$$ng off numercial values ( revised ).

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Is : 10803 1984

2. BACKlNG PLATE FOR PADS

2.1 Parent Metal - The parent m.etal used as backing plate shall be ofmild steel conforming to IS : 226-1975*, IS : 2002-19621 or IS : 2062-

1980$.

2.2 Dimensions - The dimensions of the backing plate shall not be lessthan the following:

Electrode Size, mm Backi ng Pl ate Si ze, mm

1’6, 2’0, 2’5, 3’15 55 x 55 x 10

4’0, 5’0, 6’3 65 x 65 x 10

2.3 Surface Condition -- The surface of the plate shall be thoroughlycleaned by brushing and grinding to remove all grease, paint, rust, scaleand other contaminants.

3. METHOD OF WELDING

3.1 Current and Polarity - The deposition shall be carried out using thetype of current ( ac/dc ) and polarity ( -+ve/ -ve ) as indicated by themanufacturer of the electrodes. IF the manufacturer leaves the choice oftype of current to the user, the user shall carry out the depositionusing the current of his choice.

3.2 Welding Position - The weld deposition shall be carried out in theflat position.

3.3 Weldbrg Equipment - The welding equipment shall have droopingvoltage characterrstics in conformity with the recommendations of theelectrode manufacturer. In case of alternating current, the weldingequipment should exhibit a minimum open circuit voltage at least equal tothe one recommended by the electrode manufacturer.

3.4 Drying of Electrodes - Prior to welding, the electrodes shall beproperly dried as per recommendation of the electrode manufacturer. Incase of low hydrogen electrodes, extra care shall be taken in baking andremoving moisture from the electrode covering.

3.5 Fusion of tRe Electrode

3.5.1 The electrode shall be fused completely leaving the usual length of

stub which Wdd vary betweeil 30 t6 50 mm depending on size and typeof electrodes.

*Structural steel ( standard quality ) (fifth r evhi dn .K&eel plate fdc boilers.*Structural steel ( fusion welding quality ) ( secor i d r evi si on .

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IS : 10803 1984

3.5.2 The arc length shall be kept as short as possible. A stable arc

3.5.3 Deposition should be carried out at normal speed without weaving.each weld bead shall be 1’5 to 2’5 times the diameter of the

of the electrodes.

3.5.4 The current intensity shall be equal to the mean value recom-for welding in the flat position or, if not specified, it shall

to 70 percent of the maximum current value indicated by the

3.5.5 M et hod of Bui l ding Up and Cool i ng of the Deposi t

3.5.5.1 Weld layers shall be built up in such a way that the beads ofnext layer shall be laid in a direction opposite to the previous layer

see also 3.5.5.4 ). The width of the runs shall be as indicated in 3.5.3.

3.5.5.2 The backing plate, during welding, shall be kept on the welding

3.5.5.3 After each pass the deposited metal shall be cooled byin 10 litres of water for about 30 seconds, the depth of immer-

being at least 10 cm.

3.5.5.4 The second and subsequent layers shall be deposited afterdrying. After each cooling, the test piece shall be placed in front

the welder in the opposite direction in order that the ends of the runs inprevious layer coincide with the beginning of runs in the following

DlMENSIONS OF WELD DEPOSIT

At least eight layers shall be deposited. The sampling will be doneupper t.hree layers. The dimensions of the deposit shall be not lessthose indicated below:

Electrode Size Di mensi ons of Deposi t , M i n

mm mm1’6, 2’0, 2’5 30 x 30 X 133’15, 4’0, 5.0 40 x 40 x 16

6’3 .56 x 55 X 20

5, REMOVAL OF CHIPS FOR CHEMICAL ANALYSIS *

5.1 The top most layer of the deposit, which is often contaminated andoxidised to somt: extent, shall be removed and discarded. The removal maybe done by shaping, milling or grinding.

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IS 110803 1984

5.2 he chips for chemical analysis shall be removed by dry machining thelayers indicated in Fig. 1. A minimum distance X from the surface of thebacking plate shall be left out as shown below as it may contain dilutedmetal.

Electrode Size

mm

1’6, 2’0, 2’53’15, 4’0, 5’0

6’3

X

mm

1:12

FIG. 1 WELD PAD FOR CHEMICAL ANALYSIS

5.3 If chemical analysis is carried out by spectrochemical method, theanalysis should be performed at least on three spots ( see Fig. 2 ) lying ona &gonal reprksented by the voltllflt: of metal, represented by the hei ghtB cjf the wtld pad. Sample cif suithble shape dnd sizt tiay be machiriedodt fbt this ptirpcisr, having their t&t sur’face lying on the diagoM1. Anaverage of the three retidir%g$ &ken from the& spots &till be reported.

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I S: 10803 - 1984

TYPICAL SPOTS FORc:

FIG. METHOD OF SELECTION F SPOTS FOR SPARKING

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is : 1osoi - 19i4

( Continued f rom page 2 )

Subcommittee for Welding Consumables, SMDC 14 : 1

Convener

SHRI D. S. HONAVARMembers

Representing

D & H Sechron Electrodes Pvt Ltd, Indore

SHRI S. R. J ANA( Alternate toShri D. S. Honavar )

Sum S. K. BASU Indian Oxygen Ltd, CalcuttaSHRIR. BANERJ EE Alternate )

SHRI S. BHATJ A Peico Electronics and Electricals Ltd, BombaySHRIC. C. GIROTRA Alternate )

CHEMIST& METALLURGIST-& Ministry of Railways

RDSO, LUCKNOWASSJ STANT ESEARCH FFJ CER( MET-IV ) RDSO, LUCKNOW ( Alternate )

SHRI R. KRISHNAMURTHI Bharat Heavy Electricah Ltd, HyderabadSHRI . C. MAGOO (AIternate >

SHRIS. KRISHNAMOORTHY ACC-Babcock Ltd , Durgapur

SrmrPREMKRISHNA (Afternate )SHRI A. C. MUKHERJ EE Adsons Engineering Enterprises, Nadia

SHRI ANIL PANDYA Steel Authority of India Ltd ( Bokaro SteelPlant ), Bokaro Steel City

SHRI J . R. PRA~HER Engioeers India Ltd, New Delhi

SHRI M. R. C. NAGARAJ AN -4trhcrr;t )WEPRFSENTATIVE Heavy Plate & Vessels

VishakhapatnamLtd,

REPRESENTATIVE Power Projects Division, BARC, Bombay

REPRESENTATIVE Dalmia Institute of Scientific and IndustrialResearch, Rajgangpur

SHRI S. D. SEHGAL Ministry of Defence ( DGI )

SHR~ . R. UPADHYAY Apar Pvt Ltd. Vadodara

SHRI P. S: VISVANATH Advani-Oerlikon Ltd, Bombay

Sum M. P. DHANUKA ( Alternate )

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10803