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Rutile electrodes for MMA steel welding

Rutile Mild Steel welding Electrodes

There are 18 products in category Rutile electrodes for MMA steel welding.
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Rutile electrodes: choose the right electrode

When it comes to choosing a rutile electrode, there are always many doubts, questions and perplexities. Sometimes even those who are welding experts find themselves faced with great difficulty in choosing the right electrode. Yet, it is not at all as difficult as it might initially seem. What you need is to take some time and understand the various factors that influence the right choice.

Rutile electrodes: What are they for and why are they important?

Metal welding is a complex physical-chemical process that involves various chemical compounds. The quality of the welding largely depends on the coating used in the electrodes: the lower the quality of the electrode coating, the lower the quality of the whole work. The electrode is designed to protect the welding pool from atmospheric gases. It also allows you to create a joint with the desired properties. This, in turn, is necessary to allow the welder to create refined works in all senses.

All electrodes are made according to the same principle: a special coating is applied on a metal rod made of a special alloy. Normally, the use of this type of electrodes depends on the type of coating. As you can understand, nowadays there are many such alternatives on the market.

Rutile coated electrodes are designed for manual arc welding. The coating consists mainly of titanium dioxide. This makes it possible to obtain high-quality welds and has a positive effect on the entire welding process. However, choosing a good electrode of this type is by no means as easy as it might seem at first glance. Several factors must be taken into consideration and, sometimes, you must also adapt to changes in the market.

Why are rutile electrodes so popular?

Rutile electrodes are considered to be among the best. They have a number of advantages that allow welders with all levels of experience to perform high-quality welding. All you need is to pay attention to the smallest details.

  •          Electrodes of this type can be used both in alternating and direct current. In any case, the welding arc maintains stability to combustion.
  •          It is possible to weld metal compounds coated with a thin layer of primer.
  •          Ideal for short welds or in uncomfortable places. The arc is easily ignited and just as easily ignited repeatedly.
  •          It makes it possible to create a weld with high impact resistance. This is possible due to the higher alkalinity of the slag.
  •          Rutile welding has excellent durability and fatigue resistance. Even in case of prolonged exposure to alternating loads, it maintains its qualities.
  •          When welding with rutile electrodes, a low spatter ratio is characteristic. This makes the welding process more convenient for the welder.
  •          It is convenient to reuse the electrode. At the end of welding, a soot remains on the tip of the rod, which does not need to be cleaned (unlike other types of coating). The carbon of the rutile electrode is a semiconductor, so you can continue working without further problems.
  •          Less damage to health. No hazardous substances are released during the burning of the rutile coating. Therefore, there is less negative impact on the welder’s respiratory system.



Features of rutile coating

Electrodes with this type of coating can often be of two main types: E42 and E46 (according to state standard). The type must be indicated on the package label. Metal welded with E42 type electrodes has the following technical characteristics:

Tensile strength - 410 MPa;

Relative elongation - 22%;

Impact resistance - 80 J / cm2.

Welding with E46 electrodes has more durable indicators:

Tensile strength - 450 MPa;

Relative elongation - 20%;

Impact resistance - 147 J / cm2.

In the production of rutile electrodes, a low carbon welding wire (SV-08 or SV-08A) is used. The rutile coating is also applied. In the labeling of these electrodes there is the letter “P”, which indicates the type of coating. Normally, two numbers always follow after the letter “P”:

  •          The first indicates in which spatial positions welding can be performed. Most rutile electrodes can be fired in any position.
  •          The second indicates the type of welding current: alternating or constant, its polarity and open-circuit voltage.

Depending on the manufacturer and the various modifications, the composition of the rutile coating may vary slightly. However, in most cases, the composition is as follows:

  •          Rutile concentrate (titanium dioxide) - 48%.
  •          Feldspar - 20%.
  •          Ferromanganese - 15%.
  •          Magnesite - 15%.
  •          Dextrin - 2%.

Some types of rutile electrodes may also contain additional elements: cellulose, for example. This varies greatly depending on the manufacturer, as the different brands involved in the production of rutile electrodes may in turn contain different elements.

Rutile coated electrodes: application

Due to its excellent qualities, rutile coatings are widely used in various conditions and are considered some of the most practical materials. It is no coincidence that electrodes coated with these materials are so popular on the market. Below list the main applications in which such electrodes perform well:

  • Welding of low carbon steel structures. The chemical composition of the coating allows to work effectively with ferrous and low alloy metals. In such cases, the weld is smooth and without cracks.
  • Welding of pipes. Excellent for repairing pipes carrying fluids. In this case, it is difficult to completely drain the metal surface. However, the welding arc of rutile electrodes burns constantly even when drops of water enter the combustion zone. This helps make a very strong weld.
  • Widely used to repair parts or tools that wear over time. Rutile electrodes make it possible to create a very thick weld in the most efficient way possible.

Rutile coated electrodes: Pros and Cons

Compared to other types of coatings, rutile has many advantages:

  •          Durability of a weld. The welded metal is not susceptible to cold or hot cracks.
  •          In contrast to acid coating, the welding arc of rutile burns as intensely with alternating current as with direct current.
  •          Easy to work areas where short welds are required. If the main coating requires continuous operation of the joint, since the welding arc is difficult to re-ignite, then it is easier with rutile. The arc is easily ignited, while the rod tip does not need to clean the carbon deposits.
  •          It is not necessary to prepare a working surface. Other types of electrodes are sensitive to oxidation and rust, causing weak welding. Rutile coated electrodes allow a stable and resistant weld to form, regardless of surface quality.
  •          After welding, the slag is easily separated and the surface of the joint needs practically no finishing.

There are also disadvantages:

  •          Not suitable for all kinds of design. The small range of metals with which this type of coating can be used imposes some restrictions on their operation. To weld high carbon steel, these electrodes cannot be used, which is a serious limitation.
  •          The properties deteriorate sharply as voltage increases. Therefore it is necessary to monitor compliance with the nominal indicator.
  •          Preparation work is necessary: drying and calcination.

Some considerations to keep in mind when performing welding work:

  •          Check what material the electrode is made of. We are not talking about the coating, but the core itself. To obtain the highest welding quality, the metal of the rod must correspond to the metal of the structure to be welded.
  •          It is also important to consider the thickness of the electrodes. It should correspond to the thickness of the metal of the structure, although it may be thicker or thinner if compensated for by the strength of the current and the skill of the welder.

Electrodes of this type require preliminary calcination before use. Common calcination requirements: at least one hour in a furnace at temperatures up to 350° C.

These are general requirements and exact instructions vary by brand. Some models are weakly sensitive to moisture and may be calcined at relatively low temperatures (up to 90° C), or it may not be necessary to calcinate them at all. Although there are brands that can dampen and lose their properties. The exact method of calcination is indicated by the manufacturer.

Types of rutile electrodes

The most commonly used classification of products is dividing them by their purpose. According to this parameter, products are divided into:

  •          Electrodes for working with low alloy and carbon steels.
  •          For work with heat-resistant and high-strength steels.
  •          For work with high-alloy steels, known also as “stainless steel electrodes”.
  •          For working with aluminum and various alloys based on it.
  •          For firing copper and various alloys based on it.
  •          To work with cast iron and its alloys.
  •          For repair and coating work.
  •          For work with welds and steels of indefinite structure.

You need to know what polarity and type of current you have to work with. Most inverter models generate direct current.

There are 3 very important characteristics related to each other, namely:

  •          Welding current.
  •          The diameter of the product.
  •          The thickness of the working materials.

First of all, it is necessary to address the relationship between the diameter of the working electrodes and the thickness of the processed materials.

How to choose the suitable electrodes?

After analyzing the information above, it is possible to identify a series of basic criteria to pay attention to when selecting electrodes for welding with an inverter.

First of all, it is necessary to decide which metals will be processed. The electrode is chosen according to the type of metal. If responsible welding is performed, it is best to purchase quality products from a well-known manufacturer. Secondly, if you are going to weld carbon steel, you will need to pay attention to cleaning the surface of the material. If the metal is wet or covered with rust, you will need to use rutile coating.

How to choose the electrode diameter according to the thickness of the metal?

When choosing the electrode, you should take into account the dependence of the electrode diameter on the thickness of the welded metal. The thicker the latter, the greater the thickness of the electrode rod. Follow these instructions:

  •          with a thickness of 1.5-2.5 mm, the electrode thickness will be 2-2.5 mm;
  •          with a thickness of 3 mm - 2.5-3 mm, respectively;
  •          at 4-5 mm - 3-4 mm;
  •          at 6-10 mm - 4-5 mm.

The permitted welding current values also vary according to the diameter of the consumable. With increased current values (always indicated on the package) and exceeding the recommended diameter indicators, there is a risk of porous welds forming in the metal. It should also be noted that if the thickness of the products does not exceed 1.5 mm, manual arc welding is usually not used.

The choice of welding current directly affects the quality of the weld and the result. If it is not prepared correctly, the workpiece may simply burn during welding or, on the contrary, the metal will not melt to the desired depth. One of the key rules is the dependence of the current force on the electrode diameter. An important role is also played by:

  •          piece thickness;
  •          spatial position of welding;
  •          arc length;
  •          the number of layers of the seam.

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