specification for aluminum and aluminum-alloy electrodes for...

AWS A5.3/A5.3M:1999 (R2007)An American National Standard

Specification forAluminum andAluminum-AlloyElectrodes forShielded MetalArc Welding

550 N.W. LeJeune Road, Miami, FL 33126

AWS A5.3/A5.3M:1999 (R2007)An American National Standard

Approved by theAmerican National Standards Institute

February 11, 1999

Specification for

Aluminum and Aluminum-Alloy

Electrodes for Shielded

Metal Arc Welding

Supersedes ANSI/AWS A5.3-91

Prepared by theAmerican Welding Society (AWS) A5 Committee on Filler Metals and Allied Materials

Under the Direction of theAWS Technical Activities Committee

Approved by theAWS Board of Directors

AbstractThis specification prescribes requirements for the classification of covered (flux coated) E1100, E3003, and E4043

aluminum-alloy electrodes for shielded metal arc welding. Tests conducted for classification are chemical analysis of thecore wire as well as tensile and bend tests from groove weld test assemblies fabricated with each of two sizes of electrodefor each classification. Standard electrode sizes, electrode identification, and chemical composition limits are specified.

This specification makes use of both U.S. Customary Units and the International System of Units (SI). Since these arenot equivalent, each system must be used independently of the other.

Key Words—Covered aluminum electrodes, aluminum welding electrodes, shielded metal arc welding, filler metal specifications

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AWS A5.3/A5.3M:1999 (R2007)

International Standard Book Number: 0-87171-561-9American Welding Society

550 N.W. LeJeune Road, Miami, FL 33126© 1999 by American Welding Society

All rights reservedPrinted in the United States of America

Reaffirmed: February 21, 2007

Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyrightowner.

Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:<www.copyright.com>.

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AWS A5.3/A5.3M:1999 (R2007)

Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documents that are included in federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction before they can become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whetherspecial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for oron behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement ofany patent or product trade name resulting from the use of this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society,Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex B).With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered.These opinions are offered solely as a convenience to users of this standard, and they do not constitute professionaladvice. Such opinions represent only the personal opinions of the particular individuals giving them. These individualsdo not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations ofAWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS A5 Committee on Filler Metals and Allied Materials. It mustbe reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquarters. Such comments will receive careful consideration by the AWS A5 Committee onFiller Metals and Allied Materials and the author of the comments will be informed of the Committee’s response to thecomments. Guests are invited to attend all meetings of the AWS A5 Committee on Filler Metals and Allied Materials toexpress their comments verbally. Procedures for appeal of an adverse decision concerning all such comments areprovided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained fromthe American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

This page is intentionally blank.

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AWS A5.3/A5.3M:1999 (R2007)

Personnel (Reaffirmation)

AWS A5 Committee on Filler Metals and Allied MaterialsD. A. Fink, Chair The Lincoln Electric Company

J. S. Lee, 1st Vice Chair CB&IH. D. Wehr, 2nd Vice Chair Arcos Industries, LLC

R. Gupta, Secretary American Welding SocietyJ. M. Blackburn Department of the Navy

R. S. Brown RSB Alloy Applications, LLCJ. C. Bundy Hobart Brothers Company

R. J. Christoffel ConsultantD. D. Crockett The Lincoln Electric Company

J. J. DeLoach, Jr. Naval Surface Warfare CenterD. A. Del Signore Consultant

J. DeVito ESAB Welding and Cutting ProductsH. W. Ebert ConsultantD. M. Fedor The Lincoln Electric Company

J. G. Feldstein Foster Wheeler North AmericaS. E. Ferree ESAB Welding and Cutting Products

G. L. Franke Naval Surface Warfare CenterR. D. Fuchs Böhler Thyssen Welding USA, Incorporated

C. E. Fuerstenau Lucas-Milhaupt, IncorporatedJ. A. Henning DeltakR. M. Henson J. W. Harris Company, Incorporated

M. Q. Johnson Metallurgy GroupS. D. Kiser Special Metals

P. J. Konkol Concurrent Technologies CorporationD. J. Kotecki The Lincoln Electric Company

L. Kvidahl Northrop Grumman Ship SystemsA. S. Laurenson Consultant

W. A. Marttila DaimlerChrysler CorporationR. Menon Stoody Company

M. T. Merlo Edison Welding InstituteD. R. Miller ABS Americas Materials Department

B. Mosier Polymet CorporationC. L. Null Consultant

M. P. Parekh ConsultantR. L. Peaslee Wall Colmonoy Corporation

S. D. Reynolds, Jr. ConsultantP. K. Salvesen Det Norske Veritas (DNV)

K. Sampath ConsultantW. S. Severance ESAB Welding and Cutting Products

M. J. Sullivan NASSCO—National Steel & ShipbuildingR. C. Sutherlin ATI Wah Chang

R. A. Swain Euroweld, LimitedR. D. Thomas, Jr. R. D. Thomas and CompanyK. P. Thornberry Care Medical, Incorporated

L. T. Vernam AlcoTec Wire CorporationF. J. Winsor Consultant

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AWS A5.3/A5.3M:1999 (R2007)

Advisors to AWS A5 Committee on Filler Metals and Allied Materials

R. L. Bateman Electromanufacturas, S. A.R. A. Daemen La Grande Tuiliere

J. P. Hunt ConsultantS. Imaoka Kobe Steel Limited

M. A. Quintana The Lincoln Electric CompanyE. R. Stevens Stevens Welding Consulting

E. S. Surian National University of Lomas de Zamora

AWS A5C Subcommittee on Aluminum Alloy Filler MetalsL. T. Vernam, Chair AlcoTec Wire Corporation

N. Dietzen, Vice Chair Gulf Wire CorporationR. Gupta, Secretary American Welding Society

B. E. Anderson ConsultantB. C. Boehringer The Lincoln Electric Company

S. A. Collins Marine Maritime AcademyR. M. Henson J. W. Harris Company, Incorporated

G. M. Hergenrather Harley-DavidsonJ. S. Lee CB&I

G. H. Musselman Dana Corporation—Parish DivisionE. R. Pickering Reynolds Metals Corporation

D. A. Wright Zephyr Products, Incorporated

Advisors to AWS A5C Subcommittee on Aluminum Alloy Filler Metals

B. E. Anderson ConsultantR. D. Thomas, Jr. R. D. Thomas and Company

V. Van der Mee Lincoln Electric Europe bv

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AWS A5.3/A5.3M:1999 (R2007)

Personnel (Original)

AWS A5 Committee on Filler Metals and Allied MaterialsR. A. LaFave, Chair Elliott Company

J. P. Hunt, 1st Vice Chair ConsultantD. A. Fink, 2nd Vice Chair The Lincoln Electric Company

R. K. Gupta, Secretary American Welding Society*R. L. Bateman Electromanufacturas, S.A.

R. S. Brown Carpenter Technology CorporationR. A. Bushey ESAB Welding and Cutting Products

J. Caprarola, Jr. Consultant*L. J. Christensen Consultant

R. J. Christoffel ConsultantD. D. Crockett The Lincoln Electric CompanyR. A. Daemen Consultant

D. A. DelSignore ConsultantR. L. Drury III Caterpillar, Incorporated

H. W. Ebert Exxon Research and Engineering CompanyJ. G. Feldstein Foster Wheeler Energy Corporation

S. E. Ferree ESAB Welding and Cutting ProductsL. Flasche Delphi Delco Electronic Systems

R. D. Fuchs Böhler Thyssen Welding USA, IncorporatedC. E. Fuerstenau Alloy Ring ServiceG. Hallstrom, Jr. Hallstrom Consultants

J. A. Henning Deltak, IncorporatedR. B. Kadiyala Techalloy Maryland, Incorporated

P. J. Konkol Concurrent Technologies CorporationD. J. Kotecki The Lincoln Electric Company

D. Y. Ku American Bureau of ShippingN. E. Larson Consultant

A. S. Laurenson ConsultantJ. S. Lee Chicago Bridge and Iron Company, Incorporated

G. H. MacShane MAC AssociatesW. A. Marttila DaimlerChrysler

R. Menon Stoody CompanyM. T. Merlo Select Arc, IncorporatedA. R. Mertes Ampco Metal, IncorporatedM. D. Morin ABB Power Generation

C. L. Null Department of the NavyJ. J. Payne Consultant

R. L. Peaslee Wall Colmonoy CorporationE. W. Pickering, Jr. Consultant

M. A. Quintana The Lincoln Electric Company*H. F. Reid Consultant

*S. D. Reynolds, Jr. ConsultantL. F. Roberts Canadian Welding Bureau

P. K. Salvesen Det Norske Veritas (DNV)J. M. Sawhill, Jr. Newport News Shipbuilding

*Advisor

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AWS A5.3/A5.3M:1999 (R2007)

*Advisor

A. P. Seidler Armco SteelW. S. Severance ESAB Welding and Cutting Products

*W. A. Shopp ConsultantM. S. Sierdzinski ESAB Welding and Cutting Products

*R. G. Sim The Lincoln Electric Company (Australia)E. R. Stevens Consultant

*R. W. Straiton Bechtel CorporationR. A. Sulit Digital Systems Research

R. A. Swain Euroweld, LimitedR. D. Thomas, Jr. R. D. Thomas and CompanyK. P. Thornberry J. W. Harris Company, Incorporated

*R. Timerman Conarco, S.A.*S. Tsutsumi Kobe Steel, LimitedL. T. Vernam AlcoTec Wire Corporation

G. J. Vytanovych Mobil Technology CompanyT. R. Warren Ingalls Shipbuilding, Incorporated

H. D. Wehr Arcos Alloys*F. J. Winsor Consultant

K. G. Wold Siemens Power Corporation

AWS A5 Subcommittee on Aluminum and Aluminum-Alloy Filler Metals

L. T. Vernam, Chair AlcoTec Wire CorporationW. N. Dietzen, Vice Chair Gulf Wire Corporation

R. K. Gupta, Secretary American Welding Society*B. E. Anderson AlcoTec Wire Company

S. A. Collins Maine Maritime Academy*P. B. Dickerson Consultant

S. A. Gedeon IntellAction, IncorporatedR. M. Henson J. W. Harris Company, Incorporated

G. Hergenrather United Defense LP—Division of FMCL. L. Herl Consultant

J. S. Lee Chicago Bridge and Iron Company, IncorporatedG. H. Musselman Dana Corporation

E. R. Pickering Reynolds Metals Company*R. D. Thomas, Jr. R. D. Thomas and Company

D. A. Wright, Sr. Zephyr Products, Incorporated

AWS A5 Committee on Filler Metals and Allied Materials (Continued)

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AWS A5.3/A5.3M:1999 (R2007)

Foreword

This foreword is not part of AWS A5.3/A5.3M:1999 (R2007), Specification for Aluminum and Aluminum-AlloyElectrodes for Shielded Metal Arc Welding, but is included for informational purposes only.

This document represents the sixth revision of the first aluminum covered electrode specification issued in 1943. Theoriginal document was prepared by a joint AWS/ASTM Committee and published as an ASTM Standard.

During the mid-to-late 1960s, ASTM agreed to accept AWS as the sole agency responsible for the development andpublication of filler metal specifications. In recent years, AWS filler metal specifications have been recognized by theAmerican 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 ElectrodesASTM B184-62T

AWS A5.3-69 Specification for Aluminum and Aluminum-Alloy Arc-Welding ElectrodesANSI W3.3-1973

ANSI/AWS A5.3-80 Specification for Aluminum and Aluminum-Alloy Covered Arc-Welding Electrodes

ANSI/AWS A5.3-88 Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding

ANSI/AWS A5.3-91 Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,AWS A5 Committee on Filler Metals and Allied Materials, American Welding Society, 550 N.W. LeJeune Road, Miami,FL 33126.


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Table of Contents

Page No.

Personnel (Reaffirmation) ............................................................................................................................................vPersonnel (Original) ..................................................................................................................................................viiForeword .....................................................................................................................................................................ixList of Tables ..............................................................................................................................................................xiiList of Figures.............................................................................................................................................................xii

1. Scope....................................................................................................................................................................1

Part A—General 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—Manufacture, Identification, and Packaging...................................................................................................5

13. Method of Manufacture.....................................................................................................................................5

14. Standard Sizes and Lengths ..............................................................................................................................5

15. Core Wire and Covering ...................................................................................................................................5

16. Exposed Core......................................................................................................................................................6

17. Electrode Identification .....................................................................................................................................6

18. Packaging ............................................................................................................................................................7

19. Marking of Packages .........................................................................................................................................7

Annex A (Informative)—Guide to AWS Specification for Aluminum and Aluminum-Alloy Electrodes forAnnex A (Informative)—Shielded Metal Arc Welding...............................................................................................9

Annex B (Informative)—Guidelines for the Preparation of Technical Inquiries.......................................................15

AWS Filler Metal Specifications by Material and Welding Process .........................................................................17

AWS Filler Metal Specifications and Related Documents ........................................................................................19

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AWS A5.3/A5.3M:1999 (R2007)

List of Tables

Table Page No.

1 Chemical Composition Requirements for Core Wire .....................................................................................22 Required Tests.................................................................................................................................................33 Base Metal for Test Assemblies......................................................................................................................54 Tension Test Requirements .............................................................................................................................55 Standard Sizes .................................................................................................................................................6A1 Designation Reference Guide........................................................................................................................10

List of Figures

Figure Page No.

1 Groove Weld Test Assembly for Mechanical Properties................................................................................4

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AWS A5.3/A5.3M:1999 (R2007)

1. ScopeThis specification prescribes requirements for the

classification of aluminum and aluminum-alloy elec-trodes for shielded metal arc welding.

Part AGeneral Requirements

2. Normative References2.1 The following ANSI/AWS standards1 are referencedin the mandatory sections of this document:

(1) ANSI/AWS A5.01, Filler Metal ProcurementGuidelines.

(2) ANSI/AWS B4.0, Standard Methods for Mechan-ical Testing of Welds.

2.2 The following ASTM standards2 are referenced inthe mandatory sections of this document:

(1) ASTM E 29, Standard Practice for Using Signifi-cant Digits in Test Data to Determine Conformance withSpecifications.

(2) ASTM E 34, Standard Methods for ChemicalAnalysis of Aluminum and Aluminum Alloys.

(3) ASTM B 209, Standard Specification for Alumi-num and Aluminum-Alloy Sheet and Plate.

1 AWS Standards are published by the American WeldingSociety, 550 N.W. LeJeune Road, Miami, FL 33126.2 ASTM Standards are published by the American Society forTesting and Materials, 100 Barr Harbor Drive, West Consho-hocken, PA 19428-2959.

2.3 The following ISO standard3 is referenced in themandatory sections of this document:

(1) ISO 544, Filler Materials for Manual Welding—Size Requirements.

3. Classification3.1 The electrodes covered by the A5.3/A5.3M specifi-cation are classified using a system that is independent ofU.S. Customary Units and the International System ofUnits (SI). Classification is according to the chemicalcomposition of the core wire, as specified in Table 1, andmechanical properties of a groove weld.

3.2 An electrode classified under one classification shallnot be classified under any other classification in thisspecification.

4. AcceptanceAcceptance4 of the electrode shall be in accordance

with the provisions of ANSI/AWS A5.01, Filler MetalProcurement Guidelines.

5. CertificationBy affixing the AWS specification and classification

designations to the packaging, or the classification to the

3 ISO Standards are published by the American NationalStandards Institute (ANSI), 11 West 42nd Street, New York,NY 10036.4 See Section A3, Acceptance (in Annex A) for further infor-mation concerning acceptance, testing of the material shipped,and ANSI/AWS A5.01, Filler Metal Procurement Guidelines.

Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding

AWS A5.3/A5.3M:1999 (R2007)

2

product, the manufacturer certifies that the product meetsthe requirements of this specification.5

6. Units of Measure and Rounding-Off Procedure

6.1 This specification makes use of both U.S. CustomaryUnits and the International System of Units (SI). Themeasurements are not exact equivalents; therefore, eachsystem must be used independently of the other withoutcombining in any way. The specification with the desig-nation A5.3 uses U.S. Customary Units. The specifica-tion A5.3M uses SI Units. The latter are shown inappropriate columns in tables or within brackets [ ] whenused in the text.

6.2 For the purpose of determining conformance withthis specification, an observed or calculated value shallbe rounded to the nearest 1000 psi [10 MPa] for tensilestrength, and to the “nearest unit” in the last right-handplace of figures used in expressing the limiting value forother quantities in accordance with the rounding-offmethod given in ASTM E 29, Practice for Using Signifi-cant Digits in Test Data to Determine Conformance withSpecifications.

5 See Section A4, Certification (in Annex A) for further infor-mation concerning certification and the testing called for tomeet this requirement.

Part BTests, Procedures, and Requirements

7. Summary of TestsThe tests required for each classification are specified

in Table 2. The purpose of these tests is to determine thechemical composition of the core wire and the mechani-cal properties of the weldment. The base metal for theweld test assemblies, the welding and testing proceduresto be employed, and the results required are given in Sec-tions 9 through 12.

8. Retest8.1 If the results of any test fail to meet the requirement,that test shall be repeated twice. The results of both testsshall meet the requirement. Specimens or samples for re-test may be taken from the original test assembly or sam-ple, or from a new test assembly or sample. For chemicalanalysis, retest need be only for those specific elementsthat failed to meet the test requirement.

8.2 If the results of one or both retests fail to meet the re-quirement, the material under test shall be considered asnot meeting the requirements of this specification for thatclassification.

Table 1Chemical Composition Requirements for Core Wire

AWS Classificationf

UNS Designationc

Weight Percenta,b

Si Fe Cu Mn Mg Zn Ti Be

Other Elements

AlEach Total

E1100 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 Remaindera 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 limitsspecified 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 and the sum of all other metallic elements present in

amounts of 0.010 percent or more each, expressed to the second decimal before determining the sum.f Refer to Table A1 for Proposed ISO Designations.

AWS A5.3/A5.3M:1999 (R2007)

3

8.3 In the event that, during preparation or after comple-tion of any test, it is clearly determined that prescribed orproper procedures were not followed in preparing theweld test assembly or test specimens or in conducting thetest, the test shall be considered invalid, without regardto whether the test was actually completed, or whetherthe 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-bling the number of test specimens does not apply.

9. Weld Test Assembly9.1 One weld test assembly is required as specified inTable 2. It is the groove weld in Figure 1 for mechanicalproperties.

9.2 Preparation of the weld test assembly shall be as pre-scribed in 9.3, Figure 1, and Table 2 (Notes e and f) usingbase metal of the appropriate type specified in Table 3.Testing of the assembly shall be as specified in Sections11, Tension Test, and 12, Bend Test. The assembly shallbe tested in the as-welded condition.

9.3 The test assembly shall be preheated to a temperaturebetween 350° and 400°F [175° and 200°C], and shieldedmetal arc (SMA) welded from one side, in the flat posi-

tion. The test assembly should be precambered or re-strained so that warping due to welding will not cause thefinished test assembly to be out-of-plane by more than5 degrees. If the completed test assembly is more than5 degrees out-of-plane it shall be straightened at roomtemperature.

10. Chemical Analysis10.1 A sample of the core wire, or the stock from whichit is made, shall be prepared for chemical analysis.

10.2 The sample shall be analyzed by accepted analyticalmethods. The referee method shall be ASTM E 34, Stan-dard Methods for Chemical Analysis of Aluminum andAluminum Alloys.

10.3 The results of the analysis shall meet the require-ments of Table 1 for the classification of electrode undertest.

11. Tension Test11.1 Two transverse rectangular tension test specimensshall be machined from the groove weld described inSection 9, Weld Test Assembly, and shown in Figure 1.

Table 2Required Tests

AWS Classification

Electrode Size

Chemical Analysisa Tension Testb Bend Testcin. mm

E1100, E3003, and E4043

3/32

1/85/32

2.42.53.24.0

RequiredRequiredRequiredRequired

Not Requiredd

Not Requiredd

Not Requiredd

Requirede

Not Requiredd

Not Requiredd

Not Requiredd

Requirede

3/16

1/45/163/8

4.85.06.06.48.09.5

RequiredRequiredRequiredRequiredRequiredRequired

Not Requiredd

Not Requiredd

Requiredf

Requiredf

Not Requiredd

Not Requiredd

Not Requiredd

Not Requiredd

Requiredf

Requiredf

Not Requiredd

Not Requiredd

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. [6.0 or 6.4 mm] size of the same

classification.

AWS A5.3/A5.3M:1999 (R2007)

4

Figure 1—Groove Weld Test Assembly for Mechanical Properties

AWS A5.3/A5.3M:1999 (R2007)

5

The dimensions of the specimens shall be as specified inthe tension test section of AWS B4.0, Standard Methodsfor Mechanical Testing of Welds. All dimensions shall bethe same as shown in the AWS B4.0 figure for transverserectangular tension test specimens (plate) except the re-duced section radius shall be 2 in. [50 mm].

11.2 The specimens shall be tested in the manner de-scribed in the tension test section of ANSI/AWS B4.0,Standard Methods for Mechanical Testing of Welds.

11.3 The results of the tension test shall meet the require-ments specified in Table 4.

12. Bend Test12.1 One transverse face and one transverse root bendspecimen, as required in Table 2, shall be machined fromthe groove weld test assembly described in Section 9 andshown in Figure 1. The dimensions of these bend speci-mens shall be the same as those shown in the bend testsection of AWS B4.0 in the figure for transverse face andtransverse root-bend specimens (plate).

12.2 The specimens shall be tested in the manner de-scribed in the guided bend test section of ANSI/AWSB4.0 by bending them uniformly through 180 degreesover a 1-1/4 in. [32 mm] radius in any suitable jig. Typi-cal bend test jigs as shown in bend test section of AWSB4.0 shall be used. Positioning of the face-bend speci-men shall be such that the face of the weld is in tension.Positioning of the root-bend specimen shall be such thatthe root of the weld is in tension. For both types of trans-verse bend specimen, the weld shall be at the center ofthe bend.

12.3 Each specimen, after bending, shall conform to the1-1/4 in. [32 mm] radius, with an appropriate allowancefor spring back, and the weld metal shall show no crackor other open defect exceeding 1/8 in. [3.2 mm] mea-sured in any direction on the convex surface, when ex-amined with the unaided eye. Cracks that occur on thecorners of a specimen during testing and which show noevidence of inclusions or other fusion-type discontinui-ties, shall be disregarded.

Part CManufacture, Identification, and

Packaging

13. Method of ManufactureThe electrodes classified according to this specifi-

cation may be manufactured by any method that willproduce electrodes that meet the requirements of thisspecification.

14. Standard Sizes and Lengths14.1 Standard sizes (diameter of the core wire) andlengths of electrodes are shown in Table 5. Other sizesand lengths meet the requirements of this specificationwhen agreed by the purchaser and supplier.

14.2 The diameter of the core wire shall not vary morethan ±0.002 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 Covering15.1 The core wire and covering shall be free of defectsthat would interfere with uniform deposition of theelectrode.

Table 3Base Metal for Test Assemblies

Electrode Base Metal

AWS Classification

Aluminum Alloya

ASTM Specification

UNS Designation

E1100E3003, E4043

1100b3003b

B209B209

A91100A93003

a Aluminum Association, Inc. registration numbers.b When welding 3003 with E4043 electrodes, 3003-0 (annealed temper)

plate is preferred.

Table 4Tension Test Requirements

AWS Classification

Tensile Strength, min.a

psi MPa

E1100E3003E4043

12 00014 00014 000

809595

a Fracture may occur in either the base metal or the weld metal.

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15.2 The core wire and the covering shall be concentricto the extent that the maximum core-plus-one-coveringdimension shall not exceed the minimum core-plus-one-covering dimension by more than the following:

(1) Seven percent of the mean dimension in sizes3/32 in. [2.4 and 2.5 mm]

(2) Five percent of the mean dimension in sizes 1/8and 5/32 in. [3.2 and 4.0 mm]

(3) Four percent of the mean dimension in sizes3/16 in. [4.8 mm] and largerConcentricity may be measured by any suitable means.

15.3 The coverings shall be such that they are not readilydamaged by ordinary handling and the coverings shallnot blister when heated to 400°F [200°C]. They shall beconsumed uniformly during welding, and they also shallnot blister or melt back from the core wire. The flux resi-due they produce shall be readily removable.

16. Exposed Core16.1 The grip end of each electrode shall be bare (free ofcovering) for a distance of not less than 1/2 in. [12 mm],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]nor more than 1-1/2 in. [38 mm] for electrodes 3/16 in.[4.8 mm] and larger, to provide for electrical contact withthe electrode holder.

16.2 The arc end of each electrode shall be sufficientlybare and the covering sufficiently tapered to permit easystriking of the arc. The length of the bare portion (mea-sured from the end of the core wire to the location where

the full cross-section of the covering is obtained) shallnot exceed 1/8 in. [3 mm] or the diameter of the corewire, whichever is less. Electrodes with chipped cover-ings near the arc end, baring the core wire no more thanthe lesser of 1/4 in. [6 mm] or twice the diameter of thecore wire, meet the requirements of this specification,provided no chip uncovers more than 50% of the circum-ference of the core.

17. Electrode IdentificationAll electrodes shall be identified as follows:

17.1 At least one imprint of the electrode classificationshall be applied to the electrode covering within 2-1/2 in.[65 mm] of the grip end of the electrode.

17.2 The numbers and letters of the imprint shall be ofbold block type of a size large enough to be legible.

17.3 The ink used for imprinting shall provide sufficientcontrast with the electrode covering so that, in normaluse, the numbers and letters are legible both before andafter welding.

17.4 The prefix letter E in the electrode classificationmay be omitted from the imprint.

17.5 In lieu of imprinting, electrodes may be identifiedby the following:

(1) Attaching to the bare grip end of each electrode apressure sensitive tape bearing the classification number

(2) Embossing the classification number on the baregrip end of each electrode. In this case, a slight flattening

Table 5Standard Sizes

AWS Classification

Diameter of Core Wire Standard Lengths

in. mm in. mm

E1100, E3003, and E4043

3/32

1/85/323/16

1/4

(0.094)(0.098)(0.125)(0.156)(0.188)(0.197)(0.236)(0.250)

a2.4a

2.53.24.0

a4.8a

5.06.0

a6.4a

14 350

5/163/8

(0.312)(0.375)

8.0a9.5a

18 450

a These sizes are not included in ISO 544.

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of the grip end will be permitted in the area of theembossing.

18. Packaging18.1 Electrodes shall be suitably packaged to protectthem from damage during shipment and storage undernormal conditions.

18.2 Standard package net weights shall be 1 lb [0.5 kg],5 lb [2.5 kg], and 10 lb [5 kg]. Other package weightsmeet the requirements of this specification when agreedby the purchaser and supplier.

19. Marking of Packages19.1 The following product information (as a minimum)shall be legibly marked on the outside of each unitpackage:

(1) AWS specification and classification designations(year of issue may be excluded)

(2) Supplier’s name and trade designation(3) Size and net weight(4) Lot, control, or heat number

19.2 The following precautionary information (as a mini-mum) shall be prominently displayed in legible print onall packages of electrodes, including individual unitpackages enclosed within a larger package.

WARNING:

PROTECT yourself and others. Read and understand thisinformation.

FUMES AND GASES can be hazardous to your health.

ARC RAYS can injure eyes and burn skin.

ELECTRIC SHOCK can KILL.

• Before use, read and understand the manufacturer’s in-structions, Material Safety Data Sheets (MSDSs), andyour employer’s safety practices.

• Keep your head out of the fumes.

• Use enough ventilation, exhaust at the arc, or both, tokeep fumes and gases away from your breathing zoneand the general area.

• Wear correct eye, ear, and body protection.

• Do not touch live electrical parts.

• See American National Standard ANSI Z49.1, Safetyin Welding, Cutting, and Allied Processes, publishedby the American Welding Society, 550 N.W. LeJeuneRoad, Miami, FL 33126; and OSHA Safety and HealthStandards, available from the Superintendent of Doc-uments, U.S. Government Printing Office, Washing-ton, DC 20402. Phone: (202) 512-1800.

DO NOT REMOVE THIS INFORMATION

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9

AWS A5.3/A5.3M:1999 (R2007)

A1. IntroductionThe purpose of this guide is to correlate the electrode

classifications with their intended applications so thespecification can be used effectively. Reference to appro-priate base metal specifications is made whenever thatcan be done and when it would be helpful. Such refer-ences are intended only as examples rather than completelistings of the materials for which each filler metal issuitable.

A2. Classification SystemA2.1 The system for identifying the electrode classifica-tions in this specification follows the standard patternused in other AWS filler metal specifications. The letterE at the beginning of each classification designationstands for electrode. The numerical portion of the desig-nation in this specification conforms to the AluminumAssociation registration for the composition of the corewire used in the electrode.

A2.2 An international system for designating weldingfiller metals is under development by the InternationalInstitute of Welding (IIW) for use in future specificationsto be issued by the International Standards Organization(ISO). Table A1 shows the proposed designations foraluminum filler metals. In that system the initial “E” des-ignates a covered electrode, the letter “A” the alloy sys-tem, followed by a four-digit number. For wroughtaluminum alloys, the four-digit number is the same asthat commonly recognized worldwide.

A3. AcceptanceAcceptance of all welding materials classified under

this specification is in accordance with ANSI/AWSA5.01, Filler Metal Procurement Guidelines, as the spec-ification states. Any testing a purchaser requires of thesupplier, for material shipped in accordance with thisSpecification, shall be clearly stated in the purchase or-der, according to the provisions of ANSI/AWS A5.01. Inthe absence of any such statement in the purchase order,the supplier may ship the material with whatever testingnormally is performed on material of that classification,as specified in Schedule F, Table 1, of ANSI/AWSA5.01. Testing in accordance with any other Schedule inthat Table shall be specifically required by the purchaseorder. In such cases, acceptance of the material shippedshall be in accordance with those requirements.

A4. CertificationThe act of placing the AWS specification and classifi-

cation designations on the packaging enclosing the prod-uct, or the classification on the product itself, constitutesthe supplier’s (manufacturer’s) certification that the prod-uct meets all of the requirements of the specification.

The only testing requirement implicit in this certifica-tion is that the manufacturer has actually conducted thetests required by the specification on material that is rep-resentative of that being shipped and that material metthe requirements of the specification. Representative ma-terial, in this case, is any production run of that classifi-cation using the same formulation. “Certification” is not

Annex A (Informative)

Guide to Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding

This annex is not part of AWS A5.3/A5.3M:1999 (R2007), Specification for Aluminum and Aluminum-AlloyElectrodes for Shielded Metal Arc Welding, but is included for informational purposes only.

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to be construed to mean that tests of any kind were nec-essarily conducted on samples of the specific materialshipped. Tests on such material may or may not havebeen conducted. The basis for the certification requiredby the specification is the classification test of “represen-tative material” cited above, and the “Manufacturer’sQuality Assurance Program” in ANSI/AWS A5.01.

A5. Ventilation During WeldingA5.1 Five major factors govern the quantity of fumes inthe atmosphere to which welders and welding operatorsare exposed during welding:

(1) Dimensions of the space in which welding is done(with special regard to the height of the ceiling)

(2) Number of welders and welding operators work-ing in that space

(3) Rate of evolution of fumes, gases, or dust, accord-ing to the materials and processes used

(4) The proximity of the welders or welding opera-tors to the fumes as the fumes issue from the weldingzone, and to the gases and dusts in the space in whichthey are working

(5) The ventilation provided to the space in which thewelding is done.

A5.2 American National Standard ANSI Z49.1, Safety inWelding, Cutting, and Allied Processes (published by theAmerican Welding Society), discusses the ventilationthat is required during welding and should be referred tofor details. Attention is drawn particularly to the Sectionof that document on Health Protection and Ventilation.

A6. Welding ConsiderationsA6.1 Welding aluminum by the shielded metal arc pro-cess is a well established practice. However, develop-

ment of the gas shielded arc welding processes and themany advantages these processes offer has caused a shiftaway from the use of covered electrodes. When shieldedmetal arc welding, a flux-covered electrode is held in thestandard electrode holder, and welding is done with di-rect current, electrode positive (DCEP). Important fac-tors to be considered when welding aluminum withcovered electrodes are moisture content of the electrodecovering, and cleanliness of the electrode and base metal.Preheat is usually required to obtain good fusion and toimprove soundness of the weld. Residual flux removalbetween passes is required to provide improved arc sta-bility and weld fusion. Complete removal of the residualflux after welding is necessary to avoid corrosive attackin service.

A6.2 The presence of moisture in the electrode coveringis a major cause of weld porosity. Dirt, grease, or othercontamination of the electrode can also contribute to po-rosity. The absorption of moisture by the covering can bequite rapid, and the covering can deteriorate after only afew hours exposure to a humid atmosphere. For this rea-son, the electrodes should be stored in a dry, clean loca-tion. Electrodes taken from previously opened packagesor those exposed to moisture should be “conditioned” byholding them at 350° to 400°F [175° to 200°C] for anhour before welding. After conditioning, they should bestored in a heated cabinet at 150° to 200°F [65° to 95°C]until used.

A6.3 The minimum base metal thickness recommendedfor shielded metal arc welding of aluminum is 1/8 in.[3.2 mm]. For thicknesses less than 1/4 in. [6.4 mm], noedge preparation other than a relatively smooth, squarecut is required. Material over 1/4 in. [6.4 mm] should bebeveled to a single-V-groove with a 60 to 90-degree in-cluded angle. On very thick material, U-grooves may beused. Depending upon base metal gauge, root-face thick-nesses range between 1/16 and 1/4 in. [1.6 and 6.4 mm].

Table A1Designation Reference Guide

AWS Composition Designationa UNS Number Proposed ISO Designationb AWS Classification Numberc

110030034043

A91100A93003A94043

EA1100EA3003EA4043

E1100E3003E4043

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-1232-91) 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.

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A root opening of 1/32 to 1/16 in. [0.8 to 1.6 mm] is de-sirable for all groove welds.

A6.4 Because of the high thermal conductivity of alumi-num, preheating to 250° to 400°F [120° to 200°C] isnearly always necessary on thick material to maintain theweld pool and obtain proper fusion. Preheating will alsohelp to avoid porosity due to too rapid cooling of the weldpool at the start of the weld. On complex assemblies, pre-heating is useful in avoiding distortion. Preheating may bedone by torch using oxygen and acetylene or other suit-able fuel gas, or by electrical resistance heating. Mechani-cal properties of 6XXX series aluminum-alloy weldmentscan be reduced significantly if the higher preheating tem-peratures, 350°F [175°C] or higher, are applied.

A6.5 Single-pass SMA welds should be made wheneverpossible. However, where thicker plates require multiplepasses, thorough cleaning between passes is essential foroptimum results. After the completion of any welding,the weld and work should be thoroughly cleaned ofresidual flux. The major portion of the residual flux canbe removed by mechanical means, such as a rotary wirebrush, slag hammer, or peening hammer, and the rest bysteaming or a hot-water rinse. The test for complete re-moval of residual flux is to swab a solution of five-percent silver nitrate on the weld areas. Foaming willoccur if residual flux is present.

A6.6 Interruption of the arc when shielded metal arcwelding aluminum can cause the formation of a fusedflux coating over the end of the electrode. Reestablishinga satisfactory arc is impossible unless this formation isremoved.

A7. Description and Intended Use of Electrodes

A7.1 Electrodes of the E1100 classification produceweld metal of high ductility, good electrical conductivity,and a minimum tensile strength of 12 000 psi (80 MPa).E1100 electrodes are used to weld 1100, 1350(EC), andother commercially pure aluminum alloys.

A7.2 Electrodes of the E3003 classification produceweld metal of high ductility and a minimum tensilestrength of 14 000 psi [95 MPa]. E3003 electrodes areused to weld aluminum alloys 1100 and 3003.

A7.3 The E4043 classification contains approximatelyfive-percent silicon, which provides superior fluidity atwelding temperatures, and for this reason is preferred forgeneral purpose welding. The E4043 classification pro-duces weld metal with fair ductility and a minimum ten-sile strength of 14 000 psi [95 MPa]. E4043 electrodescan be used to weld the 6XXX series aluminum alloys,

the 5XXX series aluminum alloys (up to 2.5-percent Mgcontent), and aluminum-silicon casting alloys, as well asaluminum base metals 1100, 1350(EC), and 3003.

A7.4 For many aluminum applications, corrosion resis-tance of the weld is of prime importance. In such cases, itis advantageous to choose an electrode with a composi-tion as close as practical to that of the base metal. Forthis use, covered electrodes for base metals other than1100 and 3003 usually are not stocked and must be spe-cially ordered. For applications where corrosion resis-tance is important, it may be advantageous to use one ofthe gas shielded arc welding processes for which a widerrange of filler metal compositions is available.

A8. Special TestsIt is recognized that supplementary tests may be re-

quired for certain applications. In such cases, tests to de-termine specific properties such as corrosion resistance,electrical conductivity, mechanical properties at elevatedor cryogenic temperatures, and suitability for weldingdifferent combinations of aluminum base alloys may berequired.

A9. Chemical AnalysisThe accepted and most widely used method for chem-

ical analysis is found in ASTM E 227, Optical EmissionSpectrometric Analysis of Aluminum and AluminumAlloy by the Point-to-Plane Technique. This method ana-lyzes a bulk sample and all elements simultaneously. TheASTM E 34, Test Method for Chemical Analysis of Alu-minum and Aluminum Alloy, prescribes individual testmethods for which each element is tested. The ASTM E34 test methods are used as a referee method if a disputearises concerning a specific element analysis.

A10. General Safety ConsiderationsA10.1 Burn Protection. Molten metal, sparks, slag, andhot work surfaces are produced by welding, cutting, andallied processes. These can cause burns if precautionarymeasures are not used. Workers should wear protectiveclothing made of fire-resistant material. Pant cuffs, openpockets, or other places on clothing that can catch and re-tain molten metal or sparks should not be worn. High-topshoes or leather leggings and fire-resistant gloves shouldbe worn. Pant legs should be worn over the outside ofhigh-top shoes. Helmets or hand shields that provide pro-tection for the face, neck, and ears, and a head covering

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to protect the head should be used. In addition, appropri-ate eye protection should be used.

When welding overhead or in confined spaces, earplugs to prevent weld spatter from entering the ear canalshould be worn. Goggles or equivalent should also beworn to protect eyes. Clothing should be kept free ofgrease and oil. Combustible materials should not be car-ried in pockets. If any combustible substance has beenspilled on clothing, a change to clean, fire-resistant cloth-ing should be made before working with open arcs orflame. Aprons, cape-sleeves, leggings, and shoulder cov-ers with bibs designed for welding service should beused.

Where welding or cutting of unusually thick basemetal is involved, sheet metal shields should be used forextra protection. Mechanization of highly hazardous pro-cesses or jobs should be considered. Other personnel inthe work area should be protected by the use of noncom-bustible screens or by the use of appropriate protection asdescribed in the previous paragraph. Before leaving awork area, hot work pieces should be marked to alertother persons of this hazard. No attempt should be madeto repair or disconnect electrical equipment when it isunder load. Disconnection under load produces arcing ofthe contacts and may cause burns or shock, or both.(Note: Burns can be caused by touching hot equipmentsuch as electrode holders, tips, and nozzles. Therefore,insulated gloves should be worn when these items arehandled, unless an adequate cooling period has been al-lowed before touching.)

The following sources are for more detailed informa-tion on personal protection:

(1) ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, published by the American Welding Society,550 N.W. LeJeune Road, Miami, FL 33126.

(2) Code of Federal Regulations, Title 29 Labor,Chapter XVII, Part 1910, OSHA General Industry Stan-dards available from the U.S. Government Printing Of-fice, Washington, DC 20402.

(3) ANSI/ASC Z87.1, Practice for Occupational andEducational Eye and Face Protection, American Na-tional Standards Institute, 11 West 42nd Street, NewYork, NY 10036-8002.

(4) ANSI Z41, American National Standard for Per-sonal Protection—Protective Footwear, American Na-tional Standards Institute, 11 West 42nd Street, NewYork, NY 10036-8002.

A10.2 Electrical Hazards. Electric shock can kill. How-ever, it can be avoided. Live electrical parts should notbe touched. The manufacturer’s instructions and recom-mended safe practices should be read and understood.Faulty installation, improper grounding, and incorrectoperation and maintenance of electrical equipment are allsources of danger.

All electrical equipment and the workpieces should begrounded. The workpiece lead is not a ground lead. It isused only to complete the welding circuit. A separate con-nection is required to ground the workpiece. The work-piece should not be mistaken for a ground connection.

The correct cable size should be used, since sustainedoverloading will cause cable failure and result in possibleelectrical shock or fire hazard. All electrical connectionsshould be tight, clean, and dry. Poor connections canoverheat and even melt. Further, they can produce dan-gerous arcs and sparks. Water, grease, or dirt should notbe allowed to accumulate on plugs, sockets, or electricalunits. Moisture can conduct electricity. To prevent shock,the work area, equipment, and clothing should be keptdry at all times. Welders should wear dry gloves and rub-ber soled shoes, or stand on a dry board or insulated plat-form. Cables and connections should be kept in goodcondition. Improper or worn electrical connections maycreate conditions that could cause electrical shock orshort circuits. Worn, damaged, or bare cables should notbe used. Open-circuit voltage should be avoided. Whenseveral welders are working with arcs of different polari-ties, or when a number of alternating-current machinesare being used, the open-circuit voltages can be additive.The added voltages increase the severity of the shockhazard.

In case of electric shock, the power should be turnedoff. If the rescuer must resort to pulling the victim fromthe live contact, nonconducting materials should be used.If the victim is not breathing, cardiopulmonary resuscita-tion (CPR) should be administered as soon as contactwith the electrical source is broken. A physician shouldbe called and CPR continued until breathing has been re-stored, or until a physician has arrived. Electrical burnsare treated as thermal burns; that is, clean, cold (iced)compresses should be applied. Contamination should beavoided; the area should be covered with a clean, drydressing; and the patient should be transported to medi-cal assistance.

Recognized safety standards such as ANSI Z49.1,Safety in Welding, Cutting, and Allied Processes; the Na-tional Electrical Code; and NFPA No. 70, available fromNational Fire Protection Association, 1 BatterymarchPark, Quincy, MA 02269, should be followed.

A10.3 Fumes and Gases. Many welding, cutting, and al-lied processes produce fumes and gases which may beharmful to health. Fumes are solid particles which origi-nate from welding filler metals and fluxes, the basemetal, and any coatings present on the base metal. Gasesare produced during the welding process or may be pro-duced by the effects of process radiation on the surround-ing environment. Management, personnel and weldersalike should be aware of the effects of these fumes andgases. The amount and composition of these fumes and

AWS A5.3/A5.3M:1999 (R2007)

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gases depend upon the composition of the filler metaland base metal, welding process, flux, current level, arclength, and other factors. Fluxes, used for oxyfuel gaswelding of aluminum alloys, are composed primarily ofchlorides plus small fluoride additions. The coatingsused in covered electrodes of the types shown in thisspecification A5.3/A5.3M contain both chlorides andfluorides.

The possible effects of overexposure range from irri-tation of eyes, skin, and respiratory system to more se-vere complications. Effects may occur immediately or atsome later time. Fumes can cause symptoms such as nau-sea, headaches, dizziness, and metal fume fever. Thepossibility of more serious health effects exists when es-pecially toxic materials are involved. In confined spaces,the fumes might displace breathing air and cause asphyx-iation. One’s head should always be kept out of thefumes. Sufficient ventilation, exhaust at the arc or flame,or both, should be used to keep fumes and gases fromyour breathing zone and the general area.

In some cases, natural air movement will provideenough ventilation. Where ventilation may be question-able, air sampling should be used to determine if correc-tive measures should be applied.

All aluminum electrodes possess a compositionalcontrol of 0.0008 percent maximum beryllium content.This provides a check by the manufacturer that the fillermetal is essentially free of this element and thus avoidsthe presence of concentrations of this highly toxic metal-lic particulate during the filler metal transfer across thearc. Since the electrode core wire is fabricated as drawn,wrought aluminum wire, the same beryllium control hasbeen applied to all filler metals covered by this ANSI/AWS A5.3/A5.3M specification. Thus all electrodes pos-sess a 0.0008 percent beryllium maximum limit.

More detailed information on fumes and gases pro-duced by the various welding processes may be found inthe following:

(1) The permissible exposure limits required byOSHA can be found in CFR Title 29, Chapter XVII Part1910. The OSHA General Industry Standards are avail-able from the Superintendent of Documents, U.S. Gov-ernment Printing Office, Washington, DC 20402.

(2) The recommended threshold limit values forthese fumes and gases may be found in Threshold LimitValues for Chemical Substances and Physical Agents inthe Workroom Environment, published by the AmericanConference of Governmental Industrial Hygienists(ACGIH), 1330 Kemper Meadow Drive, Suite 600, Cin-cinnati, OH 45240-1643.

(3) The results of an AWS-funded study are availablein a report entitled, Fumes and Gases in the WeldingEnvironment, available from the American WeldingSociety, 550 N.W. LeJeune Road, Miami, FL 33126.

A10.4 Radiation. Welding, cutting, and allied operationsmay produce radiant energy (radiation) harmful tohealth. One should become acquainted with the effects ofthis radiant energy.

Radiant energy may be ionizing (such as x-rays), ornonionizing (such as ultraviolet, visible light, or infra-red). Radiation can produce a variety of effects such asskin burns and eye damage, depending on the radiant en-ergy’s wavelength and intensity, if excessive exposureoccurs.

A10.4.1 Ionizing Radiation. Ionizing radiation isproduced by the electron beam welding process. It is or-dinarily controlled within acceptance limits by use ofsuitable shielding enclosing the welding area.

A10.4.2 Nonionizing Radiation. The intensity andwavelengths of nonionizing radiant energy produced de-pend on many factors, such as the process, welding pa-rameters, electrode and base metal composition, fluxes,and any coating or plating on the base metal. Some pro-cesses such as resistance welding and cold pressurewelding ordinarily produce negligible quantities of radi-ant energy. However, most arc welding and cutting pro-cesses (except submerged arc when used properly), laserbeam welding and torch welding, cutting, brazing, or sol-dering can produce quantities of nonionizing radiationsuch that precautionary measures are necessary.

Protection from possible harmful effects caused bynonionizing radiant energy from welding include the fol-lowing measures:

(1) One should not look at welding arcs exceptthrough welding filter plates which meet the require-ments of ANSI/ASC Z87.1, Practice for Occupationaland Education Eye and Face Protection, published byAmerican National Standards Institute, 11 West 42ndStreet, New York, NY 10036-8002. It should be notedthat transparent welding curtains are not intended aswelding filter plates, but rather are intended to protectpassersby from incidental exposure.

(2) Exposed skin should be protected with adequategloves and clothing as specified in ANSI Z49.1, Safety inWelding, Cutting, and Allied Processes, published byAmerican Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126.

(3) Reflections from welding arcs should be avoided,and all personnel should be protected from intense re-flections. (Note: Paints using pigments of substantiallyzinc oxide or titanium dioxide have a lower reflectancefor ultraviolet radiation.)

(4) Screens, curtains, or adequate distance fromaisles, walkways, etc., should be used to avoid exposingpassersby to welding operations.

AWS A5.3/A5.3M:1999 (R2007)

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(5) Safety glasses with UV-protective side shieldshave been shown to provide some beneficial protectionfrom ultraviolet radiation produced by welding arcs.

A10.4.3 Ionizing radiation information sourcesinclude:

(1) AWS F2.1-78, Recommended Safe Practices forElectron Beam Welding and Cutting, available from theAmerican Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126.

(2) Manufacturer’s product information literature.

A10.4.4 Nonionizing radiation information sourcesinclude:

(1) Hinrichs, J. F., Project Committee on Radiation—summary report. Welding Journal, January 1978.

(2) Nonionizing Radiation Protection Special StudyNo. 42-0053-77, Evaluation of the Potential Hazardsfrom Actinic Ultraviolet Radiation Generated by ElectricWelding and Cutting Arcs, available from the NationalTechnical Information Service, Springfield, VA 22161,ADA-033768.

(3) Nonionizing Radiation Protection Special StudyNo. 42-0312-77, Evaluation of the Potential Retina

Hazards from Optical Radiation Generated by ElectricWelding and Cutting Arcs, available from the NationalTechnical Information Service, Springfield, VA 22161,ADA-043023.

(4) Moss, C. E., and Murray, W. E. Optical RadiationLevels Produced in Gas Welding, Torch Brazing, andOxygen Cutting. Welding Journal, September 1979.

(5) Optical Radiation Levels Produced by Air-Carbon Arc Cutting Processes, Welding Journal, March1980.

(6) ANSI/ASC Z136.1, Safe Use of Lasers, publishedby American National Standards Institute, 11 West 42ndStreet, New York, NY 10036-8002.

(7) ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, published by the American Welding Society,550 N.W. LeJeune Road, Miami, FL 33126.

(8) ANSI/ASC Z87.1, Practice for Occupational andEducational Eye and Face Protection, published byAmerican National Standards Institute, 11 West 42ndStreet, New York, NY 10036-8002.

(9) Moss, C. E. Optical Radiation Transmission Lev-els through Transparent Welding Curtains, Welding Jour-nal, March 1979.

15

AWS A5.3/A5.3M:1999 (R2007)

B1. IntroductionThe American Welding Society (AWS) Board of

Directors has adopted a policy whereby all official inter-pretations of AWS standards are handled in a formalmanner. Under this policy, all interpretations are madeby the committee that is responsible for the standard.Official communication concerning an interpretation isdirected through the AWS staff member who works withthat committee. The policy requires that all requests foran interpretation be submitted in writing. Such requestswill be handled as expeditiously as possible, but due tothe complexity of the work and the procedures that mustbe followed, some interpretations may require consider-able time.

B2. ProcedureAll inquiries shall be directed to:

Managing DirectorTechnical Services DivisionAmerican Welding Society550 N.W. LeJeune RoadMiami, FL 33126

All inquiries shall contain the name, address, andaffiliation of the inquirer, and they shall provide enoughinformation for the committee to understand the point ofconcern in the inquiry. When the point is not clearlydefined, the inquiry will be returned for clarification. Forefficient handling, all inquiries should be typewritten andin the format specified below.

B2.1 Scope. Each inquiry shall address one single provi-sion of the standard unless the point of the inquiry

involves two or more interrelated provisions. The provi-sion(s) shall be identified in the scope of the inquiryalong with the edition of the standard that contains theprovision(s) the inquirer is addressing.

B2.2 Purpose of the Inquiry. The purpose of the inquiryshall be stated in this portion of the inquiry. The purposecan be to obtain an interpretation of a standard’s require-ment or to request the revision of a particular provisionin the standard.

B2.3 Content of the Inquiry. The inquiry should beconcise, yet complete, to enable the committee to under-stand the point of the inquiry. Sketches should be usedwhenever appropriate, and all paragraphs, figures, andtables (or annex) that bear on the inquiry shall be cited. Ifthe point of the inquiry is to obtain a revision of the stan-dard, the inquiry shall provide technical justification forthat revision.

B2.4 Proposed Reply. The inquirer should, as aproposed reply, state an interpretation of the provisionthat is the point of the inquiry or provide the wording fora proposed revision, if this is what the inquirer seeks.

B3. Interpretation of Provisions of the Standard

Interpretations of provisions of the standard are madeby the relevant AWS technical committee. The secretaryof the committee refers all inquiries to the chair of theparticular subcommittee that has jurisdiction over theportion of the standard addressed by the inquiry. Thesubcommittee reviews the inquiry and the proposed replyto determine what the response to the inquiry should

Annex B (Informative)

Guidelines for the Preparation of Technical Inquiries

This annex is not part of AWS A5.3/A5.3M:1999 (R2007), Specification for Aluminum and Aluminum-AlloyElectrodes for Shielded Metal Arc Welding, but is included for informational purposes only.

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be. Following the subcommittee’s development of theresponse, the inquiry and the response are presented tothe entire committee for review and approval. Uponapproval by the committee, the interpretation is an officialinterpretation of the Society, and the secretary transmitsthe response to the inquirer and to the Welding Journalfor publication.

B4. Publication of InterpretationsAll official interpretations will appear in the Welding

Journal and will be posted on the AWS web site.

B5. Telephone InquiriesTelephone inquiries to AWS Headquarters concern-

ing AWS standards should be limited to questions of ageneral nature or to matters directly related to the use ofthe standard. The AWS Board Policy Manual requiresthat all AWS staff members respond to a telephone

request for an official interpretation of any AWS stan-dard with the information that such an interpretation canbe obtained only through a written request. Headquartersstaff cannot provide consulting services. However, thestaff can refer a caller to any of those consultants whosenames are on file at AWS Headquarters.

B6. AWS Technical CommitteesThe activities of AWS technical committees regarding

interpretations are limited strictly to the interpretation ofprovisions of standards prepared by the committees or toconsideration of revisions to existing provisions on thebasis of new data or technology. Neither AWS staff northe committees are in a position to offer interpretive orconsulting services on (1) specific engineering problems,(2) requirements of standards applied to fabricationsoutside the scope of the document, or (3) points notspecifically covered by the standard. In such cases, theinquirer should seek assistance from a competent engi-neer experienced in the particular field of interest.

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AWS Filler Metal Specifications by Material and Welding Process

OFW SMAW

GTAWGMAW

PAW FCAW SAW ESW EGW Brazing

Carbon Steel A5.20 A5.10 A5.18 A5.20 A5.17 A5.25 A5.26 A5.8, A5.31

Low-Alloy Steel A5.20 A5.50 A5.28 A5.29 A5.23 A5.25 A5.26 A5.8, A5.31

Stainless Steel A5.40 A5.9, A5.22 A5.22 A5.90 A5.90 A5.90 A5.8, A5.31

Cast Iron A5.15 A5.15 A5.15 A5.15 A5.8, A5.31

Nickel Alloys A5.11 A5.14 A5.14 A5.8, A5.31

Aluminum Alloys A5.30 A5.10 A5.8, A5.31

Copper Alloys A5.60 A5.70 A5.8, A5.31

Titanium Alloys A5.16 A5.8, A5.31

Zirconium Alloys A5.24 A5.8, A5.31

Magnesium Alloys A5.19 A5.8, A5.31

Tungsten Electrodes A5.12

Brazing Alloys and Fluxes A5.8, A5.31

Surfacing Alloys A5.21 A5.13 A5.21 A5.21 A5.21

Consumable Inserts A5.30

Shielding Gases A5.32 A5.32 A5.32

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AWS A5.3/A5.3M:1999 (R2007)

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AWS Filler Metal Specifications and Related Documents

Designation Title

FMC Filler Metal Comparison Charts

IFS International Index of Welding Filler Metal Classifications

UGFM User’s Guide to Filler Metals

A4.2M (ISO 8249:2000 MOD)

Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content Austenitic andDuplex Ferritic-Austenitic Stainless Steel Weld Metal

A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic SteelWeld Metal Produced by Arc Welding

A4.4M Standard Procedures for Determination of Moisture Content of Welding Fluxes and Welding Electrode Flux Coverings

A5.01 Filler Metal Procurement Guidelines

A5.02/A5.02M Specification for Filler Metal Standard Sizes, Packaging, and Physical Attributes

A5.1/A5.1M Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding

A5.2/A5.2M Specification for Carbon and Low Alloy Steel Rods for Oxyfuel Gas Welding

A5.3/A5.3M Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding

A5.4/A5.4M Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding

A5.5/A5.5M 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/A5.8M Specification for Filler Metals for Brazing and Braze Welding

A5.9/A5.9M Specification for Bare Stainless Steel Welding Electrodes and Rods

A5.10/A5.10M 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 Surfacing Electrodes for Shielded Metal Arc Welding

A5.14/A5.14M Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods

A5.15 Specification for Welding Electrodes and Rods for Cast Iron

A5.16/A5.16M Specification for Titanium and Titanium Alloy Welding Electrodes and Rods

A5.17/A5.17M Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding

A5.18/A5.18M Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding

A5.19 Specification for Magnesium Alloy Welding Electrodes and Rods

A5.20/A5.20M Specification for Carbon Steel Electrodes for Flux Cored Arc Welding

A5.21 Specification for Bare Electrodes and Rods for Surfacing

A5.22 Specification for Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods forGas Tungsten Arc Welding

A5.23/A5.23M Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding

A5.24/A5.24M Specification for Zirconium and Zirconium Alloy Welding Electrodes and Rods

A5.25/A5.25M Specification for Carbon and Low-Alloy Steel Electrodes and Fluxes for Electroslag Welding

A5.26/A5.26M Specification for Carbon and Low-Alloy Steel Electrodes for Electrogas Welding

A5.28/A5.28M Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding

A5.29/A5.29M Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding

A5.30/A5.30M Specification for Consumable Inserts

A5.31 Specification for Fluxes for Brazing and Braze Welding

A5.32/A5.32M Specification for Welding Shielding Gases

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