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In Welding, substances called filler materials or consumables are used. As the name implies, these substances provide a filler or a body of molten materials that provides a strong bond to be formed between the base metals used. Most welding processes will also require some form of shielding to protect both the main components and filler from being oxidized during the process.

Metal parts that are joined during welding are called the parent material. Consumables are the material added to help form this joint. The form of these materials may see them referred to as parent plate or pipe, filler wire, consumable electrode (for arc welding), etc.

Using the correct consumables or filler material in welding brings about a strong bond between the two metals involved. These are one of the four most important components involved in welding, others include, the metal to be used, the source of heat, and the shield from air. The consumable is added to the point that is to be linked together to form a single piece of metal when the metal is heated to its melting point while being shielded from air. In arc welding, consumable does not only act as a filler during the heating but also helps in stabilizing the flame.

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TYPES OF WELDING CONSUMABLES

The type of consumable used during welding depends on the nature of the job intended. Electrodes draw the necessary energy in order to perform welding applications. Consumables includes

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• Stick Electrodes

  • Stick welding requires a lot of skill and also some know-how about stick electrodes (also called welding rods). There are different types of stick electrode, some of them includes (According to the American Welding Society); The E6010, E6011, E6012, E6013, E7014, E7024 and E7018 electrodes. Variables such as storage techniques, electrode diameter and flux composition all contribute to stick rod selection and performance, with basic knowledge one can minimise difficulty which will ensure better outcome in the welding processes.​

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• Fluxes

  • Flux is commonly used to produce a shield of gas around the weld pool to prevent oxidation of the hot metals. Flux typically acts as a deoxidizer preventing the formation of porosity in the weld pool. Flux and filler metals together are known as welding consumables. When an arc is struck, the flux burns and produces a series of complex chemical reactions. As the flux ingredients burn in the welding arc, they release shielding gas to protect the molten weld pool from atmospheric impurities. When the weld pool cools, the flux forms slag to protect the weld metal from oxidation and prevent porosity in the weld bead. Flux also contains ionizing elements that make the arc more stable (especially when welding with an AC power source), along with alloys that give the weld its ductility and tensile strength. Some electrodes use flux with a higher concentration of iron powder to help increase deposition rates, while others contain added deoxidizers that act as cleaning agents and can penetrate corroded or dirty workpieces or mill scale.​

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• Flux cored wires

  • There are two types of flux-cored wires — gas-shielded and self-shielded. Gas-shielded flux-cored wires require external shielding gas, and the slag is easy to remove. Consider using gas-shielded flux-cored wires when welding on thicker metals or in out-of-position applications. Gas-shielded flux-cored wires have a flux coating that solidifies more quickly than the molten weld material. As a result, it creates a shelf to hold the molten pool when welding overhead or vertically up. Self-shielding flux-cored wire does not require external shielding gas because the weld pool is protected by gas generated when flux from the wire is burned. As a result, self-shielding flux-cored wire is more portable because it does not require an external gas tank. This has a larger ball type transfer and produces low spatter levels, it also produces a rounder penetration profile with excellent side wall fusion. Flux cored wires is wasted during the course of welding because it does not form part of the final weld.​