Abstract: Flux cored welding electrodes comprise a iron based metal sheath and either a flux or metal core within the sheath, enclosing core ingredients. The core ingredients and sheath together comprise, in weight percentages based on the total weight of the electrode, very low levels of manganese. While having low levels of manganese the electrodes satisfy the strength and safety requirements required of commercial electrodes. Embodiments contain manganese in the range of 0.09 to 0.19% by weight of the electrode, along with other components.

Abstract: Methods for rating welding electrodes are presented, in which a standardized vertical-down double cap pass welding procedure is performed using a test electrode to create a test weld on a substantially flat workpiece surface, and the electrode is rated according to the amount of porosity in the test weld. A first vertical-down bead-on-plate welding operation is performed to create a substantially straight first weld bead on the workpiece surface, followed by a standardized moderate first slag removal operation to expose an upper portion of the first bead while leaving some slag along one or both longitudinal sides of the first weld bead. A standardized second vertical-down welding operation is then performed with the test electrode to cover the first weld, and another slag removal operation is used to remove any remaining slag. The test electrode is then rated according to the ratio of the number of visually discernable pores in the second weld bead divided by the test weld length.

Abstract: A welding electrode comprising a metal core and a coating material that includes flux compounds is at least partially coated on an outer surface of said metal core. The tip of the welding electrode is beveled and a portion of the beveled tip has an end coating material which includes an electrically-conductive material.