XHD 646 Welding Electrodes

At Metals And Welding Specialities, our XHD 646 Welding Electrodes set a benchmark in high-alloy welding consumables designed for demanding restoration, overlay, and joint applications. These premium coated electrodes deliver outstanding wear resistance, high impact strength, and excellent crack resistance even under cyclic load or severe working conditions. Because they are engineered for both cladding and joining of manganese steels, alloy steels, and dissimilar metal transitions, they offer tremendous flexibility in heavy duty repair and maintenance operations.

Each electrode is manufactured to meet ASTM Grade requirements appropriate for high-alloy austenitic manganese weld deposits. The UNS number for these electrodes is typically aligned with UNS J92205 (or an equivalent manganese-chromium weld alloy classification), and they conform to UNS J92205 / AWS ER 646 conventions. In universal standards, they are often referenced under the E 18 8 Mn R 52 classification, making them suitable as buffer or intermediate layers before hardfacing. (This universal standard nomenclature ensures wide compatibility in industrial welding codes.)

When used, our XHD 646 electrodes deposit a CrNiMn-based weld metal with excellent ductility and a capacity for work hardening in service. The as-deposited structure is ductile and tough, but under load it can yield a high surface hardness, making it ideal for abrasive and impact environments. This makes XHD 646 especially effective in refurbishing worn components like crusher jaws, bucket teeth, undercarriage parts, sprockets, rails, and grinder components.

Welders appreciate the smooth arc action and stabilized deposition rate offered by these electrodes. The slag is self-releasing, facilitating easy cleaning between passes, while the weld beads remain uniform without excessive spatter or undercut. Because of its high metal recovery (up to 150 %) and efficient deposition, downtime is minimized and filler usage is optimized. The electrode is equally suited for AC or DC+ (DCEP) operation, giving flexibility across different welding setups and power sources.

In practice you can use XHD 646 in single- or multi-pass build-ups, and it performs well when bridging dissimilar joints between carbon steel and high manganese steel. Its crack resistance, impact resilience, and scale tolerance up to 900 °C make it a reliable choice even in high temperature or heavy vibration zones. The structure of the deposit remains stable under cyclic loads and resists hot cracking or cold cracking when employed correctly.

To achieve the best results, precleaning of the weld zone is essential—removing rust, scale, and contaminants. For multi-pass welds, interpass temperature must be controlled, and post-weld cooling should be gradual (for example by insulating wraps) to avoid thermal shock. In alloys with 12 % or more manganese, avoid excessive heat input that pushes temperature beyond recommended limits (e.g. over 204 °C). When correctly applied, the weld deposit will exhibit a balance of toughness, ductility, and wear-resistant surface hardness.

By choosing Metals And Welding Specialities’ XHD 646 Welding Electrodes, you secure a welding solution that combines durability, versatility, and consistent performance. This product is ideal for industries dealing with mining, construction, earthmoving equipment, rail wear parts, and wherever restoration under harsh mechanical stress is required. Our technical support and quality assurance ensure you receive genuine, high-performance electrodes backed by engineering expertise.

• Specification XHD 646 Welding Electrodes

  Product Name	XHD 646 Welding Electrodes
  Classification	AWS A5.1 : E7016 / IS 814 : ER 5296
  Type of Coating	Low Hydrogen, Iron Powder
  Welding Current	AC / DC (Electrode Positive)
  Typical Applications	Fabrication of heavy structures, pressure vessels, shipbuilding, bridges, and machinery parts requiring high tensile strength and crack resistance.
  Typical Mechanical Properties	Ultimate Tensile Strength: 540–640 MPa Yield Strength: ≥ 460 MPa Elongation: ≥ 26% Impact Strength: 80 J at 0°C
  Typical Chemical Composition of Weld Metal (%)	C: 0.07 Mn: 1.00 Si: 0.50 S: 0.020 P: 0.020
  Operating Range (Amps)	2.5 mm: 70–100 A 3.15 mm: 90–130 A 4.0 mm: 120–170 A 5.0 mm: 160–220 A
  Welding Position	All positions except vertical down
  Storage	Keep in a dry place; re-dry at 300°C for 1 hour before use if moisture is absorbed.
  Packing	Available in 5 kg and 20 kg boxes

• XHD 646 Welding Electrodes Parameters

  Parameter	Typical Value
  Classification	High-alloy austenitic / Cr-Ni-Mn type (manufacturer classification: e.g., E Fe10 / Xuper 646 XHD)
  Tensile strength	~88,000 psi (≈ 62 kg/mm²)
  Hardness (as deposited / work-hardened)	As deposited: ~HRB 95 (manufacturer PDF); Work-hardened: ~HRC 30
  Typical diameters available	2.5 mm, 3.15 mm, 3.2 mm, 4.0 mm, 5.0 mm (common commercial sizes)
  Recommended current type / polarity	AC or DCEP (DC+)
  Recommended amperage ranges (typical)	• 2.5 mm: 100–140 A (A range), 75–100 A (B range) • 3.15 / 3.2 mm: 140–180 A (A range), 90–130 A (B range) • 4.0 mm: 180–250 A (A range), 120–160 A (B range) • 5.0 mm: 210–260 A (A range), 160–190 A (B range)
  Metal recovery / deposition	High metal recovery (~150% reported)
  Operating characteristics	High deposition rate; excellent crack & impact resistance; weld metal machinable with carbide tools
  Typical applications	Joining and rebuild of carbon & manganese steels — sprockets, rails, crusher jaws, bucket lips, undercarriage parts, etc.

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