BRITISH STANDARD BS EN ISO

544:2003

Welding
consumables —
Technical delivery
conditions for welding
filler metals — Type of
product, dimensions,
tolerances and
markings

The European Standard EN ISO 544:2003 has the status of a

British Standard

ICS 25.160.20

12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:
BS EN ISO 544:2003

National foreword
This British Standard is the official English language version of
EN ISO 544:2003. It is identical with ISO 544:2003. It supersedes
BS EN 759:1997 which is withdrawn.
The UK participation in its preparation was entrusted to Technical Committee
WEE/39, Welding consumables, which has the responsibility to:

— aid enquirers to understand the text;

— present to the responsible international/European committee any

enquiries on the interpretation, or proposals for change, and keep the
UK interests informed;
— monitor related international and European developments and
promulgate them in the UK.

A list of organizations represented on this committee can be obtained on

request to its secretary.
Cross-references
The British Standards which implement international or European
publications referred to in this document may be found in the BSI Catalogue
under the section entitled “International Standards Correspondence Index”, or
by using the “Search” facility of the BSI Electronic Catalogue or of
British Standards Online.
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Summary of pages
This document comprises a front cover, an inside front cover, the EN ISO title
page, pages 2 to 12, an inside back cover and a back cover.
The BSI copyright notice displayed in this document indicates when the
document was last issued.

Amendments issued since publication

This British Standard was
published under the authority Amd. No. Date Comments
of the Standards Policy and
Strategy Committee on
27 November 2003

© BSI 27 November 2003

ISBN 0 580 43006 5

EUROPEAN STANDARD EN ISO 544
NORME EUROPÉENNE
EUROPÄISCHE NORM December 2003

ICS 25.160.20 Supersedes EN 759:1997

English version

Welding consumables - Technical delivery conditions for welding

filler materials - Type of product, dimensions, tolerances and
markings (ISO 544:2003)

Produits consommables pour le soudage - Conditions Schweißzusätze - Technische Lieferbedingungen für

techniques de livraison des matériaux d'apport pour le metallische Schweißzusätze - Art des Produktes, Maße,
soudage - Type de produit, dimensions, tolérances et Grenzabmaße und Kennzeichnung (ISO 544:2003)
marquage (ISO 544:2003)

This European Standard was approved by CEN on 16 May 2003.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official
versions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and United
Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2003 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 544:2003 E
worldwide for CEN national Members.
EN ISO 544:2003 (E)

Contents

Foreword......................................................................................................................................................................3
1 Scope ..............................................................................................................................................................4
2 Normative references ....................................................................................................................................4
3 Type of product and relevant processes.....................................................................................................5
4 Dimensions and dimensional limits.............................................................................................................5
4.1 Filler wires, covered electrodes and filler rods ..........................................................................................5
4.2 Strip electrodes ..............................................................................................................................................7
4.3 Cored strip electrodes and thin foils ...........................................................................................................7
5 Condition of consumables............................................................................................................................7
5.1 Covered electrodes........................................................................................................................................7
5.2 Filler wires, filler rods and strip electrodes ................................................................................................7
6 Marking .........................................................................................................................................................11
6.1 Marking on the product ...............................................................................................................................11
6.1.1 Covered electrodes......................................................................................................................................11
6.1.2 Filler wires and strip electrodes .................................................................................................................11
6.1.3 Filler rods......................................................................................................................................................11
6.2 Marking on the package ..............................................................................................................................11
7 Packaging .....................................................................................................................................................11
8 Inspection documents.................................................................................................................................12

2
EN ISO 544:2003 (E)

Foreword
This document (EN ISO 544:2003) has been prepared by Technical Committee CEN/TC 121 "Welding", the
secretariat of which is held by DS in collaboration with Technical Committee ISO/TC 44 "Welding and allied
processes".

This European Standard shall be given the status of a national standard, either by publication of an identical text or
by endorsement, at the latest by May 2004, and conflicting national standards shall be withdrawn at the latest by
May 2004.

This document supersedes EN 759:1997.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,
Slovakia, Spain, Sweden, Switzerland and the United Kingdom.

3
EN ISO 544:2003 (E)

1 Scope

This European Standard specifies technical delivery conditions for filler materials for fusion welding.
This European Standard does not apply to auxiliaries such as shielding gases.

2 Normative references

This European Standard incorporates by dated or undated reference, provisions from other
publications. These normative references are cited at the appropriate places in the text and the
publications are listed hereafter. For dated references, subsequent amendments to or revisions of any
of these publications apply to this European Standard only when incorporated in it by amendment or
revision. For undated references the latest edition of the publication referred to applies (including
amendments).

EN 10204, Metallic products – Types of inspection documents.

EN ISO 4063, Welding and allied processes – Nomenclature of processes and reference numbers
(ISO 4063:1998).

4
EN ISO 544:2003 (E)

3 Type of product and relevant processes

Table 1 below indicates the range of products covered by this standard and processes in which they
are used. Within brackets reference numbers from EN ISO 4063 are given.

Table 1 - Type of product and relevant processes

Type of product Applied in welding processa

Cored strip electrode EG, ES, S

Covered electrode E

Solid rod W, O, P

Solid strip electrode ES, S

Solid wire W, P, L, EB

Solid wire electrode EG, ES, G, S

Tubular cored rod W, O, P

Tubular cored wire L, W

Tubular cored electrode EG, ES, P, S, T

Thin foil L, EB
a
Correspondence between symbols used in this standard and reference numbers of
EN ISO 4063, see below:
E Manual metal-arc welding (111)
EB Electron beam welding (51)
EG Electro gas welding (73)
ES Electro slag welding (72)
G Gas-shielded metal-arc welding (131, 135)
L Laser beam welding (52)
O Oxy-fuel gas welding (31)
P Plasma arc welding (15)
S Submerged arc welding (12)
T Tubular cored electrode arc welding with or without a shielding gas (136, 114)
W Tungsten inert-gas arc welding (141)

4 Dimensions and dimensional limits

4.1 Filler wires, covered electrodes and filler rods

Table 2 indicates standardized dimensions and tolerances for filler wires, covered electrodes and
filler rods.

5
EN ISO 544:2003 (E)

Table 2 - Dimensions and tolerancesa

Dimensions in millimetres

Solid wires and wire Tubular cored wires

Filler rods Covered electrodes b
electrodes and electrodes
Welding G, W, L, EB S, ES, EG T, S, EG W, O, P E
process
Diameter Diameter Diameter Diameter Length Diameter Diameter Length
Nominal tolerance tolerance Tolerance tolerance Length tolerance core wire tolerance Length tolerance
diameter
0,5 − − − − − − − − −
+0,01 / −0,03
0,6 − − −
0,8 − − − −
0,9 +0,02 / −0,05 − − −
1,0 − − −
1,2 − − −
1,4 +0,01 / −0,04 − − −
500
1,6 ±5
±0,04 ±0,1 up to 1,6 200
1,8 1000
2,0 2,0 ±0,06 up to ±5
2,4 +0,02 / −0,06
2,5 350
2,5
2,8 − − −
3,0 +0,01 / −0,07 − − −
3,2 +0,02 / −0,07 3,2
4,0 ±0,06 4,0 275
±0,10
5,0 5,0 up to ±5
c
6,0 − +0,02 / −0,08 6,0 450
8,0 8,0 ±0,1
− means not applicable.
b
Dimensions for the core wire.
a c
Other dimensions may be agreed. For intermediate dimensions For special cases (for example gravity welding) length up to 1000 mm.
tolerances given in the table shall be used.
6
EN ISO 544:2003 (E)

4.2 Strip electrodes

Table 3 indicates dimensions and tolerances for strip electrodes.

Table 3 - Dimensions and tolerances for strip electrodes

Dimensions in millimetres

Dimensions Tolerances

Nominal ≤ 1,0 ± 0,05

thickness

Nominal width ≤ 100 + 0,5 / 0

> 100 + 0,8 / 0

4.3 Cored strip electrodes and thin foils

For cored strip electrodes and thin foils dimensions and dimensional limits shall be as required by the
application standard.

5 Condition of consumables

5.1 Covered electrodes

The covering of the electrodes shall be concentric and consistent along the length in order to avoid
asymmetrical melting-off of the covering when welding. The electrode covering shall not exhibit any
irregularities, cracks or other surface defects, which would adversely affect the welding operation. It shall
firmly adhere to the core wire and shall not break off during proper handling and usage.

The grip end of the electrode shall be free from covering material for a length of at least 15 mm.

NOTE The striking end may be provided with arc ignition enhancing material.

5.2 Filler wires, filler rods and strip electrodes

The surface of the welding consumables shall be free from contamination and surface defects that can
adversely affect welding. Any surface finish is allowed, provided that welding operation and properties of
the weld metal are not adversely affected. All cored products shall have the core ingredients distributed
throughout their length with uniformity such that the performance of the products, the chemical
composition and the properties of the deposited weld metal thereby are not adversely affected.

Filler wires and strip electrodes are delivered in coils or wound on spools in accordance with Figure 1
and Table 4. They shall not exhibit kinks, waves, sharp bends or other irregularities that could interfere
with continuous feeding. The beginning and end of the wire, spooled in one length, shall be secured.

Welding consumables on coils without formers shall be tied at three places, at least, approximately
equally spaced around the circumference of the coil.

The solid wires and solid wire electrodes for steel shall not exhibit helix greater than described below.
Helix is defined as the vertical separation between any part of one loop of wire placed on a flat surface
without restraint and the flat surface. It shall not be more than 25 mm for spools having an outside

7
EN ISO 544:2003 (E)

diameter of up to 200 mm (S 200) and not more than 50 mm for spools having a diameter of more than
200 mm (see Table 4).

The cast (diameter of some loops of wire placed on a flat surface without restraint), helix and condition of
all the wires shall be such as to be suitable for uniform uninterrupted feeding on automatic or semi-
automatic welding equipment.

8
EN ISO 544:2003 (E)

Figure 1a) - Rim (R) Figure 1b) - Reel/Spool (S) Figure 1c) - Coil (C)
NOTE: Reel/Spool (S) may
have two pinholes

Figure 1d) - Basket rim (B) Figure 1e) - Basket spool (BS)

Figure 1 - Reels, rims, spools and coils

9
EN ISO 544:2003 (E)

Table 4 - Dimensions and tolerances of reels, rims, spools and coils a)

Dimensions in millimetres

Pin Hole
Type Denomination Outer diameter Inner diameter Outer width Bore diameter
d1 d2 b d3 Diameter Distance from axis
d4 d5 e1 e2
Reel/Spool (S) S 100 100 ± 2 − 45 + 0/ − 2 16,5 + 1/ − 0 - - - -
Reel/Spool (S) S 200 200 ± 3 − 55 + 0/ − 3 50,5 + 2,5/ − 0 10 + 1/ − 0 - 44,5 ± 0,5 -
Reel/Spool (S) S 300 300 ± 5 − 103 + 0/ −3 50,5 + 2,5/ − 0 10 + 1/ − 0 - 44,5 ± 0,5 -
Reel/Spool (S) S 350 350 ± 5 − 103 + 0/ −3 50,5 + 2,5/ − 0 10 + 1/ − 0 - 44,5 ± 0,5 -
560 + 0 / −10 305 + 0/ −10
b
Reel/Spool (S) S 560 35,0 ± 1,5 18,7 ± 0,7 18,7 ± 0,7 63,5 ± 0,7 63,5 ± 0,7
610 + 0 / −10 345 + 0/ −10
b
Reel/Spool (S) S 610 35,0 ± 1,5 16,7 ± 0,7 16,7 ± 0,7 63,5 ± 0,7 63,5 ± 0,7
Reel/Spool (S) S 760E 760 + 0 / −10 − 290 +10/ −1 40,5 + 1/ − 0 25 + 1/ − 0 35 + 1/ − 0 65 ±1 110 ±1
760 + 0 / −10 345 + 0/ −10
b
Reel/Spool (S) S 760A 35,0 ± 1,5 16,7 ± 0,7 16,7 ± 0,7 63,5 ± 0,7 63,5 ± 0,7
Rim (R) R 435 435 ± 5 300 +15/ − 0 90 + 0/ −15 − - - -
Basket rim (B) B 300 300 + 0/ −5 180 ± 2 100 ± 3 − - - - -
Basket rim (B) B 450 max450 300 ± 5 100 ± 3 − - - - -
Basket spool (BS) BS 300 300 ± 5 189 ± 0,5 103 + 0/ −3 50,5 + 2,5/ − 0 - - - -
Coil (C) C 435 max435 300 +15/ − 0 90 + 0/ −15 − - - - -
Coil (C) C 450 max450 300 +15/ − 5 100 +10/ −5 − - - - -
Coil (C) C 800 max800 600 +20/ − 0 120 +10/ −5 − - - - -
a
Other dimensions can be agreed.
b
Outside diameter of barrel, d2 shall be such as to permit feeding of the filler materials.

10
EN ISO 544:2003 (E)

6 Marking

6.1 Marking on the product

6.1.1 Covered electrodes

Covered electrodes shall be durably marked on the covering near the grip end or on the grip end,
exhibiting at least an identification traceable to the unique product type of the manufacturer or supplier.

NOTE In addition to the traceable identification it is recommended also that at least the compulsory part of the standard
designation or colour paint for identification be used.

6.1.2 Filler wires and strip electrodes

Welding filler materials wound on spools or in coils shall be durably marked on the coil or spool with an
identification traceable to the unique product type of the manufacturer or supplier.

6.1.3 Filler rods

Each filler rod for TIG and plasma arc welding shall be durably marked with an identification traceable to
the unique product type of the manufacturer or supplier.

NOTE In addition to the traceable identification it is recommended also that at least the compulsory part of the standard
designation be used or colour print for identification.

6.2 Marking on the package

The outside of each smallest unit package shall be clearly marked with the following information as a
minimum:

- name of manufacturer or supplier;

- trade name;

- designation in accordance with the relevant Standard;

- dimensions in accordance with clause 4;

- batch/heat or lot number;

- type of current and polarity, where applicable ;

- number of pieces or nominal net weight;

- redrying instructions or reference to information source, where applicable;

- approvals, where applicable;

- health and safety warnings as required.

7 Packaging

The manufacturer, supplier or distributor shall pack welding filler metals so that when suitably
transported and stored in a dry storeroom, sufficient safeguard against damage and deterioration is
provided.

11
EN ISO 544:2003 (E)

8 Inspection documents

If inspection documents for a welding filler material are required they shall be established according to
EN 10204 and details shall be as required by the application standard.

12
blank
BS EN ISO
544:2003
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