Hello Nalla;
Are you working to an ASME construction code or AWS?
Sticking my neck out and assuming you are, the carbon steel filler metals for SMAW, GMAW, GTAW, and FCAW are contained in the following standards:
AWS A5.1 / ASME SFA5.1
AWS A5.18 / ASME SFA5.18
AWS A5.20 / ASME SFA5.20
AWS A5.28 / ASME SFA5.28
AWS A5.29 / ASME SFA5.29
The warning that the PMI should be preformed on a weld deposit is worth considering. Alloys can be added to the flux to provide the proper alloy balance in the weld deposit. Consider E316-26 SMAW electrode, the weld deposit is similar to the AISI alloy 316, but the core wire of the electrode is similar to that of an E6010. All the chrome and nickel required to provide the proper balance is contained in the flux covering.
The PMI "guns" used by some inspectors uses the principle of X-ray diffraction. These guns can not detect and measure the lighter elements such as carbon.
I usually weld a sample as described in the appropriate filler metal specification and send it to a lab for testing. The test method should be as defined by the filler metal specification.
Best regards - Al
What I have done in the past is what we called a "Button Weld Metal Test".
This is where we would have the welders burn half to a complete rod (or Electrode) in a one inch diameter puddle. Then let it cool for a minute or five. Clean slag (if applicable) and lay down another rod on top of that. This was to ensure that we had as pure of weld metal deposit as reasonably possible that was not diluted /adulterated by base metal. Then PMI that "button" of weld metal.
If memory serves me, there was a Spread sheet made up that recorded all these tests and was entered in the "Job Book".
Acceptance criteria was that the resultant chemistry met the manufacturer's claim.
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