Comparative XRD Characterization of Three SMAW Electrode Flux Coatings: Prospects for Nigerian Raw-Material Substitution

X-ray diffraction (XRD) was used to screen the crystalline phases in the flux coatings of three commercial shielded metal arc welding (SMAW) electrodes: a general-purpose rutile electrode (E6013), a cast-iron repair electrode (ENi-CI) and an austenitic stainless-steel electrode (E308-16). The aim was to produce a preliminary reference for later evaluation of locally sourced Nigerian raw materials. Coatings were removed by scraping, ground and sieved below 75 μm. Patterns were recorded on a Shimadzu XRD-6000 with Cu-Kα radiation (λ = 1.5406 Å) over 10–80° 2θ at a step size of 0.02°. Phases were identified provisionally by comparing peak positions with reference values. The E6013 coating showed reflections at 24.9°, 26.9° and 29.4°, provisionally matched to kaolinite (002), quartz (101) and calcite (104), plus an unresolved reflection at 31.8°. The strongest reflection of the cast-iron electrode coating, at 48.1°, is consistent with anatase TiO₂ (200). Its intensity relative to the absent anatase (101) reflection may indicate preferred orientation, but this could not be confirmed. The stainless-steel coating gave reflections consistent with γ-austenite (43.7°, 51.1°, 74.7°), together with a tentative reflection at 65.6° near the ferrite (200) position. These metallic reflections may arise wholly or partly from core-wire or metal-powder material in the scraped coating. Kaolinite and quartz reflections at 24.9° and 26.9° appeared in both the E6013 and stainless-steel coatings. The results are qualitative. No Rietveld refinement or phase quantification was performed, and neither local raw materials nor welding performance were tested.