A Brief Guide To Welding Rods and Electrodes  

The welding electrodes utilized in almost all commercial-level welding projects involving structural steel construction or pipe welding in the industrial or energy sectors are listed in the contract agreements and prescribed welding codes. However, what happens if you are working on a building project or repair job that is not subject to welding codes or clear instructions from the engineer? It is now your responsibility as the welder to choose the appropriate welding electrode for the job at hand. This book will help you fulfill this duty by assisting you in selecting the welding electrode—also known as “rods” in shops and on construction sites—that is most appropriate for your application. In this blog, we will deep dive into the guide to welding rods and electrodes. 

Types Of Welding Rods

Consumable Rods/Electrodes

When the electrode and the filler metal are the same, a consumable electrode works well. You are utilizing a “consumable” electrode when it comes into contact with the workpiece and melts into the molten weld puddle where the base metal, flux (i.e., protective layer), and electrode are united in the weld joint. When using shielded metal arc welding (SMAW), every welding electrode is regarded as consumable.

Non-Consumable Rods/Electrodes

Conversely, non-consumable electrodes are typically connected to gas tungsten arc welding (TIG welding). The non-consumable electrode used in TIG welding is held in place inside the TIG flame and is utilized to create and maintain the arc; it is never to be consumed into the pool of molten weld. To finish the weld joint, a different bare metal filler is applied to the molten weld metal puddle. Tungsten electrodes are among the most frequently used electrodes of this kind.

Welding Rod Numbers

The numbers written on the ends of each welding rod in the package are used to categorize welding electrodes. The tensile strength rating, the position in which the rod can be welded, and the unique qualities of each welding rod are all quickly and easily discerned by the welder from the numbers.

The strength, welding positions to be employed, kind of flux coating, and alloying elements if the electrodes are alloyed are the factors that the American Welding Society (AWS) used to classify the welding electrodes.

What Do Welding Rod Numbers Mean?

We can make well-informed decisions thanks to the numerical designations written on every welding rod available on the market. We will restrict the electrode selection for this article to the shielded metal arc welding technique (SMAW), also referred to as “stick” welding. Many of the basic principles used in the selection of welding wires for GMAW (MIG), FCAW (Flux-core), and GTAW (TIG) welding are also applicable to these processes.

The First 2 Numbers

The first two, and occasionally the third, numbers on the welding rod, according to the AWS classification, stand for the tensile strength, or the capacity to withstand being ripped apart X 1,000. For instance, the number “70” in the name 7018 denotes the ability of a well-formed weld made using 7018 to sustain a tensile stress of 70,000 pounds per square inch (psi).

A weld capable of withstanding tensile stress of 110,000 pounds per square inch (psi) can be made with a rod designated as 11018. The standard welding rod 6010 has a pressure rating of only 60,000 psi.

The Third Number

The location in which you can utilize the rod is indicated by the third number. When a rod has a “1,” it can be utilized in every position. If the rod has a “2,” it can usually be used both horizontally and flatly. The number “4” can only be used in the flat position.

The Last Number

The final number in the series denotes the type of rod or any other unique feature, particularly the flux covers. For instance, the “8” on a 7018 welding rod indicates that it has a basic flux covering and is a low-hydrogen rod.

As a class of “rapid freeze” with cellulosic flux coating, the “0” in 6010, 7010, and 8010 is ideal for out-of-position welding tasks because it hardens the molten weld puddle quickly. Although it is utilized with AC power sources, the “1” in the final digit of 6011 shares many properties with the number 6010. 

Common Welding Rods

E6010

The E6010 is a highly liked and frequently utilized rod and with good reason. The arc is deep penetrating, easy to start, and permits fast travel speeds due to its spray-arc features. It is an excellent welder in any position.

E6011

The main difference between the 6010 and the 6011 is that the 6011 requires an AC power supply to operate. 6011 is commonly known as “farmer rod.”

E6013

Some light-duty sheet metal applications still rely on 6013 because of its high travel speed, shallow penetration, and extreme forgivingness toward surface imperfections.

E7018

This welding electrode, which is another popular choice, is categorized as a “low-hydrogen” welding rod.

E7024

E7024 is a wonderful option for a rod when you need to lay down a lot of metal quickly because of its fast deposition rates; it is also widely referred to as a “jet rod” in the field.

E309L

This is an extremely flexible welding rod that can be used to weld the more widely available varieties of stainless steel. Let L stand for low carbon. One of the key characteristics of stainless steel, corrosion resistance, can be significantly reduced by an excessive amount of carbon in a stainless weld.

E4043

This is a very flexible aluminum welding rod that works with most grades of aluminum that you would probably come across in small-scale repair welding projects. Aluminum welding can be challenging when done incorrectly. It may require a bit more trial and error in practice than is necessary with many of the carbon steel electrodes described because of aluminum’s quick heat conductivity, but it is possible. Aluminum tends to absorb everything it comes into contact with since it is a highly soft and porous metal, especially substances like grease and oils. For this reason, preparation of the connection and cleanup are crucial when welding aluminum. For this purpose, wire brushes, rosebud torches, and muriatic acid can all be very helpful instruments. Aluminum electrodes are susceptible to moisture attraction, much as E7018, hence it is critical to store them in a warm, dry location.

When attempting to choose the appropriate rod size, a novice welder may find online welding size and electrode charts to be quite helpful. However, it is important to note that they should only be used as guidelines and not as strict regulations. When choosing the proper size welding electrode, some aspects need to be taken into account, such as material thickness, joint design, strength requirements, the position to be welded in, etc., so much so that this topic deserves to be discussed separately. Having said that, no manual can ever fully replace your ability to judge a well-made weld. When everything is said and done, your weld should be fairly uniform, free of cracks, fusion to base metal or previous weld passes, and with only a few minor flaws like undercut, slag, or porosity. 

Conclusion

In conclusion, welding rods and electrodes play a crucial role in welding projects, with consumable and non-consumable options available for different techniques. Understanding the numbering system on welding rods is essential for selecting the right rod based on tensile strength, welding positions, and unique features.

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