Complete Welding Rods and Electrodes Guide for Beginners

Welding rods and electrodes are the backbone of every successful weld. Choosing the right one can make all the difference between a weak bond and a durable, professional-quality weld. In this guide, we’ll dive into everything you need to know—from the types of welding rods to selecting the right one for your next project.

What Are Welding Rods and Electrodes?

A welding rod or electrode is a piece of filler metal that conducts electric current and melts during the welding process, creating a bond between metal pieces. They can be classified as either consumable or non-consumable:

• Consumable Electrodes: Used in processes like Shielded Metal Arc Welding (SMAW), also called stick welding, where the electrode melts and becomes part of the weld. The flux coating on the rod serves to protect the weld pool from contaminants by generating a shielding gas.
• Non-Consumable Electrodes: Typically used in Tungsten Inert Gas (TIG) welding, these electrodes do not melt into the weld pool. Instead, they help maintain the arc while a separate filler rod is used to join the pieces.

The American Welding Society (AWS) has created a numbering system to classify welding electrodes based on strength, welding positions, and flux types, which is critical for welders selecting the proper rod for their applications.

Welding Rod Classifications Explained

Welding rod classification can seem confusing at first, but understanding the meaning behind the numbers and letters can make electrode selection more precise and purposeful. The American Welding Society (AWS) classification system uses a series of letters and numbers to identify key characteristics of the welding rod, such as tensile strength, welding position compatibility, flux coating, and current type.

Breaking Down the AWS Electrode Code

The AWS electrode code for a stick welding rod typically looks like E7018, and each character or group of characters has specific meaning:

• E: Represents “Electrode”.
• First two numbers (70): The tensile strength of the weld, measured in thousands of pounds per square inch (psi). In this case, “70” indicates a weld with 70,000 psi tensile strength.
• Third number (1): Indicates the welding positions in which the electrode can be used.
  • 1 means all positions (flat, horizontal, vertical, overhead).
  • 2 means horizontal and flat only.
  • 4 implies overhead or vertical.
• Fourth number (8): Represents the coating type and current that can be used. For instance:
  • 0 indicates high cellulose sodium flux.
  • 8 indicates an iron powder low-hydrogen flux, suitable for AC or DC positive.

This classification system is designed to help welders quickly understand the electrode’s capabilities, ensuring the correct rod is selected for each specific project.

Common Welding Rods and Their Uses

Welding rods come in different varieties, each suited for specific applications and conditions. Here is an overview of some commonly used welding rods and their best uses:

E6010 Welding Rod Characteristics

E6010 rods are used widely in pipeline construction, refineries, and gas plants because they offer deep penetration and weld in all positions, including vertical and overhead. These rods feature a cellulosic coating which provides a quick “freeze” of the molten puddle, making them suitable for filling imperfect joints. However, they require skill due to their high arc force and fast solidification, which can be challenging for beginners.

Key Characteristics:

• Penetration: Deep, ideal for root passes.
• Current Type: Direct Current Electrode Positive (DCEP).
• Usage: Suitable for pipeline welding, structural work, and rusty or contaminated metals.

E6011 Welding Rod Characteristics

E6011 rods share similar properties with E6010 but can work with both AC and DC power sources. This versatility makes them popular in areas without reliable DC-only power. They are often referred to as the “farmer’s rod” for their adaptability.

Key Characteristics:

• Penetration: Deep, similar to E6010.
• Current Type: Suitable for AC and DCEP.
• Usage: Often used by farmers or in portable welding situations.

E6013 Welding Rod Characteristics

E6013 rods are perfect for light-duty welding, such as sheet metal repair. They offer shallow penetration and are forgiving of surface impurities, making them ideal for DIY projects. Their smoother arc and minimal spatter make them beginner-friendly.

Key Characteristics:

• Penetration: Shallow.
• Current Type: AC or DCEN (Direct Current Electrode Negative).
• Usage: Best for car bodywork or household appliances.

E7018 Welding Rod Characteristics

E7018 rods are low-hydrogen electrodes, suitable for applications requiring high strength and resistance to cracking, such as bridges, skyscrapers, and structural welding. Their smooth, stable arc and easy slag removal make them popular, though they require proper storage to avoid moisture contamination.

Key Characteristics:

• Penetration: Medium, suitable for high-stress applications.
• Current Type: AC or DCEP.
• Usage: Ideal for structural steel projects needing crack-resistant welds.

Comparison Table: Common Welding Rods

Choosing the Right Welding Rod

Choosing the appropriate welding rod depends on multiple factors, including the type of metal to be welded, the thickness of the material, welding position, and the required strength of the finished joint.

Factors to Consider When Selecting Welding Rods

1. Base Metal Thickness: The welding rod’s diameter should be slightly smaller than the metal being welded. For thicker metals, a larger rod can fill the joint effectively, while thinner materials require smaller rods to prevent overheating and warping.
2. Welding Position: Some rods, like the E6010, can be used in all positions (flat, horizontal, vertical, and overhead), while others are limited. For overhead or vertical welding, a smaller-diameter rod with quick-freezing properties is best.
3. Amperage Requirements: Each rod type has specific amperage ranges that work best to produce quality welds without burn-through or slag inclusion. Rods such as E7018 have higher iron content, increasing the deposition rate and making them ideal for more extensive projects needing faster weld deposition.

Handling and Storing Welding Rods

Proper handling and storage of welding rods are essential to maintain their effectiveness, especially for low-hydrogen electrodes like E7018, which are susceptible to moisture contamination.

Key Storage Tips

1. Moisture Control: Low-hydrogen rods, such as E7018, should be kept in a rod oven or a heated storage unit to prevent them from absorbing moisture. Moisture can lead to hydrogen-induced cracking in the weld, which compromises strength and durability.
2. Temperature Requirements: Rod ovens should be set to about 250°F to 300°F for most low-hydrogen electrodes, as this ensures they are kept dry and ready for use.
3. Rotation: Practice FIFO (First In, First Out) to use older rods before newer ones. This ensures rods don’t sit too long, particularly when there is a risk of moisture contamination.

Reconditioning of Electrodes

Sometimes, welding rods absorb moisture due to improper storage. In such cases, reconditioning can restore usability. To recondition, low-hydrogen rods can be placed in a rod oven at 600°F to 700°F for several hours to remove absorbed moisture.

Best Practices for Welding Success

Achieving high-quality welds requires more than just selecting the right electrode. Below are a few tips that ensure successful welding, reduced defects, and improved productivity:

Matching Electrode to Material Type

• Mild Steel: Use E6013 or E7018. E7018 provides higher strength and ductility, while E6013 is more forgiving for beginners and produces visually clean welds.
• Rusty or Contaminated Metal: E6010 is a great choice due to its deep penetration and ability to cut through rust and contaminants.

Controlling Amperage

The correct amperage depends on both the type and diameter of the electrode being used. Welding with an incorrect amperage setting can lead to numerous issues:

• Too Low Amperage: Leads to lack of penetration and can cause slag inclusions. The weld may sit on top of the material without sufficient fusion.
• Too High Amperage: Results in excessive spatter, undercutting, and even burn-through of thinner materials.

Welding Position and Technique

• When working on vertical or overhead welds, choose rods like E6010 or E6011, which can be used in all positions and have fast-freezing characteristics that help prevent sagging.
• Rod Angle and Travel Speed: Maintaining the right angle is crucial. For fillet welds, keep the electrode at a 45° angle to achieve even distribution of the weld. Travel speed must be adjusted to ensure proper bead width and to prevent porosity.

Frequently Asked Questions (FAQ)

Q1: What is the difference between E6010 and E6013 rods?
A1: E6010 provides deep penetration, ideal for rusty or dirty metals, while E6013 offers shallow penetration and is suitable for clean, light-duty applications.

Q2: Which welding rod is best for beginners?
A2: E6013 rods are often recommended for beginners because they are easy to use, forgiving of surface impurities, and provide smooth, clean welds.

Q3: Why are E7018 rods called low-hydrogen electrodes?
A3: E7018 rods contain very low moisture content, reducing the risk of hydrogen cracking, making them ideal for high-strength steel welds.

Q4: How should welding rods be stored?
A4: Low-hydrogen rods like E7018 must be kept in a rod oven to prevent moisture absorption, which can lead to weld defects.

Q5: Can I use the same welding rod for AC and DC currents?
A5: Yes, E6011 is versatile and can be used with both AC and DC power sources, making it highly adaptable for various conditions.

Conclusion

The right welding rod elevates your craftsmanship, turning welding from a challenging task to an art form. Armed with the correct knowledge and rod selection, you can conquer any project, big or small. Master these essentials, and you’re well on your way to creating reliable, long-lasting welds.