There are several types of welding rods to choose from, each offering different mechanical properties and operating with a specific type of welding power source. There are several factors to consider in welding rod selection.
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Base metal properties
Tensile strength
Welding current
Base metal thickness, shape, and joint assembly
Welding position
Specifications and conditions of use
Environmental working conditions
Please understand these factors in detail before starting the machine and picking up the electrode holder.
Electrode Holder
The first step in selecting an electrode is to determine your base metal composition. Your goal is to match (or closely match) the electrode composition to the base material type, which will help ensure a strong weld. If you are in doubt about the base metal composition, ask yourself the following questions.
What does the metal look like? If you are working with a damaged part or assembly, check for rough and grainy inner surfaces, which usually means the base material is cast metal.
Is the metal magnetic? If the base metal is magnetic, then the base metal is most likely carbon or alloy steel. If the base metal is not magnetic, the material could be manganese steel, 300 series austenitic stainless steel, or a non-ferrous alloy such as aluminum, brass, copper, or titanium.
What kind of sparks are emitted when metal is touched by the grinder? As a rule of thumb, more flare in the sparks indicates a higher carbon content, such as A-36 grade steel.
Will the chisel "bite" into the base metal or bounce off? A chisel will bite into softer metals, such as mild steel or aluminum, and bounce off harder metals, such as high-carbon steel, chromium-molybdenum or cast iron.
AWS ECI
To prevent cracking or other welding discontinuities, match the minimum tensile strength of the electrode to the tensile strength of the base material. You can identify the tensile strength of a rod electrode by referring to the first two digits of the AWS classification printed on the side of the electrode. For example, the number "60" on an E electrode indicates that the filler metal produces a weld channel with a minimum tensile strength of 60,000 psi, so it works well with steels of similar tensile strength.
Some electrodes can only be used with AC or DC power sources, while others are compatible with both. To determine the correct type of current for a particular electrode, refer to the fourth digit of the AWS classification, which represents the type of coating and the type of compatible welding current
To determine which positions are suitable for a particular electrode, refer to the third digit in the AWS classification. Here is how you can interpret the qualified electrode positions.
1 = flat, horizontal, vertical, and overhead
2 = Flat and horizontal only
For example, the electrodes can be used in flat, horizontal, vertical, and overhead positions.
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AWS A5.11 ENiCrFe-3
Be sure to evaluate the conditions that the welded part will encounter throughout its use. A low hydrogen electrode with high ductility will reduce the chance of weld cracking if it is used in a high-temperature or low-temperature environment subjected to repeated shock loads. Also, if you are involved in critical applications such as pressure vessel or boiler fabrication, be sure to check welding specifications. In most cases, these welding codes will require you to use a specific type of electrode.
For best results, you should always remove excess oxide, rust, moisture, paint, and grease. The clean base metal will help prevent porosity and increase travel speed. If it is not possible to clean your base metal, the E or E electrode provides a deeply penetrating arc with the ability to penetrate contaminants.
Considering the above factors will help you overcome the challenge of selecting the correct rod electrode for your specific application. However, given the wide range of electrodes available, multiple solutions may exist for one application. If you need additional assistance with electrode selection, your local welding supply distributor or a company representative from a reputable filler metal manufacturer can serve as a good resource.
Stick electrodes are available in a wide range of types, each of which provides different mechanical properties and operates with a specific type of welding power source. There are several factors to consider in welding rod selection:
Before you power up your machine and pick up your electrode holder, learn more about each of these factors.
The first step in choosing an electrode is to determine your base metal composition. Your goal is to match (or closely match) the electrode composition to the base metal type, which will help ensure a strong weld. If you’re in doubt about the composition of your base metal, ask yourself these questions:
To prevent cracking or other weld discontinuities, match the minimum tensile strength of the electrode to the tensile strength of the base metal. You can identify a stick electrode’s tensile strength by referring to the first two digits of the AWS classification printed on the side of the electrode. For example, the number “60” on an E electrode indicates that the filler metal produces a weld bead with a minimum tensile strength of 60,000 psi and, as a result, would work well with a steel of similar tensile strength.
Welding current
Some electrodes can be used with only AC or DC power sources while other electrodes are compatible with both. To determine the correct current type for a particular electrode, refer to the fourth digit of the AWS classification, which represents the type of coating and type of compatible welding current (see Figure 1).
Refer to the fourth digit of the AWS classification to determine the compatible welding current.The type of current you use also influences the penetration profile of the resulting weld. For example, a DCEP compatible electrode, such as an E, delivers deep penetration and produces an extremely tight arc. It also has the ability to “dig” through rust, oil, paint and dirt. A DCEN compatible electrode, such as an E, provides mild penetration and works well when bridging two joints or welding high speed, high current fillet welds in the horizontal position.
An AC compatible electrode, such as an E, produces a soft arc with medium penetration and should be used to weld clean, new sheet metal.
Thick materials require an electrode with maximum ductility and low hydrogen to prevent weld cracking. Electrodes with AWS classification numbers ending in 15, 16 or 18 provide excellent low–hydrogen properties and good toughness (high impact values) to accommodate for residual stress.
For thin materials, you will need an electrode that produces soft arcs, such as a . Also, smaller diameter electrodes will provide shallow penetration to help prevent burn-through on thinner materials.
You’ll also want to assess the joint design and fit-up. If you’re working on a joint with a tight fit-up or one that is not beveled, use an electrode that provides a digging arc to ensure sufficient penetration, such as an E or E. For materials with wide root openings, select an electrode, such as an E, that creates a concave weld face suitable for bridging gaps and making groove welds.
To determine what position(s) a particular electrode is qualified for, refer to the third digit in AWS classification. Here’s how you decipher the qualified electrode position:
1 = flat, horizontal, vertical and overhead
2 = flat and horizontal only
For example, a electrode can be used in the flat, horizontal, vertical and overhead positions.
Make sure to assess the conditions that the welded part will encounter throughout its service. If it will be used in high heat or low temperature environments subjected to repetitive shock loading, a low hydrogen electrode with higher ductility will reduce the chance of weld cracking. Also, be certain to check for welding specifications if you’re working on critical applications such as pressure vessel or boiler fabrication. In most cases, these welding specifications will require you to use specific types of electrodes.
To achieve the best results, you should always remove excessive mill scale, rust, moisture, paint and grease. Clean base metals help prevent porosity and increase travel speeds. If cleaning your base metal is not possible, E or E electrodes deliver a deep penetrating arc that has the ability to cut through contaminants.
Consideration of the above factors will help you overcome the challenges of selecting the correct stick electrode for your particular application. However, given the wide range of available electrodes, several solutions may exist for one application. If you need additional assistance with electrode selection, your local welding supply distributor or a company representative of a reputable filler metal manufacturer can serve as an excellent resource.
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