ELECTRODE SIZE

Electrodes for shielded metal arc welding range in diameter from 3/32 to 3/16 of an
inch. You may also come across some ¼ inch electrodes. They are commonly found in
9, 14 and 18-inch lengths

Electrode diameter is based on the thickness of the base metal, the welding position
and the type of joint to be welded.

Larger diameter electrodes are used on thicker metals and for flat position welding
because they offer higher deposition rates.

Smaller diameter electrodes are used for horizontal, vertical and overhead welding,
because they produce a smaller weld puddle that is easier to control than the bigger
puddle produced by larger diameter electrodes.

Joint design also affects electrode diameter. On groove welds for example, the
electrode has to be small enough to access the root of the joint. he welder’s skill also
has a bearing on electrode diameter because a more capable welder can control a
larger, more fluid weld puddle.

As a general rule, when there is no welding procedure specification, use the largest
diameter electrode possible. Larger diameter electrodes produce welds of the required
dimensions in the least amount of time and at lower cost, because they have higher
deposition rates and allow faster travel speeds.

CURRENT

Current is measured in amperes, or amps. Each type of electrode has recommended

If the amperage is set above the suggested operating range, the electrode melts too
fast. This increases deposition and the weld puddle becomes too large to control. It
could also cause the electrode coating to overheat and break down.

Amperage too high – The weld bead is wide and flat with excessive penetration and
spatter, and undercutting frequently occurs along the toes.

If the amperage is set below the designated range, there is insufficient heat to melt the
base metal, and the weld puddle is too small for proper control. The droplets forming on
the end of the electrode may bridge to the weld puddle periodically extinguishing the
arc. The weld bead will be irregular with a crowned appearance and insufficient
penetration.

Amperage too low -The weld bead will be irregular with a crowned appearance and
insufficient penetration

ARC LENGTH

Arc length is the distance from the tip of the electrode core wire to the weld puddle. Arc
length can be deceiving, because the core wire is recessed inside a cup that forms at
the tip of the electrode. You have to take this into consideration when gauging arc
length.

The correct arc length varies according to the electrode classification, diameter and
composition of the flux coating, as well as the amperage and welding position.

As a general rule, when amperage is set within the specified range, arc length should
not exceed the diameter of the core wire. Increasing the arc length increases the arc
voltage, and reduces the amperage slightly.

If the arc is too long, the metal core melts off in large globules that wobble from side to
side and drop onto the work as spatter, rather than forming useful weld metal. The weld
bead is wide with excessive spatter and undercut. The base metal is not properly
melted, so the weld metal is deposited on top of the plate with incomplete penetration,
and slag inclusions will probably occur. Long arcing is often used to preheat the base
metal directly after striking the arc.

Shortening the arc length reduces the arc voltage and increases the amperage slightly.
If the arc length is too short, the arc has a tendency to short out and the electrode
freezes to the work.

TRAVEL SPEED

Travel speed is the rate at which the electrode moves along the work. The key to
correct travel speed is “reading” the weld puddle, because the weld puddle is a liquid
version of the weld bead.

A properly formed weld bead has an oval shape with an oval crater and uniform ripple
pattern. Travel speed is influenced by the type of welding current (DCEN, DCEP or AC),
amperage, welding position, electrode melt rate, material thickness, surface condition of
the base metal, type of joint, joint fit up and electrode manipulation.
If you travel too fast, the puddle cools too quickly trapping gasses and slag. The ripples
are pointed and narrow with irregular penetration and undercut along the toes.

If you travel too slowly, the weld metal piles up forming a high, wide weld-bead with too
much reinforcement that may result in overlap. So read the puddle, and keep the arc on
the leading edge.

ELECTRODE ANGLE

In shielded metal arc welding, the work and travel angles are used to control the shape
of the weld puddle and the amount of penetration. The travel angle is the angle between
the joint and the electrode along the axis of the weld.

A push angle exists when the electrode points in the direction of travel. And
a drag angle points away the direction of travel.

When all other essentials are under control, a change in the direction of travel changes
the heat input to the puddle. A drag travel angle increases heat input because the arc is
pointing into the puddle. A push travel angle reduces heat input because the arc is
pointing away from the puddle.

The work angle is pointing between the electrode and the work surface along the work
plane, which runs perpendicular to the axis of the weld. An incorrect work angle can
cause you to favor one side of the joint more than another. The result is undercut and
lack of fusion.