Welding Electrode Complete Guide (Includes Charts)
Welding Electrode Complete Guide (Includes Charts)
Welding Electrodes
Last Updated: May 4, 2021
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It is made out of materials with a similar composition to the metal being welded.
There are a variety of factors that go into choosing the right electrode for each project.
SMAW or stick electrodes are consumable, meaning they become part of the weld, while TIG
electrodes are non-consumable as they do not melt and become part of the weld, requiring the
use of a welding rod.
The MIG welding electrode is a continuously fed wire referred to as MIG wire.
Electrode selection is critical to ease of cleanup, weld strength, bead quality, and minimizing any
spatter.
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Electrodes need to be stored in a moisture-free environment and carefully removed from any
package (follow the directions to avoid damage).
A slag cover is needed to protect molten or to solidify weld metal from the atmosphere. This
cover can be obtained from the electrode coating.
The composition of the welding electrode coating determines its usability, the composition of the
deposited weld metal, and the electrode specification.
The coating protects the metal from damage, stabilizes the arc, and improves the weld in other
ways, which include:
The metal-arc electrodes may be grouped and classified as bare or thinly coated electrodes and
shielded arc or heavy coated electrodes.
The covered electrode is the most popular type of filler metal used in arc welding.
The composition of the electrode covering determines the usability of the electrode, the
composition of the deposited weld metal, and the specification of the electrode.
The type of electrode used depends on the specific properties required in the weld deposited.
These include corrosion resistance, ductility, high tensile strength, the type of base metalto be
welded, the position of the weld (flat, horizontal, vertical, or overhead), and the type of current
and polarity required.
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Popular Welding Electrode (E6010) used for general purpose fabrication, construction, pipe welding, and shipbuilding
Classification
The welding industry has adopted the American Welding Society’s classification number series
for welding electrodes.
The electrode identification system for steel arc welding is set up as follows:
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Coating, Current and Polarity Types Designated By the Fourth Digit in the
0 * *
1 Cellulose Potassium ac, dcrp, dcsp
2 Titania sodium ac, dcsp
3 Titania potassium ac, dcsp, dcrp
4 Iron Powder Titania ac, dcsp, dcrp
5 Low hydrogen sodium dcrp
6 Low hydrogen potassium ac, dcrp
7 Iron powder iron oxide ac, dcsp
8 Iron powder low hydrogen ac, dcrp, dcsp
When the fourth (or last) digit is 0, the type of coating and current to be used is determined by
the third digit.
Table 5-4
The welding electrode identification system for stainless steel arc welding is set up as follows:
The system for identifying solid bare carbon steel for the submerged arc is as follows:
1. The prefix letter E is used to indicate an electrode. This is followed by a letter that
indicates the level of manganese, i.e., L for low, M for medium, and H for high
manganese. This is followed by a number of the average amount of carbon in points or
hundredths of a percent. The composition of some of these wires is almost identical to
some of the wires in the gas metal arc welding specification.
2. The electrode wires used for submerged arc welding are given in the American Welding
Society specification, “Bare Mild Steel Electrodes and Fluxes for Submerged Arc
Welding.” This specification provides both the wire composition and the weld deposit
chemistry based on the flux used. The specification does give the composition of the
electrode wires. This information is given in table 8-1. When these electrodes are used
with specific submerged arc fluxes and welded with proper procedures, the deposited
weld metal will meet the mechanical properties required by the specification.
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3. In the filler reds used for oxyfuel gas welding, the prefix letter is R, followed by a G
indicating that the rod is used expressly for gas welding. These letters are followed by
two digits which will be 45, 60, or 65. These designate the approximate tensile strength in
1000 psi (6895 kPa).
4. In nonferrous filler metals, the prefix E, R, or RB is used, followed by the chemical symbol
of the principal metals in the wire. The initials for one or two elements will follow. If there
is more than one alloy containing the same elements, a suffix letter or number may be
added.
5. The American Welding Society’s specifications are most widely used for specifying bare
welding rod and electrode wires. There are also military specifications such as the MIL-E
or -R types and federal specifications, normally the QQ-R type and AMS specifications.
The particular specification involved should be used for specifying filler metals.
The most important aspect of solid welding electrode wires and rods is their composition, given
by the specification. The specifications provide the limits of composition for the different wires
and mechanical property requirements.
Occasionally, on copper-plated solid wires, the copper may flake off in the feed roll mechanism
and create problems. It may plug liners or contact tips. A light copper coating is desirable. The
electrode wire surface should be reasonably free of dirt and drawing compounds. This can be
checked by using a white cleaning tissue and pulling a length of wire through it. Too much dirt
will clog the liners, reduce current pickup in the tip, and may create erratic welding operations.
The temper or strength of the wire can be checked in a testing machine. Wire of a higher
strength will feed through guns and cables better. The minimum tensile strength recommended
by the specification is 140,000 psi (965,300 kPa).
The continuous electrode wire is available in many different packages. They range from tiny
spools used on spool guns to medium-size spools for fine-wire gas metal arc welding. Coils of
electrode wire are available, which can be placed on reels that are a part of the welding
equipment. There are also huge reels weighing many hundreds of pounds. The electrode wire is
also available in drums or payoff packs where the wire is laid in the round container and pulled
from the container by an automatic wire feeder.
Coatings
The coatings of welding electrodes for welding mild and low alloy steels may have from 6 to 12
ingredients, which includes:
Cellulose – to provide a gaseous shield with a reducing agent in which the disintegration
of cellulose produces the gas shield surrounding the arc
Metal carbonates – to adjust the basicity of the slag and to provide a reducing
atmosphere
Titanium dioxide – to help form a highly fluid but quick-freezing slag and to provide
ionization for the arc
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Ferromanganese & ferrosilicon – to help deoxidize the molten weld metal and
supplement the manganese content and silicon content of the deposited weld metal.
Clays & gums – to provide elasticity for extruding the plastic coating material and to help
provide strength to the coating
Calcium fluoride – to provide shielding gas to protect the arc, adjust the basicity of the
slag, and provide fluidity and solubility of the metal oxides
Mineral silicates – to provide slag and give strength to the electrode covering
Alloying metals including nickel, molybdenum, and chromium – to provide alloy
content to the deposited weld metal
Iron or manganese oxide – to adjust the slag’s fluidity and properties and help stabilize
the arc.
Iron powder – to increase productivity by providing extra metal to be deposited in the
weld.
The principal types of welding electrode coatings for mild steel and are described below.
welds. In both cases, the deposition rate is increased based on the amount of iron
powder in the coating.
6. Low hydrogen-sodium (EXXX5): Coatings that contain a high proportion of calcium
carbonate or calcium fluoride are called low hydrogen, lime ferritic, or basic type
electrodes. In this coating class, cellulose, clays, asbestos, and other minerals containing
combined water are not used. This is to ensure the lowest possible hydrogen content in
the arc atmosphere. These electrode coatings are baked at a higher temperature. The
low hydrogen electrode family has superior weld metal properties. They provide the
highest ductility of any of the deposits. These electrodes have a medium arc with medium
or moderate penetration. They have a medium speed of deposition but require special
welding techniques for the best results. Low hydrogen electrodes must be stored under
controlled conditions. This type is normally used with direct current with electrode positive
(reverse polarity).
7. Low hydrogen-potassium (EXXX6): This type of coating is similar to the low hydrogen-
sodium, except for the substitution of potassium for sodium to provide arc ionization. This
electrode is used with alternating current and can be used with direct current, electrode
positive (reverse polarity). The arc action is smoother, but the penetration of the two
electrodes is similar.
8. Low hydrogen-potassium (EXXX6): The coatings in this class of electrodes are similar
to the low-hydrogen type mentioned above. However, iron powder is added to the
electrode, and if the content is higher than 35 to 40 percent, the electrode is classified as
an EXX18.
9. Low hydrogen-iron powder (EXX28): This electrode is similar to the EXX18 but has 50
percent or more iron powder in the coating. It is usable only when welding in the flat
position or for making horizontal fillet welds. The deposition rate is higher than EXX18.
Low hydrogen coatings are used for all of the higher-alloy electrodes. By adding specific
metals in the coatings, these electrodes become the alloy types where suffix letters are
used to indicate weld metal compositions. Electrodes for welding stainless steel are also
the low-hydrogen type.
10. Iron oxide-sodium (EXX20): Coatings with high iron oxide content produce a weld
deposit with a large amount of slag. This can be difficult to control. This coating type
produces high-speed deposition and provides medium penetration with a low spatter
level. The resulting weld has a very smooth finish. The electrode is usable only with flat
position welding and for making horizontal fillet welds. The electrode can be used with
alternating current or direct current with either polarity.
11. Iron-oxide-iron power (EXX27): This type of electrode is very similar to the iron oxide-
sodium type, except it contains 50 percent or more iron power. The increased amount of
iron power greatly increases the deposition rate. It may be used with an alternating direct
current of either polarity.
There are many types of coatings other than those mentioned here, most of which are usually
combinations of these types but for special applications such as hard surfacing, cast iron
welding, and nonferrous metals.
Storage
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Electrodes must be kept dry. Moisture destroys the desirable characteristics of the coating and
may cause excessive spattering and lead to porosity and cracks in the formation of the welded
area. Electrodes exposed to damp air for more than two or three hours should be dried by
heating in a suitable oven (fig 5-32) for two hours at 500°F (260°C).
After they have dried, they should be stored in a moisture-proof container. Bending the electrode
can cause the coating to break loose from the core wire. Electrodes should not be used if the
core wire is exposed.
Electrodes that have an “R” suffix in the AWS classification have a higher moisture resistance.
Bare Electrodes
Bare welding electrodes are made of wire compositions required for specific applications.
These electrodes have no coatings other than those required in wire drawing. These wire
drawing coatings have some slight stabilizing effect on the arc but are otherwise of no
consequence. Bare electrodes are used to weld manganese steel and other purposes where a
coated electrode is not required or undesirable. A diagram of the transfer of metal across the arc
of a bare electrode is shown in figure 5-29.
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A light coating has been applied on the surface by washing, dipping, brushing, spraying,
tumbling, or wiping. The coatings improve the characteristics of the arc stream. They are listed
under the E45 series in the electrode identification system.
Shielded arc or heavy coated welding electrodes have a definite composition on which a coating
has been applied by dipping or extrusion.
The cellulose coatings are composed of soluble cotton or other forms of cellulose with small
amounts of potassium, sodium, or titanium, and in some cases, added minerals.
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The mineral coatings consist of sodium silicate, metallic oxides, clay, and other inorganic
substances or combinations.
Cellulose-coated electrodes protect the molten metal with a gaseous zone around the arc and
the weld zone.
The shielded arc or heavy coated electrodes are used for welding steels, cast iron, and hard
surfacing. See figure 5-31 below.
These welding electrodes produce a reducing gas shield around the arc.
This prevents atmospheric oxygen or nitrogen from contaminating the weld metal.
The oxygen readily combines with the molten metal, removing alloying elements and causing
porosity.
Nitrogen causes brittleness, low ductility, and in some cases, low strength and poor corrosion
resistance.
They reduce impurities such as oxides, sulfur, and phosphorus so that these impurities will not
impair the weld deposit.
They provide substances to the arc, which increases its stability. This eliminates wide
fluctuations in the voltage so that the arc can be maintained without excessive spattering.
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By reducing the attractive force between the molten metal and the end of the electrodes or by
reducing the surface tension of the molten metal, the vaporized and melted coating causes the
molten metal at the end of the electrode to break up into fine, small particles.
The coatings contain silicates which will form a slag over the molten weld and base metal. Since
the slag solidifies at a relatively slow rate, it holds the heat and allows the underlying metal to
cool and solidify slowly. This slow solidification of the metal eliminates the entrapment of gases
within the weld and permits solid impurities to float to the surface. Slow cooling also has an
annealing effect on the weld deposit.
The physical characteristics of the weld deposit are modified by incorporating alloying materials
in the electrode coating. The fluxing action of the slag will also produce weld metal of better
quality and permit welding at higher speeds.
Tungsten Electrodes
Non-consumable welding electrodes for gas tungsten-arc (TIG) welding are of three types: pure
tungsten, tungsten containing 1 or 2 percent thorium, and tungsten containing 0.3 to 0.5 percent
zirconium.
Pure tungsten (99. 5 percent tungsten) electrodes are generally used on less critical welding
operations than the tungsten, which is alloyed. This type of electrode has a relatively low
current-carrying capacity and a low resistance to contamination.
Thoriated tungsten electrodes (1 or 2 percent thorium) are superior to pure tungsten electrodes
because of their higher electron output, better arc-starting and arc stability, high current-carrying
capacity, longer life, and greater resistance to contamination.
Tungsten welding electrodes containing 0.3 to 0.5 percent zirconium generally fall between pure
tungsten electrodes and thoriated tungsten electrodes in terms of performance. There is,
however, some indication of better performance in certain types of welding using ac power.
Finer arc control can be obtained if the tungsten alloyed electrode is ground to a point (see
figure 5-33). When electrodes are not grounded, they must be operated at a maximum current
density to obtain reasonable arc stability. Tungsten electrode points are difficult to maintain if
standard direct current equipment is used as a power source and touch-starting of the arc is
standard practice. Maintenance of electrode shape and the reduction of tungsten inclusions in
the weld can best be accomplished by superimposing a high-frequency current on the regular
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welding current. Tungsten electrodes alloyed with thorium and zirconium retain their shape
longer when touch-starting is used.
The welding electrode extension beyond the gas cup is determined by the type of joint being
welded. For example, an extension beyond the gas cup of 1/8 in. (3.2 mm) might be used for
butt joints in light gage material, while an extension of approximately 1/4 to 1/2 in. (6.4 to 12.7
mm) might be necessary on some fillet welds. The tungsten electrode of the torch should be
inclined slightly, and the filler metal added carefully to avoid contact with the tungsten. This will
prevent contamination of the electrode. If contamination does occur, the electrode must be
removed, reground, and replaced in the torch.
In most cases, straight polarity electrodes will provide less penetration than reverse polarity
electrodes, and for this reason, will permit greater welding speed. Good penetration can be
obtained from either type with proper welding conditions and arc manipulation.
Coated electrodes which can be used with either direct or alternating current are available.
Alternating current is more desirable while welding in restricted areas or when using the high
currents required for thick sections because it reduces arc blow. Arc blow causes blowholes,
slag inclusions, and lack of fusion in the weld.
An alternating current is used in atomic hydrogen welding and in those carbon arc processes
that require two carbon electrodes. It permits a uniform rate of welding and electrode
consumption. In carbon-arc processes where one carbon electrode is used, direct current
straight polarity is recommended because the electrode will be consumed at a lower rate.
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Aluminum or aluminum oxide (even when present in 0.01 percent), silicon, silicon dioxide, and
iron sulfate unstable. Iron oxide, manganese oxide, calcium oxide, and stabilize the arc.
When phosphorus or sulfur is present in the electrode more than 0.04 percent, they will impair
the weld metal because they are transferred from the electrode to the molten metal with very
little loss. Phosphorus causes grain growth, brittleness, and “cold shortness” (i. e., brittle when
below red heat) in the weld. These defects increase in magnitude as the carbon content of the
steel increases. The sulfur acts as a slag, breaks up the soundness of the weld metal, and
causes “hot shortness” (i. e., brittle when above red heat). Sulfur is particularly harmful to bare
low-carbon steel electrodes with a low manganese content. Manganese promotes the formation
of sound welds.
If the heat treatment, given the wire core of an electrode, is not uniform, the electrode will
produce welds inferior to those produced with an electrode of the same composition that has
been properly heat treated.
Deposition Rates
The different types of electrodes have different deposition rates due to the composition of the
coating. The electrodes containing iron powder in the coating have the highest deposition rates.
In the United States, the percentage of iron power in a coating is 10 to 50 percent. This is based
on the amount of iron powder in the coating versus the coating weight. This is shown in the
formula:
These percentages are related to the requirements of the American Welding Society (AWS)
specifications. The European method of specifying iron power is based on the weight of
deposited weld metal versus the weight of the bare core wire consumed. This is shown as
follows:
Thus, if the weight of the deposit were double the weight of the core wire, it would indicate a 200
percent deposition efficiency, even though the amount of the iron powder in the coating
represented only half of the total deposit. The 30 percent iron power formula used in the United
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States would produce a 100 to 110 percent deposition efficiency using the European formula.
The 50 percent iron power electrode figured on United States standards would produce
efficiency of approximately 150 percent using the European formula.
Non-Consumable Electrodes
Types
1. The carbon electrode is a non-filler metal electrode used in arc welding or cutting,
consisting of a carbon graphite rod that may or may not be coated with copper or other
coatings.
2. The tungsten electrode is defined as a non-filler metal electrode used in arc welding or
cutting, made principally of tungsten.
Carbon Electrodes
The American Welding Society does not provide specifications for carbon welding electrodes,
but there is a military specification, no. MIL-E-17777C, entitled, “Electrodes Cutting and Welding
Carbon-Graphite Uncoated and Copper Coated.”
This specification provides a classification system based on three grades: plain, uncoated, and
copper coated. It provides diameter information, length information, and requirements for size
tolerances, quality assurance, sampling, and various tests. Applications include carbon arc
welding, twin carbon arc welding, carbon-cutting, and air carbon arc cutting and gouging.
Stick Electrodes
Stick welding electrodes vary by:
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As described above, there are many kinds of electrodes. Here are the most popular stick
welding (SMAW) electrodes:
E6013 and E6012: For thin metals and joints that do not easily fit together.
E6011: Good for working on surfaces that are oily, rusted, or has dirt. Versatile in that it
works with DC or AC polarity. Creates little slag, another big plus. Note that this electrode
should not be placed into an electrode oven.
E6010: Similar to the E6011 but only works with direct current (DC). Note that this
electrode should not be placed into an electrode oven.
E76018 and E7016: Manufactured with iron powder in the flux. It creates strong welds
but has a puddle that might present some control issues for beginners.
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