Welding Electrode Comparison: Find the Right Model and Grade

Introduction to Welding Rod Grades

Welding rods, also known as electrodes, are essential components in the welding process. They serve as the filler material that joins two or more pieces of metal together, and their performance can significantly impact the quality and durability of the weld. Understanding welding rod grades is crucial for anyone involved in welding, whether you are a seasoned professional or a beginner.

Importance of Welding Rod Grades

Welding rod grades are classifications that indicate the characteristics and capabilities of each rod. These grades help welders select the appropriate rod based on the specific requirements of their projects. Factors such as tensile strength, welding position, and the type of coating are all considered in these classifications, making it easier for welders to choose the right rod for their needs.

AWS Numbering System

The American Welding Society (AWS) has established a standardized numbering system to classify welding rods. Each rod is identified by a series of numbers and letters that convey critical details regarding its properties. For example, the classification code E7018 can be broken down as follows:

• E: Indicates that it is an electrode.
• 70: Refers to the minimum tensile strength of the weld metal in thousands of pounds per square inch (psi), meaning it has a tensile strength of 70,000 psi.
• 1: Indicates the welding position; in this case, it can be used in all positions (flat, horizontal, vertical, and overhead).
• 8: Refers to the type of coating and its characteristics, which in this case is a low-hydrogen potassium coating.

This system allows welders to quickly assess the suitability of a rod for their specific application.

Classification and Numbering System of Welding Rods

The classification and numbering system for welding rods, especially those used in Shielded Metal Arc Welding (SMAW), is standardized by the American Welding Society (AWS). This system provides essential information about the welding rod’s properties, aiding welders in selecting the appropriate rod for their specific tasks.

Prefix and Tensile Strength

The classification code of a welding rod typically starts with the prefix “E,” indicating it is an electrode. The digits following this prefix convey critical information about the welding rod’s tensile strength and application.

• Prefix “E”: Denotes an arc welding electrode.
• Tensile Strength: The first two (or sometimes three) digits after “E” denote the minimum tensile strength of the weld metal in thousands of pounds per square inch (psi).
  • E6010: Indicates a tensile strength of 60,000 psi.
  • E7018: Indicates a tensile strength of 70,000 psi.

Welding Position

The next-to-last digit specifies the positions in which the electrode can be used.

• 1: Usable in all positions (flat, horizontal, vertical, and overhead).
• 2: Suitable for flat and horizontal positions only.
• 4: Usable for flat, horizontal, vertical down, and overhead positions.

Flux Coating and Current Type

The last digit provides details about the type of flux coating and the rod’s specific characteristics. Flux coating affects the rod’s performance, including penetration, spatter, and the type of current it can use.

Cellulosic Flux Coating

• 0: Cellulosic flux coating, deep penetration, fast freezing, ideal for out-of-position welding, requires DC+ polarity.
• 1: Cellulosic flux coating with potassium, can be used with AC or DC+ polarity.

Rutile Flux Coating

• 2: Rutile flux coating with sodium, medium penetration, can be used with AC or DC- polarity.
• 3: Rutile flux coating with potassium, light penetration, usable with AC, DC+, or DC- polarity.
• 4: Rutile iron powder flux coating, medium penetration, usable with AC, DC+, or DC- polarity.

Low-Hydrogen Flux Coating

• 5: Low-hydrogen flux coating with sodium, medium penetration, requires DC+ polarity.
• 6: Low-hydrogen flux coating with potassium, medium penetration, usable with AC or DC+ polarity.
• 8: Low-hydrogen iron powder flux coating, medium penetration, usable with AC or DC+ polarity.

Additional Designators

Some electrodes come with additional designators that provide more specific information about their performance characteristics and suitability for certain applications.

• E7018-H4R: Indicates a maximum diffusible hydrogen limit of 4 mL per 100 grams of deposited weld metal and compliance with AWS moisture absorption requirements. The “R” signifies the rod can be used for nine hours after the package is opened before needing to be redried.
• E7018-1 H4R: The “-1” indicates better mechanical performance at low temperatures (down to -40 degrees Fahrenheit).

Common Electrodes

Understanding the classification and numbering system helps welders choose the right electrode for their needs. Here are some common electrodes and their characteristics:

• E6010: Known for deep penetration and fast freezing, ideal for dirty or rusty materials, and out-of-position welding. Requires DC+ polarity and has a cellulosic flux coating.
• E6011: Similar to E6010 but can be used with AC or DC+ polarity, making it more versatile.
• E7018: Provides a smooth weld with minimal spatter and strong tensile strength, ideal for structural welding. Can run on AC or DC+ power sources and has a low-hydrogen iron powder flux coating.

By understanding this classification and numbering system, welders can ensure optimal performance and weld quality by selecting the appropriate welding rod for their specific applications.

Different Welding Electrode Grade Chart

1. Carbon Steel Welding Rod

Please refer to: GB/T 5117-1995 “Carbon Steel Electrodes for Shielded Metal Arc Welding.

Comparison of Old and New Designations for Commonly Used Carbon Steel Welding Rods and Their Applicable Scope:

2. Alloy Steel Welding Rod

Low Alloy Steel Welding Rod:

Comparison of old and new model numbers of alloy steel welding rods, and their application scope:

Description: E5003-A1 – Carbon Molybdenum Steel; E5503-B1, B2, B3 – Increased Chromium content, Chromium Molybdenum Steel; E5515-C2, C2, C3 – Increased Nickel content, Nickel Steel; E5518-NM – Nickel Molybdenum Steel; W6015-D1, D2, D3 – Increased Manganese content, Manganese Molybdenum Steel; E××10-G, E××03-G, etc.: Other low alloy steel welding rods.

3. Stainless Steel Welding Rod

Comparison of old and new models of stainless steel welding rods and their application range:

Description: 15, 25 – Alkaline, direct current reversed polarity; 16, 17, 26 – Titanium calcium type, alternating current or direct current reversed polarity.

4. Cast Iron Welding Rod

5. Low-temperature Steel Welding Rod

Comparison of old and new model numbers for low temperature steel welding rods and their application range

6. Welding Wires for Gas Shielded Welding, Submerged Arc Welding, and Gas Welding

7. Welding Fluxes

Welding Fluxes for Carbon Steel and Low Alloy Steel:

Welding Fluxes for Stainless Steel, Non-ferrous Metals, and Repair Welding:

Characteristics of Different Welding Rod Grades

Understanding the characteristics of different welding rod grades is crucial for selecting the right rod for specific welding tasks. Each grade has distinct properties that make it suitable for particular applications, materials, and welding conditions.

E6010

• Tensile Strength: 60,000 psi (pounds per square inch), indicating the maximum stress the weld can withstand.
• Welding Positions: All positions (flat, horizontal, vertical, and overhead).
• Coating: Cellulosic.
• Current Type: DC+ (DCEP, Direct Current Electrode Positive).
• Characteristics:
  • Provides deep penetration, ideal for welding through contaminants such as rust, oil, or paint.
  • Fast freezing puddle allows for welding in all positions.
  • Produces a strong, durable weld but requires a higher skill level due to its aggressive arc and the need for precise manipulation.
  • Commonly used in pipeline welding and for root passes in multi-pass welds.

E6011

• Tensile Strength: 60,000 psi.
• Welding Positions: All positions.
• Coating: Cellulosic with potassium.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • Similar to E6010 but more versatile as it can be used with both AC and DC power sources.
  • Good penetration and can handle dirty or rusty materials.
  • Higher spatter compared to E6010, but easier to use with AC power sources.
  • Suitable for general repair and maintenance work.

E6013

• Tensile Strength: 60,000 psi.
• Welding Positions: All positions.
• Coating: Rutile with titania potassium.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • Easy to use with a smooth arc and low spatter, making it ideal for beginners.
  • Produces a softer arc with moderate penetration, suitable for thin or sheet metal.
  • Commonly used in light fabrication, automotive repair, and hobby welding.

E7018

• Tensile Strength: 70,000 psi.
• Welding Positions: All positions.
• Coating: Low hydrogen with iron powder.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • High tensile strength and low hydrogen content reduce the risk of weld cracking.
  • Produces a smooth weld with minimal spatter and easy slag removal.
  • Suitable for critical applications requiring strong, high-quality welds, such as structural welding, pressure vessels, and high-strength low alloy steels.
  • Requires proper storage to prevent moisture absorption, which can affect weld quality.

E7014

• Tensile Strength: 70,000 psi.
• Welding Positions: All positions.
• Coating: Rutile with iron powder.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • Provides a high deposition rate and good penetration.
  • Produces a smooth and stable arc, making it easy to control and suitable for various positions.
  • Commonly used for welding mild steel and for general fabrication and construction work.

E7024

• Tensile Strength: 70,000 psi.
• Welding Positions: Flat and horizontal positions.
• Coating: Low hydrogen with iron powder.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • Known for high deposition rates and efficiency in flat and horizontal welding.
  • Produces smooth, strong welds with good slag coverage and easy slag removal.
  • Ideal for high-speed welding applications, such as heavy fabrication and production environments.

E308L

• Tensile Strength: Varies depending on the alloy composition.
• Welding Positions: All positions.
• Coating: Low carbon stainless steel.
• Current Type: AC and DC+ (DCEP).
• Characteristics:
  • Specifically designed for welding low carbon stainless steels.
  • Provides excellent corrosion resistance, commonly used in the food processing, chemical, and petrochemical industries.
  • Produces a clean, aesthetically pleasing weld with minimal risk of carbide precipitation.

Specialized Coatings and Additives

• Cellulosic Coatings: Enhance deep penetration, ideal for out-of-position welding and works well on dirty or contaminated surfaces.
• Rutile Coatings: Known for ease of use, providing medium to light penetration with a smooth arc and low spatter, suitable for various welding applications.
• Low Hydrogen Coatings: Minimize hydrogen pickup to reduce the risk of weld cracking, essential for critical applications like structural welding.
• Iron Powder Coatings: Increase deposition rates, enhancing productivity and efficiency in welding operations.

By understanding the unique characteristics of these welding rod grades, welders can select the most appropriate rod for their specific needs, ensuring high-quality, reliable welds tailored to the demands of their projects.

Comparative Analysis of Popular Welding Rod Grades

In the realm of welding, selecting the appropriate welding rod grade is pivotal to achieving high-quality, durable welds. This section provides a detailed comparative analysis of some of the most commonly used welding rod grades, focusing on their unique characteristics, applications, and performance metrics.

E6010 Welding Rod

Tensile Strength: 60,000 PSI
Welding Positions: All positions (flat, horizontal, vertical, and overhead)
Coating: High cellulose-sodium
Current: DC-only (DCEP)
Penetration: Deep
Arc Characteristics: Tight, erratic

Special Applications: E6010 is ideal for root passes, welding through dirty, oily, or painted surfaces, and stove pipe welding. It excels in pipeline welding due to its ability to penetrate surface contaminants and provide strong, reliable welds in all positions. For instance, E6010 is extensively used in the construction of oil and gas pipelines, where weld integrity is critical.

E6011 Welding Rod

Tensile Strength: 60,000 PSI
Welding Positions: All positions
Coating: High cellulose-potassium
Current: AC and DC (DCEP & AC)
Penetration: Deep
Arc Characteristics: Tight, erratic

Special Applications: Similar to E6010, E6011 is versatile and preferred for general industrial tasks, including root passes and welding on dirty or painted surfaces. Its compatibility with both AC and DC power sources makes it a popular choice for home welding setups and for learners who need easier arc control. E6011 is often used in repair and maintenance work on farms, where equipment may have rust or other contaminants.

E6013 Welding Rod

Tensile Strength: 60,000 PSI
Welding Positions: All positions
Coating: High titania-potassium
Current: AC, DCEN, and DCEP
Penetration: Shallow to medium
Arc Characteristics: Smooth

Special Applications: Known for its smooth arc and ease of use, E6013 is ideal for beginners and is commonly used for welding clean sheet metal. It produces a softer arc with moderate penetration, making it suitable for thin or light-gauge metals in light fabrication and automotive repair. E6013 is often chosen for projects such as car body repairs and thin metal structures due to its ease of use and clean weld appearance.

E7018 Welding Rod

Tensile Strength: 70,000 PSI
Welding Positions: All positions except vertical down
Coating: Low-hydrogen iron
Current: AC and DC
Penetration: Medium
Arc Characteristics: Smooth, clear puddle

Special Applications: E7018 is a high-strength, low-hydrogen electrode used for structural welding, power generation, petrochemical applications, pressure vessels, and piping. Its low hydrogen content minimizes the risk of weld cracking, and it is highly resistant to hydrogen embrittlement, making it suitable for critical infrastructure projects. For example, E7018 is commonly used in the construction of bridges and high-rise buildings where weld strength and integrity are paramount.

Key Differences and Applications

Penetration and Arc Characteristics

• E6010 and E6011: Both offer deep penetration and are suitable for root pass welds and welding through surface contaminants. E6010’s tighter arc is DC-only, while E6011 can be used with both AC and DC and has a slightly smoother arc.
• E6013: Provides shallow to medium penetration with a smooth arc, making it ideal for clean sheet metal and beginner welders.
• E7018: Offers medium penetration with a smooth, clear puddle, suitable for a wide range of structural and general-purpose welding applications.

Tensile Strength

• E6010, E6011, and E6013: All have a tensile strength of 60,000 PSI, suitable for most general welding tasks.
• E7018: Higher tensile strength of 70,000 PSI, making it more suitable for high-strength applications.

Current and Position

• E6010: DC-only, usable in all positions.
• E6011: AC and DC, usable in all positions.
• E6013: AC, DCEN, and DCEP, usable in all positions.
• E7018: AC and DC, usable in all positions except vertical down.

Coating and Slag

• E6010 and E6011: High cellulose coatings with light, flaky slag.
• E6013: High titania-potassium coating with light, easy-to-remove slag.
• E7018: Low-hydrogen iron coating with easy slag release and minimal spatter.

Choosing the Right Welding Rod

When selecting the appropriate welding rod, consider the specific requirements of your project. Factors such as the type of metal being welded, the welding position, and the power source available are crucial. For instance, E6010 and E6011 are excellent for projects requiring deep penetration and the ability to weld through contaminants, while E6013 is ideal for clean, thin metals. E7018 is the go-to choice for high-strength, critical applications where weld integrity is essential. Understanding these differences can help ensure optimal performance and high-quality welds.

Choosing the Right Welding Rod Grade for Your Project

Selecting the appropriate welding rod grade is essential for achieving high-quality, durable welds. The choice of welding rod depends on various factors such as the type of metal being welded, the welding position, the power source available, and the specific requirements of the project. Understanding these factors will help you make an informed decision.

Assessing Material Type and Thickness

Different metals and their thicknesses require specific welding rod grades to ensure optimal performance. For example, mild steel, which is commonly used in construction, automotive, and general fabrication, requires particular attention to the choice of welding rod:

• Mild Steel: E6010 and E6011 are excellent choices due to their deep penetration capabilities and ability to handle dirty or rusty surfaces. For instance, E6010 is often used in pipeline welding where cleanliness cannot always be guaranteed. E7018 is suitable for thicker sections where higher tensile strength is required, making it ideal for structural welding projects such as bridges and buildings.
• Stainless Steel: E308L is the preferred choice as it offers excellent corrosion resistance and produces clean, aesthetically pleasing welds. This rod is commonly used in the food processing and pharmaceutical industries, where cleanliness and corrosion resistance are critical.
• High-Strength Low-Alloy Steel (HSLA): E7018 is ideal for welding HSLA steels due to its high tensile strength and low hydrogen content, minimizing the risk of cracking. It is frequently used in the construction of heavy machinery and pressure vessels.

Determining Welding Positions

The welding position plays a crucial role in selecting the right rod. For instance, if you’re welding in various positions, you need a versatile rod:

• All Positions: E6010, E6011, E6013, and E7018 can be used in all positions (flat, horizontal, vertical, and overhead). These rods are versatile and suitable for complex welding tasks, such as repairing farm equipment or constructing metal frameworks.
• Flat and Horizontal Only: E7024 is designed for high deposition rates and is best suited for flat and horizontal welding positions. It is ideal for high-speed welding applications like manufacturing large steel tanks.

Considering Welding Environment and Conditions

Environmental factors such as the presence of contaminants, the power source, and whether the work is indoors or outdoors affect rod selection. For example:

• Contaminated Surfaces: E6010 and E6011 are excellent for welding on surfaces with rust, oil, or paint. Their deep penetration and aggressive arc allow them to weld through contaminants effectively, making them suitable for repair work on old machinery.
• Power Source: E6011 is versatile as it can be used with both AC and DC power sources, making it suitable for home welding setups and areas with limited power options. E6010, on the other hand, requires DC+ power, often used in industrial settings.
• Indoor vs. Outdoor: For outdoor welding, where wind and weather conditions might affect the welding process, E6011 is a good choice due to its ability to handle AC power, which is less affected by environmental factors. It is often used in construction sites and field repairs.

Evaluating Project Requirements

Specific project requirements such as tensile strength, ease of use, and desired weld appearance also influence rod selection. For example:

• Tensile Strength: For projects requiring high-strength welds, E7018 with a tensile strength of 70,000 PSI is the best choice. It is commonly used in structural welding and critical applications, such as building bridges and high-rise buildings.
• Ease of Use: For beginners and light fabrication work, E6013 is recommended due to its smooth arc, low spatter, and ease of handling. It is ideal for welding thin or sheet metal, such as in automotive body repairs.
• Weld Appearance: For applications where weld appearance is important, such as in the food processing industry, E308L produces clean, aesthetically pleasing welds with excellent corrosion resistance.

Special Considerations

Certain projects may have specific requirements that necessitate the use of specialized rods. For instance:

• Moisture Sensitivity: E7018 H4R has specific moisture absorption requirements and must be stored properly to prevent moisture pickup, which can lead to weld defects. This rod is often used in critical applications where weld integrity is paramount.
• Low Temperature Applications: For welding in low-temperature environments, electrodes like E7018-1 H4R are designed to perform better at sub-zero temperatures, ensuring weld integrity. These are used in the construction of pipelines in arctic regions.

By carefully considering these factors and understanding the characteristics of different welding rod grades, you can select the most suitable rod for your project. This ensures high-quality welds that meet the specific demands of the task at hand.

Technical Guidance for Using Specific Welding Rod Grades

Successfully using welding rods requires understanding the specific techniques and considerations for each grade. Here are detailed guidelines for effectively using some of the most common welding rod grades:

E6010 Welding Rod

Preparation and Technique:

• Surface Preparation: Clean the metal surface to remove dirt, rust, or oil. While E6010 can handle some contaminants, a clean surface improves weld quality.
• Amperage Settings: For E6010, recommended amperage ranges are as follows:
  • 1/8″ rod: 90-125 amps
  • 3/32″ rod: 60-90 amps
  • 1/16″ rod: 30-60 amps
• Welding Technique: Use a whipping or weaving motion to control the puddle and prevent burn-through, especially on thin materials. Maintain a tight arc length to stabilize the arc.
• Polarity: Use DC+ (DCEP) for optimal performance.

Applications:

• Root Passes: Ideal for root passes in pipe welding due to its deep penetration and ability to handle contaminants.
• Out-of-Position Welding: Suitable for vertical and overhead positions, making it versatile for various field applications.

E6011 Welding Rod

Preparation and Technique:

• Surface Preparation: Clean the surface, but E6011 can handle slightly rusty or painted surfaces.
• Amperage Settings: Suggested amperage ranges include:
  • 1/8″ rod: 90-125 amps
  • 3/32″ rod: 60-90 amps
  • 1/16″ rod: 30-60 amps
• Welding Technique: Use a whipping or circular motion to control the arc and penetration. Keep a short arc length for better control.
• Polarity: Compatible with both AC and DC+ (DCEP).

Applications:

• General Repair Work: Effective for maintenance and repair tasks where surface preparation is challenging.
• Field Welding: Useful for outdoor applications due to its versatility with power sources.

E6013 Welding Rod

Preparation and Technique:

• Surface Preparation: Clean the surface thoroughly; E6013 performs best on clean surfaces.
• Amperage Settings: Recommended amperage ranges are:
  • 1/8″ rod: 70-90 amps
  • 3/32″ rod: 50-70 amps
  • 1/16″ rod: 30-50 amps
• Welding Technique: Employ a drag technique, keeping the electrode at a slight angle to produce a smooth arc. Maintain a consistent travel speed for even weld beads.
• Polarity: Can be used with AC, DCEN, or DCEP.

Applications:

• Light Fabrication: Ideal for thin metals and sheet metal work due to its smooth arc.
• Automotive Repairs: Commonly used in automotive body repairs for clean welds.

E7018 Welding Rod

Preparation and Technique:

• Surface Preparation: Thoroughly clean the surface to remove rust, oil, or paint. Proper preparation prevents hydrogen-induced cracking.
• Amperage Settings: Suggested amperage ranges are:
  • 1/8″ rod: 90-130 amps
  • 3/32″ rod: 50-90 amps
  • 1/16″ rod: 30-50 amps
• Welding Technique: Use a slight weave or drag technique, maintaining a steady travel speed for smooth bead formation. Keep the arc length short to control the puddle.
• Polarity: Suitable for both AC and DC+ (DCEP).

Storage and Handling:

• Moisture Control: Store E7018 rods in a dry environment and use rod ovens to keep them at 250-300°F to prevent moisture absorption.

Applications:

• Structural Welding: Widely used in structural applications due to its high tensile strength and low hydrogen content.
• Pressure Vessels: Suitable for welding pressure vessels and critical applications requiring robust weld integrity.

E308L Welding Rod

Preparation and Technique:

• Surface Preparation: Thoroughly clean the stainless steel surface to avoid contamination, which affects corrosion resistance.
• Amperage Settings: Recommended amperage ranges include:
  • 1/8″ rod: 90-120 amps
  • 3/32″ rod: 60-90 amps
  • 1/16″ rod: 30-60 amps
• Welding Technique: Maintain a short arc length and use a slight weaving motion for even bead formation. Control heat input to avoid excessive heat.
• Polarity: Typically used with DC+ (DCEP).

Applications:

• Stainless Steel Fabrication: Ideal for welding low carbon stainless steels in environments requiring high corrosion resistance, such as food processing and pharmaceuticals.

Where to Buy High-Quality Welding Rods

Reputable Brands and Products

Purchasing high-quality welding rods is essential for achieving excellent weld results and ensuring the durability of your projects. Some of the most reputable brands known for their reliable and durable welding rods include:

• Lincoln Electric: Renowned for products like the 5P+ and Excalibur 7018, Lincoln Electric is a preferred choice for many professional welders. The 5P+ is particularly effective for pipe welding and has a strong root pass due to its deep penetration capabilities. The Excalibur 7018, on the other hand, is known for its low hydrogen content, making it ideal for structural steel applications where strength and ductility are crucial.
• Hobart Brothers: Another reputable source for high-quality stick welding electrodes. Hobart’s 7018 rod is well-regarded for its good arc stability, reliable re-strikes, and easy slag release. This rod excels in construction projects requiring robust and durable welds, particularly in structural applications.

Understanding Welding Rod Grades

When selecting welding rods, it is crucial to understand the different grades and their specific applications:

• AWS E6010: This rod is used for general-purpose welding, especially where deep penetration is required. It is ideal for pipe welding and other applications where strong root passes are necessary. For instance, E6010 is often employed in the construction of pipelines and is favored for its ability to perform well in all positions.
• AWS E6011: Similar to E6010, E6011 can be used with both AC and DC power sources, making it versatile for various welding environments. It is suitable for welding on dirty or rusty materials, making it a good choice for repair work.
• AWS E6013: Known for its smooth and stable arc, this rod is often used for general fabrication and repair work. It is ideal for thin or sheet metal applications. E6013 is commonly used in automotive bodywork and home projects due to its ease of use and good appearance.
• AWS E7018: This rod is preferred for welding structural steel and other critical applications due to its high strength and low hydrogen content. It is commonly used in construction projects requiring robust and durable welds, such as bridges and buildings.

Retailers and Online Platforms

High-quality welding rods can be sourced from various retailers and online platforms, providing both convenience and a wide selection of products. Here are some of the best places to purchase welding rods:

• Home Depot: This retailer offers a range of welding rods from brands like Lincoln Electric, Hobart Brothers, and Forney. You can check availability and prices online or visit their physical stores. Home Depot is a convenient option for both professional welders and DIY enthusiasts.
• WeldingMart: Known for its extensive selection of high-quality stick electrodes and rods, WeldingMart stocks products like Lincoln Electric’s Fleetweld 5P+ and Excalibur 7018. Although specific products may occasionally be unavailable, WeldingMart provides various other options suitable for different welding needs.
• Amazon: Amazon offers a broad range of welding rods from multiple brands, including Forney, TOOLIOM, and more. The platform provides customer reviews and ratings, which can be helpful in making informed decisions. Amazon is a great choice for those looking to compare different brands and read user feedback.

Selection Criteria

To choose the right welding rods for your projects, consider the following factors:

• Welding Applications: Identify the primary materials you will be working with, such as structural steel, stainless steel, or cast iron. Different rods are designed to optimize weld quality for specific materials.
• Amperage and Duty Cycle: Ensure the electrodes you select have appropriate amperage ratings and duty cycles for your specific projects. This ensures that the rods perform well under the conditions you will be using them.
• Versatility: Opt for electrodes that can handle a wide range of materials and applications. This flexibility can be particularly beneficial for welders who work on diverse projects.
• Quality and Durability: Investing in high-quality electrodes from reputable brands ensures consistent performance and minimal downtime. Quality rods contribute to the overall success and longevity of your welding projects.

By understanding the different welding rod grades, their specific applications, and where to purchase them, you can make informed decisions that lead to successful welding outcomes.

Frequently Asked Questions

Below are answers to some frequently asked questions:

What do the numbers on welding rods mean?

The numbers on welding rods are part of a classification system established by the American Welding Society (AWS) to indicate key characteristics of the electrode. These numbers provide information about the tensile strength, positional usability, and type of flux coating of the electrode.

• The letter “E” at the beginning of the code stands for “electrode.”
• The first two (or three) digits represent the minimum tensile strength of the electrode in thousands of pounds per square inch (psi). For instance, “60” in E6010 indicates a tensile strength of 60,000 psi, while “70” in E7018 indicates 70,000 psi.
• The next to last digit specifies the positions in which the electrode can be used. A “1” means it can be used in all positions (flat, horizontal, vertical, and overhead), while “2” indicates suitability for flat and horizontal positions only.
• The last two digits denote the type of flux coating and the current type the electrode can be used with. For example, “10” in E6010 indicates a high cellulose sodium coating suitable for DC+ (direct current positive) welding, and “18” in E7018 indicates a low-hydrogen sodium coating suitable for DC+ welding and sometimes AC.

Understanding these codes helps in selecting the right welding rod for specific projects, ensuring the appropriate tensile strength, positional usability, and flux characteristics are met.

How do I choose the right welding rod for my project?

Choosing the right welding rod for your project involves several key considerations to ensure a strong, durable, and high-quality weld. Start by identifying the composition and properties of the base metal you are welding. Matching the electrode composition to the base metal type is crucial. For example, when welding steel, select an electrode with a similar tensile strength to the base metal.

Next, consider the tensile strength of the electrode, which should match or exceed that of the base metal. This is indicated by the first two digits of the AWS (American Welding Society) classification on the electrode. For instance, an E6011 electrode has a minimum tensile strength of 60,000 psi.

The type of welding current (AC or DC) compatible with the electrode is also important. The fourth digit of the AWS classification reveals the type of coating and compatible welding current. For example, E6010 is suitable for DCEP (Direct Current Electrode Positive) for deep penetration, while E6013 is compatible with AC and produces a soft arc with medium penetration.

Additionally, consider the welding position. The third digit of the AWS classification indicates the qualified welding positions: 1 for all positions (flat, horizontal, vertical, and overhead) and 2 for flat and horizontal only. For example, a 7018 electrode can be used in all positions.

Evaluate the joint design and fit-up. For joints with tight fit-ups or those that are not beveled, electrodes like E6010 or E6011 that provide a digging arc are ideal. For joints with wide root openings, E6012 is suitable for bridging gaps.

The thickness of the base metal also dictates the size and type of electrode needed. Thicker materials require electrodes with maximum ductility and low hydrogen content to prevent weld cracking, while thinner materials benefit from smaller diameter electrodes with soft arcs, like E6013, to prevent burn-through.

Consider the environmental and service conditions the welded part will encounter. Use low hydrogen electrodes with higher ductility for high heat, low temperature, or repetitive shock loading to reduce the risk of weld cracking. Adhere to specific welding specifications for critical applications such as pressure vessel or boiler fabrication.

Finally, industry regulations and specific application requirements can dictate the use of certain electrodes. For example, in construction, welding must be robust for safety reasons, and specific electrodes may be mandated. By taking these factors into account and understanding the AWS classification system, you can select the right welding rod for your project.

What is the difference between E6013 and E7018 welding rods?

The main difference between E6013 and E7018 welding rods lies in their tensile strength, coating, performance, ease of use, and typical applications.

E6013 welding rods have a tensile strength of 60,000 PSI and are coated with a titania potassium material. This provides a smooth penetrating arc and makes them versatile for use in all positions. E6013 rods are often recommended for beginners because they are easy to start and maintain the arc. They are ideal for lighter to medium penetration tasks, such as welding thin or sheet metal, and are commonly used in manufacturing truck frames, metal furniture, and farm implements. However, they tend to produce more spatter and have harder-to-remove slag.

On the other hand, E7018 welding rods have a higher tensile strength of 70,000 PSI and feature a low-hydrogen iron coating, which makes them crack-resistant and suitable for use in colder environments. E7018 rods produce minimal spatter, have easy slag release, and provide a smooth puddle flow. They require higher amperage and are better suited for high-strength applications, including structural welding and critical infrastructure projects like bridge construction. These rods need to be stored in a rod oven to prevent moisture absorption due to their low-hydrogen content. E7018 rods are known for their stable arc, ease of control, and ability to produce high-quality welds, making them a favorite among experienced welders.

In summary, E6013 rods are suitable for lighter applications and easier for beginners to use, while E7018 rods are preferred for demanding, high-strength applications and offer superior performance in challenging environments.

Can I use the same welding rod for different types of steel?

Using the same welding rod for different types of steel is generally not recommended due to the varying properties and compositions of different steels. The compatibility between the welding rod and the base metal is crucial to ensure a strong, durable, and reliable joint. For instance, welding low-carbon steel typically requires an electrode like E7018, which is suitable for low and medium-carbon steels. However, when welding dissimilar steels, such as alloyed steel to mild steel, specialized electrodes like ER312 stainless filler wire are necessary to accommodate the differences in material properties.

Additionally, the American Welding Society (AWS) classification system provides guidance on the appropriate electrode for specific steels, indicating tensile strength and suitable welding currents. For example, an E6011 electrode is designed for steels with a similar tensile strength.

Using the correct welding rod also depends on the welding technique and joint design. Some electrodes, like E6010 and E6011, are preferred for deep penetration and handling contaminants, while others, like E6013, are better for clean, new sheet metal.

Specialized electrodes are essential for specific applications, such as using E309 or E312 for welding stainless steel to mild steel, to prevent cracks and ensure weld integrity.

In summary, matching the electrode to the base metal composition, considering welding techniques and joint design, and using specialized electrodes for dissimilar metals are critical factors in selecting the appropriate welding rod. Therefore, using the same welding rod for different types of steel without these considerations is not advisable.

Where can I purchase specialized welding rods?

To purchase specialized welding rods, you have several reliable options. Online retailers such as WeldingMart offer a broad selection of high-quality stick electrodes from well-known brands like Lincoln Electric, including popular types like Excalibur 7018 MR and Fleetweld 5P+. Home improvement stores such as Lowe’s and Home Depot also stock a variety of welding rods from reputable brands, providing options in different sizes and classifications, such as AWS E6010 and AWS E6013. For those who prefer buying directly from manufacturers, Lincoln Electric’s official website and authorized distributors are excellent sources for high-quality products. Additionally, local suppliers like Air Liquide may carry welding rods, allowing for immediate access without waiting for shipping. When selecting specialized welding rods, consider your welding applications, required amperage, and the quality of the electrodes to ensure you choose the right products for your projects.