Stick welding can be difficult to master. It begins with selecting the correct electrode for each job.
Stick electrodes are available in many types, each of which provides different mechanical properties and operates with a type of welding power source.
When selecting a stick electrode, farmers must consider base metal type, joint fit and welding positions.
The first step is to determine the base metal composition to match the electrode composition to the base metal type as closely as possible.
Welders who aren’t sure about the base metal composition should ask themselves these questions:
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- Appearance – When working with a broken part or component, check for a coarse and grainy internal surface, which usually means the base material is a cast metal.
- Magnetic – If the base metal is magnetic, chances are good it is carbon steel 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.
- Sparks – As a rule of thumb, more flare in the sparks indicates a higher carbon content such as in A-36 grade steel.
- Bite – A chisel will bite into a softer metal, such as mild steel or aluminum, and bounce off harder metals, such as high carbon steel, chrome-moly or cast iron.
To prevent cracking or other weld problems, match the minimum tensile strength of the electrode to the tensile strength of the base metal.
Operators 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. The number “60” on an E6011 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.
Some electrodes can be used with only AC or DC power; 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.
The type of current used also influences the penetration profile of the weld.
A DCEP compatible electrode, such as an E6010, delivers deep penetration and produces an extremely tight arc. It also has the ability to penetrate through rust, oil, paint and dirt.
A DCEN compatible electrode, such as an E6012, 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 E6013, 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.
Thin materials will need an electrode that produces soft arcs, such as a 6013. As well, smaller diameter electrodes provide shallow penetration to help prevent burn-through on thinner materials.
Welders should also assess the joint design and fit-up. If they are working on a joint with a tight fit-up or one that is not beveled, they should use an electrode that provides a digging arc to ensure sufficient penetration, such as an E6010 or E6011.
For materials with wide root openings, welders should select an electrode such as an E6012 that creates a concave weld face suitable for bridging gaps and making groove welds.
To determine welding positions suitable for a particular electrode, refer to the third digit in the AWS classification. This is how to decipher the qualified electrode position: 1 = flat, horizontal, vertical and overhead; 2 = flat and horizontal only.
A 7018 electrode can be used in the flat, horizontal, vertical and overhead positions.
Assess conditions the welded part will encounter throughout its service. If it will be used in high heat or low temperature environments or subjected to repetitive shock loading, use a low hydrogen electrode with higher ductility to reduce the chance of weld cracking.
As well, check for welding specifications if working on critical applications such as a pressure vessel or boiler fabrication. In most cases, these welding specifications require specific types of electrodes.
To achieve best results, remove excessive mill scale, rust, moisture, paint and grease. Clean base metals help prevent porosity and increase travel speeds.
If cleaning the base metal is not possible, E6010 or E6011 electrodes deliver a deep penetrating arc that can cut through contaminants.
These factors will help overcome the challenges of selecting the correct stick electrode. However, given the range of available electrodes, several solutions may exist for one application.
