Documente Academic
Documente Profesional
Documente Cultură
weldguru.com/welding-electrode/amp/
Table of Contents
An electrode is a metal wire that is coated. 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 wire.
Electrode selection is critical to ease of cleanup, weld strength, bead quality and for minimizing any spatter. Electrodes need to be stored
in a moisture free environment and carefully removed from any package (follow the directions to avoid damage).
For the past 5 years I’ve helped well over 10,000 beginners and hobbyists get started learning to weld through my free training. If you’d
like to get started, Download my FREE beginner’s guide to MIG welding.
A
slag cover is needed to protect molten or solidifying weld metal from
the atmosphere. This cover can be obtained from the electrode coating.
The
composition of the welding electrode coating determines its usability,
as well as the composition of the deposited weld metal and the electrode
specification.
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 metal to be welded, the position of the weld (flat,
horizontal, vertical, or overhead); and the type of current and polarity
required.
Welding Electrode
1/11
Popular Welding Electrode (E6010) used for general purpose fabrication, construction, pipe welding, and shipbuilding
Classification
The American Welding Society’s classification number series for welding electrodes has been
adopted by the welding industry. The electrode identification system for
steel arc welding is set up as follows:
Coating, Current and Polarity Types Designated By the Fourth Digit in the
Electrode Classification Number
0 * *
If you're new to welding and you'd like a simple training so you can learn quickly, without the headaches,
Download my FREE beginner’s
guide to MIG welding.
When the fourth (or last) digit is 0, the type of coating and current to be used are determined by the third digit.
Table 5-4
The welding electrode identification system for stainless steel arc welding is set up as follows:
2/11
Classification System for Submerged Arc Electrodes
The system for identifying solid bare carbon steel for submerged arc is as follows:
The most important aspect of solid welding electrode wires and rods in
their composition, which is given by the specification. The
specifications provide the limits of composition for the different wires
and mechanical property requirements.
Coatings
The coatings of welding electrodes
for welding mild and low alloy steels may have from 6 to 12 ingredients,
3/11
which includes:
If you're new to welding and you'd like a simple training so you can learn quickly, without the headaches,
Download my FREE beginner’s
guide to MIG welding.
The principal types of welding electrode coatings for mild steel and are described below.
Storage
Electrode Oven
5/11
Figure 5-32: Electrode Drying Oven
Electrodes that have an "R" suffix in the AWS classification have a higher resistance to moisture.
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 for welding manganese steel and
other purposes where a coated electrode is not required or is
undesirable. A diagram of the transfer of metal across the arc of a bare
electrode is shown in figure 5-29.
Bare Electrodes
Molten metal transfer with a bare electrode.
If you're new to MIG welding and you'd like a simple training so you can learn quickly, without the headaches,
Download my FREE
beginner’s guide to MIG welding.
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 increase its stability. This
eliminates wide fluctuations in the voltage so that the arc can be
maintained without excessive spattering.
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.
Tungsten Electrodes
Nonconsumable 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.
7/11
Pure tungsten (99. 5 percent tungsten) electrodes are generally
used on less critical welding operations than the tungstens which are
alloyed. This type of electrode has a relatively low current-carrying
capacity and a low resistance to contamination.
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 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 welding current. Tungsten
electrodes alloyed with thorium and zirconium retain their shape longer
when touch-starting is used.
If you're new to MIG welding and you'd like a simple training so you can learn quickly, without the headaches,
Download my FREE
beginner’s guide to MIG welding.
8/11
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.
Deposition Rates
The different types of electrodes have different deposition rates due to
the composition of the coating. The electrodes containing iron power in
the coating have the highest deposition rates. In the United States,
the percentage of iron power in a coating is in the 10 to 50 percent
range. This is based on the amount of iron power in the coating versus
the coating weight. This is shown in the formula:
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 power in the coating represented only half of
the total deposit. The 30 percent iron power formula used in the United
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 an efficiency of approximately 150
percent using the European formula.
9/11
Non-consumable Electrodes
Types
There are two types of nonconsumable
welding electrodes.
Carbon Electrodes
The American
Welding Society does not provide specification 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".
Stick Electrodes
Stick welding electrodes vary by:
size: common
sizes are 1⁄16, 5⁄64, 3⁄32 (most common), 1⁄8, 3⁄16, 7⁄32, 1⁄4, and 5⁄16
inch. Core wire used with electrodes needs to be narrower than the
materials that are welded.
material: stick welding electrodes come in cast iron, high carbon steel, mild steel, iron-free (nonferrous) and special alloys.)
strength:
referred to as tensile strength. Each weld needs to be stronger than
the metal being welded. This means that the materials in the electrode
need to be stronger as well.
welding position (horizontal, flat etc): different electrodes are used for each welding position.
iron powder mix
(up to 60% in flux): iron powder in the flux increases the amount of
molten metal available for the weld (heat turns powder into steel).
soft arc designation: for thinner metals or for metals that don't have a perfect fit or gap.
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. Creates strong welds, but has a puddle that might present some
control issues for beginners.
For Additional Reading
Storing and Redrying Electrodes
NEXT: Flux Cored Electrodes >>>
10/11
Page Author: Jeff Grill
11/11