When manual metal arc welding, which electrode polarity should I use?

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WHEN MANUAL METAL ARC

WELDING, WHICH ELECTRODE
POLARITY SHOULD I USE?

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Frequently Asked Questions

The first important point is that not all MMA electrodes can be used with all

polarities. Electrode manufacturer information and specifications such as BS EN

ISO 2560:2009 and AWS A5.1-2012, define the polarity with which different coated

electrodes may be used. The choice of polarity also depends on the type of the

material, welding position and joint design. A welding procedure should specify

the polarity for each weld run.

It is necessary to define terms to specify the polarity of the welding process. The

part of the welding circuit that is positive (attracts electrons in the arc) is the

anode. The part of the welding circuit that is negative (produces electrons in the

arc) is the cathode. A useful mnemonic for this is PANiC (Positive Anode, Negative

Cathode).

When the welding process is performed in DC mode, the electrode (either MMA

electrode, MIG/MAG/flux- or metal-cored wire or tungsten electrode), can be either

positive or negative. This results in either Direct Current Electrode Positive (DCEP)

or Direct Current Electrode Negative (DCEN). DCEP was also historically known as

Direct Current Reverse Polarity (DCRP) or simply "Reverse", whereas DCEN was

also known as Direct Current Straight Polarity (DCSP) or simply "Straight".

In TIG welding, the split of heat between the anode and cathode is significant.

Approximately 2/3rds of the heat is generated at the positive anode, due to the

impingement of high speed, high energy electrons. The negative cathode does not

experience this effect, and can even undergo cooling by thermionic emission

dependent on the material. For example, the tungsten electrode is thermionic, so

will experience this cooling effect. For this reason, DCEN polarity is the most

common choice for TIG welding when the cleaning action of the DCEP process is

not needed. The use of DCEP for TIG welding necessitates larger diameter

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tungsten electrodes and water-cooling, and is most commonly used as only part of

the cycle in AC welding.

The MMA process however, with its consumable electrode, does not have these

concerns. The heat distribution between the electrode and the workpiece is also

different, and is not as strongly controlled by the polarity. In particular, the

movement of material directly from the consumable electrode to the workpiece

results in significant balancing of the heat between the two points.

What is more important than the heat distribution is the effect of polarity on

penetration in MMA welding. In general, operating on DCEP results in greater

penetration, and DCEN results in reduced penetration and a reduction in dilution

of the weld metal with the substrate. This is important for electrodes that are

capable of being used on both DC polarities (and AC). The DCEN mode is often

used on open root runs to reduce the risk of burn-through, whereas DCEP is used

to reduce the risk of lack of fusion defects. DCEN can also be used for surfacing

applications in order to minimise penetration, and thin sheet welding. AC is also

used as a method of reducing the potential for arc blow. The overruling factor

however is still the electrode flux coating, which is inherent to the welding

electrode, and results in polarity restrictions specified by the manufacturer.

For completeness, information is given here about the MIG/MAG and submerged

arc process and the influence of polarity.

For MIG/MAG welding, DCEN and AC are not commonly used because it is difficult

to achieve a stable spray condition, mostly operating in globular transfer, which

does not necessarily result in an acceptable weld. Equipment manufacturers are

increasingly looking to develop power sources that can use these conditions

however. The DCEP condition also aids melting of the wire due to the

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impingement of electrons. This heat is again transferred to the weld pool through

the passage of molten droplets, helping balance the anode and cathode.

Submerged arc welding is similar to MIG/MAG, with DCEP being the most

commonly used polarity, but DCEN is seen more often in this process, particularly

for surfacing applications, where reduced penetration and dilution with the

substrate is preferred. AC is used when performing multiple wire welding, typically

with a DC leading wire and AC for all trailing wires to reduce arc blow problems.

References

AWS Welding Handbook - American Welding Society

Jefferson's Welding Encyclopedia, 18th Edition - American Welding Society

Principles of Welding - Robert W. Messler, Jr

Procedure Handbook of Arc Welding - Lincoln Electric

Welding Metallurgy, 2nd Edition - Sindo Kou

ANSI/AWS A5.1-2012 Specification for carbon steel electrodes for shielded metal

arc welding

BS EN ISO 2560:2009 Welding consumables. Covered electrodes for manual metal

arc welding of non alloy and fine grain steels. Classification

For more information, please contact us.

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