Arc-Welding Fundamentals The Lincoln Electric Company, 1994.

Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix directly, or more commonly, with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. Since the joining is an intermixture of metals, the final weldment potentially has the same strength properties as the metal of the parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the mechanical and physical properties of the base materials cannot be duplicated at the joint.

connected by a work cable to the workpiece and by a "hot" cable to an electrode holder of some type, which makes an electrical contact with the welding electrode. An arc is created across the gap when the energized circuit and the electrode tip touches the workpiece and is withdrawn, yet still with in close contact. The arc produces a temperature of about 6500F at the tip. This heat melts both the base metal and the electrode, producing a pool of molten metal sometimes called a "crater." The crater solidifies behind the electrode as it is moved along the joint. The result is a fusion bond. Arc Shielding However, joining metals requires more than moving an electrode along a joint. Metals at high temperatures tend to react chemically with elements in the air - oxygen and nitrogen. When metal in the molten pool comes into contact with air, oxides and nitrides form which destroy the strength and toughness of the weld joint. Therefore, many arc-welding processes provide some means of covering the arc and the molten pool with a protective shield of gas, vapor, or slag. This is called arc shielding. This shielding prevents or minimizes contact of the molten metal with air. Shielding also may improve the weld. An example is a granular flux, which actually adds deoxidizers to the weld.

Fig. 1 The basic arc-welding circuit In arc welding, the intense heat needed to melt metal is produced by an electric arc. The arc is formed between the actual work and an electrode (stick or wire) that is manually or mechanically guided along the joint. The electrode can either be a rod with the purpose of simply carrying the current between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the current but also melts and supplies filler metal to the joint. Most welding in the manufacture of steel products uses the second type of electrode. Basic Welding Circuit The basic arc-welding circuit is illustrated in Fig. 1. An AC or DC power source, fitted with whatever controls may be needed, is

Fig. 2 This shows how the coating on a coated (stick) electrode provides a gaseous shield around the arc and a slag covering on the hot weld deposit. Figure 2 illustrates the shielding of the welding arc and molten pool with a Stick

electrode. The extruded covering on the filler metal rod, provides a shielding gas at the point of contact while the slag protects the fresh weld from the air. The arc itself is a very complex phenomenon. In-depth understanding of the physics of the arc is of little value to the welder, but some knowledge of its general characteristics can be useful. Nature of the Arc An arc is an electric current flowing between two electrodes through an ionized column of gas. A negatively charged cathode and a positively charged anode create the intense heat of the welding arc. Negative and positive ions are bounced off of each other in the plasma column at an accelerated rate. In welding, the arc not only provides the heat needed to melt the electrode and the base metal, but under certain conditions must also supply the means to transport the molten metal from the tip of the electrode to the work. Several mechanisms for metal transfer exist. Two (of many) examples include: 1. Surface Tension Transfer - a drop of molten metal touches the molten metal pool and is drawn into it by surface tension. 2. Spray Arc - the drop is ejected from the molten metal at the electrode tip by an electric pinch propelling it to the molten pool. (great for overhead welding!) If an electrode is consumable, the tip melts under the heat of the arc and molten droplets are detached and transported to the work through the arc column. Any arc welding system in which the electrode is melted off to become part of the weld is described as metal-arc. In carbon or tungsten (TIG) welding there are no molten droplets to be forced across the gap and onto the work. Filler metal is melted into the joint from a separate rod or wire.

More of the heat developed by the arc is transferred to the weld pool with consumable electrodes. This produces higher thermal efficiencies and narrower heat-affected zones. Since there must be an ionized path to conduct electricity across a gap, the mere switching on of the welding current with an electrically cold electrode posed over it will not start the arc. The arc must be ignited. This is caused by either supplying an initial voltage high enough to cause a discharge or by touching the electrode to the work and then withdrawing it as the contact area becomes heated. Arc welding may be done with direct current (DC) with the electrode either positive or negative or alternating current (AC). The choice of current and polarity depends on the process, the type of electrode, the arc atmosphere, and the metal being welded.

A BASIC GUIDE OF ARC WELDING ELECTRODES by Bruce Bauerlein

INTRODUCTION
There are many different types of electrodes used in the shielded metal arc welding, (SMAW) process. The intent of this guide is to help with the identification and selection of these electrodes.

ELECTRODE IDENTIFICATION
Arc welding electrodes are identified using the A.W.S, (American Welding Society) numbering system and are made in sizes from 1/16 to 5/16 . An example would be a welding rod identified as an 1/8" E6011 electrode.

The electrode is 1/8" in diameter The "E" stands for arc welding electrode. Next will be either a 4 or 5 digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 3 digits of a 5 digit number indicate the minimum tensile strength (in thousands of

pounds per square inch) of the weld that the rod will produce, stress relieved. Examples would be as follows: E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi The next to last digit indicates the position the electrode can be used in.
1. EXX1X is for use in all positions 2. EXX2X is for use in flat and horizontal positions 3. EXX3X is for flat welding

second by it's self and can not be changed as can DC current.

ELECTRODE SIZE AND AMPS USED

The following will serve as a basic guide of the amp range that can be used for different size electrodes. Note that these ratings can be different between various electrode manufactures for the same size rod. Also the type coating on the electrode could effect the amperage range. When possible, check the manufactures info of the electrode you will be using for their recommended amperage settings. Electrode Table ELECTRODE DIAMETER (THICKNESS) 1/16" 3/32" 1/8 5/32"

The last two digits together, indicate the type of coating on the electrode and the welding current the electrode can be used with. Such as DC straight, (DC -) DC reverse (DC+) or A.C. I won't describe the type of coatings of the various electrodes, but will give examples of the type current each will work with.

AMP RANGE 20 - 40 40 - 125 75 - 185 105 - 250 140 - 305 210 - 430 275 - 450

PLATE UP TO 3/16" UP TO 1/4" OVER 1/8" OVER 1/4" OVER 3/8" OVER 3/8" OVER 1/2"

ELECTRODES AND CURRENTS USED

EXX10 DC+ (DC reverse or DCRP) electrode positive. EXX11 AC or DC- (DC straight or DCSP) electrode negative. EXX12 AC or DCEXX13 AC, DC- or DC+ EXX14 AC, DC- or DC+ EXX15 DC+ EXX16 AC or DC+ EXX18 AC, DC- or DC+ EXX20 AC ,DC- or DC+ EXX24 AC, DC- or DC+ EXX27 AC, DC- or DC+ EXX28 AC or DC+

3/16" 1/4" 5/16"

Note! The thicker the material to be welded, the higher the current needed and the larger the electrode needed.

SOME ELECTRODE TYPES

This section will briefly describe four electrodes that are commonly used for maintenance and repair welding of mild steel. There are many other electrodes available for the welding of other kinds of metals. Check with your local welding supply dealer for the electrode that should be used for the metal you want to weld.

CURRENT TYPES
SMAW is performed using either AC or DCcurrent. Since DC current flows in one direction, DC current can be DC straight, (electrode negative) or DC reversed (electrode positive). With DC reversed,(DC+ OR DCRP) the weld penetration will be deep. DC straight (DCOR DCSP) the weld will have a faster melt off and deposit rate. The weld will have medium penetration. Ac current changes it's polarity 120 times a

E6010 This electrode is used for all position welding using DCRP. It produces a deep penetrating weld and works well on dirty,rusted, or painted metals E6011 This electrode has the same characteristics of the E6010, but can be used with AC and DC currents.

E6013 This electrode can be used with AC and DC currents. It produces a medium penetrating weld with a superior weld bead appearance. E7018 This electrode is known as a low hydrogen electrode and can be used with AC or DC. The coating on the electrode has a low moisture content that reduces the introduction of hydrogen into the weld. The electrode can produce welds of x-ray quality with medium penetration. (Note, this electrode must be kept dry. If it gets wet, it must be dried in a rod oven before use.) It is hoped that this basic information will help the new or home shop welder identify the various types of electrodes and select the correct one for their welding projects.

7014: Iron powder coating allows for higher welding speeds and use of a drag technique. Easier to use than most electrodes. AC/DC electrode works well on poor fitting joints and welds requiring a very flat bead. 7018: High quality weld for mild steel makes this the first choice for field construction applications where weld quality is critical. Ideal for carbon steel where cracking is a concern. Keep in a sealed container or an electrode oven when not in use. DC electrode positive. 7018 AC: Designed to operate on AC welders. Easier to operate than most other low hydrogen electrodes. Preferred for its high purity, crack resistant welds on mild and carbon steels. 80LV Red: AC/DC straight or reverse polarity, all position electrode can be used with low voltage machines for short, intermittent or tack welds on thin, medium and heavy sections of mild steel. 252: Welds 310 and 314 stainless subjected to corrosion at elevated temperatures as well as dissimilar steels and stainless of unknown analysis. 275: Produces high tensile and yield strengths on tool, high alloy, string, stainless, aircraft, nickel clad and dissimilar steels. HY-10: Special high strength electrode is machinable and ideal for joining or build up of low alloy and sulphur steels. 8: Provides a high nickel machinable deposit for welding parts, filling holes and defects and salvaging imperfect castings on thin sections of cast iron. Meets AWS A5.15 Class ENiCl-A. 8-60: Nickel electrode provides machinable deposits with high strength and good ductility for heavy sections of cast iron and ductile iron. Meets AWS A5.15, Class ENiFeCl-A. 6: Provides high strength, dense, sound welds on cast iron where machinability is

Types of Welding Electrodes

There are a lot of choices when it comes to choosing the proper welding electrode for the job. The difference between the proper welding rod, and the wrong one can be as small as slightly more difficult arc starts or it can weaken the weld. Here is a chart of the different types of electrodes, the numbers designated to them, their specifications and the proper uses for them. 6010: Deep penetration with a smooth arc and low spatter. Ideal for use on farm and road equipment, tanks, piping, wrought iron, building structures, jigs, fixtures and general maintenance. DC electrode positive unit must be run on DC welder. 6011: Popular electrode for utility type welders. Works well on rusty, dirty steel. Deep penetration allows for use on bridges, pressure vessels, farm and road equipment, building structures, tanks and pipe. Similar to 6010, but can be used on AC or DC current. Ideal for use on AC welders. 6013LV : Easy operation with a soft arc make it ideal for sheet metal use. Especially poor fitting applications and general repair on light thickness fabrication. AC/DC electrode works well on low cost hobby type welders.

not needed. Excellent for dirty or grease soaked castings. 4-60: Straight or reverse polarity electrodes provide strong machinable, crack resistant and spatter free deposits without porosity. Fort heavy sections of cast iron, ductile iron, and dissimilar metals. Will not overheat at rated amperage. 24 AC/DC: AC/DC all position electrode produces sound, porosity-free deposits on bronze, brass, copper, cast iron and steel. Joins dissimilar metals or overlay on cast iron or steel. 34 DC: Premium DC reverse, all position, aluminum electrode for joining, build up, cladding and reinforcing of aluminum sheets, plates and castings of 1/8 or thicker. Has extruded coating, and leaves dense smooth deposits that provide good color match to base metal. 308L AC/DC: Excellent wetting action and bead appearance makes this all position electrode ideal for welding most types of 188 stainless steel (304,302). Deposit is highly resistive to corrosion. 309L AC/DC: Higher corrosion resistance and strength than type 308 make this all position electrode ideal for 304 to 309 and 308 to carbon steels. Excellent weld appearance. 316L AC/DC: Provides a stable smooth arc and fine spray metal transfer with a uniform bead that is flat or slightly concave with straight edges. Penetration is complete and the weld metal is free from porosity. Also has good out-of-position characteristics. For 316L and 318 type steels in the chemical industry. Maximum of .03% carbon deposit. 308L-17: Used in paper and chemical industries, food processing equipment, dairies, breweries, distilleries, kitchens and hospitals for welding Cr/Ni steels such as 304L, 308L, 301, 303, 304 and 309. 309L-17: AC/DC reverse, all position electrode for welding carbon steels to

stainless at service temperatures below 600 degrees Fahrenheit. 316L-17: AC/DC reverse, all position electrode, low-carbon electrode for join 316 and 316L stainless subject to corrosive media. HS-2C: Hard facing electrode for severe abrasion and moderate impact with hardness 58-62 Rockwell C. HS-65W: Hard facing electrode for superior wear resistance involving extreme abrasion with hardness 63-67 Rockwell C. Ni-Matrix: All position hard facing electrode for constant heavy impact and abrasion with hardness 48 Rockwell C. Super Join-M: Hard facing electrode resistant to corrosion from water and mild corrosives with severe impact protection on manganese steel and unknown iron base metals. Chamfer Rod: AC/DC straight all position gouging electrode for ferrous and nonferrous metals. Stud Plus: AC/DC reverse polarity gouging electrode for removing broken studs and bolts.