Choosing the correct welding electrode, often called a rod or stick, is a challenging part of stick welding. Using the wrong electrode can lead to a bad weld and potential part rejection.
Inexperienced welders often make this mistake and suffer the consequences. They get confused by the numerous welding rods available and the many variables to consider.
However, it is possible to overcome this mistake by educating yourself on welding rods.
In this article, we’ll tackle this important topic and guide you on the most common rods, their classifications, their differences, and how to choose the correct rod for your job.
What Stick Weld Classifications Mean
There is a wide variety of rods available to a welder, but in general, a stick electrode has a coated metal core.
However, they differ in the type of core metal and coating/flux types and are designed to provide different strengths and performance in various welding positions.
SMAW ElectrodeTo help classify the electrodes, the American Welding Society (AWS) has developed the popular “E” code. You may have noticed it imprinted on your rods.
Each alphanumeric character in this code provides specific information about the electrode. A brief rundown is as follows:
You can learn more about the numbers on a welding rod here.
Types of Welding Electrodes
The code mentioned above is widely used for electrodes. However, you may frequently encounter other terms used to classify welding rods. A few of these terms are described below:
Now, let’s move on to the electrodes that you’ll commonly encounter.
E6010 Welding Electrode
FeatureE6010CoatingHigh Cellulose SodiumPositionAll PositionsCurrentDCEPPenetrationDeepTensile Strength60,000 PSIThe E6010 is one of the most common sticks used in industry. It is an all-position, DC-only rod. It is well-known for its deep penetration, which is why it is widely used for root pass welds.
Its deep penetration and fast-freeing cellulose flux make it a prime choice for stove pipe welding. Moreover, its performance is unaffected by rusty, unclean, or galvanized surfaces.
The E6010 bead is smooth and flat. The slag is light and paper-like, and mildly tricky to remove. However, you may see some spatter and the DC arc is difficult to control. The whip-and-pause technique is often suggested to control the weld pool temperature.
E6011 Welding Electrode
FeatureE6011CoatingHigh Cellulose SodiumPositionAll PositionsCurrentDCEP & ACPenetrationDeepTensile Strength60,000 PSIThe E6011 can be used in all positions. It has a cellulose flux coating that is slightly rich in potassium. Potassium helps stabilize the arc, allowing it to be used with both DC and AC power supplies.
Because of its AC capability, E6011 is often used in home welding setups. It is also used as an alternative to E6010.
It produces deep penetration joints. Plus, the arc can dig through surface contaminants like dirt, paint, and galvanized metals.
E6011 is also the preferred choice of learners as its AC arc is less intense and is easier to manage with an unsteady hand.
E6012 Welding Electrode
FeatureE6012CoatingHigh Titania SodiumPositionAll PositionsCurrentDCEN & ACPenetrationMediumTensile Strength60,000 PSIThe E6012 is an all-position stick that works with both AC/DC power supplies. It produces a moderate quality arc with decent deposition and penetration.
Its rutile flux coating makes it a fill-freeze electrode. The resulting filler material freezes and spreads quickly. For this reason, it works well in applications that require a balance between joint penetration and fill.
The arc is very stable and easily managed. Welders like it because of the smooth seam, and low spatter.
Because it supports low voltage and freezes quickly, it is also regularly used in high-speed, high-current applications.
E6013 Welding Electrode
FeatureE6013CoatingHigh Titania PotassiumPositionAll PositionsCurrentDCEP, DCEN & ACPenetrationShallowTensile Strength60,000 PSIThis rod is suitable for AC and DC power supplies and may be used in any position. It is coated with a rutile flux made up of titanium dioxide (“titania”) and potassium. Like E6012, this is also a fill-freeze flux.
This rod is suitable for mild-intensity jobs. It has a soft arc with shallow penetration that runs very smoothly. It also produces minimal spatter and an easy-to-remove slag. These characteristics make it a popular choice as a general-purpose rod.
However, it’s somewhat limited in its applications since its arc is not that powerful. Because of its performance characteristics, it is only applicable for use on clean sheet metal.
E7018 Welding Electrode
FeatureE7018CoatingLow Hydrogen, Iron Powder PositionAll PositionsCurrentDCEP & ACPenetrationShallow to MediumTensile Strength70,000 PSIE7018 is an all-position, low hydrogen electrode. It is suitable for both AC/DC supplies but is mainly used with a DC input.
It runs very quietly and smooth with low amounts of spatter. It is a fill-freeze rod with shallow-to-moderate penetration and medium fill. The arc is stable and easily controlled as well.
The inherent low hydrogen levels prevent cold cracking (also known as hydrogen cracking). Due to this, it is ideal to use with metals like structural and high-carbon steels.
Of note, the flux produces heavy slag that sticks to the metal. Therefore, some effort is required to remove it from the joint completely.
It is recommended to store E7018 rods in moisture-free environments and to oven-bake them before use to ensure the desired low levels of hydrogen.
E7024 Welding Electrode
FeatureE7024CoatingLow Hydrogen, Iron Powder PositionFlat & HorizontalCurrentDCEN & ACPenetrationShallow to MediumTensile Strength70,000 PSIThe E7024 is a unique stick on our list. It is an AC/DC electrode that can only be used in flat and horizontal orientations. Significantly, its low hydrogen flux contains up to 50% iron powder content.
This high iron content results in high deposition rates, producing a wide, convex seam. For this reason, it is used for plates at least ¼” thick like ship structures, bridges, structural steels for buildings. Also, the produced joint has high strength (even at low temperatures) and is compatible with high-carbon steels.
The slag it produces is heavy and must be carefully removed from all pockets and surfaces. Since it is a low hydrogen rod, it must also be kept in moisture-free storage like E7018.
We understand that all this information might be a bit too much to absorb at first, but you will have no trouble recalling it once you gain some experience. So, for now, we have summarized the main points in the table above for the upcoming discussion.
New to stick welding? Check out these stick welding tips to improve your technique.
Quick FAQs
It can be difficult to choose the right stick for your job with so many options. This decision is easy when you know the key differences between the electrodes.
So, we directly compared some of the common electrodes.
6010 vs. 6011 Electrodes
The 6010 and 611 are similar electrodes and are often used interchangeably.
Their flux composition is different, which gives E6011 the additional ability to be used with AC. Due to this, the E6011 arc is also slightly less intense and easier to control when used with an AC power supply.
Electrodes60106011Flux CoatingHigh CelluloseSodiumHigh CellulosePotassiumTensile Strength60,000 psi60,000 psiWelding PositionAll PositionsAll PositionsWelding CurrentDCAC/DCArc CharacteristicsTight, ErraticTight, ErraticPenetrationDeepDeepFillNarrowNarrowSlag TypeLight, FlakyLight, FlakySpecial ApplicationsRoot Pass, Dirty/Oily/Painted Surfaces, Stove Pipe WeldingRoot Pass, Dirty/Oily/Painted Surfaces, General Industrial6010 Vs. 7018 Electrodes
6010 and 7018 electrodes differ in joint strength, flux coating, and applications.
E7018 produces stronger joints, and it is compatible with high-carbon steels due to its low hydrogen content. Its slag is thicker and more difficult to remove than E6010. Both rods are widely used in the industry for their specific purposes.
Electrodes60107018Flux CoatingHigh CelluloseSodium25% Iron PowderLow HydrogenTensile Strength60,000 psi70,000 psiWelding PositionAll PositionsAll PositionsWelding CurrentDCAC/DC (Usually DC)Arc CharacteristicsTight, ErraticSmoothPenetrationDeepShallow to MediumFillNarrowMedium to WideSlag TypeLight, FlakyThickSpecial ApplicationsRoot Pass, Dirty/Oily/Painted Surfaces, Stove Pipe WeldingHigh-Carbon Steels, Low-Alloy/High-Strength Joints6011 vs. 6013 Electrodes
The E6011 and E6013 are comparable in tensile strength, welding positions, and current types.
E6011 is more of a heavy-duty industrial rod better suited for deep joints. E6013 has a delicate arc that is better for clean sheet metal welds. Also, the E6011 requires a steady, skilled hand to get good results.
Electrodes60116013Flux CoatingHigh Cellulose, PotassiumHigh Titania, PotassiumTensile Strength60,000 psi60,000 psiWelding PositionAll PositionsAll PositionsWelding CurrentAC/DCAC/DCArc CharacteristicsTight, ErraticSmoothPenetrationDeepShallow to MediumFillNarrowMediumSlag TypeLight, FlakyLight, Easy to RemoveSpecial ApplicationsRoot Pass, Dirty/Oily/Painted Surfaces, General IndustrialSheet Metal6011 vs. 7018 Electrodes
The 6011 and 7018 sticks have little in common. E7018 produces stronger joints and can handle high-carbon alloys, unlike the E6011 electrode. E7018 is a fill-freeze rod, so it has medium penetration and fill. The fast-freeze E6011 is well-known only for its deep penetration.
Electrodes60117018Flux CoatingHigh Cellulose, Potassium25% Iron Powder, Low HydrogenTensile Strength60,000 psi70,000 psiWelding PositionAll PositionsAll PositionsWelding CurrentAC/DCAC/DC (Usually DC)Arc CharacteristicsTight, ErraticSmoothPenetrationDeepShallow to MediumFillNarrowMedium to WideSlag TypeLight, FlakyThickSpecial ApplicationsRoot Pass, Dirty/Oily/Painted Surfaces, General IndustrialHigh-Carbon Steels, Low-Alloy/High-Strength Joints6013 vs. 7018 Electrodes
6013 and 7018 electrodes do not share many qualities.
E6013 has a rutile flux, while E7018 is a low hydrogen rod. The E6013 is used almost exclusively for thin sheets, while the E7018 can handle thicker workpieces, a wider range of materials, and has better strength.
Electrodes60137018Flux CoatingHigh Titania, Potassium25% Iron Powder, Low HydrogenTensile Strength60,000 psi70,000 psiWelding PositionAll PositionsAll PositionsWelding CurrentAC/DCAC/DC (Usually DC)Arc CharacteristicsSmoothSmoothPenetrationShallow to MediumShallow to MediumFillMediumMedium to WideSlag TypeLight, Easy to RemoveThickSpecial ApplicationsSheet MetalHigh-Carbon Steels, Low-Alloy/High-Strength JointsSelecting the Right Electrode
You can follow our step-by-step guide below to choose an electrode that fits your application.
Usually, the selection process goes like this:
This was just a sample selection guide. Every application is unique, and you must study it carefully before finalizing a rod.
Conclusion
We covered six common welding electrodes and outlined their main characteristics as well as the best applications for each. It is critical to have the right stick electrode for every job, which requires some know-how.
But with this basic knowledge, you will be able to find the right stick electrode for every job. It will take some time and practice to engrain this information into your memory, but it is not as hard as it sounds, and with some experience, it will become second nature for you.
We hope this was a fun, educational read. If you have any questions or feedback, let us know in the comments below.
If you have any questions on AWS A5.1 E6013 Welding Electrodes. We will give the professional answers to your questions.