ELECTRODES There are numerous types of electrodes, each manufactured to exacting standards by companies all

over the world. The success (or failure) of any weld is, to a large degree, dependant on the electrode selected, or
"specified" in the "welding procedure". Arc welding electrodes are identified under the AWS numbering system
(American Welding Society). In this training series we are concerned only with electrodes fitting into the "mildsteel"
category which fit into the AWS system under the specification A5.1. The "size" of an electrode is determined by
(measuring) the diameter of the "wire" (the bare section). Common (for general-purpose) sizes: 2.0mm, 2.5mm,
3.15mm and 4mm. When specifying an electrode we need to give the "wire-size" and then the AWS specification.
The most commonly used electrodes in maintenance and repair of mild-steel structures are listed below. There are
many other types of electrodes available for other types of metals and you will need to ask your Facilitator or your
electrode supplier for information about welding other metals. E6010 - This electrode is used when welding with
DCEP (Reverse Polarity). This type provides for deep penetration into thick metal, and can be used where the parent
metal is difficult to clean. (Dirty, rusty or painted). E6011 - This is used for both AC and DC operations on thick metal.
E6013 - This is a "general-purpose electrode". Is used where the weld appearance is important and where "medium
penetration" is required. Suitable for both AC and DC. E7018 - Also known as a "low hydrogen", this electrode can be
used with AC and DC. This electrode is used for "high quality" welds such as needed on pipes. Low hydrogen
electrodes must be kept DRY as moisture in the flux will increase the "hydrogen content" and severely weaken the
weld. These rods must be kept in a "drying oven" once the pack has been opened.

WHERE TO LOOK FOR ELECTRODE IDENTIFICATION (And what you're looking at) Most electrodes, from 2mm up in
size, will have the AWS number printed on the flux at the "bare-wire end". This identification, as well as other
information, will also be printed on the "packaging label". In the AWS system an electrode is given the letter "E"
followed by a 4 or a 5 digit numeral. A typical number is E6013, (but you will normally only see "6013" on the
electrode). "E" indicates that it is an "electrode". The first two numbers of a four-digit number, or the first 3 numbers
of a five-digit number, indicate the "tensile strength" (in "thousands of pounds per square-inch") of the weld that the
electrode will produce. In other words an "E 60xx" numeral will produce a weld with a tensile-strength of 60,000 psi.

The second to last digit indicates the welding position, for example Exx1x is for all positions. Exx2x means that the
rod is for use in "flat" (down-hand) and "horizontal position" welding. Exx3x means that the rod is only suitable for
"flat position" welding. The last two digits, in combination with each other, refer to both the flux composition and
the type of current that should be used.

Last 2 digits Use Current Type Flux Covering

Exx10 DC + (DCEP) Organic
Exx11 AC or DC- (DCEN) Organic
Exx12 AC and DC- Rutile
Exx13 AC and DC- and DC+ Rutile
Exx14 AC and DC- and DC+ Rutile, iron powder (30%)
Exx15 DC+ Low hydrogen
Exx16 AC or DC+ Low hydrogen
Exx18 AC, DC- or DC+ Low hydrogen, iron powder (25%)
Exx20 AC, DC- or DC+ High iron oxide
Exx24 AC, DC- or DC+ Rutile, iron powder (60%)
Exx27 AC, DC- or DC+ Mineral, iron powder (50%)
Exx28 AC or DC+ Low hydrogen, iron powder (50%
The composition (chemical) of the "flux coating" plays a major part in the selection of a rod for metals to be welded.
The purpose of the "flux" includes the following: o Create a protective gas shield around the arc and the molten
material. o Removes impurities from the molten metal. o Create a protective layer of "slag" to protect the weld as it
cools.
o Improve the mechanical properties of the weld through the addition of certain elements.
o Some fluxes also provide additional "filler material".
The current (amp load) supplied to a given electrode is dependent on the wire diameter. Table - 2 offers a guide to
wire size/current setting range.
Diameter (mm) Current (Amps)
1.6 20 – 40
2 40 – 80
2.5 60 – 95
3.15 110 – 130
4 140 – 165
STORAGE OF ELECTRODES Electrodes must never be allowed to become "wet". Moisture present in the atmosphere
will render most types of electrodes useless over time. Some electrodes, notably "low hydrogen" types, cannot be
used after they have been exposed to the air for more than 15 minutes. As a rule electrodes are obtained in sealed
(airtight) packets that protect them from the atmosphere. As soon as the packet has been opened the electrodes will
be at risk of becoming damp. The correct way to store electrodes, after the packet has been opened, is in a
"warming box" or "drying oven". Such a device may be as simple as a sealed cupboard with a small electric lamp
burning inside to keep the air warm and dry. More elaborate "thermostatically controlled" ovens are used in some
establishments. Using a "damp rod" will result in poor quality of your weld, including weakness. Damp rods may be
"re-dried" by baking in an oven at the "specified temperature and for a specified time". (See manufacturers'
instructions on packaging)
WELDERS TOOLS The welder does not require many "hand-tools" in the process of welding. The primary tools are: o
A Chipping Hammer. o A wire-brush. The chipping hammer is used to break off the hard (yet sometimes "brittle")
layer of slag after the weld has cooled. If this slag is not removed then the next layer of weld will have slag trapped
within it resulting in "inclusions". An "inclusion" causes mechanical "weakness" and "failure of a joint".
The wire brush is required to loosen and remove "stubborn" slag from a welding bead. The brush is also used to
loosen and remove rust or other deposits on metal prior to welding. Spanners may be required for attending to
welding cable terminals and for securing earth-clamp attachments. Pliers, usually of the heavy-duty variety and
"tongs" are useful tools for manipulating work-pieces, especially if they are hot. Clamps of all types, especially the
"locking types", are used extensively for securing work. A ball-peen hammer (approx. 750g - 1 kg) is a useful tool for
"setting" purposes.
QUESTIONS
1. What are the 3 basic types of welding machines?
1) _______________________________________________
2) _______________________________________________
3) _______________________________________________
2. What "current range" is required for most SMAW operations?
ANS: _________________________________________________
3. In DC terms, what is "straight polarity"? ANS: _________________________________________________
4. What does the term "DCEN" mean? ANS: _________________________________________________
5. What must you be sure to do before you change polarity on a machine? ANS:
_________________________________________________
6. What are the main details, from the welder’s point of view, that you can read from a "name-plate"?
i) _______________________________________________
ii) _______________________________________________
iii) _______________________________________________
iv) _______________________________________________
7. If a machine has a duty cycle of 20% at its maximum output, how long can it be operated before it has to cool? ANS:
_________________________________________________
8. What factors in a "welding-lead / cable" determines the maximum current that it can carry?
a) _______________________________________________
b) _______________________________________________
9. What should you always be wearing when you handle the "live" electrode holder? ANS:
_________________________________________________
10. What does the size of an electrode refer to? ANS: _________________________________________________ 11. How
should electrodes be stored? ANS: _________________________________________________
12. List 4 tools that a welder should have available at the work station.
i) _______________________________________________ ii) _______________________________________________ iii)
_______________________________________________ iv) ______________________________________________