1. Introduction to Arc Welding Rods
When it comes to metal joining, arc welding rods are the unsung heroes behind every durable weld. Whether in construction, shipbuilding, pipeline fabrication, or manufacturing, these electrodes determine the strength and finish of your welds.
Choosing the right welding rod can make the difference between a clean, high-quality joint and a weak, brittle connection.
In Shielded Metal Arc Welding (SMAW), often called stick welding, the rod not only conducts electricity but also provides filler metal. Its coating generates gas and slag that protect the molten weld from contamination. Understanding the types of arc welding rods allows you to select the most suitable one for your material, position, and power source.
2. What Does the Welding Rod Number Mean?
Each arc welding rod carries a number like E6010 or E7018. This code, created by the American Welding Society (AWS), reveals crucial details about the rod’s composition and performance.
Here’s how to read it:
- E stands for electrode.
- First two digits = tensile strength (in thousands of pounds per square inch).
- Example: E70XX means 70,000 PSI tensile strength.
- Third digit = welding position.
- “1” = all positions, “2” = flat or horizontal, “3” = flat only.
- Last two digits = coating type and current compatibility (AC/DC).
For example:
E7018 means a steel electrode with 70,000 PSI tensile strength, usable in all positions, and suitable for AC or DC currents with a low-hydrogen coating.
3. Main Types of Arc Welding Rods
Let’s look at the most commonly used types of arc welding rods, each with its own strengths and applications.
3.1 E6010 Welding Rod
- Type: High cellulose sodium
- Current: DC+ only
- Penetration: Deep
- Use: Pipeline welding, shipyards, field repairs
The E6010 rod produces a strong, penetrating arc, making it ideal for vertical and overhead welds. Its fast-freeze slag allows for quick solidification, suitable for out-of-position work and structural steel.
3.2 E6011 Welding Rod
- Type: High cellulose potassium
- Current: AC or DC+
- Penetration: Deep
- Use: Rusty or painted surfaces, general repair
E6011 rods offer similar strength to E6010 but can run on both AC and DC currents, making them more versatile for maintenance shops and fieldwork. They are a top choice for welding through dirt, rust, or old paint.
3.3 E6013 Welding Rod
- Type: Rutile potassium
- Current: AC, DC+, or DC–
- Penetration: Medium
- Use: Sheet metal, thin steel fabrication
This is one of the easiest electrodes to strike and control, producing a smooth, attractive bead with minimal spatter. The E6013 is excellent for beginners and light fabrication tasks.
3.4 E7014 Welding Rod
- Type: Iron powder rutile
- Current: AC or DC+
- Penetration: Medium to deep
- Use: Heavy sheet metal, structural work
E7014 electrodes have added iron powder for higher deposition rates, meaning faster welding and better productivity. They’re ideal for horizontal fillets and production welding.
3.5 E7016 Welding Rod
- Type: Low hydrogen potassium
- Current: AC or DC+
- Penetration: Medium
- Use: Pressure vessels, pipelines, critical structures
E7016 rods deliver smooth, ductile welds with low hydrogen content—reducing cracking risks in high-stress applications.
3.6 E7018 Welding Rod
- Type: Low hydrogen iron powder
- Current: AC or DC+
- Penetration: Medium
- Use: Bridges, heavy structures, high-strength steel
The E7018 welding rod is one of the most popular electrodes worldwide. Known for its clean, strong welds and moisture-resistant coating, it’s used extensively in construction, power plants, and industrial fabrication. Its low-hydrogen flux ensures excellent crack resistance.
3.7 E7024 Welding Rod
- Type: Iron powder rutile
- Current: AC or DC+
- Penetration: Shallow
- Use: Flat and horizontal welding only
E7024 rods provide a smooth bead and extremely high deposition rates, perfect for thick plates and long fillet welds where speed is key.
4. Choosing the Right Arc Welding Rod
Selecting the right electrode isn’t guesswork—it depends on several factors:
- Base Metal Type – Match the rod to the parent metal. For carbon steel, use E6013 or E7018.
- Position – Some rods are all-position (E6010, E7018), while others are limited to flat (E7024).
- Current Type – Know whether your machine uses AC, DC+, or DC–.
- Joint Design – Deep penetration rods like E6010 suit root passes; E7018 fits finishing passes.
- Environment – For outdoor or field welding, choose rods with better arc stability and resistance to wind.
A practical rule:
- Use E6010/E6011 for root passes or dirty metal.
- Use E7018 for high-strength, clean welds.
- Use E6013/E7014 for thin materials or smooth finishes.
5. Storage and Care of Welding Rods
To maintain performance, arc welding rods must be kept dry and clean. Moisture can destroy low-hydrogen coatings like E7018, causing porosity and cracking.
Storage tips:
- Keep rods in airtight containers after opening.
- Use rod ovens (250°F–300°F) for low-hydrogen types.
- Avoid direct contact with oily or rusty surfaces.
Proper storage not only improves weld quality but also extends electrode shelf life.
6. Common Problems and Solutions
| Problem | Possible Cause | Solution |
|---|---|---|
| Porosity in weld | Moisture in rod or metal | Keep rods dry; clean metal |
| Cracking | Too high current or poor rod choice | Use E7018; control amperage |
| Excessive spatter | Wrong polarity or high heat | Adjust settings; use proper electrode |
| Poor penetration | Low current or wrong rod | Switch to E6010 or E7018 |
| Sticking electrode | Incorrect arc length | Maintain 3 mm arc gap |
Understanding these issues helps ensure consistent, professional results for every welding project.
7. Comparison Table of Common Arc Welding Rods
| Electrode | Tensile Strength (PSI) | Positions | Coating Type | Current | Typical Use |
|---|---|---|---|---|---|
| E6010 | 60,000 | All | Cellulose Sodium | DC+ | Pipelines, field repair |
| E6011 | 60,000 | All | Cellulose Potassium | AC/DC | Rusty surfaces |
| E6013 | 60,000 | All | Rutile Potassium | AC/DC+/DC– | Sheet metal |
| E7014 | 70,000 | Flat/Horizontal | Iron Powder Rutile | AC/DC+ | Structural steel |
| E7016 | 70,000 | All | Low Hydrogen Potassium | AC/DC+ | Pressure vessels |
| E7018 | 70,000 | All | Low Hydrogen Iron Powder | AC/DC+ | Bridges, buildings |
| E7024 | 70,000 | Flat/Horizontal | Iron Powder Rutile | AC/DC+ | Thick plates |
8. How Arc Welding Rods Affect Productivity
In industrial projects, electrode selection directly affects speed, cost, and weld integrity.
For instance:
- E7018 provides fewer defects, reducing rework time.
- E7024 delivers rapid deposition, ideal for mass production.
- E6011 minimizes surface preparation, saving cleaning time.
By using the right combination of rods for root, fill, and cap passes, factories can achieve up to 30% higher welding efficiency.
9. Safety Tips for Using Arc Welding Rods
Even professionals should follow strict safety practices:
- Wear insulated gloves and face shields.
- Ensure proper ventilation to avoid fume buildup.
- Use dry rods only—moisture may cause explosions in the coating.
- Check polarity and current settings before striking an arc.
Safety not only protects welders but also ensures stable weld quality during production.
10. Future Trends in Welding Electrodes
Modern industries demand faster, cleaner, and more eco-friendly welding solutions. Manufacturers are now producing:
- Low-hydrogen rods with improved moisture resistance.
- Flux coatings that emit less fume and spatter.
- High-efficiency rods that shorten welding time without sacrificing quality.
As automation grows, consistent-quality electrodes will be vital for robotic welding lines and smart manufacturing systems.
11. Conclusion
Understanding the types of arc welding rods empowers your welding team to deliver stronger, cleaner, and more efficient joints. From the deep-penetrating E6010 to the reliable, low-hydrogen E7018, every electrode has its purpose in industrial welding.
When your project demands quality, durability, and precision, the right choice of welding rod is not just a tool—it’s your guarantee of performance.
Choose wisely, store carefully, and weld confidently.