Different Types Of Welding Rods

Welding is a multi-faceted career. There are several aspects of welding that a professional or anyone interested in welding should be aware of. This article will teach you everything you need to know about welding rods and their applications.? Let's start with a definition of welding.

Simply said, welding is the process of connecting two materials. Welding is a fabrication method in which two materials are joined by melting them together with heat or pressure. Metals and thermoplastics are the most popular materials for welding, but they can also be used on wood. A weldment is a term for a fully welded joint.

Welding Rods

The welding materials that are melted and infused during processes like stick welding are called electrodes or welding rods. The initial step in using a welding rod is to connect it to your welding apparatus, which will generate an electric arc between the rod and the base metal. The metal is rapidly melted by the powerful electric arc, enabling it to be fused for welding.

Types of Welding Rods

Welding rods are of two types: consumable and non-consumable welding rods. Consumable electrodes are incorporated into the weld bond. The electrode acts as filler metal, melting together with the metals to be welded. Non-consumable electrodes, on the other hand, are not consumed during welding since a separate welding rod is used as the filler metal that melts and binds the metals together.

The components that are connected together are referred to as base materials. The material used to construct the joints is referred to as a consumable or filler.  Because of their shape, these materials are also referred to as consumable electrodes (for arc welding), flux-cored wire, base plates or tubes, and so forth.

Welding requires careful electrode selection. Choosing a substance that is chemically compatible with the metals being welded together is crucial because consumable materials are completely absorbed during the operation. One of the most popular materials for consumable electrodes is steel, including nickel steel and low alloy steel. It is also possible to determine the kind and level of flux or coating on the electrodes, ranging from heavily coated types to those with no flux coating at all.

Conversely, non-consumable electrodes remain intact and are not consumed during welding. Hence the kind of electrode material is unimportant. Carbon, graphite, or pure tungsten or tungsten alloys are common electrode materials. 

Welding Rod Types and Their Uses

Choosing the appropriate welding rod, however, can be challenging due to the large number of options available. As a result, the following are some of the most regularly used welding rods and their characteristics:

1. 6010 Welding Rod

one of the most popular options since it works well for high-power density welds. These kinds of welding rods are frequently used in water towers, steel storage tanks, shipyard welding, pipes, and other thick metal applications. However, the 6010 welding rods are only compatible with DC welding equipment.  Another difficulty is that, because they have a tight arc, beginners may find it difficult to handle these welding rods.

2. 6011 Welding Rod

these welding rods can be used with either AC or DC welding machines, depending on your requirements. However, as with the prior one, these welding rods will provide excellent penetration, which is always a plus. This type of welding rod is appropriate for heavier metals, coated surfaces, and even greasy surfaces. If you like a smooth finish, however, the ripples, weld beads, and rough finish left by this welding rod may disappoint you.

3. 6012 Welding Rod

The great thing about 6012 welding rods is that they provide a steady arc with minimal splatter, making it easy to weld on both AC and DC welding equipment. Unlike 6010 and 6011, however, 6012 cannot be used for thick materials. 6012 welding rods also produce a lot of waste material, forcing you to clean your welds frequently. This welding rod can be used for open joints, repair welding, and welding carbon steel that is rusted and corroded.

4. 6013 Welding Rod

If you want clean results with little splatter, 6013 welding rods are a good option. Even though it produces less splatter, it has moderate penetration, making it suitable for a wide range of applications. Welding metal sheets, ship construction and maintenance, and working on mild steel surfaces and objects are just a few of the applications for the 6013 welding rod. Depending on your requirements, this welding rod, like the majority of others, can be used with either AC or DC currents.

5. 7018 Welding Rod

This welding rod is considered to be one of the most versatile welding rods available. This is best for working with poor to intermediate-quality carbon steel. The beads and splatter created by the welding are properly shielded from external elements such as air and moisture present in the 7018 welding rod because it has an iron compound covering that contains a very small quantity of hydrogen. Furthermore, because the 7018 welding rod is suitable for both AC and DC welders, it is employed in factories, bridges, power plants, and a variety of other heavy-duty applications.

6. 7024 Welding Rod

This welding rod contains a large level of iron power, which makes it stand out. As a result, its deposition rate is quite high, making the welding procedure relatively simple, especially for beginners. If your desired application demands a smooth finish, the 7024 welding rod is an excellent option.

How To Choose The Right Welding Rods?

The following are some considerations to keep in mind when choosing the right welding rods or electrodes.

Base Metal

It's critical to match the base metal to the metal you're welding for the best outcomes. This will provide a high-quality, long-lasting weld.

Appearance Of Metal

You can determine the type of base metal you're dealing with by looking at it. It's likely made of cast metal if it's grainy and rough.

Type Of Spark

Another approach to examining your base metal is to run it through a grinder and see the sparks it produces. If there are several sparks, the carbon concentration is likely to be high. You can also use a chisel to smash your base metal, although this can leave marks on lighter metals like aluminum.

Check For Magnetism

You can also test your base metal for magnetism, as magnetic materials include iron, carbon steel, and alloy steel. If it's not magnetic, it's probably genuine stainless steel, brass, copper, aluminum, or something similar.

Strength Of Tensile

You must match the tensile strength of your welding rod to that of the base metal. The weld may crack over time if they are not the same.

Welding Current

Before buying one, make sure your welding current is supported by your welding rods. In most circumstances, a larger welding current, such as 225 amps for 7018, is preferable to 125 amps for 6010. The supported current type (AC or DC) is also something to consider before purchasing a welding rod.

Safety Measures

Make sure both your hands and the welding rods are dry before beginning any work with them. Weld contamination or electric shock might result from moisture. To keep the rods from rusting or being damaged, always wear welding gloves and store them properly.

Furthermore, check the welding rods for flaws before utilizing them since employing broken rods can lead to a subpar weld.

A number of parameters, including metal type, appearance, strength, and welding location, should be taken into account while selecting the right welding rod for your project. It's crucial for both guaranteeing safety throughout the welding process and for obtaining a quality weld.

Conclusion

We have covered everything there is to know about welding rods, including their types and applications, in the hopes of giving you a better understanding of electrodes. All you need for long-lasting professional welding is the proper type of rod that matches the composition of your workpiece.