Table 12-8 Relative Ratings of Factors Affecting the Preliminary Selection of Electrodes

Electrode Class
Variable Factors (a) E6010 E6011 E6012 E6012X E6013 E7014 E7016 E7018 E6020 E7024 E6027
1Groove butt welds, 4 5 3 2 8 8 7 9 10 9 10
flat (>14 in.)
2Groove butt welds, all 10 9 5 4 8 8 7 6 (b) (b) (b)
positions (>14 in.)
3Fillet welds, flat or 2 3 8 7 7 7 5 7 10 10 7
horizontal
4 Fillet welds, all positions 10 9 6 4 7 7 8 6 (b) (b) (b)
5Current a.c. a.c. a.c. a.c. d.c. a.c. a.c. a.c. a.c. a.c.
DCEP DCEP DCEN DCEN d.c. d.c. DCEP d.c. d.c. d.c. d.c.
6 Thin material (<14 in.) 5 7 8 10 9 8 2 2 (b) 7 (b)
7Heavy plate or highly 8 8 6 (b) 8 8 10 9 8 7 8
restrained joint
8High sulfur or off-analysis (b) (b) 5 4 3 3 10 9 (b) 5 (b)
steel
9Deposition rate 5 5 7 7 7 9 5 8 9 10 10
10 Depth of penetration 10 9 6 5 5 5 7 7 8 4 8
11 Appearance, undercutting 6 6 8 7 9 9 7 10 9 10 10
12Soundness 6 6 3 3 5 5 10 8 9 8 9
13Ductility 6 7 4 3 5 5 10 10 10 5 10
14Low-temperature impact 8 8 4 4 5 5 10 10 8 9 9
strength
15 Low spatter loss 1 2 6 6 7 7 6 8 9 10 10
16 Poor fitup 6 7 10 10 8 8 4 4 (b) 8 (b)
17 Welder appeal 7 6 8 8 9 10 6 8 9 10 10
18 Slag removal 10 8 6 6 8 8 4 7 8 8 8
(a) Rating (for same size electrodes) is on a comparative basis for electrodes listed in this table: 10 is the highest value. Ratings may change with achange in size.
(b) Not recommended.

Position of the joint the operating characteristics of the electrode. Different

Type and preparation of joint electrodes require different welding techniques. Thus,
Heat-treating requirements electrodes may be grouped according to their operating
Environmental job conditions characteristics and the requirements of the joints to be
Expansion and contraction problems welded as fast fill, fast follow, and fast freeze.
Amount of weld required
Tightness of fitup Fast Fill The fast-fill electrode deposits weld metal rap-
Type of welding current available idly. It is the opposite of the fast-freeze electrode. The
Thickness and shape of base metal fast-fill group includes the heavy-coated, iron pow-
Specifications and service conditions der electrodes that are widely used for fillet and deep
Demands of production and cost considerations groove deposition. The fast-fill electrode is especially
designed for fast, flat position welding. It has high metal
deposition and permits easy slag removal. There is little
Operating Characteristics undercutting. It burns with a soft arc and has shallow
of Electrodes penetration that causes little mixing of the base metal
The nature of the materials that go into the covering and weld metal. Bead appearance is very smooth. It has
of an electrode usually determine not only the physical a flat to slightly convex face, and there is little spatter,
and mechanical properties of the weld deposit, but also Fig. 12-4H and I.

308Chapter 12 Shielded Metal Arc Welding Electrodes

 Certain electrodes have been developed for out-of-posi-
tion welding that have faster freezing characteristics. An ex-
ample of this type of electrode is the EXX14. The EXX24
and EXX27 electrodes are generally used for flat fillets and
groove welding, Fig. 12-4.
Fast Follow This group is also known as fill-freeze elec-
trodes. They have characteristics that in some degree
combine both fast-freeze and fast-fill requirements. In
making lap welds or light gauge sheet metal welds, little
additional weld metal is needed to form the weld. The
most economical way to make the joint is to move rap-
idly. Because it is necessary to make the crater follow the
arc as rapidly as possible, the electrode is called fast fol-
low. It burns with a moderately forceful arc and has me-
dium penetration. This, together with the lower current
and lower heat input, reduces the problem of excessive
melt-through.
These electrodes have complete slag coverage, and
beads are formed with distinct, even ripples, Fig. 12-4D
and E. Many production shops use them as general-pur-
pose electrodes, and they are also widely used for repair
work. Although they may be used for all-position work,
the fast-freeze electrodes are preferable. Many shops
that engage in light gauge sheet steel fabrication use the
fast-follow electrode for vertical position, travel-down
A B C D E F G H I J
Fig. 12-4 Comparative appearance of weld beads made with different
types of electrodes.
welding. Examples of these electrodes are the EXX12 for
a.c. and DCEN welding and the EXX13 for a.c., DCEN,
and DCEP welding.
Fast Freeze Fast-freeze electrodes have the ability to
deposit weld metal that solidifies, or freezes, rapidly. This
is important when there is some chance of slag or weld
metal spilling out of the joint and when welding in the
vertical or overhead positions.
These electrodes have a snappy, deep-penetrating arc.
They have little slag and produce flat beads, Fig.12-4B
and C. With few exceptions they produce X-ray quality
weld deposits and are used for pipe and pressure vessel
code work. They are widely used for a ll-position welding,
in both fabrication and repair.
Combination Types Some joints require the character-
istics of both fast-fill and fast-freeze electrodes. When
fast-freeze is required, the best electrodes are the EXX10,
DCEP, EXX11 a.c., and DCEP types. An electrode with a
share of both characteristics is the all-position, iron pow-
der electrode EXX14. These electrodes do not have as
much fast fill as an EXX24, nor do they have the degree
of fast freeze of the EXX10. Rather they are a compro-
mise between the two types.
Low Hydrogen Low hydrogen electrodes are
those that have coverings containing practically
K
no hydrogen. They produce welds that are free
from underbead and microcracking and have
exceptional ductility, Fig. 12-4F and K. The
electrodes eliminate porosity in sulfur-bearing
steels and ensure X-ray quality deposits. Be-
cause they reduce preheat requirements, their
chief use is in the welding of hard-to-weld steels
and high-tensile alloy steels. Examples of these
types of electrodes are the EXX18 and EXX28
classifications.
Iron Powder Iron powders are added to the cov-
ering of many types of electrodes. In the intense
arc heat, the iron powder is converted to steel,
thus contributing additional metal to the weld de-
posit. When iron powder has been added to the
electrode covering in relatively large amounts (30
percent or more), the speed of welding is appre-
ciably increased, the arc is stabilized, spatter is
reduced, and slag removal is improved, Fig. 12-5.
The weld appearance is very smooth, Fig. 12-4,
welds H and I. Examples of these types of elec-
trodes are the EXX14, EXX18, EXX24, EXX27,
and EXX28.
Shielded Metal Arc Welding Electrodes Chapter 12309
 Solid Core Wire
Slag
Penetration
Conventional Electrode
Solid Core Wire
Iron Powder
Slag
Penetration
Iron Powder Electrode
Fig. 12-5 A thicker coating of iron powder on an electrode creates
a crucible effect at the tip of the electrode, making more efficient use
of arc energy. They are sometimes referred to as drag rods because
the coating can be dragged on the workpiece.
Type of Base Metal
The nature of the material to be welded is of prime impor-
tance. Satisfactory welds cannot be made if the weld metal
deposited does not have the same physical and chemical
qualities as the material being welded.
If the material specifications are not known, simple
tests such as the spark test, torch test, chip test, mag-
netic test, color test, fracture test, and sound test may
be performed. The information in Tables 12-9 through
12-12 will help you recognize the various metals ac-
cording to their characteristics. Such information can,
however, identify only broad categories of material. The
welder may be able to tell, for example, that the mate-
rial is steel rather than cast iron, but there are so many
types of alloy and stainless steels that it is necessary to
know the correct analysis of the steel as designated by
the manufacturer. For example, if the steel is high in sul-
fur or carbon, or if it contains certain alloys, the E7015,
E7016, E7018, or E7028 electrode should be chosen.
These electrodes reduce the tendency toward underbead
cracking that is characteristic of such steels. They pro-
duce welds of high tensile strength and ductility without
stress relieving, and they reduce or eliminate the need
for preheat.
310Chapter 12 Shielded Metal Arc Welding Electrodes
Nature of Welding Current
Welding machines produce two types of welding cur-
rent, alternating current and direct current. Direct
current can be either electrode negative (DCEN) or
electrode positive (DCEP). The nature of the current
available also influences the selection of the electrode.
For example, if only a.c. equipment is available, E6010
and E7015 electrodes are eliminated from consider-
ation, since they are designed to operate on direct cur-
rent. If only d.c. equipment is available, current is not
a limiting factor. Although designed for use primarily
with alternating current, E6011, E6013, E7014, E7016,
E7018, and E7028 electrodes perform adequately with
direct current.
Thickness and Shape of Material to
Be Welded
Whether the material is of heavy gauge or light gauge par-
tially determines electrode size. As a general rule, never
use an electrode having a diameter that is larger than the
thickness of the material being welded.
For light gauge sheet metal work (332 inch and thinner),
the E6013 electrode is usually the choice. The E6013
electrode was designed for this type of work, and it has
the least penetration of any electrode in the E60XX series.
Joint Design and Fitup
There are many kinds of welded joints, and each type has
particular requirements for welding. Welding fillets differ
a great deal from groove welding butt joints. Butt joints
may be either square or deep grooved. The fitup may have
large gaps, or it may be too tight.
In cases in which poor fitup is unavoidable, the E6013
electrode should be chosen for use with the d.c. equip-
ment; and with a.c. equipment. This electrode bridges
gaps very well because of the globular transfer of metal
through the arc stream.
A B OU T WEL DIN G
Electric Arc Lighting
The notion of electric arc lighting began
in London with the experiments of Sir Humphrey Davy
in 1801. He showed, using a battery, that an arc could be
made to form between two carbon electrodes. Thirty-five
years later, his cousin Edmund Davy described the proper-
ties of acetylene (which, in another 34 years, a German,
Friedrich Wohler, figured out how to produce from calcium
carbide).
Table 12-9 Temperature Data for Metals and Alloys

Temperature Data
Melting Points of Metals and Alloys of Practical Importance
M. P. M. P.
Deg. F. Deg. C. Deg. F.
Chromium 3000 3000
Color
Pure Iron 2900 Scale 1600 2900
Stainless-12% Cr.
2800 2800 Wrought Iron
Mild Steel
1500
Cobalt 2700 2700 Nickel Alloys
Nickel 2600 2600
Silicon 1400
Chromium,
2500 2500
Stainless 18.8 Nickel,
Chromium-
Hard Steel 2400 2400
1300 Nickel Steels
Inconel White and Irons
2300 2300
Monel
Manganese 2200 1200 2200
Light Yellow Cast Irons
Hynes Stellite Alloys 2100 2100
Ambrac Chromium-
2000 1100 2000
Copper Nickel-
Lemon Cast Irons
Gold 1900 1900
Red Brass Orange 1000
1800 1800
Everdur
Brasses
1700 Salmon 1700
Silver
900
Yellow Brass 1600 1600 Bronzes
Bright Red
Tobin Bronze
1500 1500
Manganese Bronze Cherry 800
1400 or 1400
Dull Red
Aluminum 1300 700 1300
Medium Cherry
Magnesium 1200 1200
Dark Cherry
Antimony 600
1100 1100 Aluminum
Blood Red
Alloys
1000 1000
Faint Red 500
900 Magnesium
900
Alloys
Zinc 800 800
400 Tin Alloys
700 700
Lead
600 600
300
Babbitt
500 500
Tin
400 200 400

300 300 Lead Alloys

200 100 200

100 100
Color Scale 0
0 0

Shielded Metal Arc Welding Electrodes Chapter 12311

 Table 12-10 Identification of Metals by Appearance

Brass and Aluminum

Alloy Steel Copper Bronze and Alloys Monel Nickel Lead
Fracture Medium gray Red color Red to White Light gray Almost White;
yellow white crystalline
Unfinished Dark gray; Various Various Evidence of Smooth; dark Smooth; Smooth;
surface relatively degrees shades mold or rolls; gray dark gray velvety;
rough; rolling of reddish of green, very light gray white to
or forging brown to brown, or gray
lines may be green due yellow due
noticeable to oxides; to oxides;
smooth smooth
Newly Very smooth; Bright Red through Smooth; very Very smooth; Very Very
machined bright gray copper red to whitish white light gray smooth; smooth;
color dulls yellow; very white white
with time smooth
Low Carbon
White Cast Gray Cast Malleable Wrought Steel and
Iron Iron Iron Iron Cast Steel High Carbon Steel
Fracture Very fine Dark gray Dark gray Bright gray Bright gray Very light gray
silvery
white, silky
crystalline
formation
Unfinished Evidence of Evidence of Evidence of Light gray; Dark gray; forging Dark gray; rolling or
surface sand mold; sand mold; sand mold; smooth marks may be forging lines may be
dull gray very dull dull gray noticeable; cast noticeable
gray evidences of mold
Newly Rarely Fairly Smooth Very smooth Very smooth; Very smooth; bright gray
machined machined smooth; surface; light surface; light bright gray
light gray gray gray
Source: American Welding Society

Welding Position
The position of welding is a very important consideration
in the choice of an electrode. Certain types of electrodes
can be used only in the flat position; others perform
equally well in all positions. The type of position also has
an influence on costs. Welding is most economical in the
flat position, then horizontal, and then vertical; the over-
head position is the least economical. As you develop
skill in welding, you will understand the limitations that
welding in the vertical and overhead positions places on
the choice of an electrode.
The size of the electrode to be used is strongly influ-
enced by the position of welding. V-butt joints in the ver-
tical and overhead positions are usually welded with a
small diameter electrode, in order to obtain complete pen-
etration at the root of the weld. In multilayer welding, the
other passes can be made with large electrodes. Welding
in the vertical and overhead positions should never be at-
tempted with an electrode larger than 316 inch in diameter.
For production work, the largest electrode size that can
be handled should be used. This permits higher weld-
ing current values, thus increasing the speed of welding.
Higher deposition rates are also achieved. The larger the
diameter of the electrode, the greater the quantity of weld
deposited in a unit of time. The cost of labor is also reduced
because fewer stops are necessary to change electrodes.
If welding must be done in an overhead, vertical, or
horizontal position, electrodes of the EXX20, EXX24,
EXX27, and EXX28 classifications cannot be used, leav-
ing the choice to be made among the remaining electrodes
in the series. The EXX15, EXX16, and EXX18 electrodes,
though classified for all positions, are more difficult to
handle in the vertical and overhead positions.
In general, the welder will find that electrodes in the
EXX12, EXX13, EXX20, EXX24, EXX27, and EXX28
classifications are easiest to handle in the horizontal and
flat positions. Vertical and overhead welding is easiest
with the EXX10 and EXX11.

312Chapter 12 Shielded Metal Arc Welding Electrodes

 Table 12-11 Identification of Metals by Flame Test
(Footnotes are listed below Table12-12)

Brass and Aluminum

Alloy1 Steel Copper Bronze and Alloys2 Monel Nickel Lead3
Speed of Slow Moderate to Faster than Slower than Slower than Very fast
melting (from fast steel steel steel
cold state)
Color change May turn black Becomes No apparent Becomes Becomes No
while heating and then red; noticeably red change in color red before red before apparent
copper color before melting melting melting change
may become
more intense
Appearance of So little Various Stiff black scum Gray scum; Gray scum; Dull gray
slag slag that quantities of considerable less slag than coating
it is hardly white fumes, amounts Monel
noticeable though bronze
may not have
any
Action of slag Quiet Appears as Quiet Quiet; hard to Quiet; hard to Quiet
fumes break break
Appearance of Has mirror- Liquid Same color as Fluid under Fluid under White
molten pool like surface unheated metal; slag slag film and fluid
directly under very fluid under under
flame slag slag
Action of Tendency to Like drops of Quiet Quiet Quiet Quiet;
molten pool bubble; pool water; with may boil
under blowpipe solidifies oxidizing if too hot
flame slowly and flame will
may sink bubble
slightly
Low Carbon
White Cast Gray Cast Malleable Wrought Steel and
Iron4 Iron Iron5 Iron Cast Steel High Carbon Steel
Speed of Moderate Moderate Moderate Fast Fast Fast
melting (from
cold state)
Color change Becomes dull Becomes dull Becomes red Becomes bright Becomes Becomes bright red before
while heating red before red before before melting red before bright red melting
melting melting melting before
melting
Appearance of A medium film A thick film A medium film Oily or greasy Similar to Similar to molten metal
slag develops develops develops appearance with molten metal
white lines
Action of slag Quiet; tough, Quiet; tough, Quiet; tough, Quiet; easily Quiet Quiet
but can be but possible to but can be broken up
broken up break it up broken
Appearance of Fluid and Fluid and Fluid and Liquid; straw Liquid; straw Lighter than low carbon
molten pool watery; watery; watery; straw color color steel; has a cellular
reddish white reddish white color appearance
Action of Quiet; no Quiet; no Boils and Does not Molten metal Sparks more freely than
molten puddle sparks; sparks; leaves get viscous; sparks low carbon steel
under blowpipe depression depression blowholes; generally quiet;
flame under flame under flame surface may be slight
disappears disappears metal sparks; tendency to
when flame is when flame is interior does spark
removed removed not

Shielded Metal Arc Welding Electrodes Chapter 12313

 Table 12-12 Identification of Metals by Chips

Brass and Aluminum

Alloy1 Steel Copper Bronze and alloys2 Monel Nickel Lead3
Appearance of Smooth Smooth Smooth Smooth Smooth Any shaped chip
chip chips; chips; chips; saw edges edges can be secured
saw edges saw edges edges where because of
where cut where cut cut softness
Size of chip Can be Can be Can be Can be Can be Can be
continuous continuous continuous continuous continuous continuous if
if desired if desired if desired if desired if desired desired
Facility of Very easily Easily cut; Very easily Chips easily Chips easily Chips so easily
chipping cut more brittle cut it can be cut
than copper with penknife
Low Carbon
White Cast Gray Cast Malleable Wrought Steel and High Carbon
Iron4 Iron Iron5 Iron Cast Steel Steel
Appearance of Small broken Small partially Chips do not Smooth Smooth edges Fine grain
chip fragments broken chips, break short as in edges where cut fracture; edges
but possible cast iron where cut lighter in color
to chip a fairly than low carbon
smooth groove steel
Size of chip 1
8 in. 1
438 in. Can be Can be Can be
continuous continuous if continuous if
if desired desired desired
Facility of Brittleness Not easy to chip Very tough, Soft and Easily cut or Metal is usually
chipping prevents because chips therefore harder easily cut or chipped very hard, but
chipping a path break to chip than cast chipped can be chipped
with smooth off from base iron
sides metal
1
Alloy steels vary so much in composition and consequently in results of tests that experience is the best solution to identification problems.
2
Because of white or light color and extremely light weight, aluminum is usually easily distinguishable from all other metals; aluminum alloys are usually harder and slightly darker in
color than pure aluminum.
3
Weight, softness, and great ductility are distinguishing characteristics of lead.
4
Very seldom used commercially.
5
Malleable iron should always be braze welded.

Conditions of Use
The service requirements are of utmost importance. The
type of structure and the stress that it will encounter in
use must be considered. Tensile strength, ductility, and
fatigue resistance are important weld characteristics that
help to determine choice of electrode. Note the variation
in weld metal properties among the electrodes compared
in Table12-3, page303.
Engineering Specifications
All code requirements and engineering specifications
must be noted carefully in any determination of the cor-
rect electrode to be used. The type of electrode to be used
is specified in the code requirements.
Production Efficiency
Several electrode classifications have high deposition
characteristics. Compare the rates of deposition given in
Table 12-4, page 304. Full advantage cannot always be
made of these characteristics because of the nature of the
material, the type of joint, and the position of the work.
For example, the electrodes classified as having a very
high rate of deposition in Table 12-4 can be used only for
flat and horizontal fillet welds.
The principal factor in the cost of a welding job is the
speed with which the welding can be done. Electrode
cost is small by comparison. E7024, E7028, and E6027
electrodes permit the highest rate of deposition; E6020,
E6013, E6011, and E6010 follow in the order given. Type
of steel, not speed, should govern the choice of the E7015
or E7018. The E7028 is similar to the E7018, but it has a
much thicker coating that contains a higher percentage of
iron powder; thus, its deposition rate is much higher.
Welding speed is increased by using electrodes with
large diameters, particularly in flat and horizontal position
welding. The E7024, E7028, and E6020 classifications,

314Chapter 12 Shielded Metal Arc Welding Electrodes

followed by the E6027, give the highest increases in weld-
ing speeds as the diameters of the electrodes are increased.
Job Conditions
Is the material clean, rusty, painted, or greasy? What is
the type of surface treatment required for the finished job?
Is the completed job to be stress relieved or heat treated?
Are the welds in a prominent location so that weld ap-
pearance is important? Only a welder with a thorough
knowledge of electrode characteristics can answer these
questions by choosing the best electrode for the job. It is
important to study manufacturers specifications.
Summary of Factors Affecting the
Selection of Electrodes
The foregoing are just a few of the considerations that
make it necessary for you to become highly familiar with
the nature of the different electrode classifications.
Selection of the proper electrode size and type for a
given welding job requires a thorough knowledge of elec-
trodes coupled with common sense. Careful study of the
physical, chemical, and working characteristics of elec-
trodes and practice in their use will enable you to make
the proper selection without difficulty.
In summary, the following factors are the most impor-
tant to consider:
Type of joint and position of welding
Type of welding current
Properties of the base metal
Thickness of the base metal
Depth of penetration desired
Weld appearance desired
Whether the work is required to meet code
specifications
Tensile strength, ductility, and impact strength
required of the weld deposit
Design and fitup of the joint to be welded
Nature of slag removal
Specific Electrode Classifications
Carbon Steel Electrodes
The carbon steel electrodes for welding low and medium
carbon steels carry AWS classification numbers E6010,
-11, -12, -13, -20, -27 or E7014, -15, -16, -18, -24, -28,
and -48.
Heavily Covered Mild Steel, Shielded Arc Electrodes
E6010: All-Position, DCEP (Fast-Freeze Type) This
electrode is
the best adapted of the shielded arc types for vertical and
overhead welding. It is, therefore, the most widely used
electrode for the welding of steel structures that cannot be
readily positioned and which require considerable multiple-
pass welding in the vertical and overhead positions. Al-
though the majority of applications are on mild steel, E6010
electrodes may be used to advantage on galvanized plate
and on some low alloy steels. In welding steel, the forceful
arc bites through the galvanizing and the light slag to reduce
bubbling and prevent porosity. Typical applications include
shipbuilding, structures such as buildings and bridges, stor-
age tanks, pipe welding, tanks, and pressure vessels.
The quality of the weld metal is of a high order
(Fig.12-4B, p. 318), and the specifications for this classi-
fication are correspondingly rigid. The essential operating
characteristics of the electrode are:
Strong and penetrating arc, enabling penetration be-
yond the root of the butt or fillet joint.
Quickly solidifying weld metal, enabling the de-
position of welds without excessive convexity and
undercutting.
J OB T IP
An Interview
In an interview for the Hobart Institute,
welding manager Anthony Morgan explained
what he looks for in hiring:
1. A person who views his or her work with a sense of
pride.
2. A person who wants to push his or her limits to see
how much can be learned and accomplished.
3. A strong work ethic.
Low quantity of slag with low melting and low
density characteristics, so that it does not become
entrapped nor interfere with oscillating and weaving
techniques.
Adequate gaseous atmosphere to protect molten metal
during welding. Electrodes of this type are usable
only with DCEN.
The E6010 electrode is commonly classified as the cel-
lulosic type. The electrode coating contains considerable
quantities of cellulose, either in a treated form or as wood
flour or other natural forms. During welding, the cellulose
is changed to carbon dioxide and water vapor, forming
the gaseous envelope that excludes the harmful oxygen
and nitrogen in the air. The water vapor from minerals
containing water and the vapor retained by the binder are
also liberated during welding.
Shielded Metal Arc Welding Electrodes Chapter 12315