It is important for both novice and experienced welding professionals to understand the various components required for successful welding operations. One of the most common pieces of welding equipment is the welding electrode. If you are looking to learn more about welding electrodes, or just want a refresher on some terminology, then this is the overview for you.
What are Welding Electrodes?
Simply put, a welding electrode is a coated metal wire. These welding electrodes are connected to a welding machine to create an electric current, or arc. The current passes through the wire to generate heat to melt and fuse the metal you are using for welding. Having the wire coated helps to protect the filler metal from damage while stabilizing the arc. This provides a better weld for your project.
Flux Coating
A major part of welding electrodes is the coating that goes over the electrode component. This coating can be made of several types of materials that provide different properties. Common examples include silicates of sodium, potassium, or magnesium, starch and calcium carbonate, or ferromanganese and ferrosilicon. The coating is added to the welding electrode in one of two ways:
Dipping Method for Flux Coating
A group of wires are clamped together and dipped vertically into a bath of the molten flux coating material. After the flux has hardened to adhere to the core wire, the group is lifted out of the liquid flux material to dry.
Extrusion Method for Flux Coating
The flux coating material is mixed and hardened into a paste-like texture. This material is then shaped into a cylinder and poured into an extrusion press. The flux material and the core wire are pressed through a die under immense pressure, which adheres the flux material around the wire. Using dies and other production tools makes it easy to adjust the size and thickness of the electrode wire.
Welding Electrode Sizing
There are different sizes of electrodes, which can change depending on the size of the core wire or the thickness of the coating. The different compositions of flux material can also have an impact on the size of the overall electrode component. When you get welding electrodes from a company, it helps to know that sizes tend to start around 300 and go up from there. You can ask the professionals at your welding supplier to help find the right size for your machine or your project.
If you are trying to read the numbers on a welding electrode by yourself, here is a quick and helpful guide to understanding what the electrode rod number means:
- The first two numbers refer to the tensile strength of the electrode. The higher the number, the more pounds per square inch (psi) the rod can withstand.
- The third number helps you determine what position the rod can be used in. For example, electrodes that have the number 1 can be used in all positions, and the number 4 can only be used in a flat position.
- The final number on the electrode helps you figure out the class or the rod or the makeup of the flux coating. Lower numbers will be found in consumable electrodes, and higher numbers tend to be used for non-consumable electrodes.
Each job will require a different type of electrode. Commonly used electrodes are able to be used in a wide range of projects and are made of materials that can run hot and deliver a deep arc.
Consumable Electrodes
There are two main types of electrodes. The first is consumable electrodes, which are used in stick, MIG, and flux-cored welding projects. These are designed to melt over time, and therefore are consumed in the welding process. These electrodes include:
- Light Coated Electrodes
- Bare Electrodes
- Shielded Arc Electrodes
Non-Consumable Electrodes
Unlike consumable electrodes, the non-consumable version doesn’t melt. This allows the welding electrode to be used multiple times for different welding applications. However, the quality of the weld itself might be of a lower quality since there was no protective layer created during the process to avoid corrosion or contamination. These types of electrodes include:
- Carbon Electrodes
- Tungsten Electrodes
Find Your Welding Electrodes at Vern Lewis Welding Supplies
Becoming a welding expert requires you to have all the equipment you need and the training to use it the right way. At Vern Lewis Welding Supplies, we have been supplying Arizona welders with equipment and supplies for over 50 years. We’re here to help you with your welding needs, whatever they may be. Contact us to learn more or stop by one of our 8 locations to purchase your welding electrodes today.
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