10 Things to Consider When Buying Cast Iron Stick Electrodes

Welding rod selection

Stick electrodes are available in a wide range of types, each of which provides different mechanical properties and operates with a specific type of welding power source. There are several factors to consider in welding rod selection:

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• Base metal properties
• Tensile strength
• Welding current
• Base metal thickness, shape and joint fit-up
• Welding position
• Specification and service conditions
• Environmental job conditions

Before you power up your machine and pick up your electrode holder, learn more about each of these factors.

Base metal properties

The first step in choosing an electrode is to determine your base metal composition. Your goal is to match (or closely match) the electrode composition to the base metal type, which will help ensure a strong weld. If you’re in doubt about the composition of your base metal, ask yourself these questions:

• What does the metal look like? If you’re working with a broken part or component, check for a coarse and grainy internal surface, which usually means the base material is a cast metal.
• Is the metal magnetic? If the base metal is magnetic, chances are good that the base metal is carbon steel or alloy steel. If the base metal is not magnetic, the material could be manganese steel, 300 series austenitic stainless steel or a non-ferrous alloy such as aluminum, brass, copper or titanium.
• What kind of sparks does the metal give off when touched by a grinder? As a rule of thumb, more flare in the sparks indicates a higher carbon content such as in A-36 grade steel.
• Does a chisel “bite” into the base metal or bounce off? A chisel will bite into a softer metal, such as mild steel or aluminum, and bounce off of harder metals, such as high carbon steel, chrome-moly or cast iron.

Tensile strength

To prevent cracking or other weld discontinuities, match the minimum tensile strength of the electrode to the tensile strength of the base metal. You can identify a stick electrode’s tensile strength by referring to the first two digits of the AWS classification printed on the side of the electrode. For example, the number “60” on an E electrode indicates that the filler metal produces a weld bead with a minimum tensile strength of 60,000 psi and, as a result, would work well with a steel of similar tensile strength.

Welding current

Some electrodes can be used with only AC or DC power sources while other electrodes are compatible with both. To determine the correct current type for a particular electrode, refer to the fourth digit of the AWS classification, which represents the type of coating and type of compatible welding current (see Figure 1).

Refer to the fourth digit of the AWS classification to determine the compatible welding current.

The type of current you use also influences the penetration profile of the resulting weld. For example, a DCEP compatible electrode, such as an E, delivers deep penetration and produces an extremely tight arc. It also has the ability to “dig” through rust, oil, paint and dirt. A DCEN compatible electrode, such as an E, provides mild penetration and works well when bridging two joints or welding high speed, high current fillet welds in the horizontal position.

An AC compatible electrode, such as an E, produces a soft arc with medium penetration and should be used to weld clean, new sheet metal.

Base metal thickness, shape and joint fit-up

Thick materials require an electrode with maximum ductility and low hydrogen to prevent weld cracking. Electrodes with AWS classification numbers ending in 15, 16 or 18 provide excellent low–hydrogen properties and good toughness (high impact values) to accommodate for residual stress.

For thin materials, you will need an electrode that produces soft arcs, such as a . Also, smaller diameter electrodes will provide shallow penetration to help prevent burn-through on thinner materials.

You’ll also want to assess the joint design and fit-up. If you’re working on a joint with a tight fit-up or one that is not beveled, use an electrode that provides a digging arc to ensure sufficient penetration, such as an E or E. For materials with wide root openings, select an electrode, such as an E, that creates a concave weld face suitable for bridging gaps and making groove welds.

Welding position

To determine what position(s) a particular electrode is qualified for, refer to the third digit in AWS classification. Here’s how you decipher the qualified electrode position:

1 = flat, horizontal, vertical and overhead

2 = flat and horizontal only

For example, a electrode can be used in the flat, horizontal, vertical and overhead positions.

Specification and service conditions

Make sure to assess the conditions that the welded part will encounter throughout its service. If it will be used in high heat or low temperature environments subjected to repetitive shock loading, a low hydrogen electrode with higher ductility will reduce the chance of weld cracking. Also, be certain to check for welding specifications if you’re working on critical applications such as pressure vessel or boiler fabrication. In most cases, these welding specifications will require you to use specific types of electrodes.

Environmental job conditions

To achieve the best results, you should always remove excessive mill scale, rust, moisture, paint and grease. Clean base metals help prevent porosity and increase travel speeds. If cleaning your base metal is not possible, E or E electrodes deliver a deep penetrating arc that has the ability to cut through contaminants.

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Choosing welding rods

Consideration of the above factors will help you overcome the challenges of selecting the correct stick electrode for your particular application. However, given the wide range of available electrodes, several solutions may exist for one application. If you need additional assistance with electrode selection, your local welding supply distributor or a company representative of a reputable filler metal manufacturer can serve as an excellent resource.

Stick welding—also known as Shielded Metal Arc Welding (SMAW)—is one of the most common welding processes used across many industries. A key component to this process is the welding rod, also known as the electrode. Choosing the right stick welding rod is essential for achieving quality welds, whether you’re working with steel, stainless steel, or specialty metals.

At WeldingMart.com, we offer a wide range of high-quality stick welding rods to meet various needs and applications. In this guide, we’ll cover everything you need to know about stick welding rods, including types, applications, and how to choose the right one for your project.

To browse our full selection of welding rods, check out the Welding Rods Collection at WeldingMart.

What Is a Stick Welding Rod?

A stick welding rod is a consumable metal rod coated in flux, which serves as the filler metal and protective shield during welding. When the arc melts the rod, it fills the joint with molten metal, while the flux coating forms a gas shield, preventing contamination from the air and leaving behind slag to protect the weld as it cools.

Types of Stick Welding Rods

The most commonly used stick welding rods are classified by the American Welding Society (AWS) standards, with each rod type denoted by a specific code. Here’s a breakdown of some popular types:

1. E Welding Rod

• Features: High penetration, deep weld pool, fast freeze.
• Applications: Ideal for root passes in pipe welding and general-purpose welding.
• Strength: 60,000 psi tensile strength.

2. E Welding Rod

• Features: Similar to E but suitable for AC or DC polarity; good for vertical and overhead welding.
• Applications: Used in repair work, rusted or dirty metals, and outdoor jobs.
• Strength: 60,000 psi tensile strength.

3. E Welding Rod

• Features: Produces a soft arc with moderate penetration; good for clean and thin materials.
• Applications: Light fabrication, thin sheet metal, hobby welding.
• Strength: 60,000 psi tensile strength.

4. E Welding Rod

• Features: Low-hydrogen electrode, smooth arc, high ductility.
• Applications: Structural steel, heavy equipment repair, pressure vessels.
• Strength: 70,000 psi tensile strength.

5. E Welding Rod

• Features: High deposition rate, suitable for flat and horizontal positions.
• Applications: Heavy fabrication, thick materials.
• Strength: 70,000 psi tensile strength.

Welding Rod Selection Chart

The following chart provides an easy guide to selecting the right welding rod based on specific materials and requirements:

Rod Type Amperage Range Polarity Position Typical Applications E 40-180 DC+ All positions Root passes, pipelines, general-purpose E 50-225 AC/DC All positions Outdoor work, dirty or rusty metals E 40-150 AC/DC All positions Thin materials, sheet metal, general repair E 90-250 DC+ All positions Structural welding, heavy equipment E 100-300 AC/DC Flat and horizontal Heavy fabrication, high deposition rate

You can find a variety of these electrodes in our Welding Rods Collection on WeldingMart.com.

How to Choose the Right Stick Welding Rod

Selecting the right welding rod is essential for ensuring quality welds. Here are some critical factors to consider:

1. Base Material

• Steel: For carbon steel, E, E, E, and E are popular choices.
• Stainless Steel: E308L and E309L rods are best suited for stainless steel applications.
• Cast Iron: Specialty electrodes, like E312 or nickel-based rods, are required for cast iron.

2. Welding Position

• All Position: For versatile applications in flat, horizontal, vertical, and overhead positions, use E, E, or E.
• Flat and Horizontal Only: E and E rods are optimal for flat and horizontal welds.

3. Polarity and Power Source

• Direct Current (DC): E and E rods perform best on DC current, typically used for structural welding.
• Alternating Current (AC): E and E rods are ideal for AC welders, making them suitable for home use.

4. Thickness of Material

• Thin Materials: For sheet metal or light fabrication, E rods are recommended due to their moderate penetration.
• Thick Materials: Use E or E rods, which have higher tensile strength and better penetration for thicker materials.

Stick Welding Techniques for Different Rods

Each rod type requires specific techniques to achieve optimal results:

• E: Known for its deep penetration, E requires a whipping motion to control the weld pool and maintain arc stability.
• E: Similar to E, but easier to use on AC; ideal for situations where quick freeze is necessary.
• E: Requires a slight drag technique for smooth, low-spatter welds. Important to store in a dry environment due to its low-hydrogen coating.
• E: Easy to use for beginners; works well with a straight drag motion on thin materials.

How to Store Stick Welding Rods

Proper storage of welding rods is critical for maintaining their performance and preventing issues such as moisture absorption or cracking. Here are some tips:

1. Low-Hydrogen Electrodes (e.g., E): Store in a rod oven to keep moisture out, as these rods are prone to hydrogen cracking.
2. General-Purpose Rods (e.g., E, E): Store in a dry, climate-controlled environment to avoid rust and moisture absorption.
3. Specialty Rods: Refer to the manufacturer’s guidelines for proper storage conditions.

FAQs on Stick Welding Rods

Q: What is the most versatile stick welding rod?

A: The E and E rods are among the most versatile, with E working well on both AC and DC and E offering a high-strength, low-spatter weld.

Q: Can I use E on a home welder?

A: Yes, E is compatible with home welders that have DC capabilities, making it a popular choice for home projects requiring a stronger weld.

Q: What rod is best for rusty or painted metal?

A: E is ideal for dirty, rusty, or painted metals due to its deep penetration and ability to cut through contaminants.

Stick Welding Rods Available at WeldingMart.com

At WeldingMart.com, we carry a broad selection of stick welding rods suited to various applications, from general-purpose rods to specialty alloys. Browse our Welding Rods Collection for high-quality electrodes that meet industry standards and provide reliable performance.

Whether you’re a professional welder or a hobbyist, having the right welding rod can make a significant difference in your work quality and efficiency. Our customer service team is available to help you choose the best products for your specific needs.

Conclusion

Choosing the right stick welding rod is essential to achieving strong, clean welds suited to your project’s requirements. By understanding the different types, applications, and storage needs, you’ll be well-equipped to tackle any welding task with confidence. From general-purpose rods like E and E to specialized rods for stainless steel and cast iron, WeldingMart has the electrodes and equipment to help you work effectively and safely.

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