166 CHAPTER In addition tothe standard rods that can be used to make welds in steel 1/8 in. (@ min) and thicker, there are a wide variety of specialty electrodes. These specialty rods allow you to use the same welding. ‘machine to weld on cast won, stainless stl, and alu- minum. There are rods for cutting that will eut cast lon and stainless steel; these are metals that cannot be cut with oxygen and ccetylene. Wear-resstant and ‘baléup rods can be used to repair scraper and front ‘end loader blades and buckets, ‘The basic stick-welding skills you will learn in this chapter are used for almost every welding fabri- cation project. Welding isa scl that takes practice to perfec. The repetition in the chapter practices and. projects Is designed to give you the apporcunity 10 develop your skill. The more time you spend veeking, the better your welding skills will become. ELECTRODES ‘Arc welding electrodes used for practice welds are grouped into three iiler metal classes (F number) according to theie major welding characteristics, The sroups are E4010 and E6011, E6012 and E6013, and E7016 and E7018. F3 E6010 and E6011 Electrodes Both ofthese electrodes have cellulose-based fluxes. ‘Asa result, these electrodes have a forceful ae with litle slag left on the weld bead. E6010 and E6011 are ‘the most uiltarian welding electrodes for welding. fabrication. They can be used on metal that has alte ‘ust, olor eit without seriously affecting the wes frength. The E6010 electroder can weld only with direct current (DC) welding machines. Because F6011 clectrodes can be used with alternating current (AC), smaller transiormer-type welders that put out only AC. welding current can be wed. F2 E6012 and E6013 Electrodes ‘These electrodes have rutile-based fluxes, giving & smooth, easy are with a thick slag left on the weld ‘bead. Both E6012 andl E6013 are easy electrodes to use. ‘They do not have focceful arcs, so they can be used. ‘on thinner metals such as some thicker sheet metal gauges that are used as guards on equipment. F4 E7016 and E7018 Electrodes Both of these clectrodes have a minerl-bared fix. “The resulting are is emootn and easy, with a very heavy lag let om the weld bead Of these two elace trodes. F718 Is the one used most often to make highstrength welds on equipment. Store these elec: trodes in a dry place. lf they get wet, they will stil ‘weld but the welds will ot be ar strong. The cellulose- and rutile-based groups F3 and 2 of electrodes have characteristics that make them the best electrodes for starting specific welds. The slectrodes with the calilose-based uxss do not have heavy slag that may interfre with the welders view ofthe weld. This feature i an advantage for fat tee and lap joints. Eletrdes with the ruil-based ‘Buxes (giving an easy arc with low spatter) arc casice to control and are used for le, stranger beads, and batons. Unless a specific electrode Is required for job, welders can select what they consider tobe the best slectrade for a specie weld. Welders often have favorte electraces to use on specific jobs Electrode with mineral-based fixes, grip Ft, should be thet choice. Welds with a good appeare ance are more easily made with these electrodes, but strong welds are hotd to obtain. Without spacial care being taken daring the start ofthe weld, porosity ll be formed in the weld. Figare 9-1 shows a general comparison of the ‘weld penetration and buildup each electrode will pro- ‘dace with approximately the same amperage. Mare information on electrode selection can be found in ‘Chapter 6. Effect of Too High or Too Low Current Settings Each welding electrode must be operated in a par- ‘cular current (amperage) range, Table 9-1. Weld- Ing with the current set too low results in poor fusion ToT ToT Tea O16 TOT FIGURE 9-1 Comparison of electrode type and weld besd shapes. © Cengege Laurin 2012Table 9-1. Welding Amperage RangeforCommon Electrode Types and Sizes and poor are stability, Figure 9-2. The weld may have slog or gas inclusions because the molten weld pool wat not uid Jong enough forthe flux to cat. Lite ‘no penetration of the weld into the baseplate may also be evident. With the current se too low, the ac length i vey short. Avery shor ae length reslts in frequent shortening and sticking ofthe electrode, The core wize of the welding electrode i limited fle meter of cuteent ah cay AS Be Gent is increased, the wire heats up because of electrical resistance. This preheating of the wire causes some fof the chemicals in the covering to be burned aut too early, Figure 9-3, The loss ofthe proper balance ‘of elements causes poor re stabilty. This condition leads to spatter, porosity and slag inclusions. An inereate in the amount of spatter ix also ‘caused bya longer ae. The weld bead made at aigh Amperage tetting fs wide and fat with deep penstrae tion. The spattr is excessive an is monly hard The spatter is called hard beens it Fass to the baseplate and is dificale to remove, Figure 9-4. The elecrode ‘covering is discolored moce than 1/8 in (3 mm) t0 FIGURE 9-2 Welding with the amperage et too low. Shielded Metal ArcWelding Plate 167 Pca ey FIGURE 9-3 Welding wthto0 high an amperage. 40, (6m) fro theend ofthe decttode Extremely high settings may also cause the electrode to discolor, crack, glow red, or bur, Electrode Size and Heat The selection ofthe correct size of welding electrode fora wad ie determined by the sil ofthe welder, the thickness of the metal to be welded, and the size of the metal The 1/&-n, (-mim) electrode ie the most commonly used size for metal fabrication. It can be ‘sed to make welds on thin metal up to thick plates Using small diameter loctrodes requires es sl than sing large diameter elactrodex. The depostion rate, o the fate thar weld metal sede tothe wl is lower when small diameter electrodes are used. Small dars- tar electrodes will make acceptable welds on a thick plate but more time is required to make the weld, FIGURE 9-4 Hard weldspater fused wo base metal ane edficutoremove. Ly te