One of the most common processes for field welding repair is Shielded Metal Arc Welding (SMAW), or Stick. Stick electrodes are self-protecting and reduces the amount of equipment required - there is no need to haul gas cylinders, hoses and regulators. It also provides adequate protection for the weld seam in outdoor applications where wind interferes with the shielding gas. It should be noted that flux cored wire (FCAW) welding is also a good option for field repairs, but for the purposes of this article we will focus on Stick, which is more readily available to many contractors.
Each application has different mechanical properties, such as required strength, ductility, wear resistance, impact strength and tensile strength. Precise material matching ensures weld quality and longevity and prevents premature failure and unplanned downtime.
AWS A5.11 ENiCrFe-3
The most common electrodes used for stick welding are 6010, 6011, 6013, 7018 and 7024, with the most common diameters ranging from 1/8 to 5/32 inch. Each of these electrodes offers all-position welding capabilities (except 7024). The first two digits of the bar electrode represent the minimum tensile strength "at weld": for example, the 6010 offers a tensile strength of 60,000 psi. The third digit represents the acceptable weld position for each electrode (1 = all positions, 2 = flat or horizontal only, 3 = flat, horizontal, vertical down and up). The fourth digit refers to the type of coating and the type of welding current (alternating current (AC)/direct current (DC)) that can be used with the electrode. The following is a brief description of each electrode commonly used in this application (courtesy of Hobart Brothers)
6010: The all-position electrode is suitable for use with DC power sources only. It has deep penetration capability and is able to penetrate rust, oil, paint and dirt. This electrode is characterised by a very tight arc, which can be difficult for inexperienced welders. Ideal for penetrating on tightly fitted joints. For use with all position electrodes in AC and DC power sources. It produces a deep, penetrating arc that cuts through corroded and unclean metals - ideal for maintenance and repair. Ideal for penetration on tight fitting joints.
AWS A5.1 E6011
6011: All-position welding rod with a soft arc, low spatter, moderate depth of fusion and easy slag removal. Suitable for AC or DC power sources, this electrode is more suitable for newer and cleaner materials, thinner materials and wider root openings.
7018: All-position electrodes with coarse flux and high iron powder content are among the easiest to use. These electrodes produce a smooth, quiet arc with minimal spatter and medium arc penetration. Produces strong welds with high impact properties (even in cold weather) and can be used on carbon, high carbon, low alloy and high strength steel base materials. Suitable for AC and DC power sources.
7024: For flat or horizontal welds using AC or DC power sources, this electrode contains a high iron powder content which helps to improve the deposition rate. Performs well on steel plates at least ¼ in. thick and can be used to measure metal over ½ in.
