How to Choose The Right Welding Rod? | D&H Secheron
                     
Description
Welding, a fabrication process used to fuse two or more metal parts together. This process typically is 
used on metals and thermoplastics. A welding rod commonly referred to as a welding electrode is 
what makes or breaks the success of this welding process. Welding electrodes are the medium used 
to fuse two metals together. These rods are available in different types and their usage depends on 
the purpose of the machinery. To enable seamless welding results, it is extremely important to choose 
the right welding electrodes at the initial stage.
There are 4 types of welding rods or welding electrodes produced by welding electrodes 
manufacturers across the world:
1. Covered rods
2. Tubular rods
3. Bare welding rods
4. Welding fluxes
But how does one select a suitable electrode from these for a welding process?
Here are a few steps to consider before you select your welding materials:
1. Know your base metal’s properties
Your base metal’s composition needs to match or at least closely match the electrode 
composition for the weld to become successful. Referring to an electrode and metal 
composition chart for this purpose can be helpful and convenient.
2. Check the tensile strength
Apart from matching the composition of base metal to the electrode, it is also important to 
match the minimum tensile strength of the electrode to the tensile strength of the metal. This 
will avoid cracking or other damage to the metal during the welding process. You can always 
check the tensile strength of the electrode by referring to the first two digits of the AWS 
classification printed on it. 
3. Check the welding current
Electrodes often come with the condition of being used only with certain power sources such 
as AC or DC current. Other electrodes on the other hand can be compatible with both. For 
medium or deeper penetration of the weld, using electrodes compatible with AC currents is 
advisable. Electrodes compatible with AC current also produce a soft arc and can be used to 
weld clean sheet metals.
4. Know the base metal’s thickness and shape
Determining the thickness of your base metal can help identify which electrode would suit 
the process. For example, thicker materials require electrodes with high ductility and low 
hydrogen. On the other hand, thinner welding materials require soft arc electrodes with 
smaller diameters. This will ensure shallow penetration and help avoid the burning of thinner 
material.
5. Determine the welding position
Basically, before choosing an electrode, you need to have a clear idea about your welding 
procedure. The position of your welding will influence the choice of welding electrode to be 
used. To find out about each electrode and the position it’s suitable for, refer to the AWS 
classification chart.
Conclusion:
Apart from this, before you begin your welding procedure, make sure your base metal is 
absolutely clean of dust, rust, grease, and other contaminants. This is an important step to 
get the perfect desired weld. We hope this article helped you understand the process of 
welding electrode selection better. If you have more questions, do reach out to us as we’ll be 
happy to help you.
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