SMAW electrodes are solid (or cast) wire rods covered with a thick flux coating.

The thickness and

composition of the flux coating determines the electrodes operating characteristics and the
mechanical and chemical properties of the deposited weld.
During welding, the flux coating dissolves and produces a gas and slag material. The gas-and-slag
shield protects the molten weld metal fro contamination. When the weld deposit has cooled, the
slag is removed.
ELECTRODE SELECTION
It is most important to select the proper electrode for each welding job. The quality, appearance,
and economy of the weld will depend upon correctly selecting the most suitable electrode. There
are a number of factors that must be considered in the choice of electrode:
1. Mechanical Properties. It is essential to know not only the kind of metal being welded
(mild steel, cast iron, etc) but also its mechanical properties. The properties of each
electrode are indicated by the identification numbers of the AWS electrode classification
system. Select the electrode with mechanical properties most closely matching those of the
base metals. The mechanical properties should also be of those that impart the highest
ductility and impact resistance to the weld.
2. Chemical Properties. The electrode should have approximately the same chemical
composition as the metal being welded. The chemical properties listed for an electrode is
analyses (expressed in percentages) of the different alloying elements contained in the
electrodes wire or core. These are nominal chemical analyses and will differ slightly among
the same electrode classification among different electrode manufacturers.
3. Welding current. The electrode selected should be the one that most closely matches the
type of power source being used. The type of welding current to be used with a particular
electrode is also indicated by the AWS electrode identification numbers. As a general rule,
the welder should select the maximum current and the maximum electrode diameter) that
can be used with the thickness of the metal being welded. Here, consideration should be
given to whether of not the metal has been preheated. Preheated metals require less current
than those that have not been preheated.
4. Welding position. The AWS electrode identification numbers also indicate the welding
position for which the electrode is designed. Not all electrodes are designed for every use
in every welding position. The welder must match the electrode with the welding position
being used.
5. Thickness of the metal. The thicker the metal, the greater the current required to produce a
suitable weld. An increase in the amount of current required a corresponding increase in
electrode diameter. The welder should match closely, the welding current being used to the
electrode diameter recommended by the manufacturer.
6. Joint design. The design of the joint (and fitup) determines the degree of arc penetration
(deep, medium, light, etc) which is specified by the AWS electrode identification numbers.
The welder should select an electrode that gives the required arc penetration.

7. Welding passes. The number of passes is also determined by the type of electrode selected.
Multiple passes require more current than a single pass.
8. Joint position. The position in which joints are welded, especially on multipass, is one of
the important considerations that affect the choice of electrodes. For flat and horizontal
joints, the so-called hot electrodes should be used. Electrodes used for vertical and
overhead work, of course, must produce deposits that will stay in place and not fall out of
the joint while in molten condition. Deposits of this type usually require an electrode no
larger than 3/16 in diameter.
9. Working conditions. Be aware of the working conditions and select an electrode
accordingly. Such factors as high temperature, low temperature, corrosive atmosphere and
impact loading are important in electrode selection.
The 2 most common steel used is Alloy Steel and Stainless Steel and only these 2 types are
discussed here.
SMAW ALLOY STEEL ELECTRODES.
The metal core of these electrodes is made of alloy steel instead of low carbon steel. The electrode
coating is similar to the low hydrogen type. Some may also contain iron powder. They are
designed for welding high strength alloy steel and can deposit welds with a tensile strength in
excess of 100,000 psi. Common applications include the welding of high temperature, high
pressure piping, carbon moly pipng used in high pressure, high temperature steam service, and
plates or casting with a molybdenum content of approximately 0.50percent.
Electrodes in the E70XX series (E7010, E7011, E7013, E7015, E7016, E7020, E7025, E7026 and
E7030) are commonly referred to as low-allow steel electrodes.
The E8010,-11,-13, E9010,-11,-13 and E10010,-11,-13 electrodes also belongs to this group.
SMAW STAINLESS STEEL ELECTRODES.
Stainless Steel electrodes are available with either lime or titanium coatings. The first is used only
with DC electrodes positive (DCEP), the second can be used with both AC and DC electrode
positive (DCEP) current.
The lime coated electrodes produces flat or slightly convex fillet welds. The slag covers the entire
weld, spatter is at a minimum, and the impurities are fluxed from the weld metal. The titania
coated electrode produces slightly concave type welds with a smother and more stable arc than that
found with the lime-coated type.
The numbering identifications systems for stainless steel electrode differs from the one used for
mild steel and low alloy electrodes. The prefixed E indicates an arc welding electrode. The 3-digit
number following the prefixed letter indicates the types of stainless steel (eg 304, 310, 316, etc).
Two more digits follow and are separated from the first three by a hypen. These last two digits
indicate the coating, current polarity, and welding position of each electrode.