Welding Rod Sizes: A Comprehensive Guide

Let’s first define what welding rods are. Another name for welding electrodes, welding rods join two metal workpieces together to form a single whole. They are only used during shielded metal arc welding.

Welding rods can be distinctly divided into two categories: consumable and non-consumable. The former type of rod melts or disintegrates once heated and thus forms the bonding material that joins the two original workpieces together.

Non-consumable rods, on the other hand, function differently and with different physical forces. They produce a catalytic reaction to the base metal, allowing them to fuse and join the two pieces together.

Welding rods are singularly important because without them, there’s no consistency in creating a new object – in other words, there’s nothing to join them together.

So what about welding rod sizes? When welding in the vertical position, there are two sizes of rods that are ideal for multiple types of jobs. These are: tacking weld joints, welding lightly-rusted metal, acting as filler metal in poorly-fit joints, and the initial penetration material.

There are some other sizes as well. We’ll get into those below.

Types of Welding Rod Sizes

As you might guess, the different size types correspond to different kinds of jobs – particularly variations in materials. For instance, a welding rod for copper will be sized differently than one for HSS.

Let’s get you started choosing the right welding rod by providing a size chart:

Chart courtesy WeldingPros.net

 This chart should serve as a guide for all your welding rod size needs and will provide education and knowledge about the selection process as well.

Now, let’s break down some different size types for jobs with different metals:

• 1: This size is used for carbon steel.
• 5: Low-alloy steel
• 4: Stainless steel
• 15: Cast iron welding
• 11: Nickel alloys
• 3: Aluminum alloys
• 6: Copper alloys
• 13: Surfacing alloys

Application for Welding Rod Sizes

The chart above indicates the numerical relationship between amperes and welding rod sizes. Now let’s explain that relationship in physical terms.

Amperage is the strength of the direct current flowing through the rod during the weld. The amperage of the welding current is adjustable, and rod sizes have different amperages. The fundamental law is this: amperage is inversely proportional to the thickness of the metal. If amperage goes up, it must correspond to a lower thickness threshold of metal.

Best Welding Rod Sizes for Different Welding Positions

Remember how there are flat, vertical, horizontal, and overhead welding positions? Well, here are the best rod sizes for each welding position:

You need to select a rod with a “1” in its designation for a welding process with vertical or overhead positions. While most widely-used rods can go with any position, there are exceptions, like the above. Also, note that you cannot use any welding rod in the vertical-down position. 

FAQs

1.  What welding rod size should I use for thin metal?

The answer to that question needs to factor in another consideration: the width of the metal. New 1/8th-inch metal will require 3/32-inch 7018 rods. Thinner surfaces will require an even smaller rod diameter.

2. How do I determine the amperage for welding with different rod sizes?

Put simply, please check our amperage-to-size table above!

3. Can I use a larger welding rod size for thinner metal?

No. The thinner the weld metal, the smaller the welding rod size should be. They are directly proportional, in other words, unlike amperage-to-metal thickness, as explained above.

4. What is the difference between 6011 and 6013 welding rods?

The answer is that they are similar in terms of tensile strength, types, and welding position. However, they differ because the 6011 welding electrodes are more conducive to heavy-duty projects, whereas the 6013s use a delicate arc more suited to sheet metal projects. The 6011 also requires more manual dexterity and skill to use.

5. What welding rod size should I use for overhead welding?

The 7018 welding rod is specifically designed for overhead welding.

In Conclusion

Ecenrode Welds is your one-stop shop for all of your welding needs. We have two product pages: one on our main site and one on our product site. You are sure to find what you need for any of your upcoming projects, so buy from us today!