SMAW Welding Rod Chart: AWS Classifications, Selection, Use & Safety Guide

If you’ve ever stared at a pack of SMAW electrodes and wondered why E6010 runs differently from E7018, you’re not alone. Knowing the AWS rod chart can be the difference between a clean, code-compliant weld and a failed joint.

1. Introduction: Why an SMAW Welding Rod Chart Matters

Walk past any active fabrication shop and you’ll notice something telling: the electrode oven gets as much attention as the power source. Different rods go to different jobs for a reason. Some are meant to dig through rust for a root pass, some are built for code work, and others are reserved strictly for low-hydrogen joints. The trick is knowing which one to grab without guessing. That is exactly what an SMAW welding rod chart is for.

By translating the AWS classification on a covered electrode into practical details, a good chart helps match filler metal to base metal, joint design, welding position, and the governing code. Get it right and the weld goes down with less frustration. Get it wrong and you could be looking at a crack, a failed inspection, or a joint that simply cannot be made in the position required.

Why Stick Welding Relies So Heavily on Selection

Shielded metal arc welding, better known as stick welding, uses a flux-covered consumable electrode. When struck, the arc melts both the core wire into filler metal and the coating, which creates its own shielding gas and a layer of slag to protect the weld as it cools. Unlike processes that rely on a separate gas cylinder, the electrode handles both jobs at once.

That dual role is what makes selection so critical. SMAW is also one of the most portable arc processes, which is why it’s still so prevalent outdoors and on less-than-perfect steel. For a broader breakdown of its staying power, see advantages of stick welding.

Small Code, Big Differences

Two rods can be the same diameter and look nearly identical, yet behave as entirely different tools. These changes come down to the coating and core wire, and they impact the weld in very real ways:

• Strength: The numbers in an electrode’s classification directly relate to its minimum tensile strength.
• Penetration: Cellulosic rods dig deep for tight or unclean joints, while other coatings spread a wider, shallower bead.
• Position: Some coatings create a fast-freezing slag that can support vertical and overhead work, while others are better suited strictly for flat or horizontal.
• Current and polarity: Not every rod runs on every machine. Some require DC electrode positive, some DC negative, and some can run on AC.
• Hydrogen control: Low-hydrogen electrodes are often required for restrained or high-strength joints, but only if they’re kept dry and properly stored.
• Workability: Arc stability, spatter, slag removal, and ease of striking can all vary drastically between classifications.

In North America, carbon steel covered electrodes fall under AWS A5.1. While this standard defines classification requirements, any project specification or welding procedure will always take precedence over a general chart.

Reading the Code and Using a Chart

The key to all of this is the “E” prefix. Take E7018 as an example: the “E” stands for electrode, “70” means a minimum tensile strength of 70,000 psi, “1” means it’s usable in all positions, and “8” denotes its coating type along with its current and polarity requirements. From there, suffixes can indicate additional details, such as impact toughness or diffusible hydrogen limits.

A usable rod chart doesn’t just show those numbers. It lays them out by position, amperage range, polarity, penetration, typical uses, and storage notes. The correct way to use one is simple: start with the base metal and any code requirements, narrow down by strength and position, confirm compatibility with your available current, and cross-reference with the manufacturer’s data sheet or qualified procedure. The chart narrows the field, but it never replaces those documents.

A Starting Point For Smarter Choices

No chart can account for every scenario. An electrode rated for all positions may still be far more difficult for vertical-up welding than another, and swapping E6010 for E7018 isn’t always a valid repair for a given joint. Some jobs may require a specific alloy match as well. For help narrowing down position-specific choices, the all position welding rod guide can be a helpful companion.

With that in mind, think of an SMAW welding rod chart as a translator, not a shortcut. Learn to read it well, and the string of letters and numbers on an electrode will start reading back to you with clear, actionable instructions for the job ahead.

2. How to Read AWS SMAW Electrode Classifications

The code printed on an SMAW electrode box is a specification, not decoration. A designation like E7018-H4R packs tensile strength, welding position, coating chemistry, current type, hydrogen limit, and moisture resistance into a few characters. These classifications come from AWS A5 filler metal specifications, mainly AWS A5.1 for carbon steel and AWS A5.5 for low-alloy steel electrodes.

The Prefix and Tensile Strength

The leading E stands for “electrode”, identifying it as a covered, consumable electrode for SMAW. The two or three digits that follow represent the minimum tensile strength of undiluted deposited weld metal in ksi:

• E60XX – 60 ksi (about 410 MPa)
• E70XX – 70 ksi (about 480 MPa)
• E80XX and above – Common for low-alloy grades, such as E9018 or E10018

This is a floor, not a guarantee for your joint. Base metal dilution, heat input, preheat, cooling rate, and restraint all affect actual strength. More often than not, toughness, ductility, and hydrogen control will matter far more than chasing a higher number.

The Position Digit

The digit after the strength number tells you which positions the electrode is designed for.

Digit	Positions Covered	Practical Meaning
1	Flat, horizontal, vertical, overhead	All-position. Found on rods like E6010 and E7018.
2	Flat and horizontal fillets only	High deposition. Best for shop work, like E7024.
3	Flat, horizontal, vertical down, overhead	Fast-freeze. Common for downhill work, like E6013.
4	Flat, horizontal, vertical down, overhead	High-iron-oxide with heavy fill, similar use to 3.

The Last Two Digits: Coating and Current

The final two digits are the most practical for setting your machine. They pair flux chemistry with compatible current and polarity:

• 10 – Cellulose sodium, DC+ only. Deep penetration, fast-freeze. A staple for pipe roots.
• 11 – Cellulose potassium, AC or DC+. The AC-capable counterpart to E6010.
• 12 – Rutile sodium, AC or DC-. Smooth arc with shallow penetration.
• 13 – Rutile potassium, AC or DC, either polarity. Easy to strike, light slag, great for thin sheet.
• 16 – Low hydrogen potassium, AC or DC+. Crack-resistant with improved AC stability.
• 18 – Low hydrogen potassium with iron powder, AC or DC+. The North American structural standard.
• 24 – Rutile with high iron powder, AC or DC. Flat and horizontal fillets with high deposition.

As a rough rule, even-ending digits tend to favor AC, while odd-ending digits are often more restrictive. However, this isn’t absolute, so always verify with the manufacturer’s data sheet.

Suffixes: Where Details Matter

Modern classifications can be extended with letters and numbers that carry real engineering weight:

• -1 – Improved Charpy V-notch toughness at lower test temperatures. Ideal for cold-service or seismic work.
• H4, H8, H16 – Maximum diffusible hydrogen in milliliters per 100 grams of deposited weld metal. The lower the number, the less crack risk.
• R – Moisture resistance. Helps the coating retain its hydrogen rating after exposure to humid conditions.

For example, E7018-H4R is 70 ksi, all-position, low hydrogen with iron powder, AC or DC+, max 4 ml/100g hydrogen, and moisture resistant. A plain E7018 still meets the base H16 requirement, but offers no documented H4 or R guarantee. In code work, that distinction is not negotiable.

Reading Beyond the Code

The classification is only a starting point. It won’t tell you spatter levels, restrike ease, or how a rod behaves at the bottom of its amperage range. Two brands of the same E7018 can feel drastically different. For verified mechanical properties and test data, consult AWS A5.1 for carbon steel electrodes. For low-alloy grades where elements like chromium or molybdenum come into play, the alloy steel welding electrodes guide breaks down how those suffixes stack up. In the end, buy the documented grade, store it correctly, and treat the classification as a minimum, not a maximum.

3. SMAW Rod Chart: Common Electrodes and Their Uses

With dozens of stick electrodes crowding a welding supply rack, trying to guess which one to grab is a recipe for wasted rods and weak joints. The easiest way to narrow things down is by using an AWS electrode classification to match a rod to your job. With that being said, here is a practical breakdown of the most common SMAW electrodes you’ll run into for mild steel fabrication and repairs.

Practical SMAW Rod Chart

The chart below covers the ten most used rods, from deep penetrating root rods all the way to high deposition fill rods. While exact amperage will depend on diameter, this will give you a solid baseline for selection:

AWS Class	Coating Type	Polarity	Positions	Penetration	Typical Applications	Notes
E6010	Cellulose Sodium	DC+	All (F,V,OH,H)	Deep	Pipe root passes, rusty/dirty mild steel, field repairs	Forceful arc, digs through contaminants. Not the cleanest looking bead.
E6011	Cellulose Potassium	AC or DC±	All (F,V,OH,H)	Deep	Farm repairs, maintenance, generator powered machines	Very similar to E6010, but much easier to strike on AC.
E6012	Rutile Sodium	AC or DC-	All (Best F/H)	Medium-Shallow	Poor fit-up, sheet metal gaps, general fabrication	Forgiving with arc control, great for bridging small gaps.
E6013	Rutile/Titania	AC or DC±	All (Best F/H)	Shallow-Medium	Sheet, light plate, general purpose mild steel	Extremely easy arc with minimal spatter. Ideal for beginners and clean work.
E6019	Rutile/Iron Oxide	AC or DC±	All	Medium	Galvanized or thin plate, smoother all-position work	Silky, stable arc with a flatter bead than many rutile rods.
E7014	Iron Powder, Titana	AC or DC±	All (Best F/H)	Medium	Heavy sheet, mild steel builds ups, production work	Iron powder allows for faster travel and higher deposition than E6013.
E7015	Low Hydrogen, Sodium	DC+	All	Medium-Deep	Pressure vessels, pipe, high strength mild steel	Low hydrogen, but requires DC+ only and stricter storage.
E7016	Low Hydrogen, Potassium	AC or DC+	All	Medium-Deep	Structural steel, pipe, out of position code work	All position, low hydrogen, and runs very well off of AC machines.
E7018	Low Hydrogen, Iron Powder	AC or DC+	All	Medium	Structural, bridges, buildings, alloy steel builds, code work	The industry standard for strength and hydrogen cracking resistance. Requires dry storage.
E7024	Iron Powder, Titana	AC or DC+/-	Flat & Horizontal Fillets Only	Shallow-Medium	Heavy plate, tank bottoms, high speed fillet production	Incredible deposition rate, however is strictly flat or horizontal.

When To Reach For Each One

For dirty, uncleaned, or heavily oxidized mild steel, nothing beats the digging power of E6010. If your only power source is a cheap AC buzzbox out in the field, E6011 will be your closest match for the same job. For tacky gaps or sheet metal where burn through is a concern, E6013 is hard to beat for its forgiving, easy arc.

When the weld must meet structural or code requirements, E7018 is almost always the answer. Its low hydrogen iron powder coating is designed to drastically reduce the chance of hydrogen induced cracking, which is why you’ll see it specified in so many buildings and heavy fabrications. If you have an AC only machine, E7016 is an excellent alternative for these same low hydrogen jobs. For maximum tonnage production on flat fillets, E7024 will out-deposit almost any other rod on this list.

Tips For Practical Selection

• For the root: Reach for E6010 or E6011 to achieve the penetration needed to fully fuse the bevel, especially for pipe work.
• For fill and cap: Switch to a more forgiving rod, such as E7014, E7016, or E7018 to stack beads cleaner and more efficiently.
• For thin metal: Stick with low penetration rods, such as E6013. Going too hot with a deep penetrating rod is the fastest way to blow holes in light gauge plate.
• For speed: Utilize E7024 only for flat or horizontal fillets. Its high deposition is wasted, and unsafe to attempt, outside of those positions.

Ultimately, there is no “universal” stick rod. The best choice will always be the one that fits your joint, your machine, your position, and any applicable code requirements. By cross referencing this chart for polarity, penetration, and positions, you’ll be able to confidently pick the correct electrode without wasting a single rod. When looking to take your stick skills further, resources covering an all position welding rod guide can help expand on these fundamentals even more.

4. Selecting the Right Electrode for the Job

Reading a chart is easy. Choosing the right line on that chart for the steel in front of you is the real skill. The same E7018 that produces a flawless structural weld on a calm bench can be the wrong call for a windy pipe rack or a dirty repair on a ranch gate. Electrode selection is a balancing act between what the metal needs, what the joint allows, what the code demands, and what your machine can actually deliver.

Here are the decision factors that matter, roughly in the order a welding procedure would consider them.

Start With the Base Metal

The first question is always: what am I welding, and how strong does it need to be? For carbon steel, the rule of thumb is to match or exceed the base metal’s tensile strength, as directed by the applicable code or welding procedure specification (WPS). A36 steel, with its 58,000 psi minimum tensile strength, is comfortably served by an E6010 or E6013 and often overmatched by E7018. Higher strength steels like A572 Grade 50 or A992 call for 70-series electrodes, and quenched-and-tempered or low-alloy grades may require specific matching fillers.

When you are joining dissimilar metals, or a low-alloy steel to carbon steel, don’t guess. Follow the filler metal specification and the manufacturer’s selection guidance for the combination. The AWS filler metal specifications exist precisely so that strength, toughness, and chemistry stay predictable across a joint. If you are working with alloy grades, our guide to alloy steel welding electrodes breaks down how those fillers differ from plain carbon rods.

Joint Design and Welding Position

A flat groove weld on a heavy plate is a different animal from a vertical-up root on pipe. Electrode choice follows the position:

• Flat and horizontal only: E7024 and similar iron-powder rods deposit metal fast but will not hold a vertical or overhead puddle.
• All-position work: E6010, E6011, E6013, E7018, and E7016 handle out-of-position joints. E6010’s forceful, fast-freezing arc makes it the classic root-pass choice on pipe.
• Tight root gaps and poor fit-up: a deep-digging cellulose rod like E6010 or E6011 can punch through where a soft-arc rod would just sit and cold-lap.

If you want a broader breakdown of which rods travel well in each position, the all position welding rod guide is a useful companion to this section.

Service Conditions: Temperature, Toughness, and Fatigue

What happens to the part after it cools matters as much as the weld itself. Components that see impact loading, subzero temperatures, or cyclic stress need filler with adequate toughness, not just tensile strength. Low hydrogen electrodes such as E7015, E7016, and E7018 are frequently specified for thick sections, restrained joints, and higher strength steels specifically to reduce the risk of hydrogen-assisted cracking. On dynamically loaded structures, that requirement is rarely negotiable.

Code Requirements and the WPS

On any code work, the electrode is not your choice alone. Structural, pressure, and pipeline codes each restrict which classifications may be used, and the WPS tells you the exact filler, diameter, current, and technique qualified for that joint. The AWS welding handbook and your project specification are the authority here. If the drawing says E7018, an E6013 substitution is not a shortcut, it’s a nonconformance.

Available Power: AC or DC

Power supply quietly eliminates half the chart. Some electrodes demand DC electrode positive (DCEP) to run properly, including E6010, E7015, and E7016. Others, like E6011, E6013, E7014, E7018, and E7024, are designed to run on either AC or DC. If your only machine is an old AC buzz box, a bucket of E6010 will frustrate you all afternoon. Check the label and your machine before you buy.

Fit-Up, Contamination, and Hydrogen Control

Rust, mill scale, paint, oil, and wide root gaps push you toward a more forgiving, deeper-penetrating electrode. Clean, tight, well-prepared joints let you use a smoother-running rod and focus on appearance and deposition rate. Finally, weigh hydrogen control against the job: routine thin-gauge work rarely needs it, but thick sections, high restraint, and high-strength steel do. When in doubt, choose the low hydrogen option and store it properly.

A Practical Selection Sequence

1. Identify the base metal and its required strength.
2. Confirm the code and WPS filler requirement.
3. Note the welding position and joint access.
4. Check service conditions for toughness and cracking risk.
5. Match the electrode to your machine’s available current.
6. Factor in fit-up and surface condition.
7. Verify storage capability if the rod is low hydrogen.

Work through that list and the chart stops being a wall of numbers. It becomes a shortlist of two or three rods, and experience tells you which one belongs in the stinger today.

5. Amperage, Technique, and Deposition Considerations

Selecting the right rod from a SMAW chart is only part of the equation. Achieving a sound weld relies heavily on heat control, arc management, and movement. These factors will dictate fusion, slag removal, and overall efficiency with every pass.

Finding the Right Amperage

Amperage will shift based off of rod classification, diameter, and position. Manufacturer recommendations should always be followed, but the ranges below can be used as a reliable baseline, as no two welding machines run identically.

Rod Classification	1/8″ (3.2mm)	5/32″ (4.0mm)	Usage Notes
E6010	75 – 125 Amps	90 – 150 Amps	Cellulosic, deep penetration, great for dirty or root passes.
E6011	75 – 120 Amps	90 – 140 Amps	Similar to 6010, but more forgiving on AC power.
E6013	80 – 110 Amps	95 – 130 Amps	Rutile, easy to run, great for sheet or general fabrication.
E7018	90 – 130 Amps	110 – 150 Amps	Low hydrogen, iron powder, smooth and code-friendly.

For out-of-position welds, amperage should be dropped towards the lower end of these ranges to prevent sagging. As outlined by the AWS electrode classification system, the electrode coating is the driving factor behind the heat input for each rod type.

Arc Length, Angle, and Travel Speed

For SMAW, arc length should remain short and tight, roughly equal to the diameter of the electrode’s core wire. A long arc is one of the most common causes of porosity and slag inclusions. For most joints, aim for a 10 to 15 degree drag angle in the direction of travel, and a 45 degree work angle when running a fillet weld.

Movement is just as crucial. Stringers are straight, narrow beads with little to no weaving. They are heavily preferred for structural and code work due to their concentrated heat input and reduced distortion. Weaving widens the bead by moving side to side and should only be used when a procedure calls for it, such as filling a wider groove. For more specifics on positioning, refer to our All Position Welding Rod Guide: Types, Uses & Tips.

Deposition Efficiency, Stub Loss, and Productivity

Not every inch of an electrode becomes weld metal. The leftover piece, known as the stub, is discarded once it’s too short to hold safely. This stub loss, paired with deposition efficiency (the percentage of a rod’s weight that ends up deposited), directly impacts cost per foot of weld.

Cellulosic rods such as E6010 and E6011 prioritize penetration over deposition, making them ideal for root passes on contaminated or tight-fit joints. Iron powder rods, specifically E7018 and E7024, offer much higher deposition rates, allowing more metal to be laid down per electrode. These tradeoffs are especially worth considering when working with thicker sections or alloys covered in our Alloy Steel Welding Electrodes: Selection, Use & Safety guide.

Practical Usage Notes

• Travel speed is everything: Moving too fast can cause lack of fusion, whilst moving too slow can pile up excess weld metal and trap slag. Aim for a consistent speed that matches your puddle.
• Adjust for position: For vertical up, utilize a slight pause at the sidewalls with a stringer to properly tie in. For overhead, drop your amperage slightly to combat sagging.
• Respect your environment: High amperages paired with certain coatings produce significant welding fumes. Proper ventilation and fume control must be implemented in accordance with OSHA 1910.252.
• Know when to stick with SMAW: For many field repairs and structural applications, the efficiency tradeoffs still heavily favor stick welding, as outlined within Advantages of Stick Welding: Why SMAW Still Wins.

Ultimately, consistency will always trump perfection. Find your sweet spot of amperage, lock in a short arc, control your travel speed, and choose between stringers or weaves based off of the procedure at hand. These small adjustments are what will turn a chart reading into a structurally sound, repeatable weld every time you strike an arc.

6. Proper Storage, Handling, and Reconditioning of Electrodes

Most welding problems announce themselves with sparks and spatter. Moisture damage does not. A damp E7018 can look perfect, strike a smooth arc, and still leave a weld that cracks hours or days later. That delayed failure is why electrode storage deserves more attention than it usually gets. The rod itself is only half the system; the condition it is in when it enters the stinger is the other half.

Why Hydrogen Control Matters So Much

Low hydrogen electrodes are hygroscopic, meaning they absorb moisture from the air. That moisture breaks down in the arc and releases hydrogen, which dissolves into the molten weld pool. As the weld cools, the metal cannot hold all of it. Hydrogen collects in high-stress areas and can trigger hydrogen-induced cracking, often called cold cracking or delayed cracking. The damage may not appear until the joint has been under load for hours or days.

This risk is highest in thick sections, restrained joints, high-strength steels, and low-temperature service. It is also why low hydrogen consumables are specified so often on structural and pressure work. If you weld alloy steels, the same logic applies with even less margin for error, which is why alloy steel welding electrodes demand strict storage discipline.

Storage, Exposure Limits, and Holding Ovens

The basic rule is simple: keep low hydrogen electrodes dry, and keep them hot until use. Hermetically sealed containers protect them in transit and in storage. Once a container is opened, the clock starts. AWS and industry guidance publish permissible atmospheric exposure times for low hydrogen electrodes, and those limits are usually measured in hours, not days. Many conventional E7018 electrodes are limited to roughly a four-hour exposure window, while some moisture-resistant products allow longer. Always confirm the exact limit for your classification and brand rather than assuming one number fits every rod.

A holding oven is not a drying oven. A holding oven keeps already-conditioned electrodes at a controlled elevated temperature, commonly around 200–300°F, to slow moisture pickup. A drying or reconditioning oven runs hotter and is used to restore electrodes that have absorbed moisture. Those two functions should not be confused, and neither should be improvised with a kitchen oven or a space heater.

Electrodes classified with an R suffix, such as E7018 H4R, have stricter moisture-resistance requirements and are tested to verify them. The H4 designation refers to a maximum diffusible hydrogen level of 4 mL per 100 g of deposited weld metal. The R indicates the electrode has passed a moisture-resistance test after exposure. These products are useful in humid conditions, but they still need proper handling. The suffix raises the bar; it does not make the electrode immune to abuse.

Reconditioning Without Ruining the Coating

Reconditioning is controlled baking, not guesswork. Follow the electrode manufacturer’s recommended temperature and time, and follow the welding procedure specification when one applies. Overheating can damage the flux coating, cause it to crack or flake, and change arc behavior. Under-drying leaves hydrogen in the system. There is no universal “bake at 700°F for an hour” rule that covers every product.

A few practical habits prevent most problems:

• Keep sealed packaging intact until the electrode is needed.
• Transfer only the amount you can use within the permitted exposure period.
• Return unused low hydrogen rods to the holding oven at the end of the shift.
• Discard electrodes with damaged, blistered, or contaminated coatings.
• Never bake cellulosic or rutile electrodes as if they were low hydrogen rods.

For a deeper look at how classifications and suffixes are structured, the AWS filler metal specifications and the AWS welding handbook material are reliable references. Manufacturer data sheets remain the final word for storage temperatures, exposure limits, and reconditioning cycles.

The Shop-Level Checklist

Good storage is boring, and that is the point. Log oven temperatures, label opened packages with the date, keep lids closed, and train everyone who handles electrodes to respect the exposure clock. On code work, be ready to show that low hydrogen rods were stored and handled according to the manufacturer’s instructions and the WPS. A clean weld starts long before the arc is struck, often in a warm, dry oven behind the welding bay.

7. SMAW Safety: Fumes, Gases, Electricity, and PPE

For as simple as striking an arc may seem, Shielded Metal Arc Welding (SMAW) carries some of the most overlooked hazards on the job. Knowing your rod chart will help you make a sound joint, but protecting your lungs, skin, and body is just as important to making sure you walk away from that joint at the end of the day.

Ventilation and Airborne Hazards

Every time you burn a stick electrode, you’re creating welding fumes and gases. The exact makeup of those fumes will vary by process, consumable, and base metal. With carbon steels, the main concern is usually metal oxides. However, when welding certain alloyed metals or working with electrodes meant for alloy steel welding electrodes, toxic constituents such as chromium compounds can be present. In some applications, this can include hexavalent chromium, which is a known health concern and requires extra caution.

To combat this, OSHA 1910.252 requires mechanical ventilation in certain spaces and conditions for welding and cutting operations. The more enclosed the area is, the stricter those requirements become. For tasks where fumes can’t be diluted by natural air movement, local exhaust ventilation (LEV) should be the first line of defense. Both OSHA and the NIOSH/CDC recommend positioning your head out of the plume, using source capture whenever possible, and relying on respiratory protection only when engineering controls are not enough to reduce exposure to safe levels.

Confined Spaces

Confined spaces are one of the highest risk environments for SMAW work. Tanks, vessels, pits, and voids can limit oxygen, trap toxic gases, and prevent fumes from escaping. Under OSHA 1910.252, welding and cutting in confined spaces have additional requirements outside of general shop ventilation. Before entering any confined space, a proper evaluation for atmospheric hazards must be made, adequate ventilation must be planned, and in many cases, a permit is required. Never assume fresh air is present just because the space is only partially open.

Electrical Safety

With stick welding, you’re working with high open circuit voltages and live cables at all times. Electrical shock is the hazard that can be instantaneous and fatal. Proper machine grounding is required, cable insulation must be free of cuts, burns, or exposed conductors, and your electrode holder must have full insulation with no loose or cracked parts. Keep your gloves dry, stand on dry insulating material when possible, and never coil wet cables around your body. Additionally, be cautious of contact with the workpiece and ground at the same time, as this is one of the most common pathways for a shock.

PPE and Respiratory Protection

The correct personal protective equipment (PPE) is your final barrier of defense. For SMAW specifically, this should include:

• Eye and face: An auto-darkening or properly shaded welding helmet rated for the amperage you’re running.
• Body: Flame-resistant welding jacket or leathers, long sleeve shirts made of natural fibers, and pants with no cuffs to catch sparks.
• Hands and feet: Dry, insulated welding gloves and steel-toe, leather, or welding-specific boots with a solid sole.
• Respiratory: Based off of the base metal, consumable, and ventilation, a respirator may be needed. This should follow NIOSH guidance and be matched to the hazard, not just used as a catch-all.

Just as proper prep matters for jobs like aluminum boat welding, safety prep matters for every stick job. A clean work area, no flammables within reach, and a fire extinguisher nearby are just as much a part of your PPE as your helmet is.

At the end of the day, SMAW safety isn’t about slowing yourself down, it’s about going home exactly how you showed up. By controlling ventilation, respecting confined spaces, mitigating electrical hazards, and utilizing the correct PPE and respiratory protection, you’re not just compliant with the standard, you’re protecting your career for the long haul.

8. Common Mistakes, Troubleshooting, and Fixes

Even with a well-read all-position welding rod guide, most SMAW defects come down to electrode choice, preparation, or technique. Catching these issues early can prevent wasted material and costly failures.

Wrong Rod Selection and Polarity

Using wrong polarity/current for a rod type causes poor arc stability and penetration. Each AWS classified rod is designed for a specific current type (AC, DCEP, or DCEN), and running it off of its recommendation can make the arc nearly unmanageable.

Always verify your machine settings against the rod’s packaging or classification before striking an arc. If penetration is shallow or spatter is excessive, polarity should be the first thing to check.

Damp or Improperly Stored Electrodes

Damp low hydrogen rods increase cracking risk. When moisture is present in electrodes like E7018, it releases hydrogen into the weld pool during solidification, which can lead to delayed cracking hours after completion.

Low-hydrogen rods must be kept in a heated electrode oven at the manufacturer’s recommended temperature, with limited exposure to open air. If they’ve exceeded their allowed exposure time, use proper reconditioning per manufacturer specifications. Never guess bake times, as over-baking can damage the flux coating just as much as moisture. These storage requirements are heavily emphasized within AWS filler metal specifications.

Poor Joint Fit-Up and Preparation

Even the correct rod cannot fix contaminated, gapped, or misaligned joints. Rust, mill scale, oil, or moisture can all disrupt fusion and shielding, while inconsistent gaps can lead to burn-through or lack of penetration.

Take the time to clean the joint to bright metal, bevel when required, and clamp for alignment. This simple step will prevent a large majority of defects before any amperage is even adjusted.

Arc Blow, Slag, and Porosity

Arc blow is a magnetic disturbance that pushes the arc away from the puddle, most common in corners, thick plates, or with DC current. To correct it, try switching to AC if available, shortening your arc length, using a smaller electrode, or changing your work lead connection.

Slag inclusions often come from incorrect technique or inadequate slag removal between passes. To prevent them, keep a tight arc length, use the correct electrode angle, and thoroughly chip and wire brush slag from each pass before laying the next.

Porosity can come from contamination, inadequate shielding, or improper storage and handling of electrodes. Re-clean your base metal, confirm your rods are dry, check your amperage is in range, and maintain a consistent arc length to remedy it.

Undercut and Cracking

Undercut appears as a groove melted into the base metal next to the toe of the weld, most often from excessive amperage, a long arc, or traveling too fast. Drop your amperage slightly, tighten your arc length, slow your travel speed, and pause at the toes while weaving to allow the puddle to fill in.

Cracking is the most severe defect, and can be hot or cold (delayed). Hydrogen is the largest contributor, especially with low-hydrogen rods that have been improperly stored, or on highly restrained joints. Prevention means using dry electrodes, following recommended preheat for thicker or higher carbon steels, limiting excess heat input, and selecting the correct filler metal. For structural work, be sure to follow safe practices outlined in OSHA 1910.252 in addition to your welding procedure specifications.

Final Troubleshooting Checklist

When defects arise, work through these checks in order:

• Settings: Verify amperage, polarity, and current type against your rod.
• Electrodes: Ensure rods are dry, within exposure limits, and properly stored.
• Preparation: Clean the base metal, check fit-up, and remove all contaminants.
• Technique: Check arc length, travel speed, angle, and slag removal between passes.
• Environment: Account for arc blow, wind (if outdoors), and joint restraint.

By treating troubleshooting as a systematic process, most SMAW defects can be corrected before they become costly failures. Consistency in these fundamentals is what separates an acceptable weld from a truly sound one.

9. SMAW Rod Comparisons and Real-World Examples

With the amount of electrodes available, the easiest way to narrow your selection down is by direct comparisons. While every job has its own variables, looking at how certain rods behave against each other can save a lot of wasted time, wire, and filler metal.

E6010 vs E6011: The Root Pass Workhorses

Both of these cellulose-based electrodes are known for their deep penetration, making them a staple for open root passes on pipe, heavy plate, and jobs with less-than-perfect fit-up. However, the smallest difference between the two can completely change their versatility.

• Power Source: E6010 is primarily a DC rod, whereas E6011 runs exceptionally well on AC. This makes E6011 far more versatile on older, or inexpensive AC welders.
• Arc Behavior: Both dig aggressively, but E6011 tends to have a slightly softer, more forgiving arc whilst still maintaining the deep penetration that is desired for a root.
• Real Use: For shop setups with DC capable machines, E6010 is still heavily used. For field repairs on unknown power sources, E6011 is often the safer bet to reach for.

E7015 vs E7018: Low Hydrogen For Critical Joints

When strength and crack resistance are non-negotiable, low hydrogen electrodes take the spotlight. Both E7015 and E7018 fall under this category, however their deposition and usability differ greatly.

• Deposition: E7018 contains iron powder, allowing for much higher deposition rates than E7015 whilst still producing a smooth, easily controllable bead.
• Versatility: Many modern E7018’s are classified to run on both AC and DC, opposed to the more DC-leaning nature of E7015. This is one of the biggest reasons as to why E7018 is so prevalent within structural work.
• Storage is Key: As both are low hydrogen, moisture control is crucial. Any amount of absorbed moisture can defeat the entire purpose of utilizing them for code or highly restrained joints.

All-Position vs Flat-Only: Picking For The Job At Hand

Not every electrode is built to fight gravity. General purpose rods such as E6013 are preferred for thin sheet and cosmetic welds due to their light slag, easy clean up, and forgiving arc. With that being said, E6013 is not typically chosen for highly restrained, code-critical, or low temperature applications. On the opposite end of the spectrum, flat and horizontal only rods can dump massive amounts of metal at a time, but become incredibly unwieldy the second you try to take them vertical or overhead.

Real-World Scenarios

Scenario	Recommended Rod	Reasoning
Pipe Root Pass (Field)	E6011	Deep penetration, excels on AC, and is forgiving to minor mill scale.
Structural Steel (Code Work)	E7018	Low hydrogen, high deposition, and widely accepted for structural applications.
Thin Sheet Repair	E6013	Soft arc allows for better heat control to prevent burn through.
Heavy Equipment Repair	E7018 (or verified alloy steel welding electrodes if specified)	Strong, ductile welds for highly stressed, load bearing repairs.

It’s also worth noting that stick welding isn’t always the most efficient process for every material. For example, when working with aluminum, processes such as aluminum MIG welding are far more common, as well as utilizing a dedicated aluminum cleaner for welding to combat its rapidly forming oxide layer. These are prime examples of selecting the correct process for the base metal, rather than forcing SMAW to do a job it’s not optimized for.

10. Conclusion and Final Selection Checklist

An SMAW rod chart is a map, not a procedure. Once you can decode E6010, E7018, and the rest, you stop asking “which rod is this?” and start asking “which rod does this joint, in this position, under this code, actually need?” That is the shift from guesswork to repeatable welding.

The classification packs a lot into a few characters: minimum tensile strength, position capability, coating and current type, and optional suffixes for toughness, hydrogen control, or moisture resistance. What it cannot see is your base metal, fit-up, service conditions, or the procedure your inspector expects. Use the chart to build a shortlist, then confirm the details that decide whether the weld passes.

Read the Rod, Then Read the Job

Start with the E-number and work left to right. E60XX gives roughly 60,000 psi minimum tensile strength; E70XX gives 70,000 psi. The third digit tells you which positions the electrode is designed for, and the fourth tells you the coating, current type, and often the penetration and deposition behavior. Suffixes such as H4R or -1 add information about diffusible hydrogen or impact toughness. If those terms still feel fuzzy, revisit the classification breakdown earlier in this guide before you order a box.

Then match the rod to the work. A fast-freeze cellulose rod such as E6010 or E6011 suits root passes and dirty, poorly fitted steel, while a low-hydrogen E7018 is the safer choice for structural work, restrained joints, and thicker sections. For vertical and overhead work, our all-position welding rod guide is a useful next read. If you are weighing stick against other processes, the advantages of stick welding explain why it remains common in repair, field, and structural work. And when the base metal moves into low-alloy territory, cross-check alloy steel welding electrodes before assuming a standard carbon-steel rod will meet the specification.

Final Electrode Selection Checklist

1. Confirm the AWS classification. Check the printed classification on the package or electrode, not just the supplier’s label. Verify carbon steel electrodes against AWS A5.1 and low-alloy electrodes against AWS A5.5 through the AWS filler metal specifications.
2. Match the base metal. Confirm strength, composition, thickness, and any preheat or post-weld requirements before choosing a rod.
3. Verify position capability. Do not assume a flat-only electrode will run overhead simply because it is in the shop.
4. Check polarity and current. Confirm AC or DC, electrode positive or negative, and the amperage range for the diameter you plan to use.
5. Read the WPS and code. The welding procedure specification overrides personal preference. If the job is code-governed, the approved procedure controls the electrode, position, and parameters.
6. Review service conditions. Consider impact toughness, low-temperature service, corrosion, and cyclic loading.
7. Assess fit-up and contamination. Poor fit-up, rust, oil, and paint favor a more forgiving rod, but cleaning is still the first fix.
8. Control hydrogen. Use low-hydrogen electrodes for restrained joints, higher-strength steels, and thicknesses where cracking risk rises.
9. Verify storage and exposure. Confirm the rod has been stored correctly and, for low-hydrogen types, that exposure limits have not been exceeded.
10. Plan ventilation and PPE. Select the rod and the protective measures together, not after the weld is done.

Safety and Storage Are Part of Selection

A rod choice is only correct if it can be used safely. Stick welding produces fumes and gases, and the electrode coating affects what is released. Follow the manufacturer’s safety data and use adequate ventilation, local exhaust where needed, and appropriate respiratory protection. OSHA 1910.252 sets requirements for ventilation and protection in welding operations, and those requirements apply whether you are welding in a shop or in the field.

Low-hydrogen electrodes deserve special attention. E7018 and similar rods can pick up moisture from the air, which raises diffusible hydrogen and increases cracking risk. Keep them in hermetic storage, follow the manufacturer’s baking and holding recommendations, and do not leave them sitting in an open rod oven or on a bench overnight. For critical work, use the exposure limits and reconditioning guidance in the applicable AWS specification and the manufacturer’s data sheet rather than guessing.

When in Doubt, Stop and Verify

No chart replaces a qualified procedure. If the joint is unusual, the base metal is unknown, or the code requirements are unclear, stop and verify. Follow the manufacturer’s recommendations, consult the applicable AWS specification, and use a qualified WPS. When a rod substitution seems convenient, check whether it changes strength, toughness, position capability, or hydrogen control before making the swap.

The best approach is simple: read the classification, match it to the job, confirm the procedure, and protect the weld with proper storage and safety practices. Do that consistently, and the rod chart becomes more than a reference table. It becomes a reliable starting point for welds that hold up in service, inspection, and the real world.

Frequently Asked Questions

What does E7018 mean on a welding rod?

E = electrode, 70 = minimum tensile strength 70,000 psi, 1 = all-position welding, 8 = low hydrogen potassium iron powder coating usable with AC or DC+ (reverse polarity). Suffixes may add toughness/hydrogen/moisture info.

What’s the difference between E6010 and E6011?

Both are cellulose electrodes with deep penetration for dirty/rusty steel and root passes. E6010 is primarily DC+ only, while E6011 contains potassium allowing it to run on AC as well as DC+.

When should I use low hydrogen electrodes like E7018?

Use low hydrogen rods for thicker sections, restrained joints, higher strength steels, code/structural work, or anytime hydrogen-induced cracking is a concern. They require proper storage and handling to avoid moisture pickup.

Can I use E6013 for structural welding?

E6013 is a general purpose rutile electrode suitable for many applications, but it is not typically the first choice for highly restrained structural joints or some code work requiring low hydrogen/toughness. Always follow the governing code/WPS.

What amperage should I run for a 3/32″ or 1/8″ E7018 rod?

Typical ranges vary by manufacturer, but 3/32″ E7018 is often around 70-110 amps and 1/8″ around 90-150 amps depending on position and machine. Always check the electrode manufacturer’s recommendations.

How should I store E7018 welding rods?

Store in a dry, sealed container or rod oven at the temperature recommended by the manufacturer (often 250-300°F / 120-150°C for low hydrogen). Avoid leaving them exposed to humid air for extended periods and follow reconditioning guidelines if exposed.

Do I need ventilation when stick welding?

Yes in many cases. OSHA 1910.252 requires mechanical ventilation under certain conditions (small spaces, low ceilings, confined spaces, or certain metals). Use local exhaust ventilation and proper positioning, and respiratory protection if needed.

What’s the difference between flat/horizontal-only (position 2) and all-position (position 1) rods?

Position 1 rods (e.g. E6010, E7018) are designed to run in all positions including vertical and overhead. Position 2 rods (e.g. E6020, some flat/horizontal types) are optimized for flat and horizontal fillets and may be harder to control out of position.

What does the suffix ‘-1’ mean on some E7018 rods?

Suffix ‘-1’ indicates the electrode meets improved Charpy V-notch impact toughness requirements at lower temperatures (as specified in AWS A5.1), often down to -50°F (-46°C) for certain classifications.

Is E6011 good for AC welders with no DC capability?

Yes. E6011 is designed for AC and DC+; its potassium coating helps with arc stability on AC, making it a common choice for older transformer welders without DC output.