Stick welding amperage depends on three things: electrode type, electrode diameter, and welding position. This chart covers the five most common mild steel electrodes you’ll find in any welding shop.
The general rule: 1 amp per 0.001" of electrode core wire diameter. A 1/8" (0.125") rod runs around 125 amps. That’s a starting point. Position, joint fit-up, and base metal thickness shift the number up or down.
Stick Welding Amperage by Electrode Type
| Electrode | Diameter | Amperage Range | Polarity | Positions | Best For |
|---|---|---|---|---|---|
| E6010 | 3/32" | 40-80 | DCEP | All | Root passes, pipe, dirty steel |
| E6010 | 1/8" | 75-130 | DCEP | All | Root passes, pipe, dirty steel |
| E6010 | 5/32" | 110-170 | DCEP | All | Root passes, pipe |
| E6011 | 3/32" | 40-85 | AC/DCEP | All | Root passes, AC machines |
| E6011 | 1/8" | 75-125 | AC/DCEP | All | General purpose, AC machines |
| E6011 | 5/32" | 110-165 | AC/DCEP | All | General purpose |
| E6013 | 3/32" | 40-90 | AC/DC | All | Sheet metal, beginners, light work |
| E6013 | 1/8" | 80-130 | AC/DC | All | General purpose, thin material |
| E6013 | 5/32" | 105-180 | AC/DC | F, H, V-down | Fillets, general purpose |
| E7018 | 3/32" | 70-110 | AC/DCEP | All | Structural, code work, X-ray quality |
| E7018 | 1/8" | 110-165 | AC/DCEP | All | Structural, code work |
| E7018 | 5/32" | 150-220 | AC/DCEP | F, H | Structural, heavy plate |
| E7018 | 3/16" | 200-275 | AC/DCEP | F, H | Heavy plate fill passes |
| E7024 | 1/8" | 100-160 | AC/DC | F, H | High deposition, flat work |
| E7024 | 5/32" | 150-210 | AC/DC | F, H | Production flat fillets |
| E7024 | 3/16" | 180-250 | AC/DC | F | High deposition flat work |
Position key: F = Flat, H = Horizontal, V = Vertical, OH = Overhead. “All” means F, H, V-up, V-down, and OH.
How to Read This Chart: Example Row
Take E7018 at 1/8" diameter. The chart shows:
- Amperage: 110-165A. Start at 120A for vertical-up and overhead. Use 140-160A for flat fillets and horizontal.
- Polarity: AC or DCEP. DCEP gives a smoother, more stable arc on 7018. AC works but requires a machine with enough open-circuit voltage (OCV) to keep the arc lit through the zero-crossing. Most inverters handle this fine. Older transformer machines may struggle.
- Positions: All positions. This makes 1/8" E7018 the go-to rod for structural work, since code jobs require out-of-position capability.
- Best for: Structural steel, code-quality welds, jobs requiring X-ray or UT inspection.
Polarity Explained
DCEP (DC Electrode Positive) sends electrons from the workpiece to the electrode. This drives 70% of the heat into the electrode, which sounds backwards, but it provides deep penetration because the electron impact zone is concentrated at the plate surface. E6010 requires DCEP. It will not run on AC.
AC (Alternating Current) works with any electrode rated for AC. The arc extinguishes and re-ignites 120 times per second on 60 Hz power. Electrodes rated for AC have flux coatings designed to re-ionize the arc gap quickly. AC machines are cheaper and simpler than DC, making them popular for farm, ranch, and hobby use.
DCEN (DC Electrode Negative) is rarely used for stick welding. E6012 runs well on DCEN. Most other rods perform better on DCEP.
Position and Amperage Adjustments
Welding position has a bigger effect on amperage than most beginners expect.
Flat position: Use the upper end of the amperage range. Gravity holds the puddle in place. More heat means better fusion and faster travel speed.
Horizontal: Drop 5-10% from flat settings. The puddle wants to sag, so you need a slightly cooler, stiffer bead. Tilt the rod 5-10 degrees upward to fight gravity.
Vertical-up: Drop 10-15% from flat settings. Use a weave or triangle pattern to control the puddle. Too much heat and the metal drips down the joint. E7018 vertical-up is a critical welding test position for structural certification.
Overhead: Same reduction as vertical, 10-15% below flat settings. Keep the arc tight and travel speed consistent. If the puddle starts to drip, you’re running too hot.
Electrode Storage
E7018 is a low-hydrogen electrode. The flux coating absorbs moisture from the air. Damp 7018 rods produce porosity, hydrogen cracking, and erratic arc behavior. Store opened cans in a rod oven at 250-300 degrees F (120-150 degrees C). If rods have been exposed to humidity for more than 4 hours, re-bake at 700 degrees F (370 degrees C) for 1 hour before use.
E6010, E6011, E6013, and E7024 are more forgiving. Keep them sealed in their original packaging or a dry cabinet. They don’t need a rod oven under normal shop conditions.