Picking the right stick electrode is half the job. The wrong rod on the wrong metal produces weak, brittle, or corrosion-prone welds. This chart covers every common electrode you’ll encounter in structural, maintenance, and fabrication work.
If you’re in a hurry: E7018 for structural steel, E6011 for dirty field repairs on AC, E308L-16 for 304 stainless, E309L-16 for stainless-to-carbon-steel joints.
Electrode Selection by Application
| Electrode | Tensile (ksi) | Coating | Positions | Polarity | Penetration | Best Applications |
|---|---|---|---|---|---|---|
| E6010 | 60 | Cellulosic | All | DCEP only | Deep | Pipe root passes, dirty/rusty steel, field repairs |
| E6011 | 60 | Cellulosic | All | AC/DCEP | Deep | Same as E6010 but works on AC machines |
| E6012 | 60 | Rutile | All | AC/DCEN | Medium | Bridging gaps, poor fit-up, thin material |
| E6013 | 60 | Rutile | All | AC/DC either | Shallow | Sheet metal, beginners, light fabrication |
| E7014 | 70 | Iron powder/rutile | F, H, V-down | AC/DC either | Medium | General purpose, smooth bead, easy slag removal |
| E7018 | 70 | Low hydrogen | All | AC/DCEP | Medium | Structural, code work, X-ray quality welds |
| E7024 | 70 | Iron powder | F, H | AC/DC either | Medium | High deposition flat fillets, production |
| E7028 | 70 | Low hydrogen/iron powder | F, H | AC/DCEP | Medium | High deposition horizontal fillets |
| E308L-16 | 70 | Rutile | All | AC/DCEP | Medium | 304 stainless steel |
| E309L-16 | 70 | Rutile | All | AC/DCEP | Medium | Dissimilar metals, stainless to carbon steel |
| E316L-16 | 70 | Rutile | All | AC/DCEP | Medium | 316 stainless steel, marine applications |
| ENi-CI | 60 | Graphite | All | DCEP | Shallow | Cast iron repair, machinable deposits |
| E4043 | N/A | Flux | F | DCEP | Shallow | Aluminum (limited use, MIG/TIG preferred) |
Position key: F = Flat, H = Horizontal, V = Vertical (up or down as noted), OH = Overhead. “All” means the rod works in every position.
Quick Decision Guide
Not sure which rod to grab? Answer these questions:
What’s the base metal?
- Mild/carbon steel: E6010, E6011, E6013, E7014, E7018, E7024
- 304 stainless: E308L-16
- 316 stainless: E316L-16
- Stainless to carbon steel: E309L-16
- Cast iron: ENi-CI
- Aluminum: E4043 (but seriously, use MIG or TIG instead)
Is it structural or code work?
- Yes: E7018. That’s the only answer for D1.1 structural steel code work in most shops. Low hydrogen coating prevents hydrogen-induced cracking on thicker plate.
Is the metal rusty, painted, or dirty?
- Yes, and you have DC: E6010. Its cellulosic coating burns through contamination and digs deep.
- Yes, and you only have AC: E6011. Same characteristics as E6010 but AC-compatible.
Is it thin sheet metal or light gauge?
- E6013. Shallow penetration prevents burn-through. Easy arc starts and smooth, low-spatter operation make it forgiving for beginners.
Do you need maximum deposition rate on flat work?
- E7024. The heavy iron powder coating adds to the deposition rate, and the rod practically runs itself with a drag technique. Limited to flat and horizontal.
Electrode Coating Types Explained
Cellulosic (E6010, E6011): The flux contains cellulose that decomposes into hydrogen and CO2 gas for shielding. This creates a forceful, digging arc with deep penetration and fast-freeze slag. The weld looks rougher than other rods. Spatter is heavier. But nothing else burns through mill scale and rust like a 6010.
Rutile (E6012, E6013, E7014): Titanium dioxide-based flux produces a smooth, easy-to-control arc with light spatter and a fine-rippled bead. Slag peels off in long sheets. Penetration is moderate to shallow. These rods are the easiest to learn on but don’t produce the strongest welds.
Low Hydrogen (E7018, E7028): Calcium carbonate and calcium fluoride flux produces very low hydrogen levels in the weld deposit, under 8 mL per 100g. This prevents hydrogen cracking in medium and high carbon steels and thick sections. The trade-off: the coating absorbs atmospheric moisture, so rods must be stored in a rod oven once opened.
Iron Powder (E7024, E7028): Iron powder added to the flux increases deposition rate by 30-50% over standard electrodes. The powder melts into the puddle, adding filler metal beyond what the core wire alone provides. These rods produce large, smooth beads but are generally limited to flat and horizontal positions.
AWS Electrode Numbering System
Understanding the numbers saves you from guessing. Here’s the breakdown for a standard 4-digit electrode like E7018:
- E = Electrode (arc welding)
- 70 = Minimum tensile strength in ksi (70,000 psi)
- 1 = Usable positions (1 = all, 2 = flat and horizontal only)
- 8 = Coating type and current (8 = low hydrogen, AC/DCEP)
The last digit tells you the most about how the rod behaves:
- 0 = cellulosic, DCEP only (E6010)
- 1 = cellulosic, AC/DCEP (E6011)
- 2 = rutile, AC/DCEN (E6012)
- 3 = rutile, AC/DC either (E6013)
- 4 = iron powder/rutile, AC/DC either (E7014, E7024)
- 8 = low hydrogen, AC/DCEP (E7018)
Stainless electrodes follow a different convention. E308L-16 means: 308 stainless composition, L for low carbon, dash-16 indicates rutile coating with AC/DCEP capability.