E7024 is the fastest-depositing stick electrode you can buy. Its extra-heavy iron powder coating (50% of the coating weight is iron powder) gives it a deposition efficiency of 150-200%, meaning each rod puts down 50-100% more weld metal than a standard 7018 of the same diameter. The catch: it only runs flat and horizontal. Try it vertical or overhead and the massive fluid puddle dumps right out of the joint. In production shops welding flat plate, fabricating beams, and filling horizontal fillet welds, 7024 burns through work faster than any other SMAW consumable.
The designation: 70,000 PSI tensile, the “2” means flat and horizontal only, and the “4” indicates an iron powder rutile coating for AC/DCEP/DCEN operation. It’s a drag rod, meaning you literally drag it across the joint at a fixed angle and let the iron powder do the work.
AWS Classification
E7024 is classified under AWS A5.1:
- E = Electrode
- 70 = 70,000 PSI (480 MPa) minimum tensile strength
- 2 = Flat and horizontal positions only
- 4 = Iron powder rutile coating, AC/DC
The “2” position digit is the immediate red flag for anyone thinking they can substitute 7024 for 7018. The “2” means this rod is designed only for flat (1F, 1G) and horizontal (2F, 2G) positions. The iron powder content makes the puddle too fluid for any position that fights gravity.
Mechanical Properties
| Property | AWS A5.1 Minimum | Typical Value |
|---|---|---|
| Tensile Strength | 70,000 PSI (480 MPa) | 72,000 - 82,000 PSI |
| Yield Strength | 58,000 PSI (400 MPa) | 60,000 - 68,000 PSI |
| Elongation (2") | 17% min | 22 - 28% |
| CVN Impact (-20F) | Not required | 20 - 40 ft-lbs |
Tensile and yield strength match 7018 specs. The difference is in toughness: AWS A5.1 doesn’t require CVN impact testing for 7024. Typical values are adequate for many applications, but if you need guaranteed impact toughness for cold-weather or dynamic service, 7018 is the better choice.
Amperage Chart
| Rod Diameter | Amperage Range | Deposition Rate | Approx. Fillet Size |
|---|---|---|---|
| 1/8" (3.2 mm) | 120 - 170A | 5 - 7 lb/hr | 3/16" - 1/4" single pass |
| 5/32" (4.0 mm) | 150 - 220A | 7 - 10 lb/hr | 1/4" single pass |
| 3/16" (4.8 mm) | 200 - 275A | 9 - 13 lb/hr | 1/4" - 5/16" single pass |
| 7/32" (5.6 mm) | 250 - 340A | 12 - 16 lb/hr | 5/16" single pass |
| 1/4" (6.4 mm) | 300 - 400A | 14 - 19 lb/hr | 3/8" single pass |
Those deposition rates are the reason 7024 exists. A 3/16" 7024 at 240 amps deposits around 11 lbs/hr, while a 3/16" 7018 at the same amperage deposits about 6 lbs/hr. Nearly double the metal for the same welding time. On flat plate production, that time savings translates directly to lower labor cost per joint.
The Drag Technique
7024 is the simplest electrode to run in terms of technique. Here’s the complete process:
- Set amperage to the middle of the range for your rod diameter
- Strike the arc by touching the rod to the work
- Tilt the rod 15-20 degrees in the direction of travel (drag angle)
- Lower the rod until the iron powder coating contacts the workpiece
- Drag the rod along the joint at a steady pace
- Don’t weave, don’t oscillate, don’t manipulate
The iron powder in the coating melts continuously, feeding extra metal into the puddle through the coating itself. The thick slag floats up and covers the bead, producing a smooth, convex profile with fine ripples. The rod literally rides on its own coating like a sled.
Travel speed control: The slag should trail the rod by about 1/2 to 3/4 inch. If the slag catches up to the rod tip, slow down. If the slag falls too far behind, speed up. The visual feedback is obvious and easy to maintain.
Arc length: Almost zero. The coating touches the work and the arc burns inside the flux cavity. This is called a “contact technique” or “touch welding.” Don’t try to hold an arc gap like you would with 7018 or 6011.
Production Welding Applications
7024 earns its keep in specific production environments:
Flat plate fillet welds: Manufacturing plants that weld angles, channels, and plate together in jigs and fixtures use 7024 to fill fillet welds in a single pass. A 5/32" rod at 200A lays a 1/4" fillet in one pass, where 7018 might need two.
Beam fabrication: Steel fabricators joining web-to-flange connections on I-beams and box sections in flat position use 7024 for the sheer speed advantage. The work is positioned flat in a positioner, and the welder drags 7024 along the joint.
Tank and vessel fabrication: Horizontal seams on large tanks and vessels, welded from the outside with the tank on rollers, are ideal 7024 applications. The horizontal position stays consistent as the tank rotates.
Preheat/post-heat controlled environments: When heating and cooling cycles cost money (preheat on thick plate, controlled cooling rates), faster deposition means less time in the heat cycle. 7024 reduces the total arc time per joint.
Surfacing and buildup: Flat-position surfacing deposits (non-hardfacing) go fast with 7024. Building up worn or undersized flat surfaces to dimension before machining is common in heavy equipment repair.
Why 7024 Isn’t Used More Widely
Given its speed advantage, you’d expect 7024 to be everywhere. Several factors limit it:
Position limitation: Most real-world welding involves all positions. A shop that needs to weld flat, vertical, and overhead on the same assembly can’t stock three different rods for three positions. They stock 7018 and use it everywhere.
Not low-hydrogen: 7024 isn’t classified as low-hydrogen, which means it’s not specified on most structural WPS documents that require diffusible hydrogen control. AWS D1.1 pre-qualified joints typically call for 7018 or 7028 (which is the low-hydrogen version of 7024).
Semi-automatic processes have overtaken it: In modern production, MIG and flux-cored wire achieve the same or higher deposition rates with continuous wire feed. A FCAW setup with E71T-1 wire at 300 amps deposits 15-20 lbs/hr without the start/stop cycle of changing rods. 7024 is fastest in the stick world, but stick isn’t the fastest process.
Thick slag can trap defects: 7024’s heavy slag occasionally traps gas or slag inclusions, especially at start/stop points and intersections. Multi-pass 7024 welds need thorough inter-pass cleaning.
E7024 vs. E7028
E7028 is the low-hydrogen version of 7024. Same position limitations (flat and horizontal), similar iron powder content, but the coating is formulated for low-hydrogen service. Where the WPS requires low-hydrogen and the joint is flat or horizontal, 7028 provides the deposition advantage of 7024 with the hydrogen control of 7018.
7028 is less common than either 7018 or 7024 because its niche is narrow: flat-position, code-qualified, high-deposition work. Most shops either use 7018 for code work (accepting the lower deposition rate for all-position flexibility) or MIG/FCAW for production speed.
Storage
7024 is not a low-hydrogen electrode. Standard dry storage at room temperature is sufficient. Rod oven storage isn’t required but doesn’t hurt. In humid environments, keep unopened cans sealed and use opened rods within a few weeks.
The heavy coating on 7024 makes the rods thicker overall than other electrodes of the same core wire diameter. A 5/32" 7024 is substantially thicker than a 5/32" 7018 because of the extra iron powder in the coating. This means fewer rods per pound and larger stinger (electrode holder) jaws may be needed for the bigger sizes.
Common Mistakes with 7024
Trying to run vertical or overhead: The rod is clearly marked for flat and horizontal only, but welders still try it out of position because they like the deposition rate. The fluid puddle and heavy slag drop immediately, creating incomplete fusion, slag inclusions, and dangerous overhead drips. Use 7018 out of position.
Too much travel speed: The drag technique is simple, but dragging too fast produces a thin, underbuilt bead that doesn’t fill the joint. Match travel speed to slag behavior: the slag should trail 1/2 to 3/4 inch behind the rod.
Confusing 7024 with 7018: Both are 70 ksi rods, and in the confusion of a busy shop, someone grabs the wrong box. 7024 used on a vertical joint fails. 7018 used on a flat production joint works but slower. Label your rod storage clearly.
Inadequate inter-pass cleaning: 7024’s thick slag traps gas and inclusions if not fully removed before the next pass. Chip, wire brush, and visually inspect every pass. The heavy slag can hide defects underneath that look fine on the surface.
Size Selection
For most flat production work, 5/32" or 3/16" diameter 7024 is the sweet spot. These sizes deposit enough metal for 1/4" to 5/16" fillets in a single pass on machines commonly found in fabrication shops (200-275A range).
Smaller 1/8" rods are available but sacrifice much of the speed advantage. If you’re only going to run 1/8" rod, you might as well use 7018 and gain all-position capability.
Larger 7/32" and 1/4" rods need 300-400A machines, which limits them to larger shop equipment. The deposition rates at these sizes are impressive but require significant power source capacity.
Common Brands
- Lincoln Electric: Jet-Weld LH-70 (the classic 7024)
- ESAB: Atom Arc 7024
- Hobart: E7024 (retail channels)
Lincoln’s Jet-Weld has been the production standard for flat-plate fabrication since the 1970s. It’s available in all standard diameters from 1/8" through 1/4" at welding supply distributors. Price at time of writing runs $2.50-3.50 per pound, comparable to 7018.
For the complete stick electrode guide, see the stick electrodes category page. Compare with E7018 for all-position structural work and the hardfacing electrode guide for wear-resistant overlay applications.