The welding electrode or welding wire is a metal wire, graphite, which is surrounded by a coating called flux, and the electric current passes through it. In other words, this metal wire that can be used for welding is called an electrode, and the material of the electrode depends on the equipment used in welding.

What is a welding electrode?

The welding electrode is a metal wire that enables welding. The material of welding electrode or welding wire is usually metal or graphite. Around it, there is a coating called flux, which causes the electric current to pass and perform welding. In simple words, the welding electrode is the interface and facilitates the welding of two members.
Application of welding electrode

For welding two surfaces, there is always an empty space between them. By filling this space, the welding electrode plays a very decisive role in the quality and performance of welding.
Welding electrode specifications

Welding electrodes have different characteristics in terms of wire material, coating type and electrode diameter. In the following, we will take a look at the features of each.
The material of the welding electrode

The type of wire used in the electrode plays an important role in quality and efficiency. One of the most important of them is the welding electrode with stainless steel wire, nickel wire, aluminum wire and low carbon steel wire.
Welding electrode diameter

The diameter of the electrode can be permanent or sectional. Diameters of 2.5, 3.25, 4 and 5 mm are widely used and common models in welding. The larger the electrode diameter, the higher the deposition rate. In other words, thicker sheets and surfaces can be welded with the help of larger diameter electrodes.
Thin electrodes are also the best choice for thin surfaces and sheets. Because due to more delicacy and accuracy, possible damage to such sheets will be avoided.
Welding wire cover

Electrode coating prevents impurities from entering the welding process. It also protects the weld metal and wire against environmental conditions. As a result, it plays an important role in the characteristics of the welding electrode and the quality of the work output.
Types of welding electrodes

The welding electrode can be divided according to different criteria. Including:

    Welding electrode in terms of consumption
    Welding electrode in terms of wire material
    Welding electrode in terms of coating type
    Welding electrode in terms of thickness
    Welding electrode by construction type

Types of electrodes in terms of consumption

According to the use, the welding electrode can be divided into two categories: consumable welding electrode and non-consumable electrode. In the following, we will get to know the outstanding features of each.
Consumable welding electrode

In the consumable welding electrode, the welding wire ends after being used in welding. It is very simple and easy to implement, which has led to the widespread use of this type of electrode. Consumable electrodes are usually manufactured and supplied in two categories, coated and uncoated. Oxide and cellulose coatings are the most important types of coating electrodes. Uncoated electrodes are also a more economical choice for situations where you don't need a coating.
Non-consumable welding electrode

Non-consumable electrodes have high thermal resistance and do not melt during welding. As a result, unlike disposable electrodes, it does not run out after use. Therefore, non-consumable welding electrode is also called refractory electrode. Not needing to change is one of the most important advantages of this type of electrodes. Carbon and tungsten electrodes are considered to be the most important types of non-consumable electrodes.
Types of welding electrodes in terms of coating type

The coating used in the welding electrode is another parameter for electrode classification. In addition to affecting the quality of welding, the electrode coating is also effective in the price of all types of welding wire. Electrode with alkaline coating, cellulose coating, tarantula coating and tarantula coating with iron powder are among the most important ones.

    Alkaline coated welding electrode is widely used in electric arc welding. The quality of welding in this type of electrodes is very favorable and satisfactory. Materials such as magnesium carbonate, calcium carbonate and calcium fluoride are among the most prominent components of alkaline coating.
    Cellulose coated welding electrode usually has high moisture penetration and produces a lot of hydrogen. As a result, it increases the crispness of the weld. Therefore, it is a more suitable option for downhill welding. The reason for this is the speed of freezing of the molten material in this state.
    The tarantula coated welding electrode usually uses sodium and potassium. The intensity of welding spatter is very low in this case. On the other hand, it has a lower penetration depth than cellulose electrode. It is not sensitive to humidity and it is very easy to work with them. The E6013 electrode is one of the most prominent and widely used types of welding electrodes with tarantula coating.

How is the welding electrode made?

The welding electrode manufacturing process has several steps. First, the core of the electrodes is made depending on the type of wire. It may be necessary at this stage to increase the flexibility of the metal. Cutting the metal of the electrode and smoothing it according to the desired sizes is the next step for making the welding electrode.

After the initial preparation of the electrode, it is time to provide compounds such as manganese, cellulose and titanium dioxide. These ingredients are poured dry into the mixer. After that, potassium silicate is added to the prepared composition. At the end, the fluxes are molded and covered by extrusion. The final step is placing the electrodes in the furnace and processing them.