Author: Adam

Weathering Steel Electrodes: USA 8018W Explained

Your go-to guide for welding atmospheric corrosion-resistant steel

Introduction

Weathering steel electrodes, especially USA 8018W, are critical tools in structural welding where durability meets the harsh elements. Designed to weld weathering steels like ASTM A588 and A242, these electrodes offer unique properties tailored for outdoor, high-strength applications that require minimal maintenance over decades.

Whether you’re a structural welder, bridge fabricator, or working in heavy equipment repair, understanding the function and behavior of the 8018W classification can mean the difference between a weld that lasts and one that fails in the field.

Types and Classifications

The 8018W designation follows the AWS A5.5 classification for low-hydrogen, iron powder-coated electrodes suited for Shielded Metal Arc Welding (SMAW) of weathering steels.

Here’s how it breaks down:

“80” = Minimum tensile strength of 80,000 psi
“1” = All-position usability
“8” = Low-hydrogen coating, iron powder added
“W” = Specifically alloyed for weathering steel compatibility

Related Electrode Variants:

E7018 – General-purpose low-hydrogen rod, not ideal for weathering steel due to mismatched corrosion resistance.
E8018-C1/Ni1 – Low alloy electrodes with better notch toughness at low temperatures, but lacking in atmospheric corrosion compatibility.
E8018-W2 – A less common variant with slightly different alloying for specific weathering grades.

Use 8018W when matching weathering steel base metals is essential to prevent premature rusting at the weld zone.

Key Characteristics and Properties

8018W electrodes are engineered with a blend of nickel, copper, and chromium, matching the alloying elements in weathering steels. These additions promote a stable oxide layer—the patina—that protects the weld from further corrosion.

Technical Specs:

Property	Value / Description
Tensile Strength	≥ 80,000 psi (550 MPa)
Yield Strength	Typically ≥ 67,000 psi (460 MPa)
Elongation	≥ 22% in 2 inches
Impact Toughness (avg)	≥ 20 ft-lbs @ -20°F (-29°C)
Coating Type	Low-hydrogen, iron powder
Typical Alloy Additions	Cu, Ni, Cr
Storage Requirement	<4% moisture, keep in rod oven at 250°F+

💡 Real-World Insight:
When left unpainted in bridges or sculptures, the weld must weather at the same rate as the surrounding metal. If a standard rod is used, you’ll see rust bleed or cracking at the joint after a few freeze/thaw cycles.

Process Considerations

USA 8018W is used exclusively in SMAW (Stick) welding and performs well across all positions, including vertical and overhead.

Process Notes:

Polarity: DCEP (Direct Current Electrode Positive)
Amperage Range: ~90–150 A (3/32″ to 1/8″ diameter)
Preheat & Interpass: 100–200°F depending on base metal thickness
Rod Oven Use: Mandatory – keep at 250°F to avoid moisture-induced cracking (hydrogen embrittlement)

Equipment Compatibility:

Compatible with any SMAW-capable machine (inverter or transformer)
Good arc stability and puddle control, even on aged, weathered base material
Can be used with basic clamps and leads; no special feeder systems needed

Challenges:

Storage sensitivity: Moisture pickup leads to serious weld defects
Slag coverage: Heavy slag, can mask undercut or porosity if not properly cleaned between passes
Arc strikes: Can cause localized corrosion if not properly grounded out

Application Use Cases

8018W electrodes are purpose-built for use on structural weathering steel, where long-term atmospheric resistance is a must without the use of paint or coating.

Industries & Projects:

Bridges & overpasses (e.g., Corten steel bridges)
Architectural facades with exposed steel elements
Railcars and shipping containers
Transmission towers
Outdoor sculptures and public installations

Why it’s ideal:

Weld metal forms a matching patina with the base metal
High mechanical strength for structural loads
Resists cracking and hydrogen-induced failure
Eliminates the need for painting or regular maintenance

Best Practices & Pro Tips

Practical Tips for Welders:

Rod Storage: Keep in a 250°F rod oven. Don’t trust rods left out overnight in humid shops.
Joint Design: Use backing bars or preheats for thick sections to prevent root cracking.
Slag Removal: Use a chipping hammer or needle scaler between passes—slag is tough and can trap inclusions.
Arc Strikes: Always grind out stray strikes. Weathering steel will corrode unevenly around them.
Weld Appearance: Don’t chase perfect beads—focus on soundness and coverage, especially on multi-pass welds.

Pro Insight:
If you’re welding a Corten beam on a high-visibility project (like sculpture or facade), your 8018W welds will age with the metal and virtually disappear after a few seasons. Just don’t expect that if you use a 7018.

Conclusion

USA 8018W electrodes are a specialized but essential choice for welding weathering steel structures. Their ability to match the corrosion resistance and aesthetic of the base metal makes them irreplaceable in applications where appearance and durability both matter.

If you’re welding outdoors on structural steel that’s designed to rust intentionally, don’t wing it with a standard rod. Stick with 8018W. It’s the right tool for the job, and your welds will last as long as the steel they’re holding together.

Washington Alloy 8018-W 10lbs Welding Stick Electrode (1/8″)

ANSI/AWS A5.5 E8018- W2 ASME SFA 5.5 E8018- W2
10 LB Package – 8018-W
1/8″ Stick Electrode
Tensile Strength (psi) 80,000
Yield Strength (psi) 67-80,000

Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

Note: Some links on this page may be affiliate links. If you click and make a purchase, we may earn a commission at no extra cost to you. We only recommend products we trust and use in the field.

July 29, 2025

Welding Galvanized: Safe Fume Control Tactics

Introduction

Welding galvanized steel presents a unique challenge: toxic fumes. The galvanizing process coats steel with a layer of zinc, which vaporizes when exposed to welding temperatures, releasing hazardous zinc oxide gas. Left uncontrolled, these fumes can lead to serious short- and long-term health effects, including metal fume fever and chronic respiratory issues.

Understanding safe fume control tactics isn’t just about compliance—it’s about protecting your lungs, your team, and the quality of your welds. Whether you’re a structural welder, pipefitter, fabrication shop operator, or welding student, mastering this topic is crucial when working with zinc-coated metals.

Galvanized Steel and Fume Hazards: What Are You Dealing With?

Galvanized steel is carbon steel that’s been hot-dip coated in zinc to resist corrosion. While excellent for long-term durability in outdoor and moist environments, that zinc layer becomes dangerous when melted.

Zinc fume hazards include:

Zinc Oxide (ZnO): Formed when zinc vapor cools in air.
Metal Fume Fever: Flu-like symptoms that appear within hours of exposure.
Chronic Exposure Risks: Repeated inhalation can cause long-term lung damage and weaken immune function.

Additional risk factors:

Galvanized coatings can include lead, cadmium, or hexavalent chromium, especially in older infrastructure or imported steel.

Fume Control Tactics: Types & Classifications

Controlling zinc oxide fumes isn’t a one-size-fits-all fix. Multiple strategies should be combined for safe welding on galvanized materials. Here are the primary categories:

1. Ventilation Systems

Local Exhaust Ventilation (LEV):
- Fume hoods, extractor arms, or downdraft tables.
- Ideal for shop environments.
- Captures fumes at the source before they spread.
General Shop Ventilation:
- Large-scale air movement and filtration.
- Supports LEV but isn’t effective on its own.

2. Personal Protective Equipment (PPE)

Powered Air-Purifying Respirators (PAPRs):
- Offer higher protection than disposable masks.
- Positive airflow prevents fume ingress.
- Find PAPR Helmets Here
Half/Full-Face Respirators:
- Use P100 or equivalent filters.
- Must be properly fitted and regularly maintained.

Miller LPR-100 Gen. II Half Mask Respirator, Nuisance OV Relief M/L – Welding Respirator Mask with Filters – P100 Respirator Mask for Filtrating Particulates & Aerosols – Respirator Under Helmet

Enhanced Protection with Nuisance OV Relief Filters: The Miller LPR-100 Gen. II Half Mask Respirator, Nuisance OV Relief M/L includes an added carbon layer feature to reduce nuisance-level organic vapor odors; Our respirator mask with filters helps ensure clean, breathable air for welders working in fume-intensive environments
Up to 99.97% Filtration: Upgrade your welding gear with our respirator mask; Strongly resistant to oil, the filters of our respirators help provide reliable filtration of airborne particles, including solid dust, metal fumes and mists
Compact Low-Profile Design for Welding Helmets: The slim design of our welding respirator under helmet offers a wide field of vision and fits easily under most welding helmets; Our respirator is designed to help provide full compatibility with your protective eyewear and headgear
Ergonomic Half-Mask Respirator for Extended Comfort: Crafted for long welding shifts, our half face respirator features minimal dead air space to reduce heat buildup; It also comes with a large non-return exhaust valve to help minimize user fatigue during high-demand tasks
Durable, Medical-Grade Materials: Made with latex- and silicone-free materials, this half mask face respirator is odor-free, hypoallergenic; It is also built to withstand demanding welding environments while providing user comfort and safety

Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

Miller LPR-100 Gen. II Half Mask Respirator, Nuisance OV Relief S/M – Welding Respirator Mask with Filters – P100 Respirator Mask for Filtrating Particulates & Aerosols – Respirator Under Helmet

Enhanced Protection with Nuisance OV Relief Filters: The Miller LPR-100 Gen. II Half Mask Respirator, Nuisance OV Relief S/M includes an added carbon layer feature to reduce nuisance-level organic vapor odors; Our respirator mask with filters helps ensure clean, breathable air for welders working in fume-intensive environments
Up to 99.97% Filtration: Upgrade your welding gear with our respirator mask; Strongly resistant to oil, the filters of our respirators help provide reliable filtration of airborne particles, including solid dust, metal fumes and mists
Compact Low-Profile Design for Welding Helmets: The slim design of our welding respirator under helmet offers a wide field of vision and fits easily under most welding helmets; Our respirator is designed to help provide full compatibility with your protective eyewear and headgear
Ergonomic Half-Mask Respirator for Extended Comfort: Crafted for long welding shifts, our half face respirator features minimal dead air space to reduce heat buildup; It also comes with a large non-return exhaust valve to help minimize user fatigue during high-demand tasks
Durable, Medical-Grade Materials: Made with latex- and silicone-free materials, this half mask face respirator is odor-free, hypoallergenic; It is also built to withstand demanding welding environments while providing user comfort and safety

Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

3. Coating Removal Techniques

Mechanical Removal (grinding or sanding):
- Eliminates zinc coating at the joint area.
- Reduces fume production but adds prep time.
Chemical Stripping:
- Effective, but may introduce other hazards.
- Requires strict disposal and PPE practices.

4. Welding Process Modifications

Low-heat welding processes
- Reduce the vaporization of zinc.
- Can include pulsed GMAW or GTAW with tight control.

Key Characteristics and Safety Specs

Let’s break down why fume control is a non-negotiable when working with galvanized:

Factor	Details
Zinc Vaporization Point	~ 1650°F (899°C) — much lower than steel’s melting point
Toxicity Threshold (ZnO)	5 mg/m³ TWA (OSHA limit) — easily exceeded without ventilation
Fume Production Rate	Increases with amperage, travel speed, and preheat
Affected Processes	All fusion welding processes can produce zinc fumes

Example Scenario:
A welder using FCAW at 250 amps on a 3/8″ galvanized plate without ventilation can easily exceed safe fume thresholds within minutes. That same weld with LEV and a PAPR drastically reduces the inhaled fume load.

Process Considerations for Welding Galvanized

SMAW (Stick Welding):

Pros: Portable, doesn’t require shielding gas.
Cons: Produces heavy fumes; not ideal without strong ventilation.
Tips: Use low-hydrogen electrodes (E7018), clean the joint first, and use a fan or LEV.

GMAW (MIG):

Pros: Cleaner arc, better control with spray or pulsed transfer.
Cons: Higher heat input can vaporize more zinc.
Tips: Use short-circuit mode or pulsed spray with adequate fume extraction.

GTAW (TIG):

Pros: Precise, low-fume process.
Cons: Slower, more prep needed; zinc still poses risks near the arc.
Tips: Remove coating at the weld zone, ensure good airflow.

FCAW:

Pros: Great for thick steel and structural work.
Cons: Very smoky—generates significant fumes.
Tips: Use self-shielded wire with LEV and respirator.

Common Applications for Galvanized Welding

Welding galvanized materials is common in industries where corrosion resistance is critical:

Construction: Fencing, walkways, structural beams, brackets.
Agriculture: Livestock enclosures, irrigation systems.
HVAC and Plumbing: Ducting, pipe systems.
Automotive and Trailers: Frames, chassis, suspension components.

Why use it? Zinc prevents rust, extending metal lifespan in outdoor or moist environments, making galvanized a smart choice for long-term infrastructure. But only when fumes are properly managed.

Best Practices & Pro Tips from the Field

Remove Zinc from Weld Zone Whenever Possible
- Grind or sand at least 1-2 inches beyond joint lines.
- Use flap discs for controlled removal without deep gouging.
Always Ventilate at the Arc
- Keep extractor hoods within 6–10 inches of the arc.
- Don’t rely solely on room fans—they just push fumes around.
Use Respirators Every Time
- Even outdoors, a breeze can’t compete with zinc vapor.
- P100 filters or PAPRs should be standard when welding galvanized.
Mind Your Heat Input
- Lower amps reduce zinc vaporization.
- Stitch weld instead of full beads to reduce fume output.
Watch for Metal Fume Fever Symptoms
- Fatigue, chills, cough, or nausea after welding could indicate overexposure.
- Rest, hydrate, and seek medical attention if symptoms persist.
Post-Weld Cleaning Helps Too
- Remove burned zinc residues to prevent toxic smoke during rework or painting.

Conclusion

Welding galvanized steel demands more than skill—it requires awareness, preparation, and the right gear. Fume control isn’t optional. It’s a safety-critical component of every galvanized job. Whether you’re laying beads on a ranch gate or structural bracing in a warehouse, make sure you’re not trading your health for corrosion resistance.

Key takeaway: If you smell it, you’re breathing it. Use ventilation, PPE, and coating removal techniques in conjunction to stay safe while welding galvanized materials.

July 28, 2025

Decoding Weld Symbols: A Quick Guide to Common Types and Their Meanings
Weld symbols are the universal language of welding blueprints, and if you’re in the welding trade or fabricating anything structural, knowing how to read them is essential. Whether you’re welding on a shop floor, out in the field, or designing something in CAD, understanding these symbols can save time, eliminate guesswork, and prevent costly mistakes.

In this guide, we break down the most common weld types and symbols, as illustrated in the image above. We’ll keep it simple and practical so you can identify the weld type, understand its application, and recognize the symbol used on technical drawings.

1. Fillet Weld
- Visual: Triangular weld filling the corner of two perpendicular pieces.
- Symbol: A simple triangle on the reference line.
- Use: Common in T-joints, lap joints, and corner joints. Found everywhere from structural steel to trailers.
2. Double Fillet Weld
- Visual: Fillet welds on both sides of a joint.
- Symbol: Two triangles, one on each side of the reference line.
- Use: Used when strength is needed from both sides — think brackets, frames, and reinforced joints.
3. All-Around Weld
- Visual: Fillet or groove that wraps completely around a joint.
- Symbol: A small circle at the junction of the arrow and reference line.
- Use: Critical for pipe joints or tube frames that require full reinforcement around the entire circumference.
4. Site Weld
- Visual: Indicates that the weld is to be done on-site, not in a shop.
- Symbol: A small flag at the intersection of the arrow and reference line.
- Use: Helpful for projects where transport, fit-up, or environmental conditions require field welding.
Groove Welds (Butt Joints)

These welds are typically used for plates or structural members joined edge to edge.

5. Full Penetration Single V Butt Weld
- Visual: One side is beveled like a “V”.
- Symbol: V symbol with filled root.
- Use: High-strength welds in thicker material. Ensures complete fusion from top to bottom.
6. Full Penetration Double V Butt Weld
- Visual: Both sides are beveled, forming a double-V.
- Symbol: Two V symbols with filled roots.
- Use: Preferred for thicker materials where welding from both sides is possible. Reduces distortion.
7. Full Penetration Double Bevel Butt Weld
- Visual: Similar to double V but with straight bevels instead of angled.
- Symbol: Two straight bevel lines.
- Use: Often used when machining bevels is easier or more practical than creating a V groove.
Partial Penetration Groove Welds

Not every job needs full penetration. These partial welds are quicker and cheaper — good for when full strength isn’t necessary.

8. Partial Penetration Y Weld
- Visual: One side beveled with limited depth penetration.
- Symbol: A Y shape.
- Use: Used in structural work where appearance or load isn’t critical, but strength still matters.
9. Partial Penetration Half Y Weld
- Visual: Shallower version of the Y weld.
- Symbol: Shorter Y symbol.
- Use: Used in sheet metal or light structural connections where minimal penetration is enough.
10. Partial Penetration Square Butt Weld
- Visual: No groove prep; just welded at the seam.
- Symbol: Straight line with hatching.
- Use: Thin plates or fast welds where penetration isn’t a concern. Not ideal for high-stress areas.
11. Full Penetration Square Butt Weld
- Visual: Clean edge-to-edge joint with full fusion.
- Symbol: Straight line, no bevel or V.
- Use: Often used in automation, where edge prep and full pen are possible without beveling.
Why These Symbols Matter

Each of these weld symbols tells the welder or fabricator exactly:
- What type of weld to use
- Where to place it
- How it should look (profile, size, and extent)
Misreading or ignoring these symbols can lead to structural failures, inspection failures, or rework that kills a project timeline and budget.

Quick Tips for Interpreting Weld Symbols
- The arrow side of the joint is always the reference point.
- Symbols below the line apply to the arrow side.
- Symbols above the line apply to the opposite side.
- A filled-in symbol usually means full penetration or completed weld.
- Additional flags, circles, or notes modify the requirement (e.g., all-around, field weld).
Final Thoughts

Understanding weld symbols is more than just a box you check for certification — it’s part of what makes you a professional in this trade. Whether you’re running beads in the shop or bidding on a structural contract, knowing the difference between a Y weld and a full-pen V groove is critical.

Print this chart, study the symbols, and keep it nearby. You’ll move faster on blueprints, communicate better with inspectors, and avoid those “I thought you meant…” moments.

Affiliate Disclosure: This post may contain affiliate links. We may earn a commission from qualifying purchases — at no cost to you — which helps support the blog and content creation.
July 27, 2025
E70S-6 MIG Welding Wire: A Complete Technical Guide for Welders
Purchase 70S-6 Mig WIre

When it comes to MIG welding mild steel, E70S-6 welding wire is a go-to filler metal used across industries—from structural steelwork to automotive fabrication. It’s known for its excellent arc stability, high deposition rate, and strong mechanical properties.

Whether you’re a welder, fabricator, or welding engineer, understanding E70S-6 is critical for making informed decisions about joint strength, weld quality, and process efficiency. In this guide, we break down everything you need to know about this essential wire type.

Types, Classifications, and Variants

E70S-6 is part of the AWS A5.18 classification system for solid carbon steel electrodes and rods used in gas metal arc welding (GMAW). Here’s what the designation means:
- E – Electrode
- 70 – Minimum tensile strength of 70,000 psi
- S – Solid wire
- 6 – Indicates the wire’s chemical composition and performance characteristics
Comparison with Other Carbon Steel MIG Wires:
- E70S-3
  - Lower deoxidizer content
  - Less tolerant of mill scale or rust
  - Cleaner base metals are required
- E70S-6
  - Higher levels of silicon and manganese
  - Designed for welding over mill scale, light rust, or surface contamination
  - More fluid weld puddle for flatter beads
- E70C-6M (metal-cored)
  - Similar chemical composition to E70S-6
  - Offers higher deposition rates
  - Requires more expensive equipment and optimized parameters
Key Characteristics & Properties

E70S-6 wire stands out for its versatility and weld quality on less-than-perfect base metals. Let’s take a closer look at its technical properties:
- Tensile Strength: 70,000 psi (minimum)
- Yield Strength: ~58,000 psi
- Elongation: ~22% in 2 inches
- Recommended Shielding Gas:
  - 75/25 Argon/CO₂ for cleaner, more controlled arcs
  - 100% CO₂ for deeper penetration and cost-effectiveness
- Silicon Content: 0.80–1.15%
- Manganese Content: 1.40–1.85%
- Diameter Availability: .023″, .030″, .035″, .045″, and larger for industrial applications
Real-World Example:
If you’re welding mild steel tubing for handrails or machinery guards with surface mill scale, E70S-6 will give you a smooth, low-spatter weld bead that requires minimal cleanup.

Process Considerations

Compatibility with Welding Processes
- ✅ GMAW (MIG Welding) – Primary application
- ❌ Not suitable for FCAW, GTAW, or SMAW
Equipment Notes:
- Compatible with both transformer and inverter-based MIG machines
- Works well in spray, short-circuit, and globular transfer modes
- Ideal for semi-automatic or robotic applications
Pros:
- High feedability in wire feeders
- Excellent bead appearance
- Tolerant to minor surface contaminants
Cons:
- Not designed for high-alloy or exotic metals
- Less effective on dirty or heavily rusted steel than flux-core options
- Needs shielding gas—can’t be used outdoors without wind protection
Application Use Cases

E70S-6 is a workhorse wire used in general fabrication and manufacturing:

Common Industries:
- Structural steel erection
- Heavy equipment repair
- Shipbuilding
- Automotive and trailer frame welding
- Agricultural implement manufacturing
Compatible Metals:
- A36 mild steel
- Hot-rolled steel
- Low-carbon structural plates and tubing
Ideal Conditions:
- When high productivity, flat bead profiles, and minimal post-weld cleanup are important
- When working with slightly rusty or mill-scaled materials
Best Practices & Pro Tips

Here’s what experienced welders need to keep in mind:
- Use the Right Gas Mix:
  75/25 Argon/CO₂ delivers cleaner welds; 100% CO₂ increases penetration but increases spatter.
- Clean Just Enough:
  Though E70S-6 handles light contamination, don’t push it—heavy rust or paint can still cause porosity.
- Dial in the Voltage and Wire Speed:
  Start with manufacturer specs and fine-tune based on sound and bead shape. A smooth “buzz” sound = optimal settings.
- Avoid Excess Heat Input:
  Especially when welding thinner material. Use pulsed MIG or short-circuit transfer to avoid burn-through.
- Watch for Silicon Islands:
  After welding, shiny silicon deposits may form in the weld toe area. These should be ground off before painting or coating.
- Store Wire Properly:
  E70S-6 is prone to rust if stored in humid conditions. Keep it in sealed containers or use wire feeders with covers.
Conclusion

E70S-6 MIG welding wire is the top choice for fabricators and welders dealing with carbon steels that aren’t in pristine condition. Its chemical makeup allows for smooth arcs, flat welds, and strong joints even when base metals have minor mill scale or rust.

If you’re looking to balance performance, affordability, and ease of use, this wire is probably the right fit for most carbon steel welding jobs.

Purchase E70S-6 Mig Wire

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July 26, 2025
Tillman Gloves: Choose the Best MIG, TIG, or Stick Welding Fit
When it comes to welding, your gloves aren’t just accessories — they’re your first line of defense. Whether you’re laying down delicate TIG beads or burning heavy rod on a stick job, the right glove makes a massive difference in comfort, control, and safety. Tillman, one of the most trusted names in welding PPE, offers gloves tailored specifically for MIG, TIG, and Stick processes. But which model is right for your work?

Let’s break it down.

TIG Welding: Thin, Precise, and Flexible

TIG welding demands finesse, and that means your gloves need to offer maximum dexterity with minimal bulk. Tillman’s TIG gloves are crafted from premium materials like top-grain goatskin or kidskin leather, both known for their softness and flexibility.

Best Pick: Tillman 24C or 1338
- Material: Kidskin (24C) or Goatskin (1338)
- Why it works: Lightweight, form-fitting, and durable enough to take the heat while giving you fingertip control.
- Bonus: Some TIG models include a seamless forefinger for improved feel on the torch.
Tillman 24CL Welding Gloves, TIG, L, Straight, PR

Sale Unit: PAIR
Brand: Tillman
Glove Type: Welding Glove
Welding Application: TIG
Glove Material: Kevlar / Leather

$24.80
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API
Sale

Tillman 1338 Top Grain Goatskin TIG Glove with Glide Patch Large White

Goatskin
superior feel and dexterity
Reinforced thumb for added strength

$15.99
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

These gloves won’t last forever if you’re dragging filler rod or working in high-amp applications — but for clean, controlled TIG work, they’re ideal.

MIG Welding: Balance of Dexterity and Protection

MIG welding hits that middle ground. You need enough finger feel to control your gun and trigger, but more insulation than TIG gloves offer. Spatter is more common here, so longer cuffs and more heat resistance matter.

Best Pick: Tillman 42 or 48
- Material: Top-grain cowhide with cotton or fleece lining
- Why it works: Durable with added lining for spatter protection, while still flexible enough for wire-feed control.
- Bonus: The reinforced palm patch on some models adds grip and extends glove life.
Tillman 48L Large Brown Top Grain Goatskin Fleece Lined Standard Grade MIG Welders Gloves with Straight Thumb, 3 1/2″ Cuff, Kevlar Stitching and Elastic Back (1/PR)

A top grain goatskin palm for best feel
MIG Welding appliations

$23.56
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API
Welding Gloves, MIG, L, Reinforced, PR

Price For: Each Stitching Material: Kevlar(R) Grade of Leather: A Design: (2) Piece Back Item: Welding Gloves Size: L Color: Tan Cuff Material: Split Cowhide Leather Lining Material: Cotton/Foam Length: 12″ Cuff: 4″ Gauntlet Cut: Gunn Thumb Style: Reinforced Application: MIG Back Material: Grain Pigskin Palm Material: Pigskin
Leather Palm Type: Top Grain Country of Origin (subject to change): Unknown

$29.46
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

These are workhorses—great for shop use, structural jobs, or fabrication tasks where comfort and toughness must coexist.

Stick Welding: Heat, Spatter, and Brutal Conditions

Stick welding is where gloves get put through hell — sparks flying, rods burning, slag popping. You need insulation, thick leather, and a long gauntlet cuff. Dexterity takes a back seat to safety and durability.

Best Pick: Tillman 750 or 850
- Material: Premium side-split cowhide or elk skin
- Why it works: High heat resistance, rugged build, and foam-lined backs for heavy-duty work.
- Bonus: Kevlar stitching on these gloves helps prevent seam blowouts under repeated thermal cycling.
Sale

Tillman 850 Gold Elk Skin Premium Welding Gloves-L

Reusable Welding Gloves: The gloves are reusable for multiple welding projects.
Elk Skin Material: Made from premium elk skin material for durability and comfort.
Lock Closure: The gloves feature a lock closure for secure fit.
Adult Size: Designed in a large adult size to fit most welders.
Welding Use: Specifically designed for welding projects and tasks.

$41.48
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API
John Tillman and Co Tillman Large 14″ Pearl Gray Premium Elkskin CottonFoam Lined Stick Welders Gloves with Welted Fingers and Kevlar Thread Locking Stitch (TIL750L)

Tillman Large Pearl Gray 14″ Top Grain Elk Cotton/Foam Lined Welders Gloves With Straight Thumb, Stiff Cowhide Cuff, Welted Fingers, Kevlar Stitching And Pull Tab (Carded)
John Tillman and Co
John Tillman and Co – 750l
Pull Tab – provides easy on/off and extra protection while dragging a welding gun. Straight Thumb – for best gun grip. Top Grain Elk Back and Palm – superior feel and performance

$40.20
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API

These gloves are built to last, especially for welders working outdoors, in field repair, or on dirty, high-amperage stick jobs.

Choosing the Right Fit

When selecting gloves, don’t go by price or looks — go by process. Consider:
- Heat exposure: TIG runs cooler, Stick runs hot.
- Dexterity needs: TIG demands precision, Stick does not.
- Work duration: Longer sessions mean you’ll want gloves that stay comfortable.
Also, sizing matters. Too loose, and you’ll lose control. Too tight, and you’ll lose circulation — and feel every arc pulse.

Final Thoughts

Tillman has been a staple in welding PPE for a reason — their gloves are purpose-built for the demands of each welding process. Choosing the right pair isn’t just about comfort — it’s about staying safe, welding better, and protecting your hands for the long haul. Stay safe, weld strong.

If you’re ready to gear up, we’ve linked our recommended Tillman gloves for each welding process below.

As an affiliate, we may earn from qualifying purchases at no extra cost to you.
July 26, 2025
Welding Cable Guide: Lead Length & Sizes Explained
When it comes to welding performance and safety, your choice of welding cable is just as important as your machine or electrode. Whether you’re setting up a new rig or upgrading your current leads, understanding cable size and lead length can make a noticeable difference in weld quality and efficiency. In this guide, we break down the key factors to help you choose the right welding cable for your needs.

What Is Welding Cable?

Welding cable is a flexible, high-amperage conductor used to connect the power source (welder) to the work clamp and electrode holder. It’s built with a heavy-duty rubber jacket and fine copper strands, designed to withstand the demanding conditions of welding environments—abrasion, oil, flame, and movement.

Understanding Cable Sizes (Gauge)

Welding cable sizes are measured in American Wire Gauge (AWG), where smaller numbers mean thicker cables. Common sizes include:
- #6 AWG – Suitable for light-duty work up to ~50 ft
- #4 AWG – Good for medium-duty up to 75 ft
- #2 AWG – Used for higher amperage up to 100 ft
- #1 or 1/0 AWG – Heavy-duty applications, great for long distances or high-amperage machines
- 2/0 or 3/0 AWG – Industrial-grade welding or extremely long lead runs
The thicker the cable, the more amperage it can carry without overheating or voltage drop. For example, a #1 AWG can carry 200 amps over 100 feet without noticeable performance issues, while a #6 might struggle past 30 feet with the same amperage.

Why Lead Length Matters

Lead length impacts voltage drop—longer cables create more electrical resistance. That resistance can reduce power at the arc, affecting penetration and weld quality. To minimize voltage loss:
- Keep leads as short as practical
- Use a thicker cable for longer distances
- Avoid excessive splicing or poor connectors
As a rule of thumb, if your leads are longer than 50 feet, consider sizing up your cable to the next thicker gauge.

Match Cable to Your Machine’s Output

Check your welder’s max output amperage and duty cycle. If you’re running a 250A MIG welder at 60% duty cycle, you’ll want a cable rated comfortably above that (like 1/0 AWG) to avoid overheating. Undersized cables not only reduce performance, they’re also a fire hazard.

Single vs. Paired Cables

For stick or TIG welding, you’ll often use two separate leads—an electrode and a ground. For wire-feed machines, the ground cable is separate, and the power flows through the MIG gun. In all cases, make sure both leads are properly rated and matched in length when possible to ensure balanced resistance.

Choosing the Right Jacket Type

Most welding cables come with either:
- EPDM Rubber – Flexible, oil-resistant, good for shop use
- Neoprene – Weather and abrasion-resistant, good for outdoor/rough use
- SJOOW/SOOW – Multi-conductor variants are often used for extension leads or industrial setups
If you’re working in cold environments or with frequent cable coiling/uncoiling, go for a high-flex cable with fine copper strands—easier to manage and less prone to cracking.

Quick Cable Sizing Table

Amps Max Length (ft) Recommended Size
150 50 ft #4 AWG
200 75 ft #2 AWG
250 100 ft 1/0 AWG
300+ 100+ ft 2/0 or 3/0 AWG

Always round up for safety and efficiency.

Final Tips
- Inspect your cable for cuts, worn insulation, or corrosion at the lugs
- Keep connections tight and clean
- Consider quick-connect ends for modular setups
Conclusion

Picking the right welding cable size and lead length isn’t just a technical detail—it directly affects your arc stability, equipment lifespan, and safety. When in doubt, go thicker and shorter. It’s a small investment that pays off every time you strike an arc.

Note: This post may contain affiliate links, and we may earn a commission if you purchase through them, at no extra cost to you.
July 25, 2025
Welding Gas Regulator Leak Detection: How to Test Properly
A leaking gas regulator can spell disaster in any welding setup. Whether you’re running MIG, TIG, or oxy-fuel equipment, a compromised regulator risks gas loss, safety hazards, and poor weld quality. Fortunately, testing for leaks is simple and only takes a few minutes — if you know what you’re doing.

In this guide, we’ll walk through how to properly check your welding gas regulator for leaks, what tools you need, and the signs that it’s time to replace or repair your setup.

Why Regulator Leaks Are a Big Deal

A leaking regulator doesn’t just waste expensive shielding gas like argon, CO₂, or acetylene — it can cause:
- Porosity in welds due to inconsistent gas flow
- Backfire or flashbacks in oxy-fuel setups
- Oxygen enrichment or fire risk in poorly ventilated areas
- Shortened regulator lifespan and failed pressure seals
Even small leaks can snowball into bigger problems if left unchecked.

Tools You’ll Need

You don’t need a high-tech lab setup to test your regulator. Here’s what you need:
- Soapy water solution (dish soap with no oil + water in a spray bottle). Be sure to get soap with no oil because it can not be around compressed oxygen.
- Leak detection fluid (optional but more precise)
- PPE: gloves and eye protection
- Regulator and gas cylinder
- Wrench for tightening connections
How to Test a Regulator for Leaks

1. Check for Physical Damage

Before you even connect it, visually inspect the regulator:
- Cracks or corrosion around the body
- Bent gauges or broken needle indicators
- Loose fittings or broken inlet/outlet threads
If you spot any of this, don’t bother testing — replace it.

2. Secure the Regulator to the Cylinder

Use the correct wrench to firmly tighten the regulator onto the gas cylinder valve. Make sure no Teflon tape is used on CGA connections — they seal via metal-to-metal compression, not threads.

3. Open the Cylinder Valve Slowly

With the regulator’s pressure-adjustment knob fully backed out (loose), crack the cylinder valve open just slightly, then fully open it. You should see tank pressure register on the gauge.

4. Apply Soapy Water or Leak Detector

Spray the soapy water solution around these key areas:
- Cylinder-to-regulator connection
- Regulator body seams
- Gauge threads and faces
- Outlet fitting and hose connection
Watch closely for bubbling — even small ones signal a leak.

Pro tip: Use a leak detection fluid rated for welding gas systems if available. It’s more sensitive than soap and less likely to corrode brass fittings.

5. Pressurize and Retest

If no bubbles show at tank pressure, dial in 10–20 psi on the working pressure side, then recheck the outlet connections. This ensures no leaks develop once the system is live.

What to Do If You Find a Leak
- At the tank connection: Try reseating and re-tightening the regulator. If it still leaks, the regulator seat may be damaged or the cylinder valve may be faulty.
- At the body or gauges: Replace the regulator. Internal leaks can’t be repaired easily or safely.
- At the outlet or hose: Check fitting tightness. If it still leaks, replace the hose or fitting.
Never use a leaking regulator during welding. It’s not worth the risk.

When to Replace Your Regulator
- If you see persistent leaks despite tightening
- If your regulator is more than 5–7 years old and shows wear
- If gauges are inaccurate or slow to respond
- If threads or seats are damaged
Upgrading to a quality regulator can save gas and headaches long term.

Final Thoughts

Testing for gas leaks should be a part of your routine maintenance, especially if your welds suddenly start looking rough or your gas tanks are draining too fast. A simple spray test can help prevent wasted gas, poor welds, and serious safety issues.

Note: Some of the links on this page may be affiliate links. If you click and buy, we may earn a small commission at no extra cost to you. We only recommend gear we trust.

If you’re regulator needs to be replaced, here are some options for replacement. Gas Regulation Replacement
July 24, 2025
DIY Welding Cart: Organizing Tools for Shop Setup
If you’re setting up a home welding shop or upgrading your garage workspace, a DIY welding cart is one of the smartest first builds you can take on. Not only does it give you a place to store your welder, cables, and consumables, but it also keeps your setup mobile, compact, and organized. Whether you MIG, TIG, or stick weld, a well-built cart saves time and space — and prevents that classic tool scramble mid-project.

Why Build Your Own Welding Cart?

Buying a pre-built welding cart can get expensive fast — especially if you want heavy-duty shelves, drawer space, or features like bottle racks and grounding studs. A DIY cart lets you:
- Customize dimensions to fit your welder or plasma cutter
- Add racks for clamps, grinders, and cables
- Use scrap metal or repurposed materials to save cash
- Learn or refine your fabrication skills in the process
For beginner to intermediate welders, it’s a perfect project to practice clean welds, square tubing, and caster alignment.

Planning Your Layout

Before you cut any steel, think about how you work. Ask yourself:
- Do you need it to roll under a bench when not in use?
- Will it carry a gas cylinder for MIG or TIG welding?
- How many shelves or drawers do you need?
- Will you add a power strip or extension cord holder?
A typical layout might include:
- Top shelf for the welder or plasma cutter
- Middle shelf for accessories like wire spools, clamps, or gloves
- Bottom shelf for heavier items or shielding gas bottles
- Cable hooks on the sides
- Locking casters for stability and movement
Optional upgrades: drawer slides, fire extinguisher mount, or tool trays for pliers, nozzles, and brushes.

Materials and Tools Needed

You don’t need much to get started. A basic welding cart can be made using:

Materials
- 1″ square tubing (14–16 gauge is plenty strong)
- Sheet metal for shelves
- Casters (2 fixed, 2 swivel with brakes)
- Flat bar or angle iron for supports
- Paint or powder coat (optional)
Tools
- MIG welder or stick welder
- Angle grinder with cut-off and flap discs
- Clamps, tape measure, square, marker
- Drill and bits (for mounting shelves or accessories)
- Safety gear: gloves, helmet, fire-resistant clothing
If you’re light on tools, consider picking up a basic welding kit or angle grinder set — many solid options are available online.

Welding Cart Build Tips
- Start square: Make sure your tubing is squared and clamped before tacking. Check alignment often.
- Tack first, weld later: Fully weld only after everything is fit up correctly. This reduces warping and rework.
- Weight balance matters: Place your gas bottle over the axle line if possible to avoid tipping.
- Ground smart: Consider welding on a ground stud or using a dedicated clamp location to make setup faster.
Once your cart is fully assembled, give it a cleanup with acetone or alcohol, hit it with primer, and paint to match your shop’s vibe — or go all black for a classic industrial look.

Final Thoughts

A welding cart might not be glamorous, but it’s a game-changer for productivity and workspace efficiency. Building your own lets you tailor it exactly to your tools, your space, and your welding style. Plus, it gives you one more project under your belt — and a functional one at that.

Disclaimer: Some of the links in this post may be affiliate links. That means we may earn a commission if you purchase through them, at no additional cost to you. Every product we recommend is something we’d use in our own shop.
July 23, 2025
MIG Problems Solved: Porosity Fix Guide
MIG welding is known for its speed and ease, but it isn’t immune to issues, especially porosity. If you’ve ever laid a bead that looked more like Swiss cheese than solid metal, you’re not alone. Porosity is one of the most common (and frustrating) MIG welding problems, but the good news is: it’s solvable. This quick guide covers the causes and actionable fixes to help you get back to laying clean, reliable welds.

What Is Porosity in MIG Welding?

Porosity happens when gas gets trapped in the molten weld pool and forms bubbles as the metal solidifies. These gas pockets can severely weaken your weld, cause leaks in pressure vessels, and ruin the appearance. There are two types:
- Surface porosity: visible holes on the weld face.
- Subsurface porosity: hidden defects inside the weld, often only found with X-ray or ultrasonic inspection.
Both types are bad news, but they’re usually preventable.

Common Causes and Fixes

1. Contaminated Base Metal

Problem: Dirt, rust, oil, paint, or moisture on the workpiece can create gas when burned, leading to porosity.
Fix: Clean the metal thoroughly with a wire brush, grinder, or acetone before welding. Even new steel can have mill scale or oil that needs removal. See the clean side on the right.

2. Poor Shielding Gas Coverage

Problem: If your gas isn’t fully protecting the weld, air can mix in and cause bubbles.
Fixes:
- Check your flow rate: For most MIG setups, 20–30 CFH is ideal. Too low or too high can cause turbulence.
- Inspect for leaks: Look for cracks in hoses or loose fittings.
- Avoid wind: Even a slight breeze can disrupt shielding gas. Weld indoors or use wind guards when possible.
3. Incorrect Stick-Out (Electrode Extension)

Problem: If your wire stick-out is too long, it reduces gas shielding and increases spatter.
Fix: Keep stick-out around 3/8″ to 1/2″ for solid MIG wire. Flux-core may allow for a bit more, but always refer to the manufacturer’s specs.

4. Wrong Gun Angle or Distance

Problem: Angling the gun too much or holding it too far away from the workpiece can compromise gas coverage.
Fix: Use a push technique with the gun held at a 10–15° angle from vertical. Keep the nozzle about 3/4″ from the puddle.

5. Dirty or Damaged Consumables

Problem: Spatter buildup inside your nozzle or a bad diffuser can affect gas flow.
Fix: Regularly clean or replace the nozzle, tip, and diffuser. Use anti-spatter spray to prevent buildup.

6. Wrong Wire or Gas Combo

Problem: Using the wrong type of wire or gas for the job can cause an unstable arc and porosity.
Fix: Make sure you’re using the right filler wire for your material. For mild steel, ER70S-6 with 75/25 argon/CO₂ is the common go-to. Stainless or aluminum will require different combinations.

Pro Tip: Keep a Checklist

If you’re running into porosity issues often, build a pre-weld checklist. Here’s a simple one:
- Clean the metal
- Check gas flow and hose integrity
- Inspect consumables
- Confirm correct wire/gas combo
- Set gun angle and stick-out properly
Final Thoughts

Porosity in MIG welds can be frustrating, but it’s rarely random. Usually, it comes down to gas coverage, cleanliness, or technique. By understanding the root causes and dialing in your setup, you’ll be able to produce clean, professional-quality welds every time.

This post may contain affiliate links. We may earn a commission if you purchase through them—at no additional cost to you. We only recommend products we trust for quality and performance in the shop.
July 22, 2025
ESAB Rebel 215ic Review: Best All-In-One 200 Amp DC Welder
Introduction & Overview

The ESAB Rebel 215ic Review: Best All-In-One Welder is a game-changer for both professional and hobby welders. Celebrated for its flexibility and portability, this welder accommodates a variety of welding processes, making it an indispensable tool in any workshop. Designed to meet the demands of modern welding needs, its versatility is its standout feature, offering a powerful solution for a wide range of projects.

Key Features

The ESAB Rebel 215ic is known for its multi-process capabilities, allowing DC MIG, TIG, and Stick welding. This versatility positions it as a valuable asset for those needing diverse welding techniques in one machine. With an output range of 120V to 230V, it can handle a variety of materials and thicknesses. The machine also boasts an intelligent sMIG (smart MIG) feature that adjusts settings automatically, simplifying usage for beginners while still catering to experts who prefer custom settings.

Pros & Cons

– Pros:
– Multi-process capability: MIG, TIG, and Stick welding.
– Portable and lightweight design.
– User-friendly interface with TFT-LCD screen.
– Durable construction for long-lasting use.
– Wide voltage range for diverse applications.

– Cons:
– Might be considered expensive by budget users.
– Requires additional purchase for TIG accessories.
– Learning curve for absolute beginners.

Who It’s For

The ESAB Rebel 215ic is ideal for welders who require flexibility and portability without compromising performance. Whether you’re a seasoned professional or an ambitious hobbyist, this all-in-one welder suits those needing to switch between different welding styles efficiently. It’s particularly beneficial for small shops or home workshops, where space and versatility are at a premium.

What Makes It Unique

What sets the ESAB Rebel 215ic apart from competitors is its innovative sMIG technology, which automatically adjusts to the operator’s style, optimizing the welding parameters. This technology not only enhances weld quality but also reduces setup time. Additionally, its lightweight, rugged construction makes it perfect for projects on the go or in varying environments.

Buying Tips

When purchasing the ESAB Rebel 215ic, consider investing in high-quality protective gear and compatible TIG accessories if you plan to maximize its features. Check the power supply requirements based on your workshop setup to ensure seamless operation. It’s wise to buy from authorized retailers to take advantage of any available warranties and customer support.

Conclusion

In summary, the ESAB Rebel 215ic Review: Best All-In-One Welder stands out for its versatility, portability, and advanced features that cater to a wide range of users. Its innovative sMIG technology and robust design make it a benchmark in the welding industry. If you’re looking to invest in a reliable, multi-process welder, the ESAB Rebel 215ic is a worthy choice.

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Esab Rebel Series EMP 215Ic Mig/Tig/Stic

Category: Welding — Replacement Parts

$2,616.71
Buy on Amazon
Last update on 2025-12-06 / Affiliate links / Images from Amazon Product Advertising API
July 21, 2025