Tag: welding tips

  • Stick Welding Rod Sticking: Causes and How to Fix It

    When your stick electrode keeps sticking to the workpiece, it usually means the arc isn’t stable enough to stay lit. This is one of the most common frustrations in stick welding and is typically caused by low amperage, poor technique, or improper setup.

    Key Takeaways

    • Rod sticking is usually caused by low amps or weak arc starts
    • Correct amperage and arc length are critical
    • Moisture and rod condition can affect performance
    • Technique (especially arc striking) plays a big role

    What’s Causing the Problem

    1) Amperage Too Low

    • Not enough heat to maintain the arc
    • The electrode fuses to the base metal instead of melting properly

    2) Poor Arc Start Technique

    • Tapping too lightly or dragging incorrectly
    • Not establishing a strong initial arc

    3) Incorrect Arc Length

    • Holding the rod too close chokes the arc
    • Too far causes instability and extinguishing

    4) Damp or Contaminated Rods

    • Moisture affects arc stability and slag formation
    • Especially common with 7018 rods

    5) Improper Ground Connection

    • Weak or inconsistent electrical circuit
    • Causes erratic arc behavior

    How to Fix It

    Step 1: Increase Amperage

    • Adjust amps based on rod size:
      • 1/8″ (3.2 mm) rod → ~90–130 amps
    • Start in the middle of the range and adjust as needed

    Step 2: Improve Arc Start

    • Use a scratch or tap method with confidence
    • Strike the arc like lighting a match, then lift slightly

    Step 3: Maintain Proper Arc Length

    • Keep arc length about equal to rod diameter
    • Too short = sticking
    • Too long = unstable arc

    Step 4: Use Dry Electrodes

    • Store rods in a dry environment
    • Use a rod oven for low-hydrogen electrodes (like 7018)

    Step 5: Check Ground Clamp

    • Attach to clean, bare metal
    • Ensure a tight connection

    Common Mistakes to Avoid

    • Running amps too low “to be safe.”
    • Hesitating during arc start
    • Welding with damp rods
    • Ignoring poor ground connections
    • Holding too tight or an inconsistent arc length

    Best Settings / Guidelines

    ParameterTypical Range
    Amperage90–130A (1/8″ / 3.2 mm rod)
    Arc LengthEqual to rod diameter
    Rod ConditionDry, properly stored
    Ground ContactClean, solid connection
    Travel SpeedModerate, consistent

    Always verify amperage with rod manufacturer recommendations.

    Safety Notes

    • Wear proper eye protection (ANSI Z87.1) and welding helmet
    • Stick welding produces significant fumes—ensure ventilation
    • Keep gloves dry to avoid shock risk
    • Inspect electrode holder and cables for damage

    FAQ

    Why does my rod stick immediately when I strike an arc?
    Usually due to low amperage or poor arc start technique.

    Can moisture really affect stick welding?
    Yes—especially with low-hydrogen rods like 7018.

    What’s the best rod for beginners?
    6013 is more forgiving and easier to start than 7018.

    Does polarity matter for sticking?
    Yes—incorrect polarity can cause poor arc stability.

    Should I increase amps if my rod sticks?
    Yes—slightly increasing amperage often solves the issue.

    Sources Checked

    • American Welding Society
    • Lincoln Electric stick welding guides
    • Miller Electric setup and troubleshooting resources

  • 7018 Rod Sticking: Causes & Solutions

    Introduction

    Welding with 7018 rods can be challenging, especially when they start sticking during operation. This issue not only affects the quality of the weld but also disrupts workflow. Understanding the underlying causes and solutions can help welders achieve more efficient results.

    Key Takeaways

    – 7018 rods are prone to sticking due to improper technique or settings.
    – Correct amperage and angle can reduce sticking.
    – Proper rod storage is crucial for optimal performance.
    – Using the right equipment can significantly improve weld quality.

    Problem / Context

    Sticking occurs when the electrode fuses to the workpiece, interrupting the arc and making it difficult to complete the weld. This is a common issue with 7018 rods, which require precise conditions to function correctly.

    Causes

    Low Amperage

    – Inadequate amperage fails to sustain the arc, causing the rod to stick.

    Incorrect Angle

    – Holding the rod at an incorrect angle reduces arc stability.

    Poor Rod Condition

    – Moisture absorption in 7018 rods can lead to sticking.

    Fixes

    Step 1: Adjust Amperage

    – Increase Amperage: Slowly increase amperage until the arc is stable and the rod flows smoothly without sticking.

    Step 2: Correct Angle

    – Maintain a 10-15 Degree Angle: Keep the rod at a consistent angle to ensure smooth arc movement.

    Step 3: Ensure Dry Storage

    – Proper Storage: Store rods in a dry, sealed container or rod oven to prevent moisture absorption.

    Step 4: Consistent Movement

    – Steady Motion: Employ a steady, consistent movement along the weld joint to reduce sticking.

    Product Section

    Washington Alloy 7018 Stick Electrode 5LB Package (7018 1/8')
    Washington Alloy 7018 Stick Electrode 5LB Package (7018 1/8″)
    • All-position, Flux coated
    • 70,000 lbs Tensile Strength
    • 5 Lb Package
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    Safety Notes

    – Eye Protection: Follow ANSI Z87.1 standards for eye protection.
    – Welding Codes: Adhere to AWS D1.1 and D1.3 for safe and effective welding practices.

    FAQ

    What amperage should be used for 7018 rods?

    Amperage settings typically range from 90 to 160 amps, depending on the rod diameter. Adjust based on welding parameters and practice.

    How should 7018 rods be stored?

    Store in a temperature-controlled rod oven at 250°F (121°C) to keep them dry and prevent moisture absorption.

    Can rod sticking damage my welding machine?

    Prolonged sticking can overheat and damage your welding machine, so it’s vital to address issues promptly.

    Conclusion / Next Step

    Addressing 7018 rod sticking involves proper technique and equipment adjustments. By implementing these solutions, welders can enhance their welding performance and minimize disruptions. For more tips on stick welding, explore additional resources and comparisons of welding rods like 7018 vs 6011.

  • Why Your MIG Weld Has Porosity (and How to Fix It Fast)

    Porosity in MIG welding shows up as pinholes or small voids in the weld bead. It weakens the weld and usually points to shielding gas failure or contamination. This guide breaks down the exact causes and the fastest way to fix it using proper setup and wire selection.

    Key Takeaways

    • Porosity is caused by poor shielding gas coverage or contamination
    • Dirty metal and bad wire are the most common causes
    • Gas flow, nozzle condition, and wire choice fix most issues
    • ER70S-6 wire helps reduce porosity on less clean steel

    What Causes MIG Weld Porosity

    Porosity occurs when atmospheric gases get trapped in the weld pool as it solidifies. In MIG welding, shielding gas is supposed to prevent this. When coverage fails, defects form.

    • Low shielding gas flow
    • Wind or airflow disrupting gas
    • Dirty or oily metal
    • Rusty or contaminated wire
    • Improper stickout or angle
    • Clogged nozzle or diffuser

    How to Fix MIG Porosity

    • Set gas flow to 20–30 CFH (verify for your setup)
    • Keep stickout around 3/8”–1/2”
    • Clean metal to bare steel
    • Check for gas leaks
    • Replace worn nozzle or diffuser
    • Switch to ER70S-6 wire if needed

    Recommended Wire for Reducing Porosity

    Hobart ER70S-6 MIG Welding Wire (.030”)



    Type: Solid MIG wire

    Diameter: .030”

    Material: Mild steel

    Deoxidizers: Higher than ER70S-3

    Specs: Unknown (Verify)

    Hobart H305406-R22 10-Pound ER70S-6 Carbon-Steel Solid Welding Wire, 0.030-Inch
    Hobart H305406-R22 10-Pound ER70S-6 Carbon-Steel Solid Welding Wire, 0.030-Inch
    • Carbon-steel sound, porosity-free welds with powerful deoxidizers for your work with shielding gases.
    • Great for construction work, farm implement fabrication, shaft buildup, tanks, truck bodies and general shop applications with poor fit-up or rusty, oily plates.
    • 10-Pound spool
    • Country of Origin: Made in China
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API


    ER70S-6 wire is more forgiving on dirty steel and helps reduce porosity compared to ER70S-3.

    Gas Flow Setup

    • Typical: 20–30 CFH (verify)
    • Too low = poor coverage
    • Too high = turbulence
    • Avoid drafts when welding

    Wire Comparison

    WireKey DifferenceBest Use
    ER70S-6More deoxidizersDirty steel
    ER70S-3Cleaner arcClean material

    Safety Notes

    Use ANSI Z87.1 compliant eye protection and proper PPE. Ensure ventilation and follow AWS welding safety guidelines.

    FAQ

    Q: Can too much gas cause porosity?
    A: Yes. It can create turbulence and pull in air.

    Q: Does wire matter?
    A: Yes. ER70S-6 is more forgiving on dirty steel.

    Next Step

    Check your gas flow and nozzle first. If needed, switch to ER70S-6 wire and clean your material before welding.

  • YESWELDER TIG Tungsten Manual Sharpener Holder (TSH-01): What It Does, What It Doesn’t, and Who It Fits

    YESWELDER TIG Tungsten Manual Sharpener Holder (TSH-01): What It Does, What It Doesn’t, and Who It Fits

    If your TIG arc is wandering, hard-starting, or “randomly” dipping out, tungsten prep is one of the first things to check. A consistent point isn’t magic—but it does remove one variable you can control.

    This post covers the YESWELDER manual tungsten sharpener holder (TSH-01): what it’s designed to do, what to compare before you buy, and where it fits in a real TIG workflow.

    Key Takeaways

    • This is a manual tool meant to help you get a more consistent tungsten point (not a powered grinder).
    • Confirm it matches the tungsten diameters you actually run (don’t assume).
    • Your grinding wheel choice and dust control matter as much as the holder itself.
    • Dedicated tungsten grinding is still the cleanest way to avoid cross-contamination.

    Product (Verified)

    YESWELDER TIG Tungsten Manual Sharpener Holder Welding Tungsten Polish Gripper 1/16'' 3/32'' 1/8'' TSH-01
    YESWELDER TIG Tungsten Manual Sharpener Holder Welding Tungsten Polish Gripper 1/16” 3/32” 1/8” TSH-01
    • APPLICATION: Hold the TIG tungsten electrodes while sharpening and polishing it. Especially the short tungsten electrodes, which is dangerous and hot to hold, our sharpener holder is here to help you.
    • EFFICIENT: It not only can provide genuine protection for your hands but also can increase your working productivity. The long back cup can be installed on your welding torch as well.
    • CPMPATIABLE DIAMETER: It comes with three collets of 1/16”(1.6mm); 3/32”(2.4mm); 1/8”(3.2mm) diameter, which fit the most popular tungsten electrodes.
    • EASY ASSEMBLY: First, put the tungsten electrode into the correspoding collet, and then put them into the silver fixed sleeve, finally install the long back cup.
    • PACKAGE INCLUDES: 1 x tungsten sharpener holder; 3 x collets; 1 x plastic case.
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    What this tool is (and isn’t) This is a handheld/manual tungsten sharpening holder. The core idea is simple: hold the electrode more consistently so you can grind a repeatable taper.

    It is not:

    • A powered sharpener
    • A substitute for a clean grinding setup
    • A guarantee of “better welds” (it just helps standardize prep)

    Where it fits in a TIG workflow A tungsten holder makes the most sense when:

    • Multiple people touch the same TIG setup and you want repeatable prep
    • You’re trying to reduce “freehand variability” on the grinder
    • You’re doing frequent regrinds and want a faster, more consistent routine

    If you only sharpen tungsten once in a while and already have a clean, dedicated wheel, you may not see a big change.

    Performance & Use The practical benefit is consistency. If you can hold the tungsten at a stable angle and keep the grind direction consistent, you reduce one common cause of unstable arcs: uneven points and contamination.

    What to compare before you buy

    • Supported tungsten diameters (verify it matches what you run most)
    • How it interfaces with your current grinding method (bench grinder vs other setup)
    • Ease of keeping tungsten dust contained (important for shop cleanliness)
    • Build quality of the clamping surfaces (avoid slipping/marring)
    • Storage/organization (small parts get lost fast in a welding cart)

    Comparable Amazon picks (optional)

    Common mistakes that make tungsten prep worse

    • Grinding on a wheel that’s also used for mild steel or other metals (contamination risk)
    • Grinding “around” the tungsten instead of lengthwise (can destabilize arc shape)
    • Skipping cleaning after accidental dips (regrind is usually faster than fighting it)
    • Letting dust build up around the grinder (mess + potential exposure)

    Safety notes (quick) Tungsten grinding creates fine dust. Use local ventilation or dust collection if possible, and don’t grind in the same area you prep food/drinks. If you’re using thoriated tungsten, follow your shop’s safety practices for dust control and disposal.

    Where to Buy (Amazon) YESWELDER TSH-01 (ASIN: B0C5QGFQ3F)
    https://www.amazon.com/YESWELDER-Tungsten-Sharpener-Welding-TSH-01/dp/B0C5QGFQ3F?tag=weldsupport-20

  • 6011 Rod: Best Practices for AC vs. DC Welding

    6011 Rod: Best Practices for AC vs. DC Welding

    Introduction

    In the world of welding, choosing the right electrode and current type is pivotal for achieving optimal results. One common question among welders is whether to run the 6011 electrode on AC or DC current. This decision significantly impacts the welding process and the final outcome. The 6011 electrode is crucial in welding for its versatility and effectiveness in penetrating rusted or dirty metals. Both experienced welders and newcomers, including fabricators, students, and engineers, often examine this electrode for its unique benefits.

    Types / Variants

    While 6011 itself is a designated type of electrode, it comes in various sizes:

    • 1/8 inch: Typically used for medium-thickness metals.
    • 3/32 inch: Better suited for thinner materials.
    • 5/32 inch: Ideal for thicker metals requiring deeper penetration.

    Each size is chosen based on the metal thickness and desired penetration.

    Key Features or Specifications

    • Material: Cellulose-based coating
    • Deposition Rate: Moderate, providing a good balance between speed and control.
    • Compatibility: Usable with both AC and DC power sources, making it versatile for different settings.
    • Certifications: Often compliant with AWS (American Welding Society) standards.

    The main advantage of the 6011 electrode is its deep penetration capability, which is crucial for welding dirty or rusty materials.

    Usage & Compatibility

    AC Current Advantages:

    • Arc Stability: While more challenging, AC offers flexibility in stabilizing the arc.
    • Cost Effectiveness: Often more affordable than DC welding machines.
    • Versatility: Suitable for basic repairs and fabrication.

    DC Current Advantages:

    • Smoother Operation: Provides more stable arcs and smoother welds.
    • Easier for Beginners: Often easier to manage and control.
    • Directional Stability: Consistent electrode behavior.

    Disadvantages:

    • AC: Can be more difficult to control and produce less stable arcs.
    • DC: Equipment is usually more expensive.

    Best Use Case:

    6011 is predominantly used in the Shielded Metal Arc Welding (SMAW) process. Welders dealing with rusted or painted surfaces often lean towards using 6011 for its penetrating power, especially when cleaning the metal isn’t entirely feasible.

    Common Applications

    • Field Repairs: Known for effectiveness in less-than-ideal conditions.
    • Pipeline Construction: Excels in tasks demanding deep penetration.
    • Automotive Work: Handles rusted or imperfect surfaces effectively.

    The electrode’s adaptability makes it a staple in industries requiring durability and reliability.

    Tips & Best Practices

    • Setup: Ensure proper machine settings based on the electrode size and type of current.
    • Technique: Maintain a slight dragging angle for deeper penetration.
    • Maintenance: Regularly clean and inspect electrode holders for starch buildup.

    Troubleshooting:

    • Starting issues on AC: Adjust arc length and ensure connections are reliable.
    • Uneven weld bead: Review travel speed and heat settings.

    Conclusion

    Whether running 6011 on AC or DC depends on several factors, like equipment availability and specific project needs. AC is cost-effective and versatile for general repairs, whereas DC offers smoother operation suitable for detailed work. The 6011 electrode’s deep penetration and versatility make it indispensable for welding professionals and students. Understanding its advantages and applications allows for informed decisions tailored to individual project goals.

    Note for Readers: This post may contain affiliate links. If you purchase through them, we may earn a small commission at no cost to you. Thank you for supporting our site.


    Washington Alloy 6011 Stick Electrode 5LB Package (6011 3/32')
    Washington Alloy 6011 Stick Electrode 5LB Package (6011 3/32″)
    • Washington Alloy’s 6011 3/32″ Electrode
    • 60,000lbs Tensile strength
    • 5 Lb Package
    • All-position, Flux coated
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    Washington Alloy 6011 Stick Electrode 5LB Package (6011 1/8')
    Washington Alloy 6011 Stick Electrode 5LB Package (6011 1/8″)
    • Washington Alloy’s 6011 1/8″ Electrode
    • 60,000lbs Tensile strength
    • 5 Lb Package
    • All-position, Flux coated
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    Washington Alloy 6011 Stick Electrode 5LB Package (6011 5/32')
    Washington Alloy 6011 Stick Electrode 5LB Package (6011 5/32″)
    • Washington Alloy’s 6011 5/32″ Electrode
    • 60,000lbs Tensile strength
    • 5 Lb Package
    • All-position, Flux coated
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    Washington Alloy 6011 10lbs Welding Stick Electrode (6011 1/8' - 10 LBS.)
    Washington Alloy 6011 10lbs Welding Stick Electrode (6011 1/8″ – 10 LBS.)
    • AWS A5.1 CLASS E6011
    • 10 LB Package – 6011
    • Tensile Strength (psi) 60,000
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

    Washington Alloy 6011 10lbs Welding Stick Electrode (6011 5/32' - 10 LBS.)
    Washington Alloy 6011 10lbs Welding Stick Electrode (6011 5/32″ – 10 LBS.)
    • AWS A5.1 CLASS E6011
    • 10 LB Package – 6011
    • Tensile Strength (psi) 60,000
    Buy on Amazon

    Last update on 2026-06-04 / Affiliate links / Images from Amazon Product Advertising API

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