How to Choose a Stick Welding Rod: AWS Numbering, Diameter, and Position Guide

Stick welding—also known as Shielded Metal Arc Welding (SMAW)—is one of the most common welding processes used across many industries. A key component to this process is the welding rod, also known as the electrode. Choosing the right stick welding rod is essential for achieving quality welds, whether you're working with steel, stainless steel, or specialty metals.

At WeldingMart.com, we offer a wide range of high-quality stick welding rods to meet various needs and applications. In this guide, we'll cover everything you need to know about stick welding rods, including types, applications, and how to choose the right one for your project.

To browse our full selection of welding rods, check out the Welding Rods Collection at WeldingMart.

What Is a Stick Welding Rod?

A stick welding rod is a consumable metal rod coated in flux, which serves as the filler metal and protective shield during welding. When the arc melts the rod, it fills the joint with molten metal, while the flux coating forms a gas shield, preventing contamination from the air and leaving behind slag to protect the weld as it cools.

Types of Stick Welding Rods

The most commonly used stick welding rods are classified by the American Welding Society (AWS) standards, with each rod type denoted by a specific code. Here's a breakdown of some popular types:

1. E6010 Welding Rod

• Features: High penetration, deep weld pool, fast freeze.
• Applications: Ideal for root passes in pipe welding and general-purpose welding.
• Strength: 60,000 psi tensile strength.

2. E6011 Welding Rod

• Features: Similar to E6010 but suitable for AC or DC polarity; good for vertical and overhead welding.
• Applications: Used in repair work, rusted or dirty metals, and outdoor jobs.
• Strength: 60,000 psi tensile strength.

3. E6013 Welding Rod

• Features: Produces a soft arc with moderate penetration; good for clean and thin materials.
• Applications: Light fabrication, thin sheet metal, hobby welding.
• Strength: 60,000 psi tensile strength.

4. E7018 Welding Rod

• Features: Low-hydrogen electrode, smooth arc, high ductility.
• Applications: Structural steel, heavy equipment repair, pressure vessels.
• Strength: 70,000 psi tensile strength.

5. E7024 Welding Rod

• Features: High deposition rate, suitable for flat and horizontal positions.
• Applications: Heavy fabrication, thick materials.
• Strength: 70,000 psi tensile strength.

Welding Rod Selection Chart

The following chart provides an easy guide to selecting the right welding rod based on specific materials and requirements:

Rod Type	Amperage Range	Polarity	Position	Typical Applications
E6010	40-180	DC+	All positions	Root passes, pipelines, general-purpose
E6011	50-225	AC/DC	All positions	Outdoor work, dirty or rusty metals
E6013	40-150	AC/DC	All positions	Thin materials, sheet metal, general repair
E7018	90-250	DC+	All positions	Structural welding, heavy equipment
E7024	100-300	AC/DC	Flat and horizontal	Heavy fabrication, high deposition rate

You can find a variety of these electrodes in our Welding Rods Collection on WeldingMart.com.

Decoding the AWS Classification Numbers

Every stick electrode sold in the United States carries an AWS (American Welding Society) designation stamped directly on the rod coating. Reading those AWS classification numbers digit by digit tells you—before you strike a single arc—what tensile strength the weld deposit will achieve, which positions you can weld in, and what flux chemistry and polarity requirements the rod demands. The following four subsections walk through each position in the code.

What the First Two Digits Mean (Tensile Strength)

The first two digits of an AWS electrode designation represent the minimum tensile strength of the deposited weld metal, expressed in thousands of pounds per square inch (ksi). Three common strength levels cover the vast majority of stick welding applications:

• 60 (E60XX series) — 60,000 psi (60 ksi) minimum tensile strength. Rods like E6010, E6011, and E6013 fall here. Suitable for mild steel with similar yield characteristics.
• 70 (E70XX series) — 70,000 psi (70 ksi) minimum tensile strength. The widely used E7018 and E7024 belong to this group. Preferred for structural steel and load-bearing joints.
• 80 (E80XX series) — 80,000 psi (80 ksi) minimum tensile strength. Used for higher-strength low-alloy (HSLA) steels and applications requiring greater joint strength, such as certain pressure vessel and pipeline work.

The rule of thumb is straightforward: always select an electrode whose tensile rating meets or exceeds that of the base metal. Under-matching the base metal risks a weld that fails before the surrounding material does.

What the Third Digit Means (Welding Position)

The third digit in the AWS code encodes the welding positions the electrode is rated for. This single digit is one of the most practically important pieces of information on the rod, because using an electrode out of its rated position produces poor fusion and inconsistent slag behavior:

• "1" — All-position capability: flat (1G/1F), horizontal (2G/2F), vertical (3G/3F), and overhead (4G/4F). Examples: E6010, E6011, E6013, E7018.
• "2" — Flat and horizontal positions only. The larger, fluid weld pool of these rods cannot be controlled in vertical or overhead orientations. Example: E7024 (fourth digit 4 also makes it a "2" rod).
• "4" — Flat, horizontal, and vertical-down positions. These rods are formulated for fast-freeze behavior in vertical-down travel but are not intended for overhead work.

For general shop or field work where position may vary, choosing a rod with a "1" in the third position gives the most flexibility.

What the Fourth Digit Means (Coating + Polarity)

The fourth digit is the most information-dense position in the AWS code. It simultaneously identifies the flux coating type, the arc characteristics that coating produces, and the compatible power source polarity. The table below summarizes the nine standard values:

4th Digit	Coating Type	Compatible Polarity	Arc Characteristics
0	High cellulose, sodium	DCEP (DC+)	Deep penetration, fast freeze, forceful arc
1	High cellulose, potassium	AC, DCEP, DCEN	Deep penetration, AC-compatible version of "0"
2	High titania, sodium	AC, DCEN (DC−)	Medium penetration, smooth arc, easy slag removal
3	High titania, potassium	AC, DCEP, DCEN	Soft arc, low penetration, minimal spatter — beginner-friendly
4	Iron powder, titania	AC, DCEP, DCEN	Higher deposition rate than "3", flat/horizontal focus
5	Low hydrogen, sodium	DCEP (DC+)	Minimal hydrogen, crack-resistant, requires dry storage
6	Low hydrogen, potassium	AC, DCEP	Low hydrogen with AC capability, smooth bead
7	Iron powder, iron oxide	AC, DCEP, DCEN	High deposition, good for flat/horizontal production welding
8	Iron powder, low hydrogen	AC, DCEP	Low hydrogen + iron powder for efficiency; smooth, ductile weld — E7018 uses this digit

F-number suffix note: Low-hydrogen rods sometimes carry a suffix after the four-digit designation that specifies alloy content or toughness classification. For example, E7018-1 indicates enhanced impact toughness at low temperatures compared to plain E7018. E7018-A1 contains approximately 0.5% molybdenum, which increases creep resistance for elevated-temperature service. Always check the full designation—including any suffix—when ordering electrodes for code work or critical joints.

Putting It All Together — A Worked Example

Reading E7018 digit by digit using the AWS classification numbers system:

• E — "Electrode" (stick electrode for SMAW).
• 70 — Minimum 70,000 psi tensile strength in the as-welded deposit.
• 1 — All-position capability: flat, horizontal, vertical, and overhead.
• 8 — Iron powder, low-hydrogen coating; compatible with AC or DCEP. Requires heated storage (rod oven) to prevent moisture pickup.

That single four-character code tells a welder the rod delivers 70 ksi welds in any position using an iron-powder low-hydrogen coating on either AC or DC+ power — without reading a single line of the datasheet. The same decoding logic applies to every other AWS-classified stick electrode.

To put this knowledge to work right away, shop welding rods and stick electrodes across every AWS classification at WeldingMart. For background on machine setup and technique, see our complete stick welding guide, and when you're ready to upgrade your equipment, shop Lincoln stick welders for professional-grade AC and DC machines.

How to Choose the Right Stick Welding Rod

Selecting the right welding rod is essential for ensuring quality welds. Here are some critical factors to consider:

1. Identify Your Base Metal

• Steel: For carbon steel, E6010, E6011, E6013, and E7018 are popular choices.
• Stainless Steel: E308L and E309L rods are best suited for stainless steel applications.
• Cast Iron: Specialty electrodes, like E312 or nickel-based rods, are required for cast iron.

Determine whether you are welding mild steel, high-strength steel, stainless steel, cast iron, or aluminum. The base metal dictates which electrode alloy is compatible. Most stick welding applications involve mild steel, which pairs with the widely available E6010, E6011, E6013, and E7018 electrodes. Stainless steel requires a 308, 309, or 316 series rod; cast iron calls for a nickel-based electrode.

2. Determine Your Joint Position

• All Position: For versatile applications in flat, horizontal, vertical, and overhead positions, use E6010, E6011, or E7018.
• Flat and Horizontal Only: E7024 and E6013 rods are optimal for flat and horizontal welds.

Identify the welding position: flat (1G/1F), horizontal (2G/2F), vertical (3G/3F), or overhead (4G/4F). Not all electrodes run in all positions — the third digit of the AWS electrode designation encodes positional capability. A "1" (as in E7018) means all-position; a "2" means flat and horizontal only.

3. Match Tensile Strength to the Base Metal

Read the first two digits of the AWS electrode number — they indicate the weld deposit's minimum tensile strength in thousands of pounds per square inch (ksi). E60XX electrodes deposit 60,000 psi tensile; E70XX deposit 70,000 psi. Always meet or exceed the base metal's tensile rating. Using an electrode with a lower tensile rating than the base metal creates a weak link in the joint that may fail under load before the surrounding steel does.

4. Choose Polarity Compatible with Your Machine

• Direct Current (DC): E6010 and E7018 rods perform best on DC current, typically used for structural welding.
• Alternating Current (AC): E6011 and E6013 rods are ideal for AC welders, making them suitable for home use.

Check the fourth digit of the AWS code (or the rod data sheet) for polarity. Common stick polarities are DC electrode positive (DCEP / reverse polarity), DC electrode negative (DCEN / straight polarity), and AC. E6010 requires DCEP; E6011 runs on both AC and DC; E7018 runs on DCEP or AC.

5. Select Rod Diameter to Match Material Thickness

• Thin Materials: For sheet metal or light fabrication, E6013 rods are recommended due to their moderate penetration.
• Thick Materials: Use E7018 or E7024 rods, which have higher tensile strength and better penetration for thicker materials.

As a general starting rule, rod diameter should not exceed the thickness of the base metal — for example, use a 1/8 in (3.2 mm) rod on metal that is at least 1/8 in thick. Thinner metal requires smaller-diameter rods (3/32 in or 5/64 in) to avoid burn-through.

6. Pick a Coating Type Suited to Your Conditions

The electrode coating controls arc stability, penetration depth, slag behavior, and moisture resistance. Low-hydrogen coatings (E7018) minimize hydrogen-induced cracking and are the standard for structural and code-quality work. Cellulosic coatings (E6010, E6011) produce a forceful, deep-penetrating arc well-suited to root passes and contaminated surfaces. Rutile coatings (E6013) run smoothly on clean, thin sheet metal with minimal operator skill required. Iron-powder coatings (E7024) boost deposition efficiency for high-volume flat welding. Match the coating type to your application, joint cleanliness, and working environment for the best results.

7. Verify Storage and Re-drying Requirements

Low-hydrogen electrodes (E7018 and similar) absorb atmospheric moisture quickly — even a few hours of exposure can raise diffusible hydrogen to levels that cause underbead cracking. Follow manufacturer guidance: typically a heated rod oven held at 250–300°F (121–149°C) for in-use storage, with longer re-drying cycles (up to one hour at 700–800°F / 371–427°C) if rods have been left out. Cellulosic rods (E6010) are moisture-tolerant by design and do not require oven storage, though a dry environment still extends shelf life.

Stick Welding Techniques for Different Rods

Each rod type requires specific techniques to achieve optimal results:

• E6010: Known for its deep penetration, E6010 requires a whipping motion to control the weld pool and maintain arc stability.
• E6011: Similar to E6010, but easier to use on AC; ideal for situations where quick freeze is necessary.
• E7018: Requires a slight drag technique for smooth, low-spatter welds. Important to store in a dry environment due to its low-hydrogen coating.
• E6013: Easy to use for beginners; works well with a straight drag motion on thin materials.

How to Store Stick Welding Rods

Proper storage of welding rods is critical for maintaining their performance and preventing issues such as moisture absorption or cracking. Here are some tips:

1. Low-Hydrogen Electrodes (e.g., E7018): Store in a rod oven to keep moisture out, as these rods are prone to hydrogen cracking.
2. General-Purpose Rods (e.g., E6010, E6011): Store in a dry, climate-controlled environment to avoid rust and moisture absorption.
3. Specialty Rods: Refer to the manufacturer's guidelines for proper storage conditions.

FAQs on Stick Welding Rods

Q: What is the most versatile stick welding rod?

A: The E6011 and E7018 rods are among the most versatile, with E6011 working well on both AC and DC and E7018 offering a high-strength, low-spatter weld.

Q: Can I use E7018 on a home welder?

A: Yes, E7018 is compatible with home welders that have DC capabilities, making it a popular choice for home projects requiring a stronger weld.

Q: What rod is best for rusty or painted metal?

A: E6011 is ideal for dirty, rusty, or painted metals due to its deep penetration and ability to cut through contaminants.

Stick Welding Rods Available at WeldingMart.com

At WeldingMart.com, we carry a broad selection of stick welding rods suited to various applications, from general-purpose rods to specialty alloys. Browse our Welding Rods Collection for high-quality electrodes that meet industry standards and provide reliable performance.

Whether you're a professional welder or a hobbyist, having the right welding rod can make a significant difference in your work quality and efficiency. Our customer service team is available to help you choose the best products for your specific needs.

Conclusion

Choosing the right stick welding rod is essential to achieving strong, clean welds suited to your project's requirements. By understanding the different types, applications, and storage needs, you'll be well-equipped to tackle any welding task with confidence. From general-purpose rods like E6010 and E7018 to specialized rods for stainless steel and cast iron, WeldingMart has the electrodes and equipment to help you work effectively and safely.

Visit WeldingMart.com to explore our full range of welding rods and accessories. For more information on specific products, don't hesitate to reach out to our knowledgeable team or check out our Welding Rods Collection to find the ideal rod for your next project.