Electrodes are one of the main components of the welding process. The electrode delivers electricity to form the arc and provide filler metal. Poor and fake electrodes may be uneven or have a powdery appearance. Consumable or non-consumable are broad categories of welding electrodes. Authentic electrodes will not have cracks, lumps, or lifted coating. It is worth considering the price of an electrode; if the price is much lower than the market value suggested retail price, it is possible that the electrode is fake. The best method to avoid a fake welding rod is to verify the source from which you procure these products.
In this article, we will know how to identify fake or substandard welding electrodes, the importance of their use, and their high-quality and superior strength.
- Understanding Welding Electrodes
A welding electrode is a metal rod that conducts the current required to produce the arc that melts and combines metals. It is made up of a core wire and a flux coating. The core wire makes up the filler metal for the weld joint, while the flux coating stabilises the arc and protects the molten metal from contamination by alloying elements that it can add to the welding and the atmosphere. Electrodes are identified by codes: AWS E7018, for example, shows electrodes tensile strength, welding position, flux type and current. Selecting the appropriate electrode is vital to ensuring weld quality and identical properties to the base metal with no defects.
- Look for Authentic Labeling and Markings
For all welders, authentic labeling and marking on the welding electrode are essential for project integrity and safety. The electrode manufactured by a reputable manufacturer has visible, permanent, and consistent markings on the flux coating that permanently mark the electrodes. Marking should include the all-important AWS classification, like E7018, which contains the electrode’s mechanical properties and intended purpose. In addition, the chemistry of the electrode composition leads to similar chemistry in the weld metals. For safety, an authentic electrode will be delivered in a sealed box, correctly labeled and bearing all information, including the brand name, batch numbers, manufacture date, and quality standard.
- Check the Packaging for Moisture Protection
For Welding rods, particularly low-hydrogen electrodes such as E7018, check the packaging for moisture protection. Good rods come in sealed tins, often vacuum packed plastic bags with desiccant packs included. This serves to protect the hygroscopic flux coating from deterioration by moisture in the atmosphere.
Stay away from cracked torn or loose packages. Damaged packaging allows humidity to get in, making the flux absorb water. This in turn results in the weld being cracked by hydrogen, and a resulting porous and weak poorly welded joint which can lead to catastrophic failure under stress. Always inspect seals before use.
- Inspect the Electrode for Physical Defects
A close look doesn’t reveal any substantial blemishes. The electrode face is smooth and not cracked, chipped or pitted. The conductive coating 14 is free of determination and other visible wear. The connector pin is straight and clean with no corrosion or deformation. Here is the insulation sleeve; it remains unharmed, no breaks or melting or adage brittleness. No remains or foreign material are stuck on the live face. The electrode in general looks to be all around great physical condition and everything looks as though it is structurally sound.
- Testing the Welding Performance
The welding capabilities of an electrode will be documented to ensure that it will have the expected performance characteristics that meet established operational limits. Like, within the inspection criteria, include establishing arc stability; it should be smooth, consistent, and easy to control to ensure a uniform bead and minimize the overlap in a weaving pattern.
Slag coverage and slag easy removability: it should ensure a clean weld and operate with limited spatter and easy clean up.
Observing the weld metal for soundness: which could include visual inspection for defects such as porosity or cracking, and other common inspection methods.
- Perform a Mechanical Properties Test
Welding electrodes have very strong and extensive testing of mechanical properties to ensure a sound, consistent, reliable weld that meets the requirements. The main test performed was the tensile strength, which provides us with an indication of the level of stress at which we will have permanent deformation. We also perform an impact toughness test to evaluate how a weld will perform at low temperatures or how much energy the weld can absorb prior to fracture.
- Buy from Trusted Suppliers
High quality consistent welds result from starting with the right welding electrodes. Reputable suppliers sell material with full certifications (AW classification etc) and stored in climate control environments where the material will not absorb moisture. This ensures the chemical composition and flux coating of your electrode are not depleted which affect welding properties, including arc stability, penetration, bead shape and slag coverage. Cutting corners with uncertified or improperly stored electrodes from questionable sources can lead to defects such as porosity, cracking and insufficient strength and a weldment is only as sound as its weakest link. Purchasing your consumables from reliable suppliers – Lead centre sourcing – increases the reliability and minimizes rework, as well as simply just being good professional welding practice.
Conclusion
Fake or Substandard welding electrodes must be picked up carefully. Carefully inspect the wrapper for bad printing and lack of certs. Check cracks or rough surface finish. Beware of the super cheap, always buy from an authorized dealer who will back up your purchase but not premium for name only on availability and price.