How to choose the right welding electrode: AWS codes, grades, and applications explained

Introduction: Why using the wrong electrode causes weld failure

Walk through any fabrication shop in India and you will often find one type of electrode being used for everything — usually E6013, because it is cheap, widely available, and easy to use. This is a mistake that costs money.

Using E6013 on a structural joint that requires E7018 produces a weld with lower tensile strength, higher hydrogen content, and increased risk of cracking under load. On a job that will be inspected or that carries safety implications — pressure vessels, lifting equipment, structural steel — this is not acceptable.

Electrode selection is not complicated once you understand the AWS classification system. This guide explains it clearly and maps it to the G Weld range available from Imperiea Engineering.

Understanding AWS electrode classification codes

AWS (American Welding Society) electrode codes are the standard classification system used globally, including for most industrial welding in India. The code tells you exactly what the electrode is designed to do.

Breaking down E6013

E	Electrode — confirms this is a stick welding electrode
60	Minimum tensile strength of the weld metal: 60,000 psi (approximately 414 MPa)
1	Welding position: 1 = all positions (flat, horizontal, vertical, overhead)
3	Coating type and current: 3 = high titania potassium, works on AC or DC, easy arc striking, light penetration

Breaking down E7018

E	Electrode
70	Minimum tensile strength: 70,000 psi (approximately 483 MPa)
1	All positions
8	Low hydrogen iron powder coating, AC or DC+, requires dry storage, deep penetration

The difference between E6013 and E7018 is significant: E7018 produces a stronger weld (70 ksi vs 60 ksi), with much lower hydrogen content that dramatically reduces the risk of hydrogen-induced cracking in high-strength or restrained joints.

Common AWS electrode classifications in the G Weld range

G Weld E6013	General purpose, all positions, AC/DC. Easy to use, smooth bead, minimal spatter. For light to medium structural work, sheet metal, general fabrication.
G Weld E7018	Low hydrogen, high strength, all positions. For structural steel, heavy fabrication, code-quality welds, high-restraint joints. Must be kept dry.
G Weld E7016	Low hydrogen, similar to E7018 but works on AC. Useful where only AC machines are available.
G Weld E308L-16	Stainless steel electrode for AISI 304 and 308 grade SS. Low carbon for corrosion resistance. Food grade and chemical equipment.
G Weld E316L-16	Stainless steel electrode for AISI 316 grade SS. Molybdenum-bearing for higher corrosion resistance in chloride environments.
G Weld EFe-Mn	Hard facing electrode. Used for wear-resistant overlay on crusher jaws, bucket teeth, digging tools, and other abrasion-exposed surfaces.
G Weld ENiCI	Nickel electrode for cast iron welding and repair. Cold weld process to avoid cracking.

Electrode selection by base metal

Mild steel (most common application)

For general fabrication, light structures, and non-critical joints: G Weld E6013

For structural steel, heavy fabrication, code-quality welds, high-strength joints: G Weld E7018

The rule of thumb: if the joint is load-bearing, subject to inspection, or part of a structure with safety implications — use E7018.

Stainless steel

Match the electrode grade to the base metal grade:

• SS 304 / SS 308: G Weld E308L-16
• SS 316 / SS 316L: G Weld E316L-16
• SS 309 (dissimilar joints, SS to mild steel): G Weld E309L-16

Always use low-carbon grades (L suffix) for stainless steel to prevent intergranular corrosion.

Cast iron

Cast iron cannot be welded with standard steel electrodes — it will crack. Use G Weld ENiCI nickel electrodes with the cold welding technique: short runs, immediate peening, controlled inter-pass temperature.

Hard facing (wear-resistant overlay)

For crusher jaws, bucket teeth, dredge equipment, and any surface subject to severe abrasion: G Weld EFe-Mn. Apply in 1–2 layers maximum; multiple layers increase cracking risk.

Electrode selection by welding position

All positions (1G, 2G, 3G, 4G)	G Weld E6013, E7018, E7016, E308L-16
Flat and horizontal only (2G)	Any electrode — no special constraint
Vertical up	G Weld E7018 (preferred for strength) or E6013
Overhead	G Weld E6013 or E7016 — E7018 possible with skilled operators

Electrode diameter selection by base metal thickness

1.5–3mm	2.0mm or 2.5mm electrode
3–6mm	2.5mm or 3.2mm electrode
6–12mm	3.2mm or 4.0mm electrode
12–25mm	4.0mm electrode, multiple passes
25mm+	4.0mm or 5.0mm electrode, multi-pass technique

Storage and handling: how moisture damages electrodes

Low-hydrogen electrodes like E7018 are hygroscopic — they absorb moisture from the air. Moisture in the electrode coating breaks down into hydrogen during welding, which dissolves into the weld metal and causes hydrogen-induced cracking (HIC) — a serious defect that can be invisible to the eye but catastrophic under load.

• Store E7018 and other low-hydrogen electrodes in sealed, dry containers or electrode ovens at 120–150°C
• Once opened, use within 8 hours or return to the oven
• Never use electrodes that have been wet — baking at 350°C for 2 hours can sometimes recover them, but prevention is better
• E6013 is less sensitive but should still be stored in a dry environment

Do not store electrodes in a cardboard box on the shop floor. Moisture absorption takes only hours in a humid Indian monsoon environment and can ruin an entire batch of E7018.

Download the G Weld electrode selection chart and datasheet from Imperiea Engineering. Contact us for bulk electrode supply across Maharashtra.