Filler Rod / Electrode Selection Guide
Filler rod and stick electrode selection by base metal — 6010 / 6011 / 6013 / 7014 / 7018 / 7024 / 11018 stick, ER70S-2 / ER70S-6 / ER80S-D2 MIG, ER308L / ER309L / ER316L stainless, 4043 / 5356 aluminum.
Reference
Pick filler that matches or slightly over-matches the strength of the base metal. AWS classification: the first 2-3 digits = tensile strength in ksi (E6010 = 60 ksi minimum; E7018 = 70 ksi). Stainless and aluminum use compositional codes (308L, 4043). For dissimilar metals, use the higher-alloy filler — e.g. join 304 to mild steel with 309L.
SMAW (stick) — mild / low-alloy steel decoder
| Code | Tensile | Position | Coating / type | Polarity | Use case |
|---|---|---|---|---|---|
| E6010 | 60 ksi | All | High cellulose, sodium | DCEP only | Pipe, structural; deep digging arc, fast freeze; needs clean / minimal cleaning. The pipeliner's electrode. |
| E6011 | 60 ksi | All | High cellulose, potassium | AC / DCEP | Same as 6010 but runs on AC; rusty / dirty steel tolerant. Farm welding. |
| E6012 | 60 ksi | All | High titania, sodium | DCEN / AC | Smooth bead, sheet metal, light penetration. Cosmetic work. |
| E6013 | 60 ksi | All | High titania, potassium | AC / DC± | Beginner-friendly all-position. Very smooth bead. Light gauge. |
| E7014 | 70 ksi | All | Iron-powder titania | AC / DC± | Iron powder = higher deposition than 6013. Production light/medium fab. |
| E7016 | 70 ksi | All | Low-hydrogen, potassium | AC / DCEP | Lo-hi like 7018 but runs better on AC machines. Older code. |
| E7018 | 70 ksi | All | Low-hydrogen, iron-powder | AC / DCEP | Structural / pressure piping default. Tough, ductile, crack-resistant. Must keep dry (rod oven). |
| E7024 | 70 ksi | Flat / horiz only | Iron-powder titania (≥50% Fe) | AC / DC± | Maximum deposition (drag rod). Heavy fillet welds in flat position only. |
| E7028 | 70 ksi | Flat / horiz only | Low-hydrogen iron-powder | AC / DCEP | Lo-hi version of 7024. Pressure work needing drag-style bead. |
| E11018-M | 110 ksi | All | Low-hydrogen, alloy | DCEP | High-strength alloy structural — bridges, military. Requires preheat. |
| E12018-M | 120 ksi | All | Low-hydrogen, alloy | DCEP | Highest standard alloy electrode. |
| ENi-1, ENi-CI | Ni base | All | Cast iron repair | AC / DCEP | Cast iron / nodular. Slow cool / peen each pass. Spec ENiFe-CI for ductile iron. |
SMAW — code suffix decoder
- E6010 — first digit
- "6" = 60 ksi minimum tensile.
- E6010 — second digit
- "1" = all positions. "2" = flat + horizontal only. "4" = flat / overhead / vertical-DOWN.
- E6010 — third digit
- Coating + polarity code: 0 = high cellulose / DCEP. 8 = low-hydrogen / DCEP. 4 = iron-powder / AC.
- Suffix -H4 / -H8
- "H4" = ≤4 mL hydrogen per 100 g weld (lowest). H8 = ≤8 mL. Critical for high-strength alloys.
- Suffix -R
- Resistant to moisture pickup. E7018-R can be exposed to humidity longer than plain E7018.
- -1 suffix (E7018-1)
- Improved low-temperature impact toughness for cold-service applications.
GMAW (MIG) wire — mild / low-alloy steel
| Code | Tensile | Composition | Best for | Notes |
|---|---|---|---|---|
| ER70S-2 | 70 ksi | Triple-deoxidized (Si/Mn/Ti/Zr/Al) | Sheet, root pass, dirty steel | Most "forgiving" wire — handles rust / mill scale better than S-6. |
| ER70S-3 | 70 ksi | Si / Mn | General fab | Mid-grade; cleaner than S-2. |
| ER70S-6 | 70 ksi | Higher Si / Mn | Production, painted / clean steel | Most popular in shops. Best mechanicals on clean steel. |
| ER70S-7 | 70 ksi | Higher Mn | Higher tensile applications | Less common; specialty. |
| ER80S-D2 | 80 ksi | Mo alloyed | Pressure piping, pipelines | Cr-Mo class. Higher heat resistance. |
| E70C-6M | 70 ksi | Metal-cored (composite) | Production high-deposition | Sheath + metallic powder; smooth fillets, high travel speed. |
GMAW (MIG) wire — stainless steel
| Code | Composition | Use | Match for base |
|---|---|---|---|
| ER308L | 20Cr-10Ni-low C | Standard 304 / 304L work | 304, 304L, 305 |
| ER309L | 24Cr-13Ni-low C | Dissimilar (SS to mild steel) + 309 base | 309, 309S, dissimilar joints |
| ER316L | 18Cr-12Ni-2Mo-low C | Marine / chemical / acid environment | 316, 316L, 317 |
| ER347 | 20Cr-10Ni-Nb | High-temp service to ~1500°F | 321, 347, 348 |
| ER2209 | Duplex (22Cr-9Ni-3Mo-N) | Duplex stainless | 2205, 2304, similar duplex |
| ER410 | 12Cr martensitic | Tool steel surfaces, cutlery | 410, 416, 420 |
| ER630 | 17Cr-4Ni-Cu (PH) | 17-4 PH stainless | 17-4 PH (UNS S17400) |
GMAW / TIG — aluminum filler
| Code | Composition | Best for | Notes |
|---|---|---|---|
| ER1100 | 99% Al | Pure aluminum (1100, 1350) | Soft; food / electrical conductor work. |
| ER4043 | 5% Si | 6061, 6063 castings, dissimilar | Most common. Smooth bead, less crack-sensitive than 5356. Slightly darker color. |
| ER4047 | 12% Si | 6061 high-temp / brazed joints | Best fluidity; sluggish puddle. |
| ER5183 | 4.7% Mg | 5083, 5086 (marine) | Higher tensile than 5356; matches marine alloys. |
| ER5356 | 5% Mg | 5052, 5083, 6061-T6 (when strength matters) | Stronger weld than 4043; brighter color match. Slightly more crack-prone. |
| ER5554 | 2.7% Mg | 5454 (elevated temperature service) | For wheels / parts running >150°F continuous. |
| ER5556 | 5% Mg + Mn / Ti | 5083, 5086, 5456 high-strength | Highest-strength Al filler; for armor / military. |
Aluminum — quick filler chooser
- 6061 → 6061
- 4043 (general) or 5356 (when strength matters and color match acceptable).
- 6061 → cast aluminum
- 4043 — better for castings, less hot crack risk.
- 5052, 5083, 5086
- 5356 (general) or 5183 (marine).
- 6061 → 5052
- 5356.
- 3003, 3004
- 4043 or 4047 (more silicon = better flow on castings).
- 7075 — DO NOT WELD
- 7075 cannot be reliably welded — matrix re-precipitation destroys T6 strength even with post-heat-treatment.
GTAW (TIG) filler — same wires, different lengths
- TIG filler is the same alloy as MIG wire, sold as 36-inch straight rods. Common diameters: 1/16", 3/32", 1/8", 5/32".
- For TIG steel: ER70S-2 is preferred over ER70S-6 because its triple-deoxidized chemistry handles slight contamination and gives a smoother puddle on TIG heat input.
- For TIG stainless: ER308L / ER316L same as MIG (low-carbon for corrosion resistance).
- For TIG aluminum: same 4043 / 5356 cut to 36" rods.
- Match diameter to amperage: rule of thumb = filler Ø ≈ amperage / 100. 100 A = 1/16" rod. 200 A = 1/8" rod.
- Cap the open end of an opened rod tube to keep oil / dust off — contaminated rod = porosity.
FCAW — flux-core wire codes
| Code | Type | Position | Use |
|---|---|---|---|
| E71T-1 | Dual-shield (gas) | All | Production fillet / structural; smooth bead; rutile slag. Workhorse code. |
| E71T-1C / -1M | Dual-shield | All | C = CO2 only · M = mixed gas (75/25 or other Ar/CO2). |
| E71T-8 | Self-shield (gasless) | All | Outdoor / wind. Heavier slag; somewhat more spatter than dual-shield. |
| E71T-11 | Self-shield | All | Hobby / field-repair gasless. Single-pass typical; larger heat-affected zone. |
| E71T-GS | Self-shield, no gas | All | Sheet metal hobby wire. Small spool sizes (4 lb). |
| E70T-1 | Dual-shield | Flat / horiz only | Heavy fillet, plate / structural. Higher deposition than E71T-1. |
| E308LT-1 | Dual-shield stainless | All | Stainless production fillet. 75% Ar / 25% CO2 typical. |
Polarity quick reference
- E6010 / E6011
- DCEP (DC+) — REQUIRED. (6011 also runs AC.)
- E6013
- AC, DCEN, or DCEP — flexible.
- E7014
- AC or DC± — flexible.
- E7018 / 7028
- DCEP or AC. NEVER DCEN — base metal not heated enough.
- E7024
- AC or DC±.
- GMAW (MIG)
- DCEP for solid wire (almost universal). DCEN for some self-shielded flux core.
- FCAW dual-shield
- DCEP (most). Check spool label.
- FCAW self-shield
- DCEN — opposite of solid wire. Many rookies miss this.
- GTAW (TIG) steel/SS
- DCEN.
- GTAW (TIG) aluminum
- AC (square-wave preferred).
Storage & handling
| Electrode | Storage | Re-bake spec |
|---|---|---|
| E6010 / 6011 / 6013 | Dry shop air; sealed tube ideal | Don't bake — moisture is part of the cellulose coating |
| E7018, 7028, 11018, 12018 (low-hydrogen) | Heated rod oven 250-300°F (120-150°C) at all times | Re-bake at 500-700°F (260-370°C) for 1 hour if exposed > 4 hours to humid air |
| Stainless (308L etc.) | Sealed container, dry shop | Re-bake at 500°F for 1 hour if rusty stains |
| MIG / TIG wire spools | Cap unused spools; store dry | Discard if surface rust or pitting visible |
| Aluminum filler | Sealed tube; capped end | Re-clean with stainless brush before use; never use rod with white "powder" oxide bloom |
Dissimilar metals — quick chart
| Joint | Recommended filler | Notes |
|---|---|---|
| Mild steel ↔ 304 / 316 stainless | ER309L | Highest single-filler choice; controls dilution / carbon migration. |
| Mild steel ↔ cast iron | ENi-CI / ENiFe-CI / 309L (if low duty) | Slow cool, peen between passes. Pre-heat 500-700°F. |
| Stainless 304 ↔ 316 | ER316L | Match higher Mo alloy. |
| Stainless ↔ duplex 2205 | ER2209 | Match duplex. |
| Aluminum 6061 ↔ 5052 | ER5356 | Mg-bearing filler — bridges both alloys. |
| Galvanized steel ↔ mild steel | ER70S-6 (after grinding zinc off 1" each side) | Zinc fumes are toxic — full ventilation / respirator. |
| Cast iron ↔ cast iron | ENi-CI (MIG nickel) | Pre-heat critical; peen each pass; blanket cool. |
Notes
- Codes per AWS A5.1 (carbon steel SMAW), A5.5 (low-alloy SMAW), A5.18 (carbon steel GMAW), A5.4 (stainless SMAW), A5.10 (aluminum), A5.20 (FCAW carbon steel).
- For pressure / structural / code work, the WPS (Welding Procedure Specification) supersedes any general guideline. Always work to the WPS on certified projects.
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