What to do if the electrode sticks - Metals and their processing

Why does the electrode stick and how to avoid it | Electric welding

It is always exciting for a novice welder to start practicing. And when the electrode begins to stick to the surface, it can be completely disappointing and discourage learning. Why does this happen and what can be done?

Reasons for electrode sticking

Among the factors affecting welding quality, there are many reasons why a coated electrode can stick to the parts being welded, preventing the job from being completed. The most common are:

general voltage drop in the network;
incorrect cross-section of ground and holder cables;
incorrectly selected current parameters on the device itself or the resistance;
electrodes that have absorbed moisture due to improper storage;
incorrect angle of inclination relative to the parts being welded;
polarity that does not comply with the recommendations on the packaging;
the diameter of the electrodes is too large for the given thickness of the parts;
contaminated surface.

What can be done to solve the problem

It is necessary to look for the cause in each specific case by eliminating options. It may turn out that several factors contribute to electrode adhesion. For example, by testing the voltage in the network with the device, you can make sure that the line is not overloaded. Otherwise, you need to wait until full power supply is restored, and if the situation repeats frequently, install a stabilizer.

It is worth making sure that the ground cable and holder have the correct cross-section. Wires that are too thin will create excess resistance and reduce current flow, which will promote electrode sticking:

for welding at 100-160 A, a 16-core copper cable with an outer diameter of 11.5 mm is suitable;
To prevent the electrode from sticking when working on thicker metal, at a current of 240-300 A, you will need a 25-core cable with a 13.5 mm outer diameter.

Each metal thickness has recommended current settings. For example, for 3 mm plates you should set 100-120 A. If this value is less, the tip of the electrode will inevitably begin to stick. Those who use a regular transformer without adjustment, with a steel spring as resistance, need to move the cable connection to such a level that the current does not burn through the metal when welding.

The coating of the electrodes is capable of absorbing moisture from the surrounding air, so even a new pack from the store, if it was stored incorrectly and with damaged packaging, may perform poorly. Pre-drying at a temperature of 170 degrees is recommended here.

When making vertical welds, some novice welders hold the electrode at a very shallow angle relative to the underside of the surface. This leads to slag rolling onto its tip and arc extinction with sticking.

It is worth positioning the electrode at 45 degrees. The polarity indicated on the packaging helps ensure proper current flow and distribution of filler materials.

Incorrect connection of wires will lead to incorrect operation, so you need to check the recommendations and actual compliance.

The diameter of the electrodes must often match the thickness of the plates being welded. When performing work with a 5-piece on 2 mm iron at a current of 70A, sticking is inevitable. The electrode should be replaced with 3 mm. A thick layer of rust also affects arc performance. A quick clean with a metal brush will correct the situation.

Additional recommendations

Most often, the electrode can stick during ignition, which leads to painful twisting of the holder and crumbling coating. To avoid this at this stage, it is necessary to have a rough plate applied to the mass, on which you can test the current parameters and ignite the electrode. Holding the arc briefly on this object will allow for quick drying and ensure trouble-free continuation of welding on the base metal.

Another recommendation is to ignite the electrode not by tapping, but by striking. Direct impact of the rod on the metal promotes instant contact and adhesion, and tangential movement will initiate an arc.

If you still have any questions about this topic, write them in the comments, and I will try to clarify everything for you.

Also write if you liked this article and what you think about it.

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Source: http://www.elektrosvarka-blog.ru/prilipaet-elektrod/

If the electrode sticks when welding

Sometimes, when trying to strike an arc, the electrode sticks to the metal. The question is, why? First of all, this is explained by the excess moisture content in the electrode coating; low quality of the material from which the electrode rod and its coating are made; and finally, incorrectly selected current or other welding parameters.

Electrodes should be stored in a dry, warm place, in plastic bags. Remember, raw electrodes or electrodes with mechanical damage cannot provide a quality connection. Such seams are subject to increased corrosion, have a porous structure and can produce microcracks. This directly affects the durability of the welded product.

Welding electrode , by definition, is a rod, not necessarily metal, through which welding current is transmitted to the parts being welded during manual arc welding. The goal of this process is to create a seamless connection between the parts.

Purpose of welding electrodes:

supply current to the workpiece being welded;
fill the welding seam with metal (in the case of consumable electrodes);
prevent oxidation and nitriding of the seam, that is, by melting its own coating, create a gas environment to protect the electric arc zone from contact with air.

It should be noted that coating also has its purpose. It can be based on gas-forming components that displace air during combustion; on alloying – influence the composition of the fused metal; on stabilizing and slag-forming agents.

Welding electrodes are classified as follows:

metal , they can be consumable, made of structural steel, and non-consumable, made of heat-resistant metals.
non-metallic , the cores of such electrodes can be carbon or graphite. Welding with carbon and graphite electrodes is carried out only with direct current of straight polarity.

Non-consumable electrodes are made from tungsten as the main component and additives of other metals and additives.

Consumable electrodes , in turn, are divided into coated ones; protective coating is used in the production of electrodes; and uncovered, without coating.

Uncoated electrodes can be presented in the form of solid wire, used in automatic and semi-automatic systems, where a separately supplied gas is used to protect the welding arc zone.

Coated electrodes are widely used, are produced individually and can be made of steel, stainless steel, cast iron, copper, aluminum and other non-ferrous metals.

For example, consider electrodes for welding copper and alloys based on it - bronze, brass. They are made from technical copper, about 95%. The peculiarity of this metal is to strongly absorb hydrogen, as a result of which molecular water appears in the crater zone. To prevent this from happening, the electrodes are pre-calcined, the welding process is carried out in a shielding gas environment, and the products themselves are heated to 400°C.

Copper electrodes for welding can be alloyed with phosphorus, and the composition of their coating is determined by iron-manganese compounds, iron-silicon compounds, fluorspar and other components.

Electrodes for aluminum welding consist of 95% Al and additives of titanium, silicon and iron. The welding technology is similar to that used when welding copper and copper alloys. It is necessary to pay attention to the high oxidability of this metal. Aluminum oxide always forms in the weld pool, so components that react with oxides are added to the coating of aluminum electrodes.

Electrodes for nickel welding are made from 92% nickel and additives of silicon, manganese, and titanium. The coating of such electrodes is basic. The welding process of nickel samples is carried out at the maximum permissible current for a specific electrode diameter. The electrodes are first calcined for 2 hours at 250°C.

Based on the type of coating, electrodes are divided into:

acidic (oxides of iron, silicon and manganese);
basic (have calcium carbonate, calcium fluoride);
cellulose (organic flour);
rutile (titanium dioxide);
mixed.

Production methods: crimping, dipping.

In the manufacture of electrodes, the main attention is paid to the coating material. Its composition may include the following components: rutile, marble powder, fluorspar, mica, compounds of manganese, titanium, silicon, etc. After proper cleaning and drying, these components enter the crusher, then in a crushed state they are transported to a vibration dryer, where they are further dried times until the moisture is completely removed.

At the same time, wire is cut into electrode rods. The wire must correspond to the parameters of the electrode for a specific purpose. If a batch of electrodes is intended for welding stainless steel, then the rods are made of the same material.

In accordance with the brand of electrodes being manufactured, the proportions of the required components are selected and transported to the mixer, where they are thoroughly mixed. Then the finished mixture is mixed with liquid glass.

The resulting mass is fed to a hydraulic coating press. The rod is placed in a special mold, into which the viscous composition of the future coating is supplied under pressure. In this way, coating is applied to the electrodes. At a certain stage of production, the thickness of the electrode coating is controlled.

After this, the electrodes enter the furnace for heat treatment. The finished electrodes are cooled and sorted according to the quality of the coating surface. They are then packed into boxes and covered with polyethylene protection.

The dipping method is significantly inferior to the method discussed above, since the coating does not spread evenly, with noticeable defects. Therefore it is used quite rarely.

Special electrodes

This category includes electrodes for special purposes, say for welding at high current, and therefore require certain impurities. Thus, tungsten thoriated electrodes consist of 98% tungsten and less than 2% thorium. The metal is radioactive, so despite its low content in the electrode, such electrodes must be handled with precautions. Such electrodes are stored only in steel, sealed boxes.

Tungsten electrodes with the addition of lanthanum oxide are an excellent replacement for thoriated electrodes, but they do not have such radioactivity. These electrodes concentrate the arc well in the desired direction and produce a high quality welded joint.

Tungsten electrodes with the addition of zirconium oxide have proven themselves to be excellent for welding with alternating current. They are used in cases where it is necessary to ensure reliable connection of parts containing aluminum, magnesium, and nickel.

Tungsten electrodes with the addition of yttrium oxide are characterized by high welding performance, good current conductivity and a narrowly directed arc. They are used in very critical structures.

How to choose and store electrodes

In order not to make a mistake with the brand of electrodes when purchasing, it is necessary to determine in advance the thickness of the parts to be welded, which assumes the permissible thickness of the welding seam; with the capabilities of your device, namely the output current and the nature of the current (DC, AC). It is important to know that the required current value directly depends on the diameter of the electrode used.

The composition of the core must be similar to the metal being welded, which means that there are electrodes designed to work on stainless steel, cast iron, high-carbon steel, alloy steel, aluminum, etc.

Having decided on the composition of the core, select the desired type and thickness of coating. The coating due to the content of calcium carbonate and magnesium carbonate is called basic. It is used for DC welding, where maximum joint quality is required, for example, for alloy steels. The seam of such compounds has low oxidizing ability.

Rutile electrodes are suitable for working on alternating and direct current, they light an arc well and do not spatter metal. The main component of these electrodes is titanium dioxide. The viability of connections made with such electrodes is much higher than that of acidic electrodes.

Electrodes with an acid coating are characterized by easy separation of slag, but it is not recommended to use them for work in enclosed spaces, as they emit a rather corrosive gas.

The main characteristic of cellulose-coated electrodes is low slag formation, but such compounds can develop cold cracks.

In general, all types of coatings provide good stability of the arc and protection of the seam from interaction with air. Rutile electrodes are considered the most popular for household work.

Source: http://themechanic.ru/prilipaet-elektrod-pri-svarke

Reasons for electrode sticking during welding

Even a highly qualified electric welder may experience a situation where the electrode sticks while welding. An experienced welder can easily solve this problem, but for beginners it is important to know the causes of sticking and be able to eliminate them.

Main causes of sticking

First of all, you should pay attention to the welding inverter. If it is of low power, it will not be able to produce enough current to weld thick parts. There are many other reasons why the electrode sticks during welding, these include:

raw electrodes;
chipped coating or its low quality;
the core material is not suitable for the metal being welded;
large voltage drops in the network can lead to low welding current or its sharp surges;
a welder with low qualifications, for fear of burning a hole, sets a very low current on the welding machine;
failure of device or inverter settings;
When connecting, the phases are reversed, welding is carried out with a current of reverse polarity. This rule does not apply when welding aluminum and its alloys;
the integrity of the welding cable may be compromised;
pay attention to the heating of the welding holder, at a very high temperature, it is necessary to connect it to the cable;
poor quality of preparatory work, parts are not cleaned of grease or rust;
the possible reason is the low qualification of the welder and the inability to maintain a normal level of electrode combustion;
The reason may be that the electrode is heavily soiled.

As you can see, the electrodes stick either due to non-compliance with the technology, or due to some defects in them themselves.

Low quality

Before you begin to eliminate electrode sticking, you need to make sure of their quality. Products produced in artisanal conditions can stick even with a perfectly selected electric welding mode.

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Counterfeits of well-known manufacturing companies are spreading on the market. Therefore, when purchasing, do not strive for cheapness; be sure to check all the documentation.

But even products from the same manufacturer may differ in different batches. Often the first batches of new brands of electrodes are of higher quality than subsequent ones.

The electrode may stick due to chipped coating. To check the quality of the coating, experienced welders advise, when purchasing, to release the electrode flat from a height of about 2 meters.

The main thing is that the landing surface is level. If the coating breaks off, it means that the electrodes are of poor quality and should not be purchased.

Damp electrodes will also stick. If humidity is high, the arc will be unstable and the welder will have to press the edge of the conductor against the base metal. This will cause sticking due to a short arc.

In this case, the quality of the welded joint is significantly reduced. The seam will become oversaturated with hydrogen, and cracks will form at the joint.

When purchasing, pay attention to the presence of a characteristic white coating on the surface of the coating. If plaque is present, it is necessary to calcine the consumables before work.

The easiest way is to short-circuit the electrode on the metal surface for a while. After inserting it into the holder, press it against the steel surface and hold for about 5 seconds. Then, by moving the holder to the side and up, tear off the electrode and begin welding the joint.

But this method leads to burning of the contacts, so it is better to use it if there is no possibility of calcination under civil conditions. For normal roasting, just place them in the oven at 150°C for 40 minutes.

Effect of current

Depending on the thickness of the part and the diameter of the electrode, it is necessary to select the normal level of welding current. If its value is insufficient, the electrode will stick to the part.

This is due to the low current for the formation of the weld pool. To weld, you have to hold the arc with a small gap from the base material, which increases the possibility of the tip of the electrode plunging into the bath and sticking. To select the correct current, you need to use tables.

The professionalism of the welder is of great importance. Theoretical knowledge in the absence of experience is a dead weight.

An inexperienced welder is very afraid of holes, so he initially sets the welding current to a low value. This leads to possible lack of penetration of the joint, and the electrode necessarily sticks to the base material.

Mains influence

If the voltage in the network is very low, this is one of the reasons why the welder’s electrode sticks, regardless of his level of skill.

Perhaps the reason lies in the small cross-section of the supply wire. It is necessary to eliminate electrical wiring deficiencies or connect to a more reliable network. Voltage stabilizers of sufficient power will help solve the problem.

If you have to connect to the network through an extension cord, make sure that the wire cross-section is at least 2.5 mm2 . If necessary, thinner wires can be used. But in this case, you will have to use thinner electrodes and reduce the welding current.

When buying welding equipment, you do not need to save money. The best option for a welding machine is one with an additional “anti-stick electrode” function. Such a convector will avoid most causes of sticking, but will not be able to completely eliminate it.

Source: https://svaring.com/welding/teorija/pochemu-prilipaet-elektrod-pri-svarke

Why does the electrode stick when welding with a resanta inverter?

Electrode sticking to a metal surface is a fairly common and inconvenient occurrence. Most often, this problem occurs with a novice welder. If the electrode is stuck, it is quite difficult to tear it off; due to the short circuit, the coating will fall off, and for a household network this can lead to an overload.

In this material we will consider the following questions: why the electrode sticks during welding, the main reasons for the occurrence of such a negative process and methods of elimination.

Causes of electrode sticking

Most often, this phenomenon occurs when using transformer welding machines, which have less precise mode settings.

Modern inverters often have an additional anti-stick feature. The principle of its operation is based on a pulsed increase in current strength while poking the electrode into the metal. As a result, the arc does not go out and a short circuit does not occur.

However, it happens that the electrode sticks when welding with inverters with an anti-stick function. This is not necessarily a defect from the device manufacturer, the reasons are simpler.

Raw electrodes

The electrode itself consists of a metal rod and coating. The coating, in turn, is made from fine powder. This coating is susceptible to atmospheric moisture. Even if the room has moderate humidity, over time the electrodes will still become damp.

Manufacturers usually additionally seal packaging with consumables in polyethylene. In such containers they can be perfectly stored for a long time. But violation of the integrity of the packaging will lead to a gradual accumulation of moisture in the coating.

Damp electrodes will constantly stick during arc ignition.

Low quality electrodes

An electrode often sticks when its type is incorrectly selected to a specific metal. To weld rough steel, stainless steel or aluminum, you need to use types of consumables designed to work with this material.

Sticking also often occurs if you use electrodes of unknown origin and dubious manufacturers. There are a lot of cheap consumables that are made from inappropriate materials. And the composition of their rods and coating may not comply with the requirements.

Incorrect machine settings

This is also a fairly common cause of sticking during arc striking. At the beginning of the welding process, you need to accurately estimate the thickness of the metal that will be welded, select the appropriate diameter of the consumable and set a certain power.

The low current does not ignite the arc, but only slightly melts the tip of the rod, which sticks to the surface.

Uncleaned metal and improper arc ignition

The contaminated surface of the parts does not facilitate proper contact of the mass holder with it, and indeed the electrode itself. When you try to light an arc, it may go out and the coating may begin to fall off. Further actions will lead to sticking of the tip of the rod.

Often, in the absence of experience, sticking occurs due to improper ignition of the arc. By tapping the tip of the rod on the workpiece, the electrode lingers on the surface for too long. A short circuit occurs, the metal at this point quickly heats up and solders the rod to the surface.

For novice welders, it is best to learn how to ignite an arc not by tapping, but by striking the consumable rod on the surface.

These are the main causes of sticking during welding. How can they be avoided?

How to eliminate electrode sticking

Eliminating the sticking phenomenon is quite simple. To do this, you need to use high-quality consumables, set the desired mode and prepare the parts before welding. And, of course, you will need a little experience in lighting an arc.

Electrode preparation

If consumables that were in sealed packaging are used in welding work, then they can be safely used. They will not stick if all other rules are followed.

If the seal is broken, after 8-10 hours, additional drying of the coating will be required.

The percentage of permissible humidity in the coating is indicated on the packaging. Of course, it is impossible to measure it in everyday conditions. But, before starting welding work, consumables that have been lying around for some time must be calcined in an oven.

To calcinate consumables, special electric furnaces are used, which allow the rods to be heated in a temperature range from 100 to 400 degrees.

To what extent it needs to be heated depends on the type. Electrodes with different markings have different heating limits.

Considering this factor, a conventional flame furnace cannot be used for calcination. The fire will not provide the desired temperature and uniform heating.

In this case, no more than three heating times are allowed. If more, then such consumables become unsuitable for work.

The electrodes must be dry before piercing!

After drying, they can be used for their intended purpose.

Hardware settings

Correctly set current strength contributes not only to the absence of sticking, but also to a high-quality welding process.

The main parameters that must be observed are indicated in the table. But these are only approximate data; more accurate ones are determined during the welding process.

Preparing and igniting the arc More experienced welders already know the capabilities of their machine and set the settings in accordance with the requirements. If you have little experience, you can adjust the mode experimentally. Starting at low power and increasing the amperage as needed.

Metal must be cleaned of various types of contamination. In the place where the mass holder will be installed, you need to do a thorough cleaning (especially remove paint and a layer of rust).

To avoid sticking, you need to ignite the arc correctly. To do this, the tip of the rod is tapped on the metal or struck. When the arc flares up, it is necessary to ensure its required length. Typically this figure is 1-1.5 times the diameter of the consumable. If this process is done slowly, the electrode will stick.

It is better for a novice welder to train this skill by striking. Technologically, this process is similar to lighting a match; the end of the rod is drawn smoothly across the surface of the part.

After this, you need to draw the seam in the required direction.

By following all these rules, you will be able to bypass the phenomenon of electrode sticking to the metal.

If you have experience on this topic, share it in the discussions for this material.

Electrodes during electric welding often stick to the metal, this problem is especially common among novice welders. When the electrode sticks to the surface being welded, it is almost impossible to quickly remove it, which leads to many problems and can result in overloading household electrical networks. In this article we will tell you why the electrode sticks when welding, look at the main mistakes made by beginners, and tell you how to prevent the electrode from sticking.

Electrode sticking: causes of the problem

Most often, this problem is encountered by welders who use transformers in their work without the ability to fine-tune the operating mode, or by beginners who use inverters. Expensive models of modern inverter devices have a function that prevents the electrode from sticking. But novice welders often purchase budget models and, due to lack of experience, immediately encounter sticking.

So, why does the electrode stick when welding with an inverter? Below we describe the main reasons.

Reason No. 1: Increased humidity of the electrode

The electrode surface is a special coating that is susceptible to the accumulation of moisture from the environment. If the electrodes are left without packaging, then over time they become damp and lose their quality characteristics, which subsequently leads to sticking.

Reason No. 2: Poor quality of electrodes

First of all, the correct choice of electrode for welding with an inverter is important. Many novice welders save on consumables by buying them from unknown artisanal manufacturers who are unable to confirm the quality of their products. Such electrodes have only one advantage - low price, but otherwise they only complicate the welder’s work. It is low-quality electrodes that can cause them to stick to the metal.

Source: https://kartinki-kletochki.ru/pochemu-zalipaet-jelektrod-pri-svarke-invertorom/

The electrode sticks during welding: we understand the reasons and what to do

Reasons for sticking electrodes

Experts, when answering the question of why the electrode sticks, distinguish three categories:

Problems with consumables.
Incorrect initial setup of the device used and instability of the electrical network;
Low user qualifications.

The first category includes the following reasons:

the consumable was stored in conditions of high humidity, which led to the accumulation of excess moisture;
mechanical damage to the coating of the rod;
incorrect choice of type for the work being carried out (correspondence of its brand to the product being welded);
increased pollution.

The second category combines the following set of reasons:

changes in the supplied voltage (the result is a change in the parameters of the welding current: its reduced value or a sharp change);
incorrect connection of contacts;
failure of the device’s initial settings;
violation of the integrity of the cable (break, damage to the braid);
Initially, the welding machine is not configured correctly.

Subjective reasons include:

low qualification of the employee (incorrect determination of current parameters);
failure to comply with the heating mode of the welding holder;
there is no experience in maintaining a stable level of arc combustion;
bad operation with the inverter.

The variety of reasons why consumables stick to metal requires careful preparation. Any reason can lead to a number of negative consequences. Electrode sticking occurs at the stage of formation of the welding arc, during welding. Any welding method can lead to sticking, including inverter welding. Despite the fact that modern units of this type provide a so-called anti-stick function, the sticking effect still appears.

Increased humidity of the electrode

The composition of the so-called coating has a porous structure consisting of fine powder. The appearance of adhesion depends on its quality. It tends to gradually accumulate moisture, even when placed in a room with natural humidity. Using consumables without first drying them leads to negative consequences. During operation, the electrode sticks when welding with an inverter. This effect is especially evident at the moment when the arc is ignited.

The adhesion can be so strong that it leads to the destruction of the consumable and deformation of the joint of the welded part. To eliminate this problem, professionals recommend using special techniques to remove excess moisture. It is advisable to store open bags with consumables left over from previous welding in a special thermal case. Before use, they must be placed in a drying cabinet.

Before welding, check the adhesion of the electrode tip to a third-party surface.

What are the best electrodes for welding with an inverter, why does the electrode stick?

It's like a person having a headache. To cure it, you need to deal with the real cause of the disease. And there are a lot of possible reasons. So it is with the sticking of electrodes during welding. What happened and why the electrode sticks - this question may arise not only for beginners, but also for quite experienced craftsmen.

Reasons for electrode sticking during inverter welding

Let's try to separate the reasons that we cannot influence:

Low or uneven mains voltage, which results in too low welding current.

Reasons we can change:

high humidity of the coating and tips due to improper storage of hygroscopic electrodes;
low quality of electrodes and their coating;
incorrect choice of electrode for welding specific metals or alloys;
incorrect inverter settings;
incorrect polarity of the welding current;
break or broken contact of the holder;
poor quality cleaning of the surfaces of welded parts
dirty electrode;
incompetence .

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As you can see, for one circumstance beyond your control, there are nine factors that you can work with in order to get rid of the unpleasant welding “syndrome” in the form of sticking electrodes. And if you figure it out, then you can cope with power surges. So everything is in your hands.

The most common cause of sticking is the use of transformer devices that do not and cannot have precise settings. But with modern inverter devices with the correct settings and an anti-stick system, such a nuisance can also happen. The reasons in such cases are much simpler and they are not at all related to the device.

The second most common reason is damp electrodes due to improper storage. The fact is that most coated consumables are extremely hygroscopic - they absorb moisture wherever possible.

Manufacturers produce such products in plastic packaging. At the slightest violation of the integrity of the moisture-proof packaging, such electrodes become wet and will always stick during welding.

“Incorrect” electrodes can occur in three variants.

The first option is incorrectly selected consumables for a specific metal or alloy. The very first requirement is that they must be for direct current only! Welding with an inverter involves only this type of consumables. If you get a copy for working with alternating current, you will get an unstable arc and overheating of the metal. A drop of molten metal will precisely seal the tip tightly to the surface. The question arises: which electrodes are better to choose for welding with an inverter - ordinary low-alloy electrodes without special requirements or high-alloy ones? Nobody will give you a definite answer. Because it is necessary to select material for welding according to many criteria for certain metals and equipment. These criteria simply need to be taken into account accurately and unconditionally.
The second is an old consumable with crumbling coating. The tip is the most important and at the same time the most vulnerable place: that’s where the old coating usually falls off. Such an instance will definitely stick. There are often cases where the tip has not crumbled and remains intact, but the consumable itself has been lying around for a long time and is simply old. Having forgotten to check the production date, the master begins to puzzle over why the electrode sticks when welding with an inverter, and cannot find the true reason.
The third option is low quality from the manufacturer itself. Here the craftsmen are faced with a dilemma. Consumables from famous companies are quite expensive material, so there is always a temptation to buy something cheaper. There are a lot of such “somethings” on the market: consumables of very dubious quality, coated with incomprehensible mixtures, in which there is no need to even talk about compliance with standards. That's not so bad. The real problem is the frequent counterfeits of German or Swedish products. The solution to this problem will be to select reputable suppliers and check product certificates. And do not forget the proverb “the miser pays twice,” which applies, first of all, to the purchase of high-quality electrodes. You can save a lot in welding. But not on electrodes. Once again: not on the electrodes !

Types of welding that prevent electrode sticking.

Setting the wrong welding current - too low power. This situation can occur as a result of illiterate installation of the inverter apparatus. The current power must exactly correspond to two things: the thickness of the edges of the metal workpieces and the diameter of the consumable. Sometimes this kind of discrepancy arises due to basic ignorance, but more often it occurs due to a deliberate reduction in current power.

This “package of troubles” also includes incorrect technology for igniting the arc. A common method is to tap the tip of the consumable on a metal workpiece, resulting in a short circuit with instant heating of the metal, which is immediately followed by tight adhesion.

Poorly cleaned metal surfaces of workpieces are a separate story, which is mentioned in almost every article on welding. Nevertheless, young craftsmen continue to neglect cleaning parts in compliance with technology. But this is the most understandable and necessary way of not only preventing consumables from sticking, but also preparatory work that directly affects the high quality of the weld.

Treatment and prevention of electrode sticking

Schematic illustration of the welding process.

First of all, we get rid of unnecessary moisture. Calcination of consumables is often done at home in the oven at a temperature of 180 - 200°C. Of course, a home oven is better than nothing. But this method is not the best drying option from a technological point of view. A special oven for calcining welding material would be optimal.

There are rules for working with such stoves. If the electrodes have a basic coating, they must be calcined for two hours at a temperature of 250°C. Before starting calcination, you need to clarify the yield strength of these consumables in the specifications; it should not be higher than 355 N/mm. It should be clarified that all of the above applies to high-alloy consumables. Low-alloy types do not require calcination.

All these “stove” difficulties can be completely avoided if you follow the rules for storing and opening packages of consumables. There is only one rule here: after opening the plastic moisture-proof packaging, you can work with the electrodes for 8 hours without fear for their condition.

How to light an arc with an electrode?

The storage conditions for welding consumables need to be discussed separately. The most optimal solution is special separate warehouses that need to be heated in winter and maintain dry air with a constant temperature of at least 14°C. Humidity should not exceed 50 percent. It is clear that such warehouses cannot do without air conditioning. Most often, consumables are stacked.

In this case, special attention should be paid to the lower boxes. If all storage requirements are followed, the shelf life of the electrodes may become unlimited.

But even in this case, it is better to first test the “old” electrodes after long storage before the main welding work. This check does not oblige you to anything; it is simple and quick.

But you can avoid one of the most unpleasant questions when working with metals: why do the electrodes stick again when welding with an inverter?

Correctly setting the current and voltage is also a mandatory procedure to prevent electrode sticking. The proven arc ignition technology can also be included in this group of actions.

What about the inverter device?

The huge selection of inverter devices on the market complicates the choice to a certain extent: this is where the “eyes run wide” symptom begins to operate. This is especially true for not very experienced craftsmen who have not encountered the problem of electrodes sticking, but have only read about it.

Meanwhile, the requirements for inverter devices are quite specific, so choosing and purchasing the right device is quite possible. So that the acquaintance with sticking remains purely theoretical and the question “why the electrode sticks” never arises on the professional path in the future.

Anti-stick function in the inverter device.

Here are the requirements for the inverter device that will reduce the risk:

Anti-stick or anti-stick function : when stuck, the current is automatically reset to zero, resulting in the preservation of the electrode and the inverter itself. This also includes a function of pulsed increase in welding current, which prevents the weld from being interrupted if the arc is about to break.
Hot start function for fast and high-quality ignition of the arc.
Automatic switch – including overheat protection.
Supply voltage range from 160 to 250 V for operation during network power surges.

electrodes for inverter

and electrodes are published constantly; they may differ significantly from each other in different sources.

Types and purpose of electrodes.

Without pretending to be objective, the “arithmetic average” rating is as follows:

rutile-cellulose consumables from the famous Swedish company ESAB ;
American Omnia 46 from Lincoln Electric;
Russian OZS-12 ;
Russian electrodes Resanta MR-3;
UONI–13/55;
ANO : the most popular in Russia.

Summary

Which electrodes are best for cooking with an inverter? Of the exact unconditional requirements, there is only one: these must be electrodes for DC welding. All other requirements are actually advice, that is, they have the status of “desirability”.

Check before work, monitor the packaging, learn to ignite and hold the arc correctly. All of the above fits into the general concept. This is following the rules and technologies, which actually means increasing the professionalism of the welder. That's what we wish for you. Good luck!

Source: https://tutsvarka.ru/vidy/elektrody-dlya-svarki-invertorom

Why electrodes stick when welding - reasons

During welding, especially for inexperienced welders, trouble often occurs - the electrode sticks to the workpiece. The arc does not ignite and the work stops. Why the electrode sticks when welding - experienced craftsmen give several reasons for this. They are related to the condition of the electrode, the equipment settings and the lack of experience of the welder.

Causes

Experts identify several typical causes of electrode sticking.

The result of repeated sticking of the electrode. If the thickness of the workpiece is small, this can lead to burn-through.

Among them: the condition of the electrodes, the quality of preparation of the workpiece surface for welding, inverter settings and incorrect ignition techniques.

Lack of experience

Why does a dry electrode stick when welding with an inverter? In addition to underestimating the current, there is another typical mistake of novice welders. This is an attempt to keep the electrode too close to the workpiece . An air gap that is too short leads to a breakdown in the arc, the beginner tries to save the matter by bringing the tip even closer - and sticks it into the weld pool, where it can stick.

Errors occur both in the trajectory of the electrode during ignition and in guiding it along the seam. With a lack of experience and an attempt to use professional electrodes, such as UOSI, they also stick, most often due to excess welding current

It is necessary to get better at training preparations; once you gain enough experience, this effect ceases to appear. It is better to train on simple structural steels, and only then switch to alloy or stainless steel. Training should be conducted on inverter welding machines.

How to fix

Sticking is not an insurmountable problem. Modern and serviceable equipment, high-quality materials, proper storage, careful preparation of workpieces for work and a set of experience allow the welder to forget about annoying sticking.

Preparation

Electrodes removed from a freshly opened film package do not require additional preparation; they can be immediately cooked. They are not in danger of sticking.

But after just a few hours of being outdoors, they can gain moisture. Then they should be dried before work . For this purpose, special drying electric ovens are used in production, heating up to 400°C.

In a home workshop, you can use a muffle furnace . Let's allow the electrodes to warm up on the radiator, but this will take several hours. It is unacceptable to use an open fire for drying - the flame temperature may exceed the permissible one.

Learn how to strike an arc correctly

Proper ignition of the arc avoids sticking. What you need to do in two main ways:

tapping;
by striking.

If you don’t have much work experience, then it is better to ignite the arc with a short strike, reminiscent of striking a match on a box. In this case, the electrode must be held perpendicular to the plane of the part. As soon as the arc flares up, you need to tilt it 15 degrees back, and, without stopping in one place, smoothly and evenly move the seam along the intended line. This prevents the tip from sticking.

Two ways to ignite an electric arc. For beginners, it is recommended to ignite the arc by striking.

It is important to maintain a constant gap between the tip of the rod and the workpiece . Exceeding the arc length leads to incomplete penetration and increases the risk of combustion failure.

The holder should also not be tilted at too sharp an angle. At the same time, the conditions for heating the workpiece worsen, the weld pool narrows, and the seam will become weak.

To prevent the electrode from sticking, it is necessary to use dry and high-quality welding materials. You should also correctly set the operating parameters of the welding machine. Finally, it is important to use proper arc starting techniques.

Source: https://svarka.guru/oborudovanie/rashodniki-i-kompletuyushie/pochemu-elektrody-prilipajut.html

5 Welding Mistakes That Can Cause Electrode Sticking

It is sometimes difficult for novice welders to get used to a new specialty. And it doesn’t matter - at a professional or amateur level. Either the arc does not work, or the bath does not form. The most common problem is electrode sticking. More often it happens on transformer devices. But this problem also happens with inverters. Why does this happen and what are the dangers? We will talk about this in the article.

Low quality consumables

This is a reason that is impossible to overcome. Unless you buy electrodes from a specific manufacturer. The welder is faced with a dilemma. Well-known brands are expensive, but they work. There is a temptation to take something cheaper and experiment. There are many such “cheaper” ones on the market and are made from materials of unknown quality and coated with dubious mixtures.

It’s worse when you buy a counterfeit brand - German or Swedish. And I paid a lot of money, and it doesn’t cook properly.

Improper storage

Storage of materials must be correct. Storage and use conditions are written on each pack of electrodes - a certain temperature and humidity. Large suppliers have warehouses with the correct temperature and humidity conditions - there are no complaints about them. Small stores sometimes store products in unheated containers or areas with high humidity.

Even with proper storage, the electrode may not light up if the expiration date has expired or the packaging is torn. Old consumables leak grease. As a rule, in the right place - at the tip. Such an instance will definitely stick. If more than 8 hours have passed since opening the box of consumables, the best solution would be to dry it at a low temperature - 100 degrees. The absorbed moisture will evaporate and the electrode will restore its properties.

Having forgotten to check the shelf life on the packaging, the technician begins to think that the inverter is faulty.

Incorrect setting

The reason may be incorrect settings of the welding machine - setting a low current. The current power must correspond to 2 values:

electrode diameter;
thickness of the edges of the metal being welded.

More often this happens due to lack of experience. Sometimes experienced welders deliberately reduce the current for fear of overheating the thin material. The current is not enough to maintain the arc and it goes out.

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Sometimes it happens that the current of the device is not designed for the diameter of the electrode that the specialist wants to use.

Incorrect selection for a certain type of metal is also one of the reasons. For aluminum, stainless steel, ferrous metal, certain types of electrodes are used.

A poorly cleaned surface is a separate issue. Beginners don’t always understand why they should do this at all. It's still metal!

After lying outside for months or years, the metal corrodes and becomes covered with dirt; old structures are often painted. Before welding, it is necessary to clean the welded surface from rust and dirt. The connection point for the mass holder is treated with particular care.

Incorrect ignition

This is a problem for a beginner welder with no experience. Ignition of the arc using the tapping method can lead to sticking due to prolonged contact with the surface to be welded. It is more correct to strike metal like a match. Inexperienced technicians sometimes fail to keep the electrode at the correct distance from the part. This is studied in special courses or comes with experience.

How to prevent

Once we have looked at the reasons for electrode sticking, we will give a number of step-by-step recommendations:

properly prepare the surfaces for welding and fastening the mass - clean, free from corrosion, paint, bitumen;
select the right consumables depending on the thickness of the metal and welding machine;
purchase high-quality domestic or imported electrodes;
prepare the electrodes, dry them open for half an hour at a temperature of 100-110 degrees;
configure the inverter correctly - set the current in accordance with special tables;
learn to ignite an arc correctly - by striking metal;
ensure sufficient arc length.

Now you know the common mistakes of a novice welder and methods for properly operating an inverter. Clean the metal, use high-quality electrodes, set up the welder correctly.

Source: https://TehnoPanorama.ru/instrumenty/5-oshibok-svarki-iz-za-kotorykh-mozhet-prilipat-elektrod.html

The electrode sticks when welding with an inverter, what should I do?

The electrode sticks when welding with an inverter

A welding inverter is an excellent alternative to old transformers for welding, which drain the power grid too much. Today, when the cost of inverters has dropped significantly, almost everyone can afford to buy an inexpensive inverter for their home. In this case, there is no need to even have the basics of a welder; everything will come with experience.

The most common problem when welding with an inverter is sticking of the electrode. This article from the construction magazine samastroyka.ru will talk about why the electrode sticks when welding with an inverter, and how to actually deal with this scourge.

Why does the electrode stick when welding with an inverter?

Electrode sticking is the most common problem among young, novice electric welders. Incorrect movement of the electrode, the arc is too short, errors in the inverter settings, and now the electrode is constantly “pulled” towards the metal, it sticks tightly to it. Of course, here, as mentioned above, everything largely depends on the welder’s experience and knowledge of using a welding inverter.

At the same time, the most common mistakes due to which the electrode sticks during welding are:

Using damp electrodes - the electrode coating may become damp after long-term storage, as a result of which the electrode will begin to stick and splash metal to the sides. To avoid this problem, you just need to dry the electrodes in a special thermal case or in a conventional electric oven at a temperature of at least 110 degrees plus. This will prevent the electrode from sticking during welding.

Bad electrodes or incorrectly selected electrodes also often cause the problem discussed in this article. This is especially true for electrodes for direct and alternating current. The main signs of this will be sticking of the electrodes and a very unstable welding arc.

How to strike an arc correctly

Mistakes during ignition of the electrode , as a rule, are made at the very beginning of their career by novice welders. The electrode simply touches the metal and does not move away from it in time, sticking in one place. To avoid such a mistake, you should hit the workpiece with the electrode and immediately move it upward, but not too high so that the arc does not go out. In the future, with the arrival of experience, this action will occur fully automatically.

An arc that is too short also causes the electrode to stick when welding with an inverter. Many experienced welders recommend learning to weld with an inverter on a short arc, about 3-4 mm. A smaller arc will cause the electrode to stick and cause the problem discussed in this article.

What current to set on the inverter

The current on the inverter is set incorrectly - before you start welding, you should figure out what current should be set on the inverter to work with certain electrodes, metal, etc. Much here depends, of course, on the diameter of the electrodes and on the thickness of the metal being welded. However, an incorrectly selected welding inverter current leads to electrode sticking.

So, for welding with an inverter, the following current values are applicable:

When working with 2 mm electrodes - the minimum current is 40A, and the maximum current is 80A;
To work with 3 mm electrodes, the welding current must be in the range from 80 to 120A;
To cook with a 4 mm electrode, the current must be set on the inverter within 120-160 A.

Modern welding inverters have smooth current regulation. Therefore, it is very easy to adjust the welding current upward when the electrode sticks, and vice versa when burning metal.

(5 5,00 out of 5)

Source: https://samastroyka.ru/prilipaet-elektrod-pri-svarke-invertorom.html

Causes of electrode sticking: why it happens, how to prevent it

Electrode sticking when welding is a common problem for beginners. A rod stuck to the surface of a part is very difficult to quickly remove.

This negatively affects the operation, the welding result and can lead to an overload of the electrical network. Therefore, it is important to know how to solve this problem.

Next, we will explain the reasons for welding rods sticking during work, the basic mistakes of novice craftsmen, and also give tips for preventing the problem.

Reasons for welding wires sticking

The problem with electrode sticking is typical when working with transformer equipment that does not have the ability to adjust the welding mode. It also often occurs among young, inexperienced specialists working with inverters.

Advanced versions of welding inverters have a function to prevent the rod from sticking, but beginners often choose simpler options that do not have this feature. And they are faced with sticking of the electrode to the metal.

What are the causes of sticking during welding? Here are the main errors and factors causing this problem.

The first reason is the increased humidity level of the welding rod. Its surface is treated with a special coating. This substance tends to accumulate moisture coming from the environment. Filler rods stored without packaging quickly become damp. This reduces their performance, leading to sticking during welding.
The second reason is poor-quality electrodes. When working with a welding inverter, it is important to choose the right rods. Beginners who are inclined to save on consumables take electrodes from little-known companies without confirming the quality of the product. These filler wires are cost effective but can complicate welding tasks. Poor quality rods often stick during operation, negating their advantage.
The third reason for sticking is incorrect equipment settings. Young professionals often ignore the preparatory stage of work. When starting welding, they do not clean or smooth the surface of the part. This breaks the contact of the welding rod with the metal surface. The welding arc in such a situation goes out immediately after starting work. To weld uncleaned parts that are unsuitable for work, you have to re-ignite it several times. As a result, the tip of the filler wire begins to stick to the joint.
The fourth reason is improper ignition of the welding arc. The main factor in the emergence of this problem is the lack of experience of the employee. Incorrect ignition using the tapping technique, or holding the edge of the wire for a long time on the working surface of the part leads to overheating of the metal. The electrode is literally soldered to the seam, and this will not be corrected until the root cause is ruled out.

Methods to prevent sticking

Correct position of the electrode - no sticking!

Having dealt with the errors and primary sources of electrode sticking during operation with a welding inverter, let’s move on to prevention methods. What should I do to prevent the filler rod from sticking to the metal?

The first solution is to prepare the welded rod and the surface of the part.

Hermetically sealed packaging and a trusted manufacturing company are the first two criteria for choosing welding wire. The domestic company Rotex or the European electrode manufacturer ESAB would be a good option.

Their product meets quality standards, and when used correctly with the equipment, it performs its task without sticking.

Wire left unpacked for longer than eight hours requires drying. You can dry it in an electric oven, taking into account the melting temperature level of the rod. Without loss of working qualities, drying is carried out no more than 3 times.

Before welding, the working surface of the part is prepared. It is cleaned of dirt, stains, excess inclusions, the edges are smoothed with a file, sandpaper or a grinding machine (depending on the type of metal).

The second solution is to properly configure the equipment.

You can prevent sticking and sticking of the rod and increase the uniformity of the seams by correctly setting the machine. Equipment settings must correspond to the type of metal and wall thickness of the part.

There are correspondence tables, but you should not rely on them alone. Paying attention to the behavior of metals and equipment during operation will help you determine the nuances of welding for yourself.

It is worth starting with lower current values, gradually increasing the power. As a result, welding experience will help you select settings intuitively, based on your knowledge.

The third solution is the correct ignition of the welding arc.

Many beginners start an arc by tapping the end of the rod on the surface of the metal. However, it is better not to knock, but to strike, as when lighting a match.

It’s worth doing a couple of workouts before work. Without turning on the device, learn to move the edge of the electrode along the metal. Slowly at first, then faster. When this becomes an easy task, you can move on to working ignition.

An important nuance when welding is the length of the welding arc. It must be sufficient for proper operation, and you need to be able to create these conditions quickly. Delay leads to electrode sticking and the part may be rejected.

Source: https://prosvarku.info/elektrody/zalipanie-elektrodov-pri-svarke

The main reasons for electrode sticking

Reason #3: The device is not configured correctly

This is another common cause of electrode sticking. The welder incorrectly estimates the thickness of the parts, selects the wrong electrode diameter and sets excessive or insufficient current power on the inverter.

Reason #4: The surface of the part is not prepared

Some beginners forget to clean the surface of dirt and rust before welding. Because of this, the contact of the electrode with the surface of the part is insufficient and the arc goes out immediately after ignition. In an attempt to correct the situation, the welder strikes the arc again and again, trying to weld the contaminated parts. This causes the electrode tip to stick.

Reason No. 5: The arc is ignited incorrectly

Another common reason is due to the inexperience of the welder. The welder incorrectly ignites the arc using the tapping method and holds the tip of the electrode on the surface to be welded for too long. The metal begins to quickly heat up and literally solder the electrode. Subsequently, the electrodes stick one after another with each new job.

How to prevent electrode sticking

Now that we have found out why the electrode sticks when welding with an inverter, we will talk about simple methods for preventing errors. What can every welder do to prevent the electrode from sticking? The solution is not difficult to find based on the essence of the problem.

Solution #1: Prepare the electrodes and metal

Buy electrodes in sealed packaging from trusted manufacturers. These can be domestic Rotex rods or European ESAB rods. They meet quality standards and should not stick if you set up the device correctly and ignite the arc.

If the electrodes have been left unpacked for more than 8 hours, they need to be dried. This can be done in an electric furnace, taking into account the melting temperature of the electrode. The electrode itself cannot be dried more than three times, otherwise it will lose its properties.

Also, do not forget about preparing the metal. Thoroughly clean the surface of the parts from dirt, rust and paint.

Solution #2: Configure your hardware correctly

By setting the correct settings for the welding inverter, you will not only prevent sticking of the electrode, but also improve the quality of the weld. Below you can find the recommended settings that you should set on your device.

But keep in mind that these are approximate values and you need to rely not only on educational tables, but also gain your own experience. We recommend that all beginners start with a low current setting and increase it gradually. Over time, you will begin to understand what parameters are needed in each individual case.

Solution #3: Learn how to strike the arc correctly

To light an arc, many welders use the method of tapping the tip of the electrode on the metal, but we recommend not tapping, but striking (similar to matches).

First, “idle”, practice moving the end of the electrode smoothly along the surface of the metal. Once you can do this quickly, you can start lighting the arc.

After igniting the arc, it is necessary to ensure that it is of sufficient length. It is important to learn how to do this quickly, otherwise the electrodes will stick and ruin the whole job.

Instead of a conclusion

Now you know how to properly weld using electric welding so that the electrode does not stick to the metal and your work is not in vain. Briefly summarizing, monitor the current parameters set on your inverter, do not skimp on high-quality electrodes and learn to ignite the arc correctly. Share your positive experience in the comments so that novice welders can adopt it. Good luck!

Source: https://svarkaed.ru/rashodnye-materialy/elektrody/pochemu-pri-svarke-prilipaet-elektrod.html