What are carbon electrodes

We perform carbon electrode welding

You should not confuse consumables for welding of carbon and graphite types, since they differ significantly from each other in the composition of the coating and scope of application. Welding with coal products is used not only for connecting various elements made of copper, but also for preparing holes, surfacing metal and a number of other technological processes. These consumables are versatile in use.

What metals are carbon electrodes used with?

Professional welders say that carbon consumables can be used not only with copper, but also with a number of other products.

• Steel of various grades, including stainless, low-alloy, low carbon, and so on.
• Heavy and light alloys, such as bronze, cast iron and some others, however in this case the tip of the electrode will need to be sharpened at an angle of 65 degrees.
• Various non-ferrous metals, and in this case a fairly strong connection is obtained, much better compared to ordinary soldering, and besides, welding work takes much less time.

Carbon electrode welding involves the use of alternating current in the rarest cases, mainly in industrial settings. This is due to the fact that with such a supply of electricity, the arc turns out to be extremely unstable, and accordingly, this moment will greatly affect the quality of the welded joints.

It is not possible to get rid of such a drawback - only in industrial conditions, they use special high-power solenoids that will form a strong magnetic field.

When manual welding is performed using these consumables, it is sometimes possible to achieve arc stability by applying flux or pastes along the line of the welded joint being formed.

It is not recommended to use reverse polarity, as this causes overheating of the consumable material, which will begin to burn out greatly, due to which the quality of work will be significantly lower, since the sharp tip of the rod will begin to become dull, the length of the arc will not be too long - about 1.5 cm, in metal Excessive amounts of carbon will be released.

Features of welding work

Carbon consumables for welding copper wires can be carried out using one of two key methods:

• right, when the electrode begins to be drawn from left to right, and the filler material moves immediately behind it;
• left - in this case, the electrode moves in the opposite direction, and the additive moves in front of it.

It is worth noting that the right method of connecting copper wires using a carbon electrode is the most effective in the application of thermal energy that will be supplied to the welding area.

This technology is convenient to use if you need to connect wires with a large cross-section, and the speed of work will be significantly higher - by about 25%. However, in practice, the second technology is most often used, since it allows one to obtain a better quality seam.

There are a number of other important features associated with the use of carbon consumables for welding.

• The arc is very sensitive to various types of influences: wind, gases of various natures, magnetic fields, and so on. In this regard, experienced welders recommend using these materials exclusively in enclosed spaces, where the influence of external factors is minimized.
• The efficiency in this case is significantly lower compared to electrodes made of ordinary metal coated with coating.
• Melting using coal consumables will not be possible. This is due to the fact that the melting and boiling points of the carbon electrode are at approximately the same level - 3,800 and 4,200 degrees, respectively.

Coal consumables are often used to weld busbars made of copper wires located in transformer booths. At the same time, as it turns out in practice, the use of other technologies is not very effective. At home, these electrodes are used to cut metal efficiently and accurately.

Typically, the material of the electrode itself is wasted on evaporation, which occurs when combined with oxygen in the air. The average voltage supplied to the electric arc is no more than 35 V.

Due to the fact that the maximum arc size is 5 cm, its minor changes in terms of length will not have a significant impact on the quality of the formed connection.

Electric current is supplied to the electrode using the so-called sliding contact, that is, the electrode itself runs along the axis of the solenoid, which forms a magnetic field located in a parallel plane to the axis of the electrode. This field reduces the diameter of the arc and increases its temperature, preventing deviations.

To protect the molten wire elements from direct contact with atmospheric oxygen and the formation of copper oxide (it does not allow the formation of a high-quality connection), various fluxes are taken, made in the form of a paper cord, which is impregnated with various types of saline solutions.

Automatic technology can also be used, when flux is constantly supplied to the welding zone. Not too long ago, carbon electrode welding technology was developed, when the weld pool is placed in a carbon dioxide environment. This way the connection turns out to be of higher quality and more reliable, and in the process of using this method there is no large amount of waste generated.

Source: https://electrod.biz/oborudovanie/elec/vyipolnyaem-svarku-ugolnyim-elektrodom.html

Carbon electrodes application

Carbon electrodes are needed specifically for making holes in various steel workpieces, for cutting and gouging metal, and also for welding copper wires.

They are necessary for industrial and steel enterprises, for the manufacture of various metal structures, in mechanical engineering and shipbuilding, as well as in other areas. Such electrodes are infusible, so their resources are practically not consumed during operation.

These tools do not deteriorate, so there is no need to constantly change them, which is extremely convenient when using them. However, they are not particularly common for private use, and in most cases are only used in industrial areas.

Carbon cutting

If you compare it with standard cutting, for example, with a saw blade, oxygen cutting and others, then purchasing carbon electrodes is very profitable. There are several factors why this happens:

1. easy to use, because you need not only an electrode, but also compressed air, as well as current;
2. cutting begins immediately and excess metal is removed;
3. the material can work with a large number of other materials, where there are a variety of light alloys, cast iron or copper;
4. It works only on the basic principle, first the arc is ignited, and then it begins to melt the metal of the main type; when cutting, a stream of air blows out all the excess parts, so the edges become perfectly smooth.

Welding with carbon electrodes on copper wires is carried out when they are copper-plated, usually called a pencil. Sometimes a situation may arise that you can use a regular carbon rod.

Carbon-copper electrodes

They can be of several types:

1. Copper-plated round ones are necessary for a wide variety of spheres; their diameter ranges from 3.2 to 19 mm.
2. Copper-plated endless ones are considered one of the most economical, their consumption is also very small, they do not leave any waste after their work. For ease of use, a specialized machine is required. Electrodes of this type have a circular cross-section and a diameter of 8 - 25 mm.
3. Copper-plated flat electrodes with a rectangular or square cross-section measuring 8 - 25 mm, however, upon individual order, larger electrodes can be produced.
4. Copper-plated semicircular ones are most often used in all areas. One side of them has a flat cross-section, and the other is round. This is why you can cut any type of metal without any problems. Also, when using it, you can make grooves of any shape. Its cross section is 10 - 19 mm.
5. Copper-plated hollows are mainly used for gouging, and oval-type grooves can be formed. They are used quite rarely, so they are very difficult to find. They have a diameter of 5 - 13 mm.

Characteristics

In addition to sizes, carbon electrodes for welding copper wires also have different characteristics, so you should carefully choose the most suitable ones:

• Current strength. Which the electrode can handle. It depends on this whether it will fit a certain type of equipment or whether it will be incompatible with it. It is also worth considering what the product will have to cope with. Indeed, for large-scale operations it may become necessary to use high current strength, with which the electrode is not able to work.
• Shapes and sizes of required grooves. These parameters are directly dependent on the end of the tool and its actual size. This is why it is necessary to select electrodes for certain types of operations, but large sizes are the most popular of all possible ones. The metal is removed very quickly and easily; with prolonged work, sometimes excess pieces of metal remain. However, when welding this is not so important.
• The thickness of the slices is directly dependent on how powerful the current is. After all, you need to monitor whether the product can withstand this.

  Which electrodes are best for welding a car body?

Features of choice

VDK carbon electrodes must be selected depending on what they are to be used for. For example, copper-plated semicircular electrodes are universal and in demand, but there are areas for which they are absolutely not suitable. When welding copper, it is recommended to use electrodes with a narrow end. Most wires are not thick and voluminous, so wide rods will only spoil the product.

Air arc gouging removes metal immediately during operation, so it must be selected with special care. Large tools are used in most cases only in production, and even then in rare cases.

Welding wires with carbon electrode

With cutting metals, everything is extremely simple and clear, but many simply do not understand how to weld using a carbon electrode.

First you need to prepare the wires, remove the insulation and top sheaths.

Then it is recommended to twist them in the place where the welding will take place.

After this, the twist is carefully cut off, while the wires remain at the same level, and the twist should be at least five centimeters.

Next, you need to remove the clamp for heat removal, and only then connect the welding machine.

The electrode is placed in a specially designated place, and its end is brought to the twist.

When copper and the electrode come into contact in working condition, a small metal ball gradually begins to form. It is at this moment that you need to stop welding.

It happens that when heated for a long time, the insulation of the wires begins to melt. This is why welding cannot be continued for more than two seconds when a metal ball is formed. When the wires cool, they are insulated using any method.

Use of carbon electrodes

Copper is used only in certain areas. That is why they require careful adherence to safety precautions.

1. It is necessary to strictly follow the instructions for using carbon electrodes.
2. Violation of the established regimes leads to damage to products and injuries, equipment may break.
3. It is necessary to give additional time for the electrodes to cool, because if they get too hot, they can burn some surfaces and harm human health. Moreover, the consequences can be the most dire.
4. When working to remove excess metal, you need to make sure that it is blown away to a safe place where there are no people or other objects.
5. You should use only serviceable electrodes, because if they break, there can be unpleasant consequences that can no longer be corrected.
6. It is imperative to maintain order and cleanliness of the workplace.

Source: https://rem-serv.com/ugolnye-elektrody-primenenie/

How to cook with carbon electrodes

Carbon arc welding was invented by Russian engineer Nikolai Benardos back in 1882. In fact, this is the oldest method of electric welding. Today, carbon or graphite electrodes are used much less frequently than metal electrodes, but they still have their own scope of application.

Properties and varieties

A carbon electrode is a solid rod consisting of coal (coke) and several additives. Resin is used here as a binding element.

These rods can be used to weld all types and varieties of metals - from refractory and heavy to light and porous. The diameter of the carbon electrode can vary from 1.5 to 25 mm, and the length - from 25 to 300 mm (the longest are used when the parts to be connected are located in a hard-to-reach place). They can also have different shapes:

• round;
• semicircular;
• rectangular;
• hollow.

In most situations, round and semicircular electrodes are used for work - this is the best option for obtaining a standard weld.

Rectangular products are mainly used to seal defects on steel surfaces, while hollow ones are characterized by the fact that they are capable of creating a U-shaped groove at the joint.

It is also worth knowing that in addition to the usual ones, there are copper-plated carbon electrodes. They are coated with copper to increase strength, but all other performance properties remain approximately the same.

Process Features

Electrodes made from coal differ from metal ones in that they are infusible. This means that during welding they act as a conductor of electricity, but do not become part of the weld pool.

During operation, the carbon rods heat up to very high temperatures. And if you continue heating, then almost immediately they will go from a molten state to a boiling state (by the way, coal boils at a temperature of 4200 ° C).

Due to the characteristics of the material, only direct electric current of straight polarity can be used in the welding process. Accordingly, the minus (cathode) here should be on the electrode, and the plus (anode) on the metal surface of the product.

When working with carbon electrodes, the welder usually requires filler elements. In this case, welding can be done in two ways:

• from left to right (in this case, the additive is behind the electrode);
• from right to left (there is an additive in front).

Interestingly, when welding from left to right, thermal energy is used more efficiently, and this allows you to increase the speed of work. However, in practice you can often find the “right to left” technology - it is more familiar.

In some situations, you can do without an additive, for example, when flanging thin metal products or when welding corner joints . Moreover, if you use a carbon electrode without additives to join metal sheets with a thickness of up to 3 mm, then the productivity will be an order of magnitude greater than when welding with other electrical conductors.

Use in home workshops

To work with carbon electrodes at home, a standard electric arc welding machine is suitable. Since the thermal conductivity of carbon rods is low, an arc can be created with a current of only 3-5 Amperes.

Moreover, this electric arc, if necessary, extends to a length of 30-50 millimeters. The electrode evaporates slowly and does not stick to the metal, so it is quite easy to guide the carbon arc in the direction of the future seam.

The skills needed to perform simple jobs (such as welding wires, welding thin metal plates, etc.) are acquired very quickly in this case.

Home craftsmen should not cook outdoors, but strictly indoors. The carbon arc reacts to wind blows, gas flows, magnetic fields and other influences.

In order not to waste time rearranging the electrode in the holder and so that it does not get too hot during welding, it can be sharpened at both ends in advance. When one end overheats, the electric holder is rotated 180° and welding continues with the other end.

Craftsmen who do not have too many consumables on hand should use this advice.

Some specialists use carbon and graphite electrodes to weld copper busbars at transformer substations. And in home handicraft workshops, such electrodes can, for example, weld copper wires.

Bronze rods would be a good filler material in this situation. The diameters of such rods are selected depending on the thickness of the parts being welded and are calculated using special formulas.

In addition, carbon electrodes can be used to perform not only welding work, but also cutting operations on metal products.

Working with aluminum

Carbon electrodes are used to connect even aluminum products, which are traditionally considered difficult to weld. Aluminum has low density, significant thermal conductivity and resistance to corrosion.

This metal melts at a temperature of 660 °C, and it combines quite well with oxygen, which is why it is covered with a film of aluminum oxide (chemical formula - Al2O3).

The presence of such a film, as well as the ease of formation of cracks and pores in the weld metal, are the main difficulties encountered when welding aluminum. But the use of carbon electrodes makes it possible to cope with them.

In particular, this is the method used to connect aluminum busbars in electrolysis shops. Tires are traditionally butt welded on a graphite or aluminum backing.

Graphite plates with cutouts opposite the seam are mounted on the sides of the tires. These cutouts make it possible to move the end and start points of the seam beyond the boundaries of the working section.

When welding aluminum surfaces using carbon arc welding, the filler material is wire or rod made of the same metal. To ensure that the oxide film does not interfere and does not affect the result, AF-4A flux, which is a homogeneous, fine white powder, is added to the edges of the seam.

Source: https://svaring.com/welding/vidy/svarka-ugolnym-elektrodom

What are electrodes and where are they used: types by materials

When creating metal structures or performing other types of repair or construction work, you cannot do without the use of welding. Connecting in this way is considered a rather complex process, requiring the use of special equipment and consumables - electrodes.

What is an electrode? A welding electrode is a rod with or without a coating, with the help of which a weld is formed and the edges of the elements are connected. For each welding method, it is necessary to select a separate type of consumable that corresponds to the required technological and quality parameters.

What's happened?

The design of the electrodes, despite the different areas of application, is the same. What are the electrodes made of? The main elements are as follows:

• rod - made of metallic or non-metallic materials;
• coating (some varieties may not have);
• contact tip.

The main part of the product is a rod that melts when heated at high temperatures by current and fills the weld pool with metal . The closer the composition of the rod is to the material of the elements being connected, the higher the quality of the created seam.

The coating is intended to create an inert gas environment around the electrode during the welding process, preventing foreign impurities from entering the bath. The correct selection of the type of electrode based on its coating is largely determined by the conditions of the welding process and the type of metal being joined.

The uncovered tip of the electrode is used to ignite an arc that melts the rod and the product space around it.

To create a seam and connect parts, the welder moves the electrode in a spiral - this is how a strong bond of substances is ensured . Thanks to this technology, the peak temperature effect is constantly shifting, elements that are not yet connected melt, the bath filled in other places gradually cools down, and a strong permanent connection is formed.

Manufacturing materials

To produce the core base of welding and surfacing electrodes, a special wire is used, the requirements for which are set out in GOST 2246-70 . The standard describes the chemical composition and grades of metal, main dimensions, special markings, storage and transportation.

Surfacing electrodes, as well as those used for welding, are made from cold-drawn steel wire with a cross-section of 0.3-12 mm.

Wire is available in three categories:

• carbon , used for welded joints of parts made of low-alloy and carbon steels;
• alloyed , used for elements made of structural, heat-resistant, low-alloy steel grades;
• high-alloy , designed for workpieces made of stainless steel, chromium-nickel and chromium alloys.

The classification of electrodes used for surfacing and welding processes is based on the following principles:

• appointment;
• technological specifics;
• thickness and type of coating;
• chemical composition of the coating and rod;
• mechanical characteristics of the seam;
• coating formation method.

The following requirements apply to the properties of consumables:

• guarantee of arc stability and a well-formed seam;
• formation of a weld with the required chemical composition;
• uniform joint melting of wire and coating;
• minimizing electrode metal spattering;
• maximum process efficiency;
• ease of slag removal;
• ensuring the required coating strength;
• possibility of long-term storage;
• minimal release of toxic substances during welding.

Less common but popular conductors include carbon electrodes for welding copper wires, for example, in an electric drill or in engines.

Coating materials

The classification of welding electrodes is based on the type of coatings, which differ in chemistry and properties. There are several types of coating:

1. Acidic , from oxides of silicon, iron or manganese. The use of products with such a coating provokes the appearance of cracks on heated parts. At the same time, the seam is reliably protected from the appearance of pores.
2. Rutile . Consists of titanium dioxide or concentrated rutile. During welding, virtually no spatter is generated; the metal completely goes into the seam being created.
3. Ilmenite . The properties of such coatings are in the middle between acidic and rutile.
4. Basic , formed from fluorine compounds or carbonates. Types of electrodes with such a coating add plasticity to the weld metal and increase its toughness during machining. They make it possible to create a crack-resistant seam, while the presence of oxidizing elements in the bath, which provoke a high susceptibility to corrosion of the connection line, is not allowed.
5. Cellulose , which contains about 50% organic substances. Hydrogen electrodes are made with such coating ; work with them is based on the phenomenon of electrolysis, the occurrence of redox reactions with changes in the pH level. A seam with increased density is formed, which allows the use of products for vertical welding.

Thickness

According to GOST 9466-75, electrodes are divided into types in accordance with the standard coating thickness . The classification is based on the calculation of the ratio of the total diameter of the product D to the cross-section of the rod d. In accordance with this parameter, electrodes are manufactured:

• thin , D/d >1.2 – designation M;
• medium size - from 1.2 to 1.45, marked with the letter C;
• thick – 1.45-1.8, designated by the letter D;
• especially thick , parameter ratio more than 1.8 (G).

Areas of application

The selection of electrodes for performing a particular job is made according to the following criteria:

• for inexperienced welders, rutile conductors should be chosen; for experienced workers, the type of coating does not matter much;
• type of electrode – consumable or non-consumable;
• type of structure, equipment or elements to be welded (for electric motors one type is needed, for surfacing excavator buckets another type is needed);
• steel grade;
• thickness of elements;
• type of current and its polarity;
• characteristics of the purchased electrodes.

For inexperienced users

For beginners in welding, it is preferable to use electrodes with a rutile layer. These products are easy to use compared to other types. The most popular brands include:

• ANO-4;
• MP-3 (also called “blue electrodes” due to the corresponding color);
• OK 46.00;
• UTP 65D.

Household use

Welding work carried out in everyday life is characterized by a low level of complexity. They require a normal or low quality seam, since the main goal is to connect the required elements that do not experience serious loads and are not subject to significant wear .

The most often performed in domestic conditions include assembly work to create small metal structures (greenhouses, fence posts), restoration welding of a car in garages or on construction sites.

For household manual arc welding, electrode brands:

• ANO . Suitable for all types of inverters used as welding power sources.
• SSSI . They allow you to create a high-strength seam, can be used for products of any complexity, but are distinguished by their “obstinate” character. To perform welding with electrodes of this brand, some experience is required.
• MP-3 . Products for universal use. Can be used to connect even damp, corroded surfaces that have not been subjected to pre-abrasive treatment.

Stainless steel

For joining stainless steel, it is preferable to use non-consumable tungsten electrodes. When using conductors for ferrous metals, the connection will not be characterized by the required strength and aesthetics of the seam.

The most commonly used brands are:

1. NZh-13;
2. OZL-8;
3. TsL-11;
4. TsT-15.

Cast iron

Cast iron is one of the most popular materials that has found its application in various branches of construction and industry.

To connect cast iron products the following are used:

• MNC-2.
• OZZHN-1.
• OZCH-2.
• TsCh-4.
• OK 92.18.

Pipes

When choosing electrodes for connecting pipes, the thickness of the elements is taken as the main parameter. The thicker the walls of the pipe, the greater the thickness of the conductor should be chosen.

The pipes are connected in one of four ways, on which the required brand of electrode also largely depends:

• overlap;
• in the corner;
• end-to-end;
• vtavr.

Welding of critical pipelines must be done with electrodes for connections of increased complexity. For domestic mains (plumbing, heating systems), there are no special requirements for the strength of seams.

The most popular types of consumables include:

• ZIO-20.
• TML-1U.
• UONI-13/55.
• TsU-5.

For inverters

Inverter welding is one of the common joining methods. The devices allow you to obtain welding current of direct or reverse polarity. In the latter case, heat is concentrated at the end of the conductor, while the product being welded acts as a positive anode, and a negative electrode as a cathode . Welding efficiency depends on the uniformity of potential distribution .

Almost all types of coated rods are suitable for work; beginners should use rutile electrodes.

Classification by purpose

The most important point in using an electrode of one brand or another is its compatibility with the material of the products to be welded or fused.

For each processing method, a specific type of conductor should be selected, used only for its intended purpose.

For example, if an electrode is produced for welding, it will definitely not be able to make surfacing. Just as a conductor produced for non-ferrous metals will not be able to connect ferrous metals.

According to their purpose, electrodes are divided into types, each of them has its own letter designation:

• U - conductors for working with parts made of carbon and low-alloy steel grades. They are distinguished by high tensile strength, the value of which reaches 600 MPa.
• M - for welding products made of alloy steels with a resistance of up to 600 MPa. This group also includes rods for fusing worn surfaces of rails, as well as stalinite electrodes.
• T - for connecting parts made of heat-resistant steel grades, often used in electrodynamics.
• B – for working with elements made of high-alloy steels with special characteristics.
• N – for welding surface layers of metal elements

The separation of electrodes is carried out in accordance with GOST standards, which provide their detailed descriptions and scope of application.

Source: https://svarka.guru/oborudovanie/rashodniki-i-kompletuyushie/chto-takoe-elektrody.html

Carbon electrode welding

Carbon electrodes for welding are used less frequently than analog electrodes with a steel consumable rod. But in some situations they are simply irreplaceable. In addition, using a carbon electrode, you can carry out a wide range of work: welding, cutting, melting. Plus, it processes almost all types of modern metals, from refractory and heavy to light and porous. But first you need to understand what a carbon electrode is.

This is a rod based on coal (coke), plus several additives: resin is used as a binder, and metal powder is used as a strengthening element. The dimensions of the carbon electrode vary in diameter from 1.5 to 25 mm, and in length from 25 to 300 mm.

The production process is very simple: making a mixture of components, molding and drying. The question may arise why there is such a large variation in length. It's all about various problems that are solved by carbon electrodes.

For example, if the parts to be welded are located in an inconvenient place, then using a long rod solves the problem.

• 1 Types of carbon electrodes
• 2 Welding mode
• 3 Welding features

Types of carbon electrodes

Today, manufacturers offer five types, which differ from each other in cross-sectional shape.

1. Round. Application is unlimited. Rod diameter – 3.2-19 mm.
2. Round endless. They got their name for the lowest consumption, that is, these are the most economical welding electrodes in this category. Diameter – 8-25 mm. Usually a special machine is used for welding.
3. Flat. The cross-section of the rods is rectangular (sometimes square) measuring 8-25 mm. Mainly used for sealing defects on the surfaces of steel castings.
4. Semicircular. Cross section – 10-19 mm. Today these are the most popular electrodes, with the help of which you can solve any problems associated with cutting metal workpieces. When welding, the seam is formed into the required shape. They have no equal when it comes to edge shaping.
5. Hollow. Rarely used. A distinctive feature is that they can be used to form a U-shaped groove. Rod diameter: 5-13 mm.

To increase the strength characteristics of consumables, their production technology began to use the method of sputtering copper powder onto the electrodes. The second method is electrolytic. This is when both the rod itself and copper powder are placed in a bath of electrolytes. Here, under the influence of an electric field, copper settles on the plane of the consumable. That is, we have a subspecies called copper-coated carbon electrodes. The type of separation is exactly the same as conventional carbon electrodes.

Welding mode

The carbon-type electrode belongs to the category of infusible elements. This is its main difference from the main category of metal welded rods. Therefore, when welding with its help, only direct current of straight polarity is used. That is, the minus is connected to the electrode, the plus to the metal workpiece.

It turns out that to weld metals using a carbon electrode, you will need a filler element. True, not always. For example, for flanging thin metal workpieces or for some options for welding corner joints. This is both more profitable and convenient. It should be added that the productivity of welding work when connecting sheets with a thickness of 1-3 mm using carbon electrodes without the use of filler material is several times higher than when welding with conventional non-carbon electrodes.

But there is one point. When welding, two workpieces are joined together by melting the metal itself. And such a seam cannot be called very durable. Therefore, this type of welding is best used for assembling non-critical structures.

There is a fairly large range of filler materials that are used in this type of welding. Everything will depend on the brand of metal being welded. For example, when welding copper, it is best to use bronze filler material.

The cross-sectional indicator of the filler wire or plate is also very important. If it is large, then there is a possibility that the welding seam will not be welded through; with a small cross-section, burnout may occur. Therefore, the choice of cross-section is made in accordance with the thickness of the workpieces being connected. Here are some ratios:

Thickness of welded workpieces, mm	Diameter of filler rod, mm
1,5	1,5
1,5-2,5	2
2,5-4	3
4-8	5
8-15	8
More than 15	10

Of course, the quality of the seam will depend on the current strength used to weld with a carbon rod. Dependency in the lower table.

Thickness of welded workpieces, mm	Welding current, A
2	160-200
3	210-260
4	240-280
5	260-300
6	300-350
7	300-360

The welding mode also depends on the diameter of the electrode used. Dependency in the table below.

Thickness of welded workpieces, mm	Carbon electrode diameter, mm
2-5	15
5-10	18
10-15	25

Welding Features

There are two types of welding.

• Right. This is when the electrode moves from left to right, and the additive follows it.
• Left. The rod moves from right to left, and the additive is in front of it.

The most surprising thing is that right-hand carbon rod welding is more efficient in terms of the use of thermal energy in the welding zone. In this case, it is more convenient to weld parts of large thickness. And the speed of the process is 20-25% faster. But in practice, it is the left technology that is most often used.

And other features.

• The electric arc is very sensitive to various external influences: wind, flows of various gases, magnetic influences, and so on. Therefore, welding with carbon electrodes must be carried out indoors.
• The efficiency of this type of welding is lower than that of processes that use metal consumable electrodes.
• It is impossible to melt with carbon rods, because the melting point and their boiling point are almost the same: Tm = 3800C, Tbp = 4200C.

The use of carbon electrodes for welding copper wires is one of the main applications. They especially make connections between electrical copper busbars in transformer substations. As practice has shown, other methods are ineffective. In home workshops, carbon electrodes are used mainly for cutting metals. That is, this happens more often than welding. It's all about the conditions and capabilities of the workshop.

Source: https://svarkalegko.com/materials/ugolnyj-elektrod.html

Carbon electrodes for welding - application and features

Carbon electrodes for welding are non-metallic infusible electrodes. They are almost not consumed during operation and do not require frequent replacement, which is very convenient. This type of consumables is not very common and is used mainly in industry. It is almost impossible to meet them in private households.

Application of carbon electrodes

This type of electrode is used to create holes in steel workpieces. They perform gouging and cutting of metal, as well as welding copper wires. Carbon rods are often used in the steel industry, shipbuilding and other similar fields.

Very often they can be found in hot welding of cast iron and when welding thin products. Using carbon electrodes, casting defects are eliminated, which is much more profitable than casting a sheet of metal again. The rods are used for surfacing hard compounds and welding non-ferrous metals.

Types of carbon electrodes

Among the carbon electrodes on the market, you can find several varieties:

• Round rods with added copper . They are used in various fields and can have a diameter from 3.2 to 19 mm.
• Endless copper plated . Very economical products that can be used for a long time. They require a special machine. Diameter 8 - 25 mm.
• Copper plated flat. They have a square or rectangular cross-section with a diameter of up to 25 mm.
• Semi-circular with the addition of copper. These rods are used most often. On one side they are flat, on the other they are round. This allows you to use them for any task. The diameter can be from 10 to 19 mm.
• Hollow copper-plated. Used for chipping and creating U-grooves. Their diameter can vary from 5 to 13 mm.

Composition and technical characteristics

The main component of coal rods is coal coke. In addition to it, the composition contains metal powder, which gives the electrode strength and a resin that connects all components. The diameter of such electrodes can be different - from 1.5 mm to 300 mm.

In addition to size and cross-section, carbon electrodes have other parameters:

• The current strength that is supplied to the electrode. It depends on the material and equipment you are working with.
• Shapes and sizes of grooves . They depend on the end of the rod and its dimensions. The most popular are large electrodes, which can be used to work with massive parts.
• The thickness of the cut depends on the current power. But here you need to carefully ensure that the product withstands and does not melt.

Markings and symbols

For the most part, only alphabetic codes can be found in the marking of carbon electrodes. The numbers in the model names indicate the diameter and length of the rod.

• the letter “C” means that the electrode is a welding electrode;
• “K” - round section;
• “VD” - air-arc welding;

Most popular brands

There are 2 main types of carbon electrodes on the market. These are SK and VDK. They are respectively designed for conventional and air-arc welding.

Arcair electrodes from Esab are most often found on the Russian market. They perform the following work:

• elimination of defects;
• repair of products and structures;
• removal of seams;
• preparatory work;
• removal of excess material;
• trimming excess reinforcement and product fragments.

In this video you can see how air arc welding is performed:

Conclusion

Carbon electrodes are used in industrial production when working with special structures and products. They are highly economical and have low consumption. In most cases, they are used together with special welding equipment, with which they show the greatest efficiency.

Source: http://instrument-blog.ru/svarka/ugolnye-elektrody-dlya-svarki-primenenie-i-osobennosti.html

Graphite electrode. welding copper wires – Master Tool

Welding is the most reliable method of connecting copper wires, thanks to which the operation of products is possible for decades.

For quick and high-quality connections, copper electrodes intended for welding and special transformers are used, the specificity of which is the variability of their load.

Such a tool can be made at home. At the same time, welding work can be performed even by an insufficiently experienced welder.

What electrodes can be used to connect copper cables

As a rule, not all electrodes are suitable for connecting copper wires. In this case, carbon and graphite electrodes are used. In everyday conditions, when doing welding work with your own hands, such electrodes may well be:

• commutator motor brushes;
• battery cores;
• other similar instruments made of graphite.

To slightly adjust the holder for graphite rods, you need to adapt a similar “crocodile”, which is used for electrodes, to connect the mass. They will be more compact than factory ones, and accordingly, working in electrical panels will be much more comfortable.

You must also not forget about the additional insulation of the handles themselves.

Carbon and graphite electrodes have a general similarity: their melting point is much higher than the melting point of pure copper by four times, as a result of which the consumption of electrodes is quite small.

The welder must take these points into account when working with electrical wiring.

What is the difference between graphite and carbon electrodes?

Despite the similarity of these tools, some of their characteristics are slightly different:

• Price. Graphite electrodes are cheaper.
• Color. Graphite electrodes have a dark gray color with a metallic sheen, while carbon electrodes are completely black.
• A carbon rod forms an arc at a fairly high temperature, so an experienced welder must work with such a tool to prevent cable destruction. But there is also a positive side - high temperatures are achieved at low current, so carbon electrodes can be used for low-power welding transformers.
• Graphite rods are more suitable for inverter-type welding with current regulators. They are ideal for beginner and amateur welders. When using this tool, welds are of better quality than those made with carbon electrodes.

Welding technology

To prevent the copper cable insulation from melting, you need to connect a metal radiator to the base of the twist. The removal of excess thermal energy from the twist will be carried out by clamping with a plane of a larger area, due to which heat exchange occurs.

Welding copper electrodes requires preliminary preparation:

• The wires must be cleaned - remove the sheath and insulating layer. In this case, the length of the exposed wires should be at least 10 cm, as a result the twist itself will be at least 5 cm.

A ground clamp is connected to the twist near the radiator, and an electrode is brought to the ends of the wires being welded. For resistance welding, the contact period should be no more than two seconds. As a result of such soldering, a small bead is formed on the twist, which has a spherical shape. The following twists are connected in the same way.

One of the most reliable methods of connecting copper wires is considered to be manual arc welding with copper electrodes designed for welding. The main advantage of this technology is the maximum approximation of the resistance value at the connection site to the resistance of the material being welded.

Due to the absence of corrosion, the connection is of the highest quality, with a fairly long service life.

Sergey Odintsov

Source: https://cs-important.ru/rejtingi/grafitovyj-elektrod-svarka-mednyh-provodov.html

Carbon electrodes for welding copper wires

Carbon electrodes are used for making holes in alloy and low-alloy steel workpieces, for gouging and cutting metal, as well as for welding copper wires. They are actively used in the steel industry, in the manufacture of metal structures, as well as in shipbuilding, mechanical engineering and other areas.

This type belongs to non-metallic and infusible electrodes. During operation, it practically does not consume its resources, so it does not require frequent replacement, therefore, it is very convenient to work with it. This is far from the most common type and is used in most industrial cases, and not in the private sphere.

When compared with standard cutting methods, such as saw blades, oxygen cutting, etc., such electrodes turn out to be more profitable. After all, here:

• It turns out to be a simple method of use, which requires only the electrode itself, electric current and compressed air;
• Cutting occurs immediately with the removal of excess metal;
• The material reveals a wide range of materials with which it can work, which includes cast iron, stainless steel, light alloys, copper and more.

The basic principle of operation is based on the fact that an arc is ignited from an infusible electrode, which melts the surrounding metal. When cutting, an air stream immediately blows away the remaining parts, which allows you to make smooth edges.

Carbon electrode welding of copper wires is carried out if they are copper-plated. They are also called "pencil". In some cases, it is allowed that a simple carbon rod can be used instead of copper-plated ones.

Carbon electrode for welding copper wires

Types of carbon electrodes

Carbon welding electrodes are presented on the market in several different versions:

• Copper-plated round - used in various fields and can have a diameter from 3.2 to 19 mm.
• Endless copper-plated ones are very economical and significantly reduce their consumption. Their work is virtually waste-free. To make them more convenient to use, a special machine is used. The cross-section of these products is round, and the diameter ranges from 8 to 25 mm.
• Flat copper-plated - have a square or rectangular cross-section. They have a cross section from 8 to 25 mm, although electrodes of larger sizes can be made to order.
• Copper-plated semicircular - of all varieties, they are the most widely used. On one side they have a flat cross-section, and on the other – round. Thus, it can solve any metal cutting problems. With its help, you can form a groove of the required shape. Section sizes range from 10 to 19 mm.
• Hollow copper-plated - used for gouging and can form U-shaped grooves. They are quite rare on the market and the diameter range here is from 5 to 13 mm.

Carbon electrode sizes

For each of the varieties, be it copper-plated carbon electrodes or others, there are nominal sizes.

Variety	Dimensions, mm
Copper plated round	3,2; 4; 5, 6,5; 8; 9; 9,5; 10; 13; 16; 19.
Endless copper plated	8; 10; 13; 16; 19; 25.
Flat copper plated

Source: https://svarkaipayka.ru/material/elektrodyi/ugolnyiy-elektrody-dlya-svarki-mednyih-provodov.html

Carbon electrode

As statistics and user reviews show, today electrodes with a steel melting rod are in greater demand. However, in some cases, a carbon electrode is simply necessary for welding. With the help of such a rod you can perform welding, cutting, and melting. You will learn about what carbon electrodes are and what their advantages are from this article.

Properties and purpose

A carbon welding electrode is a rod whose key component is coal (coke).

In addition, it contains some additives, including: resin, which acts as a unifying link, and metal powder, which gives the product strength. The dimensions of such an electrode range from 1.5 to 25 mm in diameter, and from 25 to 300 mm in length.

The products are made very easily: initially a composition is created from all the components, then the molding process occurs, and the final stage is drying.

It must be said that the use of the described products has found itself in many construction works.

Most often, a carbon electrode is used for welding metals, for performing air blast cutting of metals and other operations.

Experts who perform welding at a professional level note that the described rods can be used to work not only with copper, but also with some other products:

• steel of different grades, this also includes stainless steel, low-alloy, which contains a small amount of carbon,
• heavy and light alloys, such as bronze, cast iron. But when working with these materials, it is necessary to sharpen the end of the electrode at an angle of 65 degrees,
• all kinds of non-ferrous metals. By the way, you should know that here you can get a fairly high-quality and reliable connection, which cannot be achieved by conventional soldering. And the work process itself will be less time-consuming.

Welding principle

There are two welding methods when working with a carbon electrode:

• right, it involves moving the electrode from right to left, and the additive goes right behind it$
• left, in such a situation the rod moves from left to right, and the additive moves in front of it.

Right-hand welding is considered more effective in terms of the use of thermal energy in the welding area. This method is more convenient for welding parts of large thickness. And the speed of the process itself is approximately 20-30% higher. However, in practice, welders give greater preference to left-handed technology.

To summarize, it should be said that most often carbon electrodes are used for welding copper wires; at home, they have found their application in cutting metals.

Source: https://svarkaed.ru/rashodnye-materialy/elektrody/ugolnyj-elektrod.html

What is a carbon electrode used for, application for soldering copper wires and thin metal

A carbon electrode is a highly specialized item. It cannot boast of universal popularity and demand among welding masters, like, for example, electrodes with metal rods.

But in some cases you cannot do without coal consumables. Let's figure out what its features are, how it works, and what the carbon electrode is used for.

Internal structure of a carbon electrode

These consumables often have a round cross-section, the diameter of which can be very different - from 5 to 25 mm. The length of the angles is also varied: from 25 to 300 mm. The longest types are used for welding in hard-to-reach places.

They are available in several shapes: round, semicircular, rectangular and hollow. Round and semicircular consumables are more often used - with them the welding seam meets all the requirements of technical standards.

Rectangular rods have their own tasks: they do an excellent job of repairing a wide variety of defects in steel surfaces. As for hollow consumables, their feature is the ability to form a U-shaped groove at the welding seam.

The production technology includes separate stages. First the mixture is formed, then the rods are formed from it. The third most important technological stage is the special heat treatment of the newly formed rods. The quality of consumables depends on the thermal stage of production.

Technological scheme for the production of carbon electrodes.

Sometimes two types of specialized rods are confused: carbon and graphite electrodes. There is no need to confuse them; these are different consumables both in their composition and in their scope of application.

There is another type of carbon electrodes - the so-called copper-plated ones. These are rods coated with copper plating. This makes them more durable while maintaining all other characteristics the same.

Where are they used?

A distinctive feature of coal consumables is their versatility. The scope of application is varied: from cutting metals to surfacing and welding. The workpieces can be of any shape; the range of parts to be connected is much wider than that of electrodes with metal rods.

Almost any nature of metals is also allowed:

Steel

There can be alloys of any direction: stainless steel, alloys with low carbon content, low-alloy or higher-alloy grades, etc.

Cast iron and bronze

A carbon electrode is quite capable. There is a technical nuance here: its end needs to be sharpened at an angle of 65°.

Non-ferrous metals

Here you also need to sharpen the tip of the consumable, the angle in this case is 30°. Understanding and experienced welders prefer carbon models for welding finicky non-ferrous metals rather than traditional soldering. This is done due to the higher quality of the connection - its strength, first of all.

An additional advantage is the saving of time: welding with a carbon electrode requires much less than manipulating a soldering iron and solder with acid.

Carbon electrodes are more often used in industrial welding work on automatic equipment. A special feature is the rare AC connection. The fact is that the arc in this case is very unstable, and it is difficult to level it.

Partial stabilization of the arc can only be achieved with flux pastes applied along the seam or cut line.

The main power source is direct current with a direct polarity connection, when the positive pole is on the workpiece, and the negative pole is on the carbon rod. God knows how much current is needed to form an arc, for example, five centimeters long; 5 A is quite enough.

Welding with a carbon electrode.

If the polarity is connected incorrectly - in the reverse type, the electrode will immediately overheat entirely - along its entire length, as a result of which the carbon mass burns out and the quality of the welding process decreases.

A significant advantage of carbon consumables is the absence of a very unpleasant phenomenon in welding - sticking of the rod to the surface of the workpiece being welded. This occurs due to the low burnout rate of the consumable mass.

Sticking does not occur even if the welding technology is violated, which with other methods instantly leads to this problem. Therefore, carbon electrodes are a favorite method in the initial stages of learning to weld.

Once you have learned how to use these electrodes, you can move on to more advanced welding techniques to learn how to avoid electrode sticking.

How to cook with carbon electrodes: features

First of all, you need to know and remember that they are non-fusible consumables. This means that during the process they act only as an electrical conductor, but do not take part in the formation of the weld pool, unlike their metal counterparts.

It's hard to believe, but even coal can boil. It does this at a temperature of 4200°C, but before boiling it melts – also at sky-high temperatures. During the welding work, the carbon rods heat up, but do not melt and, moreover, do not boil: the temperature of ordinary welding is simply childish.

It has already been mentioned here that with this method you can only use direct current of straight polarity without any options.

Cooking takes place using filler materials in two ways:

• from right to left, where in the general arrangement of parts the additive is always located in front;
• from left to right with an additive that follows the trace of the electrode.

If the type of work is special and, for example, involves beading metal workpieces with thin edges, squares can be used without additives. In this case, welding productivity will be significantly higher. Under one condition, however: the thickness of the joined sheets should not exceed 3 mm.

Carbon electrodes in home workshops

Copper wire welding diagram.

To work with them in a makeshift manner, a traditional electric arc welding machine is quite suitable. One of the advantageous aspects is a very modest current strength for creating an electric arc due to low thermal conductivity: 3 - 5 A is enough.

An electric carbon arc can be extended to a length of up to 50 mm; it is very easy and comfortable to guide along the future seam due to the slow evaporation of the electrode during welding and the absence of a sticking effect.

Learn welding with carbon electrodes using examples of connecting wires, metal workpieces with thin edges, etc. – a wonderful opportunity to master all skills quickly and efficiently.

Important advice: this type of welding should only be done indoors. The fact is that the arc in such technologies can go out at the slightest breath of wind, not to mention gas flows, magnetic fields and other environmental factors.

It is best to sharpen the electrode at both ends: in this case, you will not need to waste extra time rearranging the consumables in the holder. In addition, the risk of consumable overheating during welding will be reduced.

And with sharpened ends, the holder can rotate 180° when one end overheats, so that the other end can continue working. This will also allow you to save on consumables.

The best option for filler materials is bronze alloy rods. They come with different diameters, which must be selected based on the thickness of the metal workpieces being connected, which is used in calculations using a special formula.

Another type of work in which squares are used is cutting metals.

Carbon welding of aluminum

Aluminum and its alloys are one of the most difficult and capricious metals for welding. Squares can handle aluminum.

This metal has low density combined with high thermal conductivity and resistance to corrosion. Aluminum melts at low temperatures - only 660°C. The difficulty is its intense interaction with oxygen, as a result of which the workpieces are covered with an oxide film in the form of aluminum oxide.

If we add to the “oxide” problem the high risk of formation of pores and cracks in the weld, then a complete set of “aluminum” welding problems will arise. Coal consumables can handle this set of troubles.

That is why these electrodes are widely used in specialized electrolysis shops for welding aluminum busbars. More often, butt seams are used on a graphite backing.

If two aluminum surfaces are joined, it is better to use carbon arc welding using a filler wire or rod, also made of aluminum.

As for the problem in the form of an oxide film, flux mixtures that are added directly to the edges of the weld seam can easily cope with it. Flux in this case is a homogeneous, finely dispersed mixture.

Source: https://tutsvarka.ru/vidy/ugolnyj-elektrod

Carbon electrodes

Carbon electrodes are needed specifically for making holes in various steel workpieces, for cutting and gouging metal, and also for welding copper wires.

They are necessary for industrial and steel enterprises, for the manufacture of various metal structures, in mechanical engineering and shipbuilding, as well as in other areas. Such electrodes are infusible, so their resources are practically not consumed during operation.

These tools do not deteriorate, so there is no need to constantly change them, which is extremely convenient when using them. However, they are not particularly common for private use, and in most cases are only used in industrial areas.

Carbon electrodes: what they are used for, how to cook with them correctly, pros and cons

Welding machine users mainly use low-melting steel rod electrodes.

But for non-ferrous metals or U-shaped welds, a carbon rod is required.

You can use it to cook, cut and melt. It's time to learn about the benefits of this type of product.

General information

What is such a welding electrode? This is a rod, its main component is coke coal. Its classic composition also includes other materials.

For example, metal powder, which makes the workpiece strong, resin is the unifying component. Its diameter (depending on the type) is 1.5-25 mm, and its length is 25-300 mm.

The production of a coal product is divided into three stages: at the first stage, a “mixture” of all materials is created, then the mixture is shaped, and at the end of production the rods are dried.

Scope of application

Most often, this consumable helps with air cutting of metals. Professional craftsmen who take on complex projects note that coal rods can be used to process various metals:

• Steels (carbon, low alloy);
• Non-ferrous metals (copper, aluminum, zinc);
• Light and heavy alloys (cast iron, tungsten and others).

When working with non-ferrous metals, a carbon rod will provide a reliable, neat connection. In the case of soldering with fusible rods, such a seam will not work.

Moreover, thanks to the carbon consumable, the process will be faster and easier. When processing bronze or cast iron, it is necessary to sharpen the end of the coal at an acute angle (approximately 60 degrees).

To increase the density of products, manufacturers spray a layer of copper powder on them. To save materials, this is done using an electrolytic lamp.

The coal billet along with copper powder is placed in a vessel with an electrolyte solution. There is an electrolytic field in the container, under the influence of which copper settles on the surface of the product.

The product of this process is a carbon electrode with a thin copper layer.

Varieties

The range of diameters is quite wide

Now the copper-plated electrode is available in five different versions. Each modification has its own area of ​​use. Carbon welding electrodes are:

• round (3.2-19 mm) – universal, for simple welding work;
• semicircular (diameter 10-19 mm) - they are used for cutting metal blanks;
• round endless - so called because during operation the material consumption will be minimal (compared to other types of electrodes);
• flat (diameter 8-25 mm) - such rods are square or rectangular in cross-section, and they are mainly used to correct defects on the steel surface;
• hollow (section 5-13 mm) - they are rarely used, but with the help of this type of electrodes you can form a characteristic U-shaped groove.

Results and conclusions

When working with a carbon electrode, there are two possible welding process options:

• right-handed - the welder moves the electrode from right to left, and immediately behind the rod there is an additive;
• left-handed - on the contrary, the electrode is moved from left to right, but the additive still follows it.

The right option is more efficient, taking into account the application of heat directly in the welding area. It is more convenient to weld parts with a large thickness using the right-hand method, and thin parts - using the left-hand method.

In addition, the speed of the “right-hand” work is approximately a quarter higher than the speed of the left-hand one. However, many welders often prefer the second method of work.

Carbon electrodes are generally used for working with copper and cutting metals. And thanks to their diversity, durability and convenience, they have found their use in the household.

Source: https://prosvarku.info/elektrody/ugolnyj-ehlektrod