Stick welding amperage chart
This stick welding amperage chart covers every common electrode from E6010 to E7024. Amperage ranges by rod size and by metal thickness, polarity settings, and which rod to grab for the job in front of you. Stick is the arc welding process that works outdoors in wind and on rusty steel that would ruin a MIG weld. No shielding gas, no wire feeder. Just a rod and an arc.
Quick answer
1/4 inch steel: 1/8" E7018 at 90–160 amps, DCEP (preferred) or AC. The most common structural setup.
How to read this chart
Start with the thickness table: find your metal, and it gives you a rod diameter and an amp range for the three rods most shops keep on hand. On 1/8" metal that means a 3/32" rod, and on 3/8" a 1/8" rod. The selector at the top of the page reads the same table. Then check the amps against the electrode table, which lists every size of each rod. Start in the middle of the range and drop some heat for vertical and overhead.
Arc welding amps to metal thickness
Rod size follows metal thickness. The rod sizes here are ESAB’s guideline for each thickness, and the amps are the published range for that rod size in the electrode table below, so the two tables always agree. On plate thicker than 3/4", stay on the 5/32" rod and run more passes.
Rod size per ESAB: 2.5 mm rod on 3–6 mm, 3.2 mm on 6–12 mm, 4.0 mm on 12–25 mm. A thickness right on a band edge gets the bigger rod.
Amperage by electrode and rod diameter
All ranges are starting points. Dial up or down based on joint fit-up, position, and how the puddle looks. When in doubt, start at the low end and bump up 5 amps at a time.
Polarity by electrode
Electrode selection by application
Rod storage
E7018 is a low-hydrogen rod, and so is E7028, the low-hydrogen drag rod. E7024 is not. Once the sealed can is opened, keep low-hydrogen rods in a rod oven at 250°F or hotter. For code work, AWS D1.1 gives E70XX rods 4 hours out of the oven (9 hours for moisture-resistant rods with an R in the class, like E7018 H4R). Past that, rebake them at least 2 hours at 500–800°F, and only once. Wet rods get thrown out. Your rod maker’s data sheet may be stricter. Moisture in the flux puts hydrogen in the weld, and that causes porosity and cracking.
E6010 and E6011 have cellulosic coatings that need some moisture to run right, so never bake them. E6013, E7014 and E7024 have rutile coatings. Keep all of them dry in the original packaging or a dry cabinet. No rod oven needed.
Questions welders keep asking
What amperage do I set for a 1/8 inch 7018 rod?
90–160 amps on DCEP. Most welders land around 120–130 amps for flat and horizontal on 1/4 inch steel. Start at 110 and bump up 5 amps at a time until the puddle wets out smoothly without undercutting.
What is the difference between E6010 and E6011?
Same penetration profile and tensile strength (60,000 psi). The difference is polarity: E6010 is DCEP only, E6011 runs on DCEP or AC. If you have a transformer (AC-only) machine like a Lincoln Tombstone, E6011 is your rod. If you have a DC inverter or engine drive, E6010 gives a slightly more aggressive arc.
Why won't my E6010 run on AC?
E6010 has a cellulosic (sodium-based) flux coating that needs a stable DC arc to stay lit. AC reverses polarity 120 times per second, and the E6010 coating can't re-ignite the arc fast enough. It just sputters and sticks. Use E6011 (potassium-based coating) on AC machines instead. Same penetration, just designed for AC re-ignition.
Do I need a rod oven for 7018?
Yes, if you are doing code work (AWS D1.1, API 1104, ASME). Low-hydrogen rods pick up moisture from shop air, and that moisture puts hydrogen in the weld, the main cause of hydrogen cracking. Keep opened 7018 in an oven at 250°F or hotter. D1.1 allows 4 hours out of the oven for E7018 (9 hours for H4R moisture-resistant rods). Past that, rebake at least 2 hours at 500–800°F, once. For non-code farm and ranch repair, most shops keep them in a sealed container and they are fine.
Which rod do I use on rusty or painted steel?
E6010 or E6011. The cellulosic flux coating produces a deep, digging arc that burns through rust, mill scale, paint, and galvanizing. E7018 is a smoother rod but it will not tolerate dirty base metal. If you have to weld on junk and cannot grind it clean first, grab a 6010.
What rod size should I use for thin metal?
Use the smallest rod that gets the job done. For 1/8" material, a 3/32" rod: E6013 at 40–90 amps or E7018 at 70–110 amps. Thinner than that is TIG or MIG work, but if stick is all you have, a 1/16 inch E6013 runs 20–40 amps. E6013 has the shallowest penetration of the common rods, so it is the least likely to blow through. Keep a tight arc length and move fast.
Can I run 7018 vertical up?
Yes. 7018 is one of the best rods for vertical-up. Use a slight weave or triangle pattern. Drop your amps about 10–15% below your flat setting. For 1/8 inch rod, try 100–120 amps. Keep a short arc length and let the puddle freeze before moving up. If the puddle sags, you are too hot or moving too slow.
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