Welding Rod Size to Amperage Converter
Convert welding rod electrode sizes to recommended amperage ranges for stick welding (SMAW).
Covers E6010, E6013, E7018, and E7024.
Select an electrode type and size to see the recommended amperage range.
Understanding Welding Rod Sizes and Amperage
In stick welding (Shielded Metal Arc Welding / SMAW), the electrode rod diameter directly determines the amperage range needed. Using the correct amperage is critical: too low causes poor penetration and a cold weld, while too high causes burn-through, excessive spatter, and overheating. The general rule of thumb is approximately 1 amp per 0.001 inch of electrode diameter, but the exact range varies by electrode type.
Common Electrode Classifications:
The electrode designation system (e.g., E7018) encodes key information:
- E = Electrode
- First two digits (70) = Minimum tensile strength in thousands of PSI (70,000 PSI)
- Third digit (1) = Welding positions (1 = all positions, 2 = flat and horizontal only)
- Fourth digit (8) = Flux coating type, current type, and penetration characteristics
Amperage Ranges by Rod Size and Type:
E6010 (Deep Penetration, DC only):
| Diameter | Diameter (mm) | Amperage Range | Material Thickness |
|---|---|---|---|
| 3/32" | 2.4 | 40-80 A | Up to 3/16" (4.8 mm) |
| 1/8" | 3.2 | 75-130 A | 3/16"-1/4" (4.8-6.4 mm) |
| 5/32" | 4.0 | 110-165 A | 1/4"-3/8" (6.4-9.5 mm) |
| 3/16" | 4.8 | 140-210 A | 3/8"-1/2" (9.5-12.7 mm) |
E6013 (General Purpose, AC or DC):
| Diameter | Diameter (mm) | Amperage Range | Material Thickness |
|---|---|---|---|
| 1/16" | 1.6 | 20-40 A | Sheet metal |
| 3/32" | 2.4 | 40-90 A | Up to 3/16" (4.8 mm) |
| 1/8" | 3.2 | 80-130 A | 3/16"-1/4" (4.8-6.4 mm) |
| 5/32" | 4.0 | 105-180 A | 1/4"-3/8" (6.4-9.5 mm) |
| 3/16" | 4.8 | 150-230 A | 3/8"-1/2" (9.5-12.7 mm) |
E7018 (Low Hydrogen, AC or DC, most popular structural rod):
| Diameter | Diameter (mm) | Amperage Range | Material Thickness |
|---|---|---|---|
| 3/32" | 2.4 | 65-100 A | Up to 3/16" (4.8 mm) |
| 1/8" | 3.2 | 110-165 A | 3/16"-1/4" (4.8-6.4 mm) |
| 5/32" | 4.0 | 150-220 A | 1/4"-3/8" (6.4-9.5 mm) |
| 3/16" | 4.8 | 200-275 A | 3/8"-1/2" (9.5-12.7 mm) |
| 7/32" | 5.6 | 260-340 A | 1/2"+ (12.7+ mm) |
| 1/4" | 6.4 | 300-400 A | 3/4"+ (19+ mm) |
E7024 (High Deposition, Flat and Horizontal Only):
| Diameter | Diameter (mm) | Amperage Range | Material Thickness |
|---|---|---|---|
| 1/8" | 3.2 | 100-160 A | 3/16"-1/4" |
| 5/32" | 4.0 | 140-225 A | 1/4"-3/8" |
| 3/16" | 4.8 | 180-290 A | 3/8"-1/2" |
| 7/32" | 5.6 | 250-350 A | 1/2"+ |
| 1/4" | 6.4 | 300-400 A | 3/4"+ |
Rod Selection Guidelines:
- E6010: Best for root passes, dirty or rusty metal, and pipe welding. Deep penetration. DC only.
- E6013: Good all-around rod for beginners. Easy arc start, smooth bead. Works on AC or DC.
- E7018: The industry standard for structural steel. Low hydrogen prevents cracking. Must be kept dry.
- E7024: High deposition rate for flat/horizontal welds. Iron powder coating. Great for production work.
Rod Size Selection Rule of Thumb:
The electrode diameter should not exceed the thickness of the base metal. For thin material, use a smaller rod at lower amperage. For thick material, use a larger rod (or multiple passes with a medium rod) at higher amperage.