Choosing the best welding rod for mild steel can make the difference between a strong, clean weld and a frustrating experience filled with spatter and weak joints. With several electrode types available, each designed for specific applications and skill levels, knowing which rod to reach for is essential.
Mild steel accounts for roughly 85% of all steel production, making it the most common material welders work with. Whether you're building structural frames, repairing automotive parts, or tackling DIY projects, the right electrode will save you time and deliver professional results.
This expert guide breaks down the top welding rod options, helping you match the perfect electrode to your specific project needs and welding setup.
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Types of Welding Rods for Mild Steel
Different welding rods for mild steel work better for specific jobs based on their coating and arc characteristics. The E6010, E6011, E6013, and E7018 rods each offer distinct advantages depending on your welding position, power source, and skill level.
E6010 Rods - Deep Penetration
E6010 welding rods create a deep, forceful arc that cuts through rust, paint, and mill scale on mild steel. You can only use these rods with DC power sources, which limits their flexibility but makes them excellent for root passes on pipe work.
The cellulose coating burns hot and produces a lot of spatter. This creates a rough bead appearance that requires cleanup.
You'll find E6010 rods useful when working on dirty or poorly prepared metal. They excel in vertical and overhead positions because the fast-freezing slag helps control the weld pool.
The deep penetration means you get strong welds even on contaminated surfaces. However, the aggressive arc requires steady hand control and practice to master.
These rods work well for farm repairs, pipeline construction, and structural steel where penetration matters more than bead appearance. The tensile strength of 60,000 psi makes them suitable for most mild steel applications.
E6011 Rods - AC/DC Versatility
E6011 welding rods function almost identically to E6010 rods but work with both AC and DC welding machines. This makes them more versatile if you have an AC-only stick welder or need to switch between power sources.
The potassium-based coating allows the rod to work with alternating current. You still get deep penetration and good performance on dirty metal.
The arc characteristics are slightly softer than E6010, which some welders find easier to control. You can use these rods in all positions, including vertical-up and overhead work.
E6011 rods produce similar spatter levels to E6010. The slag peels off easily after welding.
You'll appreciate these rods when equipment limitations require AC welding. They're common in maintenance and repair work where you can't always choose your power source. The 60,000 psi tensile strength handles standard mild steel fabrication needs.
E6013 Rods - Easy for Beginners
E6013 welding rods are the easiest welding rod for mild steel to learn with because they create a soft, stable arc with minimal spatter. The high-titania coating produces smooth beads that look clean without much cleanup work.
These rods work with both AC and DC current. You can weld in all positions, though they perform best on flat and horizontal joints.
The shallow penetration makes E6013 rods ideal for thin sheet metal and light gauge steel. You won't burn through material as easily as with E6010 or E6011 rods.
The slag forms a thick coating that's simple to remove. The bead appearance is smooth and uniform, which matters for visible welds.
You'll find E6013 welding rods perfect for body panels, sheet metal fabrication, and general repairs where appearance counts. They don't handle dirty or rusty metal well, so surface preparation is important. The 60,000 psi tensile strength works fine for non-critical applications.
E7018 Rods - Professional Standard
E7018 welding rods are the professional standard for structural mild steel welding because they produce strong, crack-resistant welds with excellent mechanical properties. The low-hydrogen coating prevents hydrogen-induced cracking in thick sections and high-strength applications.
You must use DC power with E7018 rods for best results, though some versions work with AC. The arc is smooth and easy to control, with very little spatter.
The slag forms a heavy coating that protects the weld as it cools. It chips off cleanly to reveal smooth, flat beads.
These rods require dry storage because moisture in the coating introduces hydrogen into the weld. Keep them in a rod oven at 250-300°F to maintain their low-hydrogen properties.
E7018 welding rods have a tensile strength of 70,000 psi, which exceeds most mild steel base metals. You can weld in all positions with proper technique.
You'll use these rods for pressure vessels, structural steel, bridges, and any critical welds that need inspection or certification. They cost more than E6013 or E6010 rods but deliver superior quality. The E7024 rod is similar but designed specifically for flat and horizontal welding with even higher deposition rates.
Need professional-grade strength for your next project? Shop our 7018 welding rod collection for high-quality electrodes that deliver reliable, structural-grade welds.
How to Choose the Right Welding Rod
Your power source, material thickness, and rod coating all play direct roles in how well your weld turns out. Getting these three factors right means better arc control, stronger welds, and less cleanup.
Consider Your Power Source
Your welding machine determines which rods you can run effectively. AC machines work well with E6011 and E6013 rods, which are designed to handle the alternating current without arc instability. DC machines give you more options, including E7018, which runs best on DC reverse polarity.
If you're using a smaller inverter welder, you need to check the amperage range. Some compact machines max out around 90-140 amps, which limits you to thinner rods like 3/32" diameter. Larger transformer-based machines handle 1/8" and 5/32" rods without issue because they provide stable power at higher amperage.
TIG welders require filler rods instead of stick electrodes. ER70S-6 is the standard choice for mild steel TIG work. It feeds smoothly and produces clean welds when you maintain proper gas coverage and torch angle.
Match Rod Size to Material Thickness
Thicker steel needs larger diameter rods and higher amperage to get proper penetration. Thin material requires smaller rods and lower heat to avoid burn-through.
|
Material Thickness |
Recommended Rod Size |
Typical Amperage |
|
Up to 1/8" |
3/32" |
70-100 amps |
|
1/8" to 1/4" |
1/8" |
90-140 amps |
|
1/4" and thicker |
5/32" or 3/16" |
140-220 amps |
A 3/32" rod works for angle iron repairs and lighter fabrication. When you're welding structural steel or heavy brackets, step up to 1/8" or larger. The rod diameter affects how much filler metal you deposit per pass and how deep the arc penetrates.
Evaluate Coating Type and Properties
Rod coating affects arc behavior, slag formation, and which welding positions you can use. E7018 has a low-hydrogen coating that produces minimal spatter and works in all positions—flat, horizontal, vertical, and overhead. This makes it reliable for structural work where weld quality matters.
E6011 has a cellulose coating that creates a forceful arc, making it good for vertical-up welding and dirty or rusty steel. The trade-off is more spatter and a rougher bead appearance. E6013 uses a rutile coating that's easier to control for beginners but produces weaker welds than E7018.
Low-hydrogen rods like E7018 need proper storage in a rod oven. Moisture absorption weakens the coating and can cause porosity in your welds. Rods with rutile or cellulose coatings are less sensitive to moisture but still perform better when kept dry.
Best Welding Rods for Common Mild Steel Projects
Different projects need different rods based on metal thickness, position, and finish quality. ER70S-6 TIG rods work well for thin materials and precision work, while 7018 welding rods handle heavy structural jobs, and 6013 welding rods fit general repairs and sheet metal.
Structural Steel and Fabrication
For structural steel work, 7018 welding rods are your best choice. These rods create strong, crack-resistant welds on thick mild steel beams, columns, and frames. They work in all positions and produce smooth beads with minimal spatter.
The 7018 rod has a low-hydrogen coating that prevents weld defects in heavy sections. You can use these rods on bridge components, building frames, and industrial equipment. They require proper storage in a rod oven to keep moisture out of the coating.
For lighter structural work under 1/4 inch thick, ER70S-6 TIG rods give you more control and cleaner welds. These rods let you run higher currents with CO2 shielding gas. The ARCCAPTAIN E7018 rods offer reliable performance for professional fabrication shops that need consistent quality across multiple projects.
Auto Body and Sheet Metal Work
Sheet metal welding requires rods that won't burn through thin material. ER70S-6 rods in 1/16 inch diameter give you the precision needed for auto body panels and thin mild steel. These rods produce minimal heat input and clean beads that need little grinding.
For stick welding on auto repairs, 6013 welding rods work well on dirty or painted surfaces. They handle rust and oil better than other mild steel welding rods. The 6013 creates a softer arc that's easier to control on thin gauge metal.
TIG welding with ER70S-6 rods gives you the smoothest finish for visible body panels. The copper coating on these rods prevents oxidation and ensures steady wire feeding. You can weld body patches, floor pans, and custom fabrication with minimal post-weld cleanup.
Pipe Welding and Repair Jobs
Pipe welding demands rods that produce strong root passes and fill layers. The best welding rods for mild steel pipe are 6010 for root passes and 7018 for fill and cap passes. This combination gives you full penetration and a smooth surface finish.
For maintenance and repair work, 6013 welding rods handle quick fixes on farm equipment, gates, and machinery. These rods work on AC or DC current and tolerate poor fit-up conditions. They're forgiving for repairs where you can't control surface preparation.
ER70S-6 TIG rods excel at joining thin-wall pipe and tubing. The 3/32 inch diameter handles pipe from 1/8 inch to 3/16 inch wall thickness. You get better control over heat input and can make precise welds on pressure vessels and hydraulic lines.
\Looking for versatile, easy-to-use electrodes? Explore our 6013 welding rods collection perfect for general fabrication and repair work on mild steel.
Conclusion: Best Welding Rods for Mild Steel
Selecting the best welding rod for mild steel depends on your specific project requirements, skill level, and working conditions. E6013 offers versatility for general work, E7018 delivers maximum strength for structural applications, and E6010 excels in challenging outdoor environments. Understanding each rod's characteristics ensures you'll achieve strong, reliable welds every time.
Start with the rod that matches your current project needs and gradually expand your skills with different electrodes. Practice proper storage techniques to maintain rod quality, and always prepare your base metal appropriately for the electrode you're using.
Want to dive deeper into one of the most popular welding rods? Check out our comprehensive guide on 6013 welding rod uses to master this versatile electrode for your next project.
Frequently Asked Questions: Best Welding Rod for Mild Steel
The right welding rod for mild steel depends on your project requirements, with E6013 being the most beginner-friendly and E7018 offering the highest strength for structural work. Storage conditions and proper rod selection can make the difference between a clean weld and a failed joint.
What is a good mild steel welding rod?
E6013 is a good all-purpose mild steel welding rod for most general projects. It produces a smooth, clean bead with minimal spatter and works well on thin to medium thickness steel. For dirtier conditions or outdoor work, E6011 cuts through rust and contaminants more effectively.
Which is better, 6013 or 7018?
E6013 is better for beginners and thin steel because it's easier to control and produces less spatter. E7018 is better for professional work requiring high strength with 70,000 psi tensile strength compared to E6013's 60,000 psi. Use E6013 for light fabrication and E7018 for critical structural welds.
What is a 309 welding rod used for?
A 309 welding rod is designed for welding stainless steel, not mild steel. It's specifically made for joining dissimilar metals like stainless steel to mild steel or carbon steel. For mild steel to mild steel welding, stick with rods like E6010, E6011, E6013, or E7018.
Is 6010 or 7018 better for welding?
E6010 is better for deep penetration welding on dirty or rusty surfaces and ideal for outdoor repair work. E7018 is better for clean steel requiring maximum strength with smoother beads and less risk of cracking. For general shop work on clean steel use E7018, for field repairs and dirty conditions use E6010.