Stick Welding Performance Charts

[Gary Fowler]

View attachment 287786

These guidelines were taken from an old Miller SMAW training publication. Does the recommended amperage still apply to the new generation of inverter welders and is the rod chart still a reliable tool for selecting type and size? Also, is there any relationship between the diameter of the rod and the thickness of the metal being worked? TIA

To the thinner of the components, yes rod size is needed to control heat input but for heavier sections, larger rods are only needed for production. You could easily weld up a 4" + thickness using a 3/32" rod if you didnt have to power to burn larger diameter, it would just take you many more hours to do it.
Amperage to burn a welding rod is pretty much standard requirement whether using an old transformer style, gasoline powered or inverter powered machine as long as they are using the same current (AC or DC) I think DC requires less amperage that AC to run smoothly for the same size rod but I never use AC current since I got an AC/DC machine. I dont weld aluminum so AC is not needed presently at least in my shop. I also dont need high dollar MIG machine even though my power source would run one. I find I can do anything I need using SMAW process. If it gets too thin to use stick, I can always break out the oxy/acetylene torch and either braze it with brass or silver solder or oxy/acetylene weld it with carbon steel rods.

 

[Shield Arc]

Here is a chart I found on line, amazing what you can find on the Internet!:laughing:

 

[Beltzington]

Thanks for the continued responses - I have another related question, has anyone ever put a clamp-on inductive amp meter on the line side of the welder and compared the actual input current for each leg to the factory specs? If so where they pretty close?

 

[Reyer Farms]

I have never heard of PA-200 ??? Lincoln has a small reference for smaw. Very nice, my wife found them on their website a few years back. We gave the kids in 4H one show they could have a guide for different rods and manipulations. It will fit in you back pocket.

 

[k0ua]

PA200 is a nice little DC only inverter welder for up to 200 amps by Everlast.
I have a PA160 its little brother DC only Inverter for up to 160 amps by Everlast.
I use it for SMAW and TIG, and really enjoy it.
It is tiny , works very well, with a nice digital readout.

James K0UA

 

[Reyer Farms]

PA200 is a nice little DC only inverter welder for up to 200 amps by Everlast.
I have a PA160 its little brother DC only Inverter for up to 160 amps by Everlast.
I use it for SMAW and TIG, and really enjoy it.
It is tiny , works very well, with a nice digital readout.

James K0UA

Oh. Sounds nice, what's the duty on that beauty?

 

[Shield Arc]

The 160 has 35% duty cycle. The 200 and 300 have 60%.

Arc Welder| Stick Welder | Power Arc

 

[k0ua]

The 160 has 35% duty cycle. The 200 and 300 have 60%.

Arc Welder| Stick Welder | Power Arc

I believe the new 160STH is 35% , but my older PA160 is also rated at 60% duty cycle. I have burnt 6 in a row E7018's as fast as I could shove them in it, and it never got hot.

James K0UA

 

[undercut]

PA200 is a nice little DC only inverter welder for up to 200 amps by Everlast.
I have a PA160 its little brother DC only Inverter for up to 160 amps by Everlast.
I use it for SMAW and TIG, and really enjoy it.
It is tiny , works very well, with a nice digital readout.

James K0UA

Shoot, James. Everytime I hear about how much fun you are having with your PowerArc 160, I wanna drag my welder out and melt some metal .... Unfortunately, it's too darn wet and cold to do it!