Welding rusty metal can be a real pain. Instead of getting a clean, strong weld, you end up with porosity, slag inclusions, and a whole lot of frustration. Using the right welding rod makes all the difference. It can turn a difficult job into a manageable one, saving you time and materials. So, if you’re tired of struggling with rusty metal, read on – I’ve tested a bunch of rods to find the best ones for the job.
Here’s a quick look at my top picks:
- Lincoln Electric Fleetweld 35: Best overall for general rusty steel.
- Hobart 770140 3/32″ Stick Electrodes: Great for thinner, heavily rusted material.
- Blue Demon E7018 AC: Low hydrogen rod, excellent for thicker rusty sections.
- Forney 309L Stainless Steel Rods: Ideal for welding stainless to rusty steel.
- US Forge E6011 Welding Rod: Deep penetration on dirty, rusty surfaces.
Top 5 Best Welding Rods for Rusty Metal
Lincoln Electric Fleetweld 35
The Lincoln Electric Fleetweld 35 is a versatile and widely available welding rod. It’s known for its ease of use and ability to produce good welds even on less-than-perfect surfaces, making it a solid choice for rusty metal. These rods run smoothly and have decent penetration.
Pros:
- ✅ Easy to strike and maintain an arc.
- ✅ Works well with AC or DC power.
- ✅ Produces a relatively clean weld with minimal spatter.
Cons:
- ❌ Slag can be a bit stubborn to remove at times.
- ❌ Not ideal for very thin gauge metal.
- ❌ Can be prone to porosity if the rust is excessive.
Verdict: A great all-around choice for general purpose welding on rusty steel. Good for beginners and experienced welders alike.
Hobart 770140 3/32″ Stick Electrodes
Hobart 770140 electrodes are designed for mild steel welding, and they perform surprisingly well on rusty metal, especially thinner materials. The 3/32″ size makes them well-suited for smaller welding machines and finer work. I’ve used these on auto body repair with good results.
Pros:
- ✅ Excellent for thin metal due to the smaller diameter.
- ✅ Relatively low spatter compared to other rods.
- ✅ Easy to control the arc, even for beginners.
Cons:
- ❌ Not suitable for thick or heavily rusted materials.
- ❌ May require a lower amperage setting, which can take some experimenting.
- ❌ Can burn through easily if you’re not careful.
Verdict: Best for welding thin, rusty sheet metal where precision and minimal heat input are required.
Blue Demon E7018 AC
The Blue Demon E7018 AC is a low hydrogen electrode that’s specifically designed to produce high-quality welds. The low hydrogen content helps prevent cracking, making it suitable for thicker sections and restrained joints, even with some rust present. These are my go-to for critical welds.
Pros:
- ✅ Produces very strong and ductile welds.
- ✅ Low hydrogen content reduces the risk of cracking.
- ✅ Works well on thicker materials and restrained joints.
Cons:
- ❌ Requires a higher level of skill to use effectively.
- ❌ Must be stored in a dry environment to prevent moisture absorption.
- ❌ More expensive than other welding rods.
Verdict: Ideal for welding thicker, load-bearing rusty steel where weld integrity is paramount. Best for experienced welders.
Forney 309L Stainless Steel Rods
Forney 309L stainless steel rods are designed for welding stainless steel to carbon steel, but they can also be used effectively on rusty steel. The stainless steel composition resists corrosion and produces a strong, durable weld. This is especially useful when dealing with dissimilar metals or situations where corrosion resistance is important.
Pros:
- ✅ Excellent for welding dissimilar metals (stainless to steel).
- ✅ Produces a corrosion-resistant weld.
- ✅ Can tolerate some surface contamination, including rust.
Cons:
- ❌ More expensive than carbon steel welding rods.
- ❌ Requires a slightly different welding technique.
- ❌ Can be prone to cracking if not used properly.
Verdict: Best for welding stainless steel to rusty steel or when you need a corrosion-resistant weld on rusty material.
US Forge E6011 Welding Rod
US Forge E6011 welding rods are known for their deep penetration and ability to weld through dirty, rusty, or painted surfaces. They’re a great choice when you don’t have time to thoroughly clean the metal. The E6011 is a fast-freeze rod, which helps with out-of-position welding too.
Pros:
- ✅ Excellent penetration for welding through rust and dirt.
- ✅ Works well on AC or DC power.
- ✅ Good for out-of-position welding.
Cons:
- ❌ Produces a rougher weld bead compared to other rods.
- ❌ More spatter than other welding rods.
- ❌ Slag can be difficult to remove.
Verdict: Best for situations where you need to weld quickly and don’t have time to clean the metal thoroughly. A good choice for field repairs and general fabrication on rusty steel.
Buying Guide
Choosing the right welding rod for rusty metal involves considering several factors. Here’s what you should keep in mind:
- Material Thickness: For thin metal, use a smaller diameter rod (like 3/32″) to avoid burn-through. For thicker metal, use a larger diameter rod (like 1/8″) for better penetration.
- Type of Rust: Light surface rust can be welded through with the right rod (like E6011). Heavy, flaking rust should be removed as much as possible before welding.
- Welding Position: Some rods are better suited for out-of-position welding (vertical, overhead) than others. E6011 is a good choice for these situations.
- Welding Machine: Make sure the rod is compatible with your welding machine (AC or DC). Some rods work with both, while others are designed for one or the other.
- Skill Level: Some rods are easier to use than others. If you’re a beginner, start with a forgiving rod like Fleetweld 35.
- Desired Weld Quality: If you need a high-quality, crack-resistant weld, choose a low hydrogen rod like E7018.
- Cleanliness: Even with rods designed for rusty metal, try to clean the welding area as much as possible. A wire brush or grinder can help remove loose rust and scale.
FAQs
Q: Can I weld directly over rust?
A: While some welding rods are designed to weld through rust, it’s always best to remove as much rust as possible for a stronger and cleaner weld. Use a wire brush or grinder to clean the area before welding.
Q: What amperage should I use when welding rusty metal?
A: The ideal amperage depends on the rod diameter, metal thickness, and type of rust. Start with the manufacturer’s recommended amperage range and adjust as needed to achieve a stable arc and good penetration. Usually, a slightly higher amperage is needed to burn through the rust.
Q: Do I need to use a special technique when welding rusty metal?
A: Yes, use a slightly slower travel speed and a weaving motion to ensure good penetration and fusion. Be prepared for more spatter and slag than when welding clean metal.
Q: What does “low hydrogen” mean?
A: Low hydrogen rods, like E7018, have a special coating that minimizes the amount of hydrogen in the weld. Hydrogen can cause cracking, especially in thicker materials or restrained joints. These rods need to be stored in a dry place to prevent moisture absorption.
Q: Why use stainless steel rods on rusty steel?
A: Stainless steel rods, like 309L, are used to weld dissimilar metals, such as stainless steel to carbon steel. They also provide a corrosion-resistant weld, which can be beneficial when welding rusty metal that may be exposed to the elements.
Conclusion
Welding rusty metal doesn’t have to be a nightmare. By choosing the right welding rod and following a few simple techniques, you can achieve strong, reliable welds. Whether you’re doing general fabrication, auto body repair, or working on a rusty trailer, there’s a welding rod out there that can make the job easier. Hopefully, this guide helps you pick the best one for your needs.
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