E6013 Welding Problems and Solutions: Complete Troubleshooting Guide
Updated March 2026 – Comprehensive troubleshooting guide for E6013 welding electrode problems including porosity, spatter, weak welds, cracking, and cold fusion.
Pre-Troubleshooting Checklist
Verify these basics before diagnosing weld problems:
- Electrode stored dry away from moisture
- Machine properly grounded to workpiece
- Correct electrode size for thickness
- Amperage set per package recommendations
- Slag removed between passes
- Base metal cleaned of rust, paint, oil
- Travel speed consistent and moderate
- Electrode angle 15-30 degrees from vertical
- Adequate work area ventilation
- All safety equipment worn
Five Major Problems with Solutions
Problem 1: Porosity
What It Looks Like
Gas pockets and holes in weld. Tiny craters visible. X-ray shows internal voids. Weld appears weak.
Causes
- Electrode exposed to moisture
- Base metal contamination from rust, oil, paint
- Travel speed too fast
- Poor ventilation and wind
- Amperage too low
- Arc length too long
- Humid storage
Solutions
- Dry electrode at 300-350F for 1 hour
- Clean base metal completely with wire brush
- Reduce travel speed
- Use correct amperage per package
- Keep arc at 1/8 inch from metal
- Eliminate wind and drafts
- Replace electrodes stored over 6 months
Problem 2: Excessive Spatter
What It Looks Like
Metal balls ejected 2-3 inches from weld. Messy appearance. Heavy cleanup required.
Causes
- Current too high
- Electrode angle incorrect
- Arc length too long
- Contaminated electrode
- Dirty base metal
- Improper storage
- Speed too slow
Solutions
- Lower amperage 10-15 percent
- Hold electrode at 15-30 degree angle
- Keep arc at 1/8 inch
- Discard damaged rods
- Clean base metal thoroughly
- Store in dry container
- Increase travel speed
- Use anti-spatter spray
Problem 3: Weak Welds
What It Looks Like
Weld breaks under light stress. Fails bend test. Poor fusion visible. Appears concave or undercut.
Causes
- Current too low
- Travel speed too fast
- Poor starts and stops
- Wrong electrode type
- Arc length too long
- Base metal too thick
- Slag not removed
- Wrong angle
Solutions
- Increase amperage
- Slow travel speed
- Complete fusion at ends
- Use E7018 for critical work
- Reduce arc length to 1/8 inch
- E6013 works to 6mm, use E7018 thicker
- Remove slag between passes
- Proper electrode angle
Problem 4: Cracking
What It Looks Like
Visible cracks in bead. X-ray shows cracks along length. Fails stress test. Hot or cold cracks.
Causes
- Rapid cooling
- Restrained joint
- High carbon steel
- Hydrogen absorption
- Poor preheat
- Too much heat
- Single pass thick material
- Bad edge prep
Solutions
- Allow slow natural cooling
- Preheat to 100-200F
- Use E7018 for critical work
- Keep electrode dry
- Use multiple smaller passes
- Reduce heat input
- Stress relieve if needed
- Proper edge preparation
Problem 5: Cold Fusion
What It Looks Like
Poor bonding between weld and base metal. Dull line at interface. Joint separates under stress.
Causes
- Arc length too long
- Current too low
- Speed too fast
- Contaminated base metal
- Wrong angle
- Poor arc starting
- Bad grounding
- Bad joint design
Solutions
- Keep arc at 1/8 inch from metal
- Increase amperage for heat
- Slow travel speed
- Clean contamination from base
- Angle electrode 15-30 degrees
- Establish arc before moving
- Ensure good ground contact
- Reject and reweld
Quick Diagnostic Table
| Problem | Cause | Fix |
|---|---|---|
| Holes or pockets | Porosity | Dry electrode, clean metal |
| Metal balls | Spatter | Lower current, reduce arc |
| Breaks under stress | Weak fusion | Increase current, slow travel |
| Visible cracks | Cracking | Slow cooling, preheat |
| Dull bond line | Cold fusion | Increase penetration and heat |
| Excessive smoke | High current | Lower amperage |
| Arc won’t start | Damp electrode | Dry electrode |
| Uneven bead | Inconsistent speed | Steady travel |
Prevention Best Practices
Storage
- Store below 85F and 50% humidity
- Use sealed containers with desiccant
- No heat sources or direct sunlight
- No exposed open packages
- Replace after 6 months improper storage
- Use first-in-first-out system
Preparation
- Clean all base metal with stainless brush
- Remove rust, scale, paint, oil
- Ground to clean steel surface
- Bevel edges over 3mm thickness
- Pre-clean all joints thoroughly
- Remove slag between passes completely
Technique
- Set amperage per package chart
- Keep arc length 1/8 inch consistent
- Hold at 15-30 degree angle
- Steady travel speed
- No excess weaving
- Establish arc before moving
- Complete fusion at ends
E6013 Amperage by Thickness
| Thickness | Size | Amperage | Passes |
|---|---|---|---|
| 0.5-1mm | 1/16 | 20-40A | 1 |
| 1-2mm | 1/16 | 30-60A | 1 |
| 2-3mm | 1/8 | 60-100A | 1-2 |
| 3-5mm | 5/32 | 100-140A | 2-3 |
| 5-6mm | 3/16 | 140-180A | 3-4 |
| Over 6mm | 3/16 | 180A+ | Multiple/E7018 |
FAQs
A: Amperage too low or arc too long. Increase current and reduce arc length.
A: Porosity forming. Lower speed, clean metal, dry electrode, reduce arc length.
A: Lower current slightly, slower speed, center arc over joint.
A: No. Clean all contamination first. Dirty metal causes poor welds.
A: Only if exposed to moisture. Dry storage needs no additional drying.
A: 1000-1200F for 1 hour, cool slowly. Check material specs.
A: No. Only mild and carbon steel. Use aluminum rods for aluminum.
A: 6 months in proper dry conditions. Replace if stored improperly.
A: Current too high or speed too slow. Lower amperage and increase speed.
A: Inspect visually for cracks. Perform bend tests on samples.
Summary
E6013 electrodes are beginner-friendly but require proper technique. Five major problems – porosity, spatter, weak welds, cracking, and cold fusion – all have identifiable causes and solutions. Success requires proper storage, preparation, correct technique, and quality control. Store electrodes dry, clean base metal thoroughly, set proper amperage, maintain 1/8 inch arc length, use steady travel speed, and remove slag between passes. E6013 works well for general purpose, automotive, and thin to medium thickness applications up to 6mm. For thicker material or critical applications, use E7018 instead. Proper diagnosis and correction of problems ensures high quality welds.