Electrode Size:

The electrode size enhance as the base metal thickness enhance. However, the selection of electrode size is significant and should be made with care, based on the particular application. For a given current, a modification to a smaller electrode size results in a faster droplet transfer rate and thrrefore a higher melting rate because of an enhance in the current density.

 Welding Current:

While the current is too low, the molten metal fails to wet the joint surface and causes lack of fusion. While the current is too high, it gives increase to spatter, porosity and poor weld bead profile. With enhancing current, the melting rate of the electrode increases. For a given electrode size, enhancing the amperage within the working range results in (a) enhanced depth and width of weld penetration, (b) enhanced deposition rate, and (c) enhanced size of weld bead, provided all the other variables are kept constant.