Electrodes used in the manual metal arc welding process are generally referred to as stick electrodes and consist of a core wire with a thick coating. Stick electrodes are produced in an electrode press, usually at a rate of 500-1,000 units per minute.

The core wire coating is a composite of many different ingredients, such as powdered minerals, ferroalloys and iron powder. Specific amounts of each constituent are weighed and then mixed together to form a dry coating mix. A liquid binder is then added to make a moist coating mix with the right consistency for extrusion.

Core wire is prepared from a wire rod, typically 5-6 mm in diameter. After de-scaling, the wire rod is drawn to the appropriate diameter, straightened, and then cut to the required length.

The moist coating mix is extruded onto the cut core wires in an electrode press. Immediately after the pressing operation, the tip at the electrode’s striking end is cleaned by brushes. A portion of the extruded coating is also brushed off the end where the electrode is to be fixed in the electrode holder. The extruded electrodes are dried in ovens to remove any residual moisture left by the binder. Finally, before packing, each electrode is printed with its classification and /or the manufacturer’s designation.