# US 9,006,611 B2 · Manual welding electrode > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,006,611 B2 - Document ID: US9006611B2 - Status: Granted - Kind: B2 - Application number: 13/714,857 - Filed: 2012-12-14 - Published: 2013-04-25 - Granted: 2015-04-14 - Earliest claimed: 2009-03-05 - Assignees: Lincoln Global, Inc. - Applicants: Lincoln Global, Inc. - Inventors: Ashish Kapoor; Michael Morlock - Web page: https://patentgrep.com/patent/US9006611B2 ## CPC - H01R 43/00: Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors (of trolley lines B60M1/28) - B23K 35/0266: {flux-cored} - B23K 35/362: Selection of compositions of fluxes (B23K35/365, B23K35/368 take precedence) - B23K 35/404: {Coated rods; Coated electrodes} - Y10T 29/49204: Contact or terminal manufacturing - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An electrode for use in a welding process may comprise a finite length electrode core. The electrode core may be encapsulated at least partially within a coating comprising a flux material. One end of the electrode core may be tapered from a first diameter D to a second smaller diameter D1. The tapered end may further be covered with a coating that enhances the arc starting capabilities of the electrode. ## Claims ### Claim 1 A method of manufacturing a manual electrode for shielded metal arc welding with improved arc striking capabilities while minimizing said electrode sticking to a weldments during arc initiation through at least a higher current density for starting the welding arc for the welding of high tensile strength weldments, comprising the steps: extruding a contiguously formed metal core wire; dividing the contiguously formed metal core wire into finite length electrode cores; tapering at least one of the ends of each of the finite length electrode cores, thereby defining an electrode core body having a diameter D and an electrode core tip having a diameter D1; wherein the electrode core tip narrows from the diameter D to the smaller diameter D1 by grinding, and wherein the electrode core tip is tapered at a substantially constant slope with respect to a centerline axis; fashioning a flat on the at least one of the ends of each of the finite length electrode cores; coating the electrode core tip and electrode core tip taper with an electrically conductive substance comprising at least one of a silicate and graphite; and coating the electrode core body with a low hydrogen flux coating. ### Claim 2 (depends on 1) The method as defined in claim 1, wherein the electrode core tip has a diameter in the range substantially between 0.039 inch and 0.052 inch. ### Claim 3 (depends on 1) The method as defined in claim 1, wherein the low-hydrogen flux coating deposits hydrogen in an amount of less than 5 ml per 100 grams of weld metal. ### Claim 4 (depends on 3) The method as defined in claim 3, wherein the low-hydrogen flux coating deposits hydrogen in an amount of less than 4 ml per 100 grams of weld metal. ### Claim 5 (depends on 3) The method as defined in claim 3, wherein the step of grinding tapers the electrode tip to the diameter D1, wherein D1 is substantially in the range between 0.039 inch and 0.052 inch. ### Claim 6 The method as defined in step 4 wherein the step of grinding tapers the electrode tip to a diameter of substantially 0.045 inch. ### Claim 7 A method of forming a stick welding electrode for shielded metal arc welding with improved arc striking capabilities while minimizing said electrode sticking to a weldment during arc initiation through at least a higher current density for starting the welding arc for the welding of high tensile strength weldments, comprising: extruding a solid electrode core comprising an electrode core body having a larger diameter D and an electrode core tip having a smaller diameter D1, wherein the diameter D1 is in a range between 0.025 inch and 0.125 inch; applying a low-hydrogen electrode coating to the electrode core body, wherein the low-hydrogen electrode deposits hydrogen in an amount of less than 5 ml per 100 grams of weld metal; shaping and substantially centering the electrode core tip about a centerline axis of the electrode core body, and wherein the electrode core tip tapers at a substantially constant slope with respect to the centerline axis of the electrode core body; coating said electrode core tip and core tip taper with an electrically conductive substance comprising a silicate; and further wherein a face of the electrode core is substantially planar. ### Claim 8 (depends on 7) The method of claim 7 wherein said electrically conductive substance further comprises graphite. ### Claim 9 (depends on 7) The method of claim 7 wherein said step of shaping and substantially centering uses at least one of grinding, coining or cold stamping. ### Claim 10 (depends on 7) The method of claim 7, wherein said step of applying the low-hydrogen flux coating deposits hydrogen in an amount of less than 5 ml per 100 grams of weld metal. ### Claim 11 (depends on 10) The method of claim 10, wherein said step of applying the low-hydrogen flux coating deposits hydrogen in an amount of less than 4 ml per 100 grams of weld metal.