Which Welding Rod for Exhaust Pipe Repair
Exhaust pipe is thin-wall tubing, usually 16-18 gauge mild steel or stainless. The challenge is welding thin material without burn-through while getting enough penetration to hold under vibration and heat cycling. The right rod depends on the pipe material, your welding process, and whether you are repairing or fabricating.
Recommended Electrodes
E6013
Best stick rod for mild steel exhaust. Light penetration and smooth arc minimize burn-through on thin pipe. Use 3/32 inch diameter at 35-50 amps.
ER70S-6
Best MIG wire for mild steel exhaust. Use 0.023 or 0.030 inch wire with 75/25 Ar/CO2. MIG gives the most control on thin material.
ER308L
Best TIG/MIG wire for 304 stainless exhaust. Use 100% argon for TIG, 98/2 Ar/CO2 for MIG. Back purge stainless tubing during TIG welding.
ER309L
For stainless-to-mild-steel joints at flanges and adapters. Compensates for carbon steel dilution to maintain corrosion resistance at the joint.
Technique Tips
Keep heat low. Tack every 1-2 inches before running full beads. Weld downhill on vertical sections for speed and reduced heat input. If stick welding, use the smallest diameter rod available. Whip technique helps control heat on thin material. For stainless, do not over-weld. One pass with proper penetration beats multiple passes that overheat the material.
Common Mistakes to Avoid
Using E6011 or E6010 on exhaust pipe. These rods have aggressive, deep-penetrating arcs that blow through thin tubing. Using 75/25 Ar/CO2 on stainless exhaust causes carbon pickup and reduces corrosion resistance. Welding over heavy rust without cleaning traps contaminants in the weld.
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