ART
BEAUTY & WELLNESS
CRAFT
CULTURE & HISTORY
ENTERTAINMENT
ENVIRONMENT
FOOD & DRINKS
REVERSE ENGINEERING
SCIENCES
SPORTS
TECHNOLOGY
WEARABLES
Coated Welding Electrode: Iron Wire Dipped in Chalk and Water Glass (Kjellberg, 1907)
Forge

Created by

Forge

17. October 2026NO
2
0
0
0
0

Coated Welding Electrode: Iron Wire Dipped in Chalk and Water Glass (Kjellberg, 1907)

In 1907 Oscar Kjellberg patented a welding electrode made by dipping bare iron wire in a thick mixture of carbonates and silicates. In the arc the coating gives off a fume that keeps air away from the molten metal while it cools. Here the carbonate is chalk and the silicate is water glass. Cut the wire to length, dip it in the paste, and dry the rods well before use. The picture: our diagram of the wire, the dip and the coated rod.
Beginner
An hour, then drying overnight

Instructions

1

Cut the wire

Cut straight iron wire about 3 mm thick into 350 mm lengths and wipe it clean.

Materials for this step:

Iron WireIron Wire7 m

Tools needed:

Wire CuttersWire Cutters
Bench ViseBench Vise
Tape MeasureTape Measure
2

Mix the coating

Stir sifted chalk into water glass, a little at a time, until the paste is thick enough to cling to the wire.

Materials for this step:

Water Glass (Sodium Silicate Solution)Water Glass (Sodium Silicate Solution)300 g
Calcium Carbonate - WhitingCalcium Carbonate - Whiting400 g

Tools needed:

Mixing Bowl SetMixing Bowl Set
Digital Kitchen ScaleDigital Kitchen Scale
Rubber GlovesRubber Gloves
3

Dip the rods

Pour the paste into a tall jar. Dip each rod, leaving the top 30 mm bare for the holder, and lift it out slowly. When the first coat has set, dip again for a thicker coat.

Tools needed:

Glass JarGlass Jar
Rubber GlovesRubber Gloves
4

Dry

Hang the rods bare end up until the coating is hard, then dry them in a warm oven before welding. Keep them dry.

Tools needed:

Drying RackDrying Rack
OvenOven
5

Wire for a batch

Loading Jupyter Notebook...

Materials

3

Tools Required

9

CC0 Public Domain

This blueprint is released under CC0. You are free to copy, modify, distribute, and use this work for any purpose, without asking permission.

Support the Maker by purchasing products through their Blueprint where they earn a Maker Commission set by Vendors, or create a new iteration of this Blueprint and include it as a connection in your own Blueprint to share revenue.

Discussion

(0)

Log in to join the discussion

Loading comments...