Are longer or shorter SMAW electrodes more likely to overheat due to resistance in the core wire?

• A. Shorter
• B. Longer
• C. Neither
• D. Both equally

Answer: (B)

Longer core wire means more electrical resistance along the path of the welding current. In SMAW, the current flows through the electrode core to the arc, and the heat generated by that resistance is given by P = I^2 R. With a longer electrode, R is higher, so more heat is produced in the core and flux area for the same current. That extra heat makes overheating of the core wire and surrounding coating more likely. Shorter electrodes have less resistance, so they generate less heat for the same current, reducing the risk of overheating.