Patent ID: 7781701

Claim:
A welding electrode tip comprising: a metal core having a cylindrical portion and a front tip region that includes a tapered metal core front tip and a front tip end, a taper of said tapered front metal core tip having an angle a defined by an angle between a tangential line drawn along said tapered tip and a longitudinal axis of said metal core, said angle a ranging from between about 25-45°, said taper having a length L as measured from said front tip end to a beginning of said cylindrical portion, said metal core front tip having a width W at said end of said tip, a coating material about an outer surface of said cylindrical portion and at least partially coated on an outer surface of said tapered metal core front tip of said metal core said coating material including gas generating compounds during the welding process with a workplace, and a tapered end coating on a remaining portion of the front tip region of the metal core and said width W of said metal core front tip, said end coating partially extending along an outer surface of said coating material, but less than length L, a taper of said tapered end coating having an angle β defined by an angle between a tangential line drawn along said tapered end coating and a longitudinal axis of said metal core, said angle β ranging from between about 45-89°, said end coating material including a binder and small particles of electrically-conductive material, said small particles have an average particle size of about 100-400 mesh, said end coating material formulated to facilitate in forming an electric arc between said electrode and said workpiece during the beginning of said welding process, said end coating material having a different composition from said coating material, a combination of said end coating material and said coating material forming a weld having lower porosity that said weld formed without using said end coating material and said coating material having said different composition.