I was just a maintenance weldor, but in my limited experience I felt I could get better "puddle control" and better looking welds using DC reverse polarity, if DC reverse rod was available and suitable. But I found AC or DC straight polarity may give better penetration sometimes and start a little easier. In our shop we had an old Hobart MG set welder that would help you lay really pretty welds using D.C. Reverse rod, but for "quickie" jobs out in the production and furnace areas we often just used a Lincoln 225 AC buzz box and never switched leads to get DC. In DC mode the electrons run from the stinger to the workpieces one way, in straight polarity from the workpieces to the stinger in reverse polarity......With AC the electrons (or current flow) run both ways....That's how it was explained to me anyway. Our fancy TIG welder had a low voltage AC auxiliary mode to help start while using DC reverse mode to make the ball on the electrode off a stainless blank for aluminum welding and straight polarity for the actual welding of the aluminum or while using a parallel ground pointed electrode doing ferrous metals (steel and iron alloys). IIRC.
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