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Good morning Allan,
wow, that's one of a good post and much more very good question(s).
I've just a few minutes before I have to run, but I just would like to mention - believe it or not - that I had a discussion recently with a welding educator, working for a very - even in these times - successful welding company.
As we passed the scrap box I saw 'tons' - o.k. this is a bit exaggerated - let's say a bunch of electrode stubs which certainly could have been classified as 'too long'.
Many of them were just once ignited, then the student obviously had problems with 'sticking to the plate' and the rest of the electrode, which was however actually almost a complete one, had been thrown away.
I asked the trainer how this behaviour could even be accepted, as this is pure money being thrown away. He said. "Well, he said, we have enough of this stuff. And why fighting battles with the students if they are not willing to follow my advice?"
I must emphasize that I very much appreciate this educator, he's both an outstanding teacher and welder, too. But I guess, he became only tired over the years of permanently stressing the students to something they are not willing to understand. I am honest, If I was him, that would be one of the first things I would change. Perhaps however, the main cause may also be another one?
Perhaps it is part of a general tendency rather, to be observed in our human society, following the slogan:
'If have not to pay for it? Who cares?!'
Not to understand in my eyes. During my personal education we had to use the electrodes until shortly before the coating has ended. And that helped and accompanied me during my whole occupational career. And to say the least, it was no fault to have learned to use an electrode as far as even possible.
If I would have thrown away such long stubs I wouldn't have like to see my educator, who was an excellent one, but who did explicitely hate dissipation.
He always told us: "The stick electrode suppliers are quite similar to the mustard suppliers! Their true turnover comes from the rests!"
No offence versus the stick electrode suppliers, anyway!
I know, you have asked many more very reasonable questions. But I am already running out of time, so I have to go.
Anyway, so far my humble .02$, but your post will certainly produce an outstanding thread - as usual! :-)
All the best,
Stephan