What is Stick Welding?
Stick welding, which is also known as Shielded Metal Arc Welding (SMAW), melts and joins
metals by using an electric current to melt the tip of an electrode, or stick. This melted
electrode mixes with the melting metals in the work piece in order to form a weld.
The electrode’s core provides the filling material for the weld, while the outer
layer of the electrode, the flux, helps create an arc and provides a shielding gas and
protective layer of slag—which keeps contaminants out of the weld and will later be
chipped away.
If performed correctly, this kind of weld will be extremely strong. Stick welding is one
of the most popular kinds of arc
welding.
Applications for Stick Welding
Repairs to farm equipment (see Welding on the Farm), hobbies, repairs at
home, and industrial projects.
About This Article
This is not an exhaustive guide to every Stick welding scenario and procedure. If you are
new to welding and unsure about your material, equipment, or technique, please consult an
expert. The following article is a series of guidelines that will provide basic welding
information and links, but is not a substitute for an expert's on-site advice. Additional
resources are included at the end of this article for those ready to take the next step.
Why Use Stick Welding?
Stick welding is one of the most effective techniques for fusing alloys and joints. While
there are other techniques, stick welding is the most economical and effective because
different metals can be welded by changing the rod. Stick welding can be done both inside
and outside. Wind or a strong draft will not affect the welding process since
there’s no shielding gas. Stick welding still works even if the welding surface is
less than perfect.
What You Need
Welding Safety
Make sure the metal is free of any oil, grease, paint, zinc, or lead. Welding
contaminated metals may create harmful fumes or smoke. In addition, clean metals will
provide a stronger weld.
Invest in a helmet, gloves, jacket, boots, clamps, and any other safety gear a project may
require. Welding produces sparks, static electricity, and possibly toxic fumes. Consult a
professional if unsure about the proper safety measures before starting a welding project.
Keep in mind that stick welding with DC power is easier to start, splatters less, has
fewer arc outages and sticking, makes better looking welds, makes it easier to weld in
different positions, gives 10% more penetration (in a DC reverse polarity over any amp in
AC), and allows a smoother arc. However, AC makes it possible to stick weld magnetized
parts.
Setting Up
When setting up a welding machine, begin by choosing an electrode rod (see this guide on
selecting a
rod) and inserting it into the electrode holder. Set the polarity and the amperage of
the welding machine according to the manufacturer’s recommendations for the type of
metal and electrode (see
Miller's calculator).
Miller's calculator will suggest which welding position and penetration will work the
best. Thick metals need more current than thin metals, and a large electrode requires more
amperage than a large electrode.
A weld is created when an electric current in the electrode holder heats the electrode. An
arc in between the electrode and work piece will melt the metal work piece and the
electrode in order to form the weld. In order to begin welding, the arc must be struck.
In order to strike an arc, lightly slide the electrode across the metal as if lighting a
match and immediately lift it after making brief contact with the metal. Don't move it too
far from the metal or the arc may go out. If electrode sticks to the metal, twist it free.
Learn how to strike an arc by watching this video.
When striking the arc, there’s a chance the flux on the outside of the electrode
will be damaged. There are two ways to proceed. One involves striking an arc on a piece of
scrap metal and then burning away the damaged flux by holding the electrode rod a quarter
inch from the metal. The other requires removing the electrode rod from the holder and
scraping away the damaged flux.
During the stick welding process, the electrode rod is typically dragged ahead of the
puddle that is formed in between the two metals that are being joined together. This
prevents slag from contaminating the weld. Depending on the nature of the project, the rod
will either be moved in a back and forth whipping motion, in circles that will help join
the metals together, or in a wide side to side weaving motion.
While welding, listen for the crackle of the burning electrode in order to determine if
the amperage is set correctly. The ideal sound is comparable to the sizzle of eggs in a
frying pan. If the electrode rod sticks, the amperage is too low. If the electrode turns
red, the amperage is too high.
When stick welding, the electrode should be almost perpendicular to the work, though a
slight angle toward the work may help. Keep the arc short, move at a constant speed, and
feed the electrode at a steady rate as it melts. For welding diagrams and tips, see the Miller Stick
Welding Guide.
After welding is completed, remove the slag with a welding hammer and wire brush. Inspect
the weld before adding another layer.
Common Challenges
While stick welding is versatile and practical, there are a few disadvantages:
- Metals cannot be thinner than eighteen gauge.
- Electrode rods must be changed often.
- There is also a lot of splatter as a result of the fast burning.
- Extra clean up is usually necessary.
- The arc can be tricky to strike and hold at first.
Additional Resources and Articles
Written Exclusively for Baker's Gas and Welding by Ed Cyzewski | 
