Stick Welding
We've spent years refining tools, testing materials, and working alongside welders in demanding environments, which has given us a clear view of why stick welding remains a go-to method in the industry. This process is valued for its durability, adaptability to different metals, and performance in outdoor or challenging conditions.
In this article, we explain what stick welding is, outline the essential equipment and setup requirements, and provide step-by-step guidance to help beginners develop a reliable technique. We'll also share practical insights gained from extensive field experience so readers can avoid common mistakes and produce strong, clean welds from the start.
What this article covers:
What Is Stick Welding?
Stick welding, also known as shielded metal arc welding or SMAW, is a process where an electric arc forms between a flux-coated stick electrode and the base metal. That arc melts both the rod and the metal, creating a weld. The flux coating vaporizes to generate a shielding gas, and what's left turns into slag that protects the hot weld until it cools.
In plain terms, stick welding is one of the oldest techniques around, but it's still widely used for its simplicity and versatility. You don't need fancy shielding gas like with the TIG welding or MIG welding process; it works even in wind or rain, and almost all metals can be welded.
It's popular in steel and pipeline work, and it's often the first welding process people learn. For windy job sites, stick welding or self-shielded flux-cored welding typically performs better than gas-shielded processes.
How to Stick Weld
Here's how we'd walk a beginner through the process of using a stick welder:
Step 1: Get Your Gear Set Up
The right setup makes all the difference. You need a proper power source, electrode holder, grounding clamp, and the right stick electrode for your material. Most beginners start with E6013 welding rods for general purpose or E7018 welding rods for nicer low-hydrogen welds.
Set your polarity correctly. Check the rod packaging. If it says AC/DC+, you connect the electrode to the positive terminal; if it's AC/DC–, reverse it. And don't guess your amp settings: start middle range based on electrode thickness. Too high and you'll get spatter; too low and the rod will stick.
Step 2: Prepare and Strike the Arc
A solid strike sets the tone. Use a match-like strike: scratch the rod tip on the workpiece, lift until the arc ignites, and don't pull too far or you'll lose it. As with other arc welding processes, keeping a short, consistent arc length improves stability and bead quality. If the rod sticks, a quick twist usually breaks it free without ruining it.
Step 3: Maintain Proper Angle, Arc Length, and Travel Speed
We've seen too many beginners hold the rod wrong. For flat or horizontal welding, drag the rod with a backhand technique, tilting about 5-15 degrees in the direction of travel. Vertical welds lean the other way.
Arc length should stay short: not more than the diameter of the rod. For a 2.6mm rod, keep it under 3 mm. Too close and it'll stick; too far and the arc stutters and spits.
Slow travel means a wide, deep weld and more penetration. Too fast and you'll get a thin weld and poor fusion. Keep a steady pace. Steady hands, steady results.
Step 4: Finish, Chip Slag, and Inspect
Once you've completed the weld, let it cool briefly, then chip away the slag, which is that white or gray crust covering your weld. Clean it off so you can inspect for undercut, porosity, or weak spots. This step is critical for quality.
Step 5: Adjust and Repeat
After your first few beads, adjust based on what you're seeing. If the weld is too high and narrow, slow down. If it's flat and wide and looks burned through, either increase your speed or lower amps.
Conclusion
Stick welding is a dependable and versatile process that delivers strong results in both controlled shop settings and challenging outdoor environments. It's effective on a variety of metals, requires minimal setup, and remains a valuable skill for anyone working in fabrication or repair. Mastering the fundamentals sets the foundation for producing durable, high-quality welds.
For welding equipment that's been thoroughly tested in the field and built for performance, visit Badass Welding Products and get the tools you need for success.