Stick Welding: The Ultimate Guide

Welding encompasses dozens of categories and subcategories, but when most people hear "welding," they think of Stick Welding—the most common, accessible, and arguably the classic welding method.

Stick welding is often the go-to choice for beginners, whether you're a DIY enthusiast, hobbyist, or professional. Its affordability, versatility, and portability make it an attractive option for various projects.

In this guide, we'll cover the basics of stick welding—its working principle, key components, and the complete process. You'll also learn how to achieve the perfect weld and when stick welding is (or isn't) the right choice.

Main Components in Stick Welding

To understand the working of stick welding and its process, it’s essential to go through the purpose and working of each component.

Here are the primary components and their working.

Welding Machine or Power Source

The first and the most important thing is the welding machine itself. It’s the powerhouse that is responsible for generating a powerful arc to melt the metal.

A stick welding machine is extremely simple. On the interface, all you see is an ON/OFF switch, amperage control, and output terminals.

The amperage control or current control is a knob or selector that allows you to adjust the welding current according to your needs. With a high current, you can generate more heat and melt more metal, and with a low current, the melting is less. This is the only variable or setting you need to adjust in stick welding, and that’s why it is the easiest of all types.

The output terminals are where you attach the welding cables. Usually, there are two output terminals only; one for +ve and the other for -ve.

If the machine is capable of switching between AC and DC, you will also have a knob or button to select. However, in some machines, you have separate terminals for the AC.

In some advanced machines, you’ll also see the Arc Force or Arc Control knob. It helps maintain the arc during the welding process. It neither lets the arc cut out nor the electrode stick to the base metal.

Electrode

In stick welding, electrodes play a major role. The process uses a consumable electrode that contains the core metal and flux.

The core metal is in the center. It is usually made of steel but cast iron, stainless steel, and some other metals and alloys can also be used.

It acts as the filler material in the welding process. It participates in the weld pool and fills the gaps to make a strong joint. The weld beads you see after post-processing are the filler or core material of the electrode.

The electrode also has a flux coating. It’s a layer that surrounds that core metal. During the welding process, some of the flux is converted into a shielding gas that protects the weld pool from the contaminants in the air.

The remaining flux is converted into the slag that stays over the molten material. It protects the weld pool and slows down the cooling process.

The shielding gas produced from the flux protects the weld pool initially when the arc is created. As the welder moves forward, the gas mixes in the atmosphere, while the slag remains at the top of the pool to protect it. Finally, when you are done with welding, the slag is removed.

Stick welding electrodes are available in a variety of types. And they are represented by a number. Usually, the number has an “E” as a prefix, which denotes Electrode.

The first two digits represent the tensile strength of the weld metal. If the number is E6010, the tensile strength is 60,000psi. It represents the maximum load the weld can bear.

The third digit is for the welding position. It explains whether you can weld flat, vertically, horizontally, or in other positions or not. You will see three common digits; 1, 2, and 4.

1 = All positions (flat, horizontal, vertical, overhead)

2 = Flat and horizontal positions only

4 = Flat, horizontal, overhead, and vertical down

The fourth and last digit indicates the type of flux in the electrode and the welding current type. For instance, E7018 is an electrode that can work with AC or DC+ current.

Electrode Holder or Stinger

The electrode holder or stinger holds the welding electrode. It is like a clamp that grips the electrode in its jaws. Once the electrode is clamped on the stinger, it does not fall during the welding process.

The stinger is connected to one of the output terminals through a welding lead. Thus, it acts as a conductor and carries welding current from the machine via cable and delivers it to the electrode.

The function of the stinger is to offer an insulated handle for the welder to hold the electrode. That way, the welder can safely hold the electrode and move it without suffering from any electric shock or intense heat.

Welding Cables and Clamp

Welding cables are responsible for completing the circuit. These are connected to the output terminals and conduct the flow of current.

They are stranded wires or cables available in different sizes and diameters. They are properly insulated to withstand harsh conditions. But at the same time, they are flexible enough to allow the welder to move the stinger and clamp without any hassle.

One welding cable is connected to the stinger while the other is connected to the clamp. The welder holds the welding stinger, and the clamp is connected to the workpiece.

How Does Stick Welding Work?

Stick Welding is also known by other names, especially Shielded Metal Arc Welding (SMAW) and Manual Metal Arc Welding (MMAW).

Even though the names sound a bit difficult, the working principle is extremely simple. And that’s the reason beginners can understand the process without any hassle.

It’s probably the most used welding process worldwide because of its availability and simplicity. It’s commonly used for construction, repairs, fabrication, shipbuilding, oil & gas industry, DIY projects, and almost everywhere.

A spark is created between the base metal and welding electrode through a short circuit. It generates enough heat to melt the base metal and the electrode and create a weld pool. When the metal weld pool solidifies, a strong weld is created.

One output terminal from the stick welding machine is connected to the welding stinger, while the other terminal is connected to the base metal.When the welder strikes the base metal with the welding electrode, it causes a short circuit. Due to this, immense current flows, and a gigantic spark is created.

This spark generates enough heat to melt the base metal and the electrode. The base metal melts and creates a weld pool. At the same time, the electrode is consumed. The core of the electrode mixes in the weld pool to fill the gaps and join both pieces strongly.

The flux from the electrode creates a shield around the and protects it from air contaminants. Some part of the flux makes a layer of slag on the molten metal. It protects the weld beads and gives them their shape.

Then, the weld pool is allowed to cool down. Finally, the slag is removed using a hammer or grinder. It unveils the weld beads.

Stick Welding Technique

Stick welding is easy to understand, but achieving good welds is not easy. It highly depends on the welder’s experience and skill. If the welder is going too slow or fast, the weld quality is badly affected. Similarly, there are other factors that a welder needs to consider.

Before we dive into the stick welding step-by-step process, here are some important techniques and factors that could affect the weld quality.

Work Angle

The work angle is the angle between the electrode and the base metal/joint.

Suppose you are doing a T welding. Two metal pieces are at 90⁰ from each other. And now, you want to join them through welding.

The angle between the electrode and the vertical metal is the work angle. Usually, it’s kept at 45⁰ in T-weld to ensure even heat penetration in both metal pieces, proper filling of the gaps, and even heat distribution. It results in excellent weld quality.

If you are doing a butt weld, which means joining two flat metal pieces together, the work angle will be 90⁰. As the hold is held straight onto the metal.

In a lap joint, the preferred work angle is 60⁰ or 70⁰. Welders must pick the right work angle for the job to achieve perfection.

Drag Angle

The second important angle in stick welding is the drag angle, which is also known as the travel angle. It’s the angle between the electrode and the direction of the weld.

The difference between work and drag angle is of the plane. The work angle is in the transverse plane across the weld, while the drag angle is in the longitudinal plan along the weld.

It’s difficult to keep the welding electrode straight and move the stinger. Similarly, the push angle won’t be ideal as it could contaminate the weld.

The best option is to slightly tilt the welding electrode away from the travel direction and then drag it. The drag angle is usually 10-15⁰, and it offers excellent results.

By controlling the drag angle, welders have a good weld bead profile. They can control the penetration and the amount of slag/shielding gas.

Arc Length

The distance between the tip of the welding electrode and the base metal is the arc length.

If the arc length is too small, the electrode could stick to the base metal. Even if it doesn’t, it produces rough and uneven weld. The weld width will also be very short.

And if the arc length is too long, it won’t be able to penetrate deeper, so the weld is not strong enough. Secondly, there will be a lot of spatter. And in the worst case, the spark will go out.

Thus, welders need to keep the electrode at the optimal distance. There is no hard and fast rule for the distance. They need to practice and find the appropriate distance according to the welding electrode, position, and other factors. However, most welders prefer to keep it at a distance equal to the diameter of the electrode.

The electrode is consumable, and it gets shorter as you go. Therefore, maintaining an even distance is a bit difficult. That’s why welders need to practice to achieve good welds.

Travel Speed

Last but not least is the travel speed. The speed at which you move the electrode also defines the weld quality.If you go too slow, it will melt excessive metal. There will be a large weld pool, and it will consume more electrodes than needed. The filler material will also accumulate on the surface and will require more post-processing.

Going fast is also bad for the weld quality. The weld will be too narrow, and there will be gaps and porosity. In the worst case, the spark won’t be able to melt enough metal and join metals properly.

Welders master the perfect travel speed through practice. The more experience they have, the better the final result will be.

How to Stick Weld? The Process Explained

Here’s the step-by-step process of stick welding that beginners can follow to get started.

Ensure Your Safety

Before you start welding, it’s necessary to have all the safety gear needed, including a welding helmet, gloves, sleeves, fire-resistant clothes, safety boots, etc.

It’s better to have a dedicated area for welding. You should also have proper tools with safety features. But if you don’t have a dedicated area like in outdoor jobs, make sure there is no combustible material around.

Clean the Metal Surface

Even though cleaning is not required in stick welding, it’s better to do it. If there is paint, you can remove it to ensure a contaminant-free weld pool. Similarly, remove the rust, dust, and other particles.

If the material is wet or covered with a layer of oil, make sure to clean it. The weld quality is the pool. There is a higher risk of porosity leading to weaker joints. The arc will also be unstable, and the metal pieces might not fuse well together.

The water on the metal surface can give you electrical shocks. And if there is oil, it can generate harmful fumes during the welding process.

Clean the Metal Surface

Even though cleaning is not required in stick welding, it’s better to do it. If there is paint, you can remove it to ensure a contaminant-free weld pool. Similarly, remove the rust, dust, and other particles.

If the material is wet or covered with a layer of oil, make sure to clean it. The weld quality is the pool. There is a higher risk of porosity leading to weaker joints. The arc will also be unstable, and the metal pieces might not fuse well together.

The water on the metal surface can give you electrical shocks. And if there is oil, it can generate harmful fumes during the welding process.

Set Up the Machine

You must connect the welding leads to the output terminals. But the question is which lead should be connected to the “+ve” and which to the “-ve.”

There are three types of polarities when you do stick welding.

The first one is the DCEP, which is also known as the Reverse Polarity. In this case, the electrode is connected to the positive terminal, and the base metal is made negative. It’s the most common polarity used in stick welding, and it offers the deepest penetration. Generally, it is a good option, and you can use it for strong welds in thick materials.

The second one is the DCEN, which is the Straight Polarity. The electrode is connected to the negative terminal, while the working metal is connected to the positive. It has the slowest penetration and is suitable for thin materials.

The last one is the AC. If your welding machine has this polarity, you can do that. It’s in the middle of the above two in terms of penetration. However, there are chances of more spatter.

You can’t select the polarity on your own. You must do it according to the electrode. Each electrode has a specific polarity for the operation. Almost all electrodes can work on AC current. For the DC current, they can work on either DCEP, DCEN, or both. However, DCEP is more common.

For instance, you can connect E6013 to AC, DCEP, and DCEN.Finally, hold the welding electrode using the stinger. Once everything is set up, you can turn on the welding machine.

Start Welding

Select the current or amperage on the welding machine. You have to select the current according to the electrode, material thickness, welding position, metal type, and other things.

For ease, you can refer to the welding amperage chart. You don’t need to select the exact value, and some welders try a bit up and down to get the perfect results.

If the weld is too wide, you can lower the amperage. And if it’s too narrow, you can increase it. The best way is to test on a spare material and do some trials. You will get the idea of the amperage you need.

To start the weld, the easiest way is to tap the electrode. Bring it close to the workpiece and slowly lift it up a bit. You will see the arc, and now, you can move along. Another way is to bring the electrode closer by rotating/twisting the stinger a bit. It’s like striking a matchstick. When you have a suitable arc length, you can proceed with the welding.

It’s better to see the result of welding at different speeds, arc lengths, and angles. It will give you a better idea of what you should adopt. Once you are confident, you can start welding on the workpiece.

For a good weld, you need to travel at the optimal speed and control the arc length. Extreme precision and control are needed.

Slag Removal and Finishing

Once the weld is cooled, you can remove the slag. For this, you can hammer the weld surface, and the slag will come out on its own. Then, use a wire brush to remove the tiny particles and make the area clean.

After removing the slag, you will see the weld beads. Check for any defects, such as cracks, holes, and gaps. If everything is perfect, use a grinder to finish the surface. Remove the excess material and make it smooth and leveled.

When is Stick Welding Preferred?

Stick welding works on various metals, such as cast iron, steel, stainless steel, nickel alloys, etc. Undoubtedly, other welding processes can be used for these materials, but often stick welding is preferred over others. Let’s see the instances where stick welding is the best option.

Outdoor and Remote Locations

Stick welding is preferred for outdoor and field jobs. It can work in windy conditions as there is no shielding gas required. It’s possible to weld even on the roadside. Thus, welders prefer stick welding for outdoor construction, pipelines, on-site repairs, remote jobs, etc.

Secondly, stick welding machines are portable. They are compact and easy to carry. Plus, the welding equipment and accessories are minimal. Welders can carry these welding machines anywhere without any hassle. It’s extremely portable.

Dirty Surfaces

Stick welding does not require pre-treatment of the base metal like other welding processes. There is no need for removing the paint layer, cleaning the rust, etc. No matter what the condition of the work surface is, stick welding can do its job.

It saves the time of pre-treatment and offers excellent quality welds. In some cases, where it is not possible to clean or treat the metal surface, stick welding is the only option left. It works in challenging conditions where other welding processes fail.

Thick Materials

Stick welding is capable of welding thicker materials. It can generate enough heat to penetrate deeper into the metal. It can create strong welds that can be used for heavy-duty applications.

We have already seen the tensile strength of the weld while discussing welding electrodes. It indicates how strong the weld is and the load it can bear. Stick welding is definitely a good option for heavy-duty applications, be it structure work, joining thick sheets, repairing car bodies, etc.

Low Budget

Compared to other welding methods and processes, stick welding is quite cost-effective. The main reason is the simplicity of the process. There is no need for shielding gas, expensive wires, cleaning tools, etc. It’s possible to complete the welding job with a minimal budget.

Moreover, stick welding machines and other accessories are also affordable. Anyone can buy the machine and necessary equipment and get started with welding. Thus, in instances where budget is an issue, stick welding is preferred. And that’s also a reason, stick welding is widely used in maintenance and repairs.

Can Laser Welding Replace Stick Welding?

Stick welding is a versatile option, but in some aspects, it lags behind. And that’s where laser welding comes into play. Here are some instances where laser welding replaces stick welding.

High Speed and Automation

Stick welding requires time. And where there is high volume production, it’s not the right option to go with.

In contrast, laser welding offers incredible speed. It can create perfect welds in no time and increase productivity. The best part is that it can be automated using robots.

Minimal Post Processing

After stick welding, the workpiece requires processing. It has to go through hammering, grinding, and finishing. All of these require time and effort. Moreover, you can’t process all workpieces.

Laser welding does not require any post-processing. It saves time and creates excellent welds in the first place. It’s an ideal option when metals can’t be post-processed as they are delicate.

Incredible Precision

Stick welding lacks precision. It’s not suitable for delicate items and intricate welds. Laser welding is the best option when extreme precision is required. It ensures fine details and optimal weld quality. It can even weld intricate electronic components, jewelry, and medical devices.

Minimal HAZ

The immense heat generated in the stick welding process can affect the area around the weld. It can even deform the whole material as the heat-affected zone (HAZ) is large.

In instances where minimal HAZ is needed, laser welding is preferred. It only heats the area to be welded. It does not deform the whole material or put the surrounding area under heat stress.

Conclusion

Stick welding is the most common and easiest welding process. However, it requires skills and experience to get the perfect welds. It’s undoubtedly simple when it comes to the working principle and operating the machine. However, it highly depends on how the welder moves the electrode. For beginners, it’s the right welding process. This ultimate guide on stick welding will help you get started without any hassle.